Мануал ниссан ноте е11

Мультимедийное руководство на английском языке по техническому обслуживанию и ремонту автомобиля Nissan Note серии E11.

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Руководство на английском языке по техническому обслуживанию и ремонту автомобиля Nissan Note серии E12.

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Сборник руководств по эксплуатации и техническому обслуживанию автомобиля Nissan Note с 2005 года выпуска.

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Руководство по эксплуатации, техническому обслуживанию и ремонту автомобиля Nissan Note с 2005 года выпуска с бензиновыми двигателями объемом 1,4/1,6 л.

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Руководство по эксплуатации и техническому обслуживанию автомобиля Nissan Note с 2005 года выпуска.

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Руководство по эксплуатации, техническому обслуживанию и ремонту автомобиля Nissan Note серии E11 с 2005 года выпуска с бензиновыми двигателями объемом 1,4/1,6 л.

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Руководство по техническому обслуживанию и ремонту автомобиля Nissan Note серии E11 2005-2009 годов выпуска.

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Руководство по эксплуатации и ремонту автомобиля Nissan Note с 2013 года выпуска с бензиновыми и дизельными двигателями.

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Скачать документацию и схемы

Подробное описание всех узлов автомобиля (Nissan Note)

Данное руководство имеет подробное описание технического обслуживания автомобиля, плюс эскизы всех узлов и агрегатов Nissan Note, электрические схемы, а так же инструкция по ремонту. Все файлы в формате (PDF)на Английском языке.

NISSAN MODEL E11 SERIES

A. скачать Общая информация (General Information)

B. Двигатель(ENGINE):

скачать Подробное описание двигателя Note (ENGINE MECHANICAL)

скачать Система смазки двигателя (ENGINE LUBRICATION SYSTEM)

скачать Система охлаждения двигателя (ENGINE COOLING SYSTEM)

скачать Система управления двигателем (ENGINE CONTROL SYSTEM)

скачать Топливная система (FUEL SYSTEM)

скачать Выхлопная система (EXHAUST SYSTEM)

скачать Система управления акселератором[педаль газа] (ACCELERATOR CONTROL SYSTEM)

C. Трансмиссия / Коробка передач (TRANSMISSION/TRANSAXLE):

скачать Сцепление (CLUTCH)

скачать МКПП (MANUAL TRANSAXLE)

скачать АКПП (AUTOMATIC TRANSAXLE)

D. Трансмиссия / Мост (DRIVELINE/AXLE):

скачать Передняя ступица и привод (FRONT AXLE)

скачать Задняя ступица (REAR AXLE)

E. Подвеска (SUSPENSION):

скачать Передняя подвеска (FRONT SUSPENSION)

скачать Задняя подвеска (REAR SUSPENSION)

скачать Опорные катки и шины (ROAD WHEELS & TYRES)

F. Тормоза (BRAKES):

скачать Тормозная система (BRAKE SYSTEM)

скачать Система стояночного тормоза (PARKING BRAKE SYSTEM)

скачать Блок управления тормозом (BRAKE CONTROL SYSTEM)

G. Рулевое управление (STEERING):

скачать Рулевая колонка и рейка (POWER STEERING SYSTEM)

скачать Эл. усилитель руля (STEERING CONTROL SYSTEM)

H. Безопасность (RESTRAINTS):

скачать Ремни безопасности (SEAT BELTS)

скачать Подушки безопасности (SUPPLEMENTAL RESTRAINT SYSTEM (SRS))

I. Кузов (BODY):

скачать Кузов; замки и система безопасности (BODY, LOCK & SECURITY SYSTEM)

скачать Окна и зеркала (GLASSES, WINDOW SYSTEM & MIRRORS)

скачать Экстерьер и Интерьер (EXTERIOR & INTERIOR)

скачать Передняя панель — торпеда (INSTRUMENT PANEL)

скачать Сиденья (SEAT)

J. Кондиционер (AIR CONDITIONER):

скачать Климат-контроль (AUTOMATIC AIR CONDITIONER)

скачать Управление кондиционером (MANUAL AIR CONDITIONER)

K. Электрика (ELECTRICAL):

скачать Запуск и системы зарядки (STARTING & CHARGING SYSTEM)

скачать Система освещения (LIGHTING SYSTEM)

скачать Приборная панель (DRIVER INFORMATION SYSTEM)

скачать Омыватели стёкол и фар, дворники (WIPER,WASHER & HORN)

скачать Контроллер системы управелния (BODY CONTROL SYSTEM)

скачать Аудио-система и телефонная система (AUDIO, VISUAL & TELEPHONE SYSTEM)

скачать Электрические схемы; питание, земля (POWER SUPPLY, GROUND & CIRCUIT ELEMENTS)

L.скачать Техническое обслуживание (MAINTENANCE)

Чехол приводного вала. Замена Внимание: Если от приводного вала исходит шум или вибрация, замените

Проверка перед разборкой Подвигайте шарнир вверх/вниз, влево/вправо и в осевом направлении. Убедитесь, что движение

Разборка 1. При помощи щипцов для стопорных колец (подходящий специнструмент) снимите кольцо датчика. 2.

Разборка 1. Выпрессуйте колесный подшипник при помощи выколотки (специнструмент). 2. Выньте стопорное кольцо из

1. Грязеотражательный щит; 2. Полуось; 3. Кольцо датчика ABS; 4. Колесный подшипник; 5. Стопорное

Снятие 1. Поднимите автомобиль и снимите колеса с автомобиля. 2. Снимите стопорную пластину со

1. Поворотный кулак; 2. Корпус датчика; 3. Колесный подшипник; 4. Стопорное кольцо; 5. Ступица

Проверьте, нет ли чрезмерного люфта, трещин, износа или других повреждений передней оси. Покачайте передние

Проверьте, нет ли чрезмерного люфта, трещин, износа или других повреждений задней оси. Покачайте задние

Компоненты шестерен 1. Смазочный канал; 2. Передний подшипник вторичного вала; 3. Вторичный вал; 4.

Get your hands on the complete Nissan factory workshop software

DRIVER INFORMATION SYSTEM

K ELECTRICAL

SECTION

DI

DRIVER INFORMATION SYSTEM

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 3
Maintenance Information …………………………………… 3
RHD MODELS ……………………………………………… 3
LHD MODELS ………………………………………………. 3
COMBINATION METERS ……………………………………. 4
Component Parts and Harness Connector Location….. 4
System Description ………………………………………….. 4
UNIFIED METER CONTROL UNIT …………………. 4
POWER SUPPLY AND GROUND CIRCUIT …….. 4
SPEEDOMETER …………………………………………… 4
TACHOMETER …………………………………………….. 4
LOW WATER TEMPERATURE INDICATOR
LAMP, HIGH WATER TEMPERATURE WARNING LAMP ……………………………………………………. 4
FUEL GAUGE ………………………………………………. 5
ODO/TRIP METER ……………………………………….. 5
CAN Communication ………………………………………… 5
SYSTEM DESCRIPTION ……………………………….. 5
CAN Communication Unit …………………………………. 5
Arrangement of Combination Meter ……………………. 6
Schematic ………………………………………………………. 7
Wiring Diagram — METER — ……………………………. 8
Terminals and Reference Value for Combination
Meter ……………………………………………………………… 9
Combination Meter Self-Diagnosis ……………………. 10
PERFORMING SELF-DIAGNOSIS MODE ……… 10
Trouble Diagnoses …………………………………………. 13
PRELIMINARY CHECK ……………………………….. 13
SYMPTOM CHART ……………………………………… 15
Check Power Supply and Ground Circuit …………… 15
Check Vehicle Speed Signal ……………………………. 16
Check Engine Revolution Signal ………………………. 17
Check Fuel Level Sensor Signal ………………………. 17
Check Water Temperature Warning/indicator Lamp… 19
Check Fuel Gauge Fluctuation …………………………. 19
Fuel Gauge Does Not Move to FULL position ……. 19
Check Electrical Components ………………………….. 19

CHECK FUEL LEVEL SENSOR UNIT ……………. 19
Removal and Installation for Combination Meter … 20
REMOVAL ………………………………………………….. 20
INSTALLATION …………………………………………… 20
Disassembly and Assembly for Combination Meter… 20
DISASSEMBLY …………………………………………… 20
ASSEMBLY ………………………………………………… 20
DRIVE COMPUTER ………………………………………….. 21
Component Parts and Harness Connector Location… 21
System Description …………………………………………. 21
DRIVE COMPUTER …………………………………….. 21
SERVICE REMINDER ………………………………….. 22
OIL LEVEL WARNING …………………………………. 22
OUTSIDE AIR TEMPERATURE …………………….. 22
CAN Communication ………………………………………. 23
SYSTEM DESCRIPTION ……………………………… 23
CAN Communication Unit ………………………………… 23
Wiring Diagram — D/COMP — ………………………… 24
Terminals and Reference Value for Combination
Meter ……………………………………………………………. 26
Check Ambient Sensor Signal ………………………….. 26
Check Steering Wheel Switch ………………………….. 29
Check Oil Level sensor ……………………………………. 30
WARNING LAMPS ……………………………………………. 32
System Description …………………………………………. 32
OIL PRESSURE WARNING LAMP ………………… 32
Component Parts and Harness Connector Location… 32
Schematic ……………………………………………………… 33
WiringDiagram —WARN — /WithGasolineEngine
Models ………………………………………………………….. 34
Wiring Diagram — WARN — / With Diesel Engine
Models ………………………………………………………….. 40
Oil Pressure Warning Lamp Stays Off (Ignition
Switch ON) ……………………………………………………. 45
Oil Pressure Warning Lamp Does Not Turn Off (Oil
Pressure Is Normal) ………………………………………… 46
Electrical Components Inspection …………………….. 47
OIL PRESSURE SWITCH CHECK ………………… 47
A/T INDICATOR ……………………………………………….. 48
System Description …………………………………………. 48

DI-1

E

F

G

H

I

J

DI

L

M

FEATURE DESCRIPTION …………………………….. 48
Wiring Diagram — AT/IND — …………………………… 49
A/T Indicator Does Not Illuminate ……………………… 51
WARNING CHIME …………………………………………….. 52
ComponentParts and Harness Connector Location… 52
System Description …………………………………………. 53
POWER SUPPLY AND GROUND CIRCUIT ……. 53
IGNITION KEY WARNING CHIME …………………. 53
INTELLIGENTKEYSYSTEMWARNINGCHIME… 53
LIGHT WARNING CHIME …………………………….. 53
SEAT BELT WARNING CHIME ……………………… 54
PARKING BRAKE WARNING CHIME …………….. 54
CAN Communication ………………………………………. 54
SYSTEM DESCRIPTION ……………………………… 54

DI-2

CAN Communication Unit …………………………………54
Schematic ………………………………………………………55
Wiring Diagram — CHIME — ……………………………56
Terminals and Reference Value for BCM …………….60
Terminals and Reference Value for Combination
Meter ……………………………………………………………..62
Trouble Diagnosis ……………………………………………63
HOW TO PERFORM TROUBLE DIAGNOSIS …63
PRELIMINARY INSPECTION …………………………63
SYMPTOM CHART ……………………………………….63
Check Front Door Switch (Driver Side) Signal ……..63
Check Seat Belt Buckle Switch Signal ………………..64
Check Parking Break Switch Signal ……………………66

PRECAUTIONS
PRECAUTIONS
PFP:00011
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

A

BKS000Z9

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Maintenance Information

B

C

D

E

F

BKS000ZA

If any of following part is replaced, always replace with new* one.
If it’s not (or fail to do so), the electrical system may not be operated properly.
*: New one means a virgin control unit that has never been energized on-board.

G

RHD MODELS

H

●
●
●
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM
IPDM E/R
Combination meter
EPS control unit

I

J

LHD MODELS
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM

DI

L

M

DI-3

COMBINATION METERS
COMBINATION METERS
Component Parts and Harness Connector Location

PFP:24814
BKS000ZD

MKIB2319E

1.

Combination meter M27

2.

ABS actuator and electronic unit
E32: With ESP
E33: Without ESP

System Description

3.

Fuel level sensor unit and fuel
pump B33

BKS0026A

UNIFIED METER CONTROL UNIT
●

●

●
●

Speedometer, odo/trip meter, tachometer and fuel gauge are controlled by the unified meter control unit,
which is built into the combination meter.
Warning lamp and indicator lamp are controlled by signals drawn from the CAN communication system,
BCM (body control module), and components connected directly to the combination meter.
Odo/trip meter and A/T indicator segments can be checked in self-diagnosis mode.
Meters/gauges can be checked in self-diagnosis mode.

POWER SUPPLY AND GROUND CIRCUIT
Power is supplied at all times
●
through 10A fuse [No. 7, located in the fuse block (J/B)]
●
to combination meter terminal 27.
With the ignition switch in the ON or START position, power is supplied
●
through 10A fuse [No. 4, located in the fuse block (J/B)]
●
to combination meter terminal 28.
Ground is supplied
●
to combination meter terminals 21, 22 and 23
●
through grounds M21 and M66.

SPEEDOMETER
The speedometer indicates the vehicle speed.
●
ABS actuator and electric unit (control unit) converses a pulse signal from wheel sensor to vehicle speed
signal, and transmit vehicle speed signal to combination meter with CAN communication.
●
Combination meter converses the vehicle speed signal to angle, and commands to speedometer.

TACHOMETER
The tachometer indicates engine speed in revolutions per minute (rpm).
●
ECM converses a signal from crank position sensor to engine speed signal, and transmits to combination
meter with CAN communication.
●
Combination meter converses the engine speed signal to angle, and commands to tachometer.

LOW WATER TEMPERATURE INDICATOR LAMP, HIGH WATER TEMPERATURE WARNING
LAMP
The water temperature warning/indicator lamp indicate the engine coolant temperature.
ECM provides a engine coolant temperature signal to combination meter for water temperature warning/indicator lamp via CAN communication line.
When turn ignition switch ON, water temperature warning/indicator lamp will be ON with red color for 1 second
then blue color for1 second.

DI-4

COMBINATION METERS
After engine started,
●
Water temperature warning/indicator lamp will be ON with blue color while engine coolant temperature is
less than 55 °C.
●
Water temperature warning/indicator lamp will be OFF with blue color, while engine coolant temperature is
more than 55 °C.
●
Water temperature warning/indicator lamp will be OFF, while engine coolant temperature is between 55
°C and 114 °C.
●
Water temperature warning/indicator lamp will be ON with red color, while engine coolant temperature is
more than 114 °C.
●
Water temperature warning/indicator lamp will be OFF with red color, while engine coolant temperature is
less than 108 °C.

A

B

C

D

FUEL GAUGE
The fuel gauge indicates the approximate fuel level in the fuel tank.
The fuel gauge is regulated by the combination meter and a variable resistor signal supplied
●
to combination meter terminal 6
●
through fuel level sensor unit and fuel pump terminal 2
●
through fuel level sensor unit and fuel pump terminal 4
●
from combination meter terminal 24.

E

F

ODO/TRIP METER

G

The vehicle speed signal and the memory signals from the meter memory circuit are processed by the combination meter and the mileage is displayed.
H

How to Change the Display
Refer to DI-21, «System Description» .

I

CAN Communication

BKS000ZF

SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul- J
tiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. DI
Each control unit transmits/receives data but selectively reads required data only.

CAN Communication Unit

BKS0026E

L

Refer to LAN-27, «CAN Communication Unit»
M

DI-5

COMBINATION METERS
Arrangement of Combination Meter

BKS0026B

MKIB2320E

DI-6

COMBINATION METERS
Schematic

BKS000ZI

A

B

C

D

E

F

G

H

I

J

DI

L

M

MKWA4297E

DI-7

COMBINATION METERS
Wiring Diagram — METER —

BKS000ZJ

MKWA4298E

DI-8

COMBINATION METERS
Terminals and Reference Value for Combination Meter

BKS000ZK

A
Condition
Terminal

Wire
color

1

L

CAN- H

2

Y

CAN- L

6

BR

Item

Fuel level sensor signal

Signal
Input/
Output

Reference value (V)
(Approx.)

Ignition
switch

Operation or
condition

Input/
Output

—

—

—

Input/
Output

—

—

—

—

Refer to (CR engine) FL-4, «FUEL LEVEL
SENSOR UNIT, FUEL FILTER AND FUEL
PUMP ASSEMBLY» .
(HR engine)FL-15, «FUEL LEVEL SENSOR
UNIT, FUEL FILTER AND FUEL PUMP
ASSEMBLY» .
(K9K engine)FL-29, «FUEL LEVEL SENSOR
UNIT» .

Input

B

C

—

21

B

Ground

—

—

—

0

22

B

Ground

—

—

—

0

23

B

Ground

—

—

—

0

24

G

Fuel level sensor ground

—

ON

—

0

27

LG

Power source (BAT)

Input

OFF

—

Battery voltage

28

W

Power source (IGN)

Input

ON

—

Battery voltage

D

E

F

G

H

I

J

DI

L

M

DI-9

COMBINATION METERS
Combination Meter Self-Diagnosis

BKS000ZL

PERFORMING SELF-DIAGNOSIS MODE
1.
2.

Turn the ignition switch ON.
Turn ignition switch OFF after setting the display to trip A or B
with the trip button (1).
Turn ON the ignition switch while pressing the trip button.
Release the trip button after 1second or more from the ignition
switch is turned ON. The sequence (A) is activated.

3.
4.

MKIB2321E

Check items

A

Display

Remarks

Segment test

All LCD segments are ON.

MKIB2322E

5.

After all segments are ON, press the trip button or clock switch within 20seconds the sequence (B to J) is
activated.
NOTE:
If either reset switch is not pressed within 20 seconds, the self-diagnosis mode is exited.
Check items

B

Display

Remarks

Work instruction code

This information is not used for service. Skip this step.

MKIB2323E

C

Software code

This information is not used for service. Skip this step.

MKIB2324E

D

EEPROM code

This information is not used for service. Skip this step.

MKIB2325E

DI-10

COMBINATION METERS
Check items

Display

Remarks

A

E

Hardware code

This information is not used for service. Skip this step.

B

C

MKIB2326E

D
F

PCB code

This information is not used for service. Skip this step.

E
MKIB2327E

G

Tachometer, speedometer and fuel level gauge have
sweeping movement test.
(The meter/gauges operate MIN. → MAX., MAX. → MIN.)
Water temperature warning/indicator lamp are ON with blue
color during the sweep movement.

Meter/gauge test
(Sweeping movement)

F

G

MKIB2327E

H
H

Error 1
(Bit 0 — Bit 3)

I
MKIB2328E

I

The segment of each bit displays “0” or “5” meaning no malfunction. If the bit(s) displays figures other than “0” or “5” the
item of the bit has malfunctioned.
For details, refer to DI-12, «Malfunction Chart for “Error 1”
and “Error E”» .

Error E
(Bit 4 — Bit 7)

DI

MKIB2329E

J

J

L

All warning lamp and indicator lamp which is control by
meter CPU are ON and odo/trip meter segment “FUEL”
flashes.

Warning lamp test

MKIB2330E

DI-11

M

COMBINATION METERS
Malfunction Chart for “Error 1” and “Error E”

MKIB2331E

Displayed figure on the
bit
Bit

0

1

2

3

4

5

Detectable items

Speedometer input signal

Tachometer input signal

Fuel level input signal

Description of the malfunction

No input signal
When no signal is detected for 2seconds minutes continuously
with the ignition ON, it should be judged as signal malfunction.

Malfunction
1

0

Unusual input signal
When invalid value is detected for 2seconds continuously with the
ignition switch ON, it should be judged as signal malfunction.

2

No input signal
When no signal is detected for 2seconds continuously with the
ignition ON, it should be judged as signal malfunction.

1

Short circuit
When short circuit of the signal line is detected for 120 seconds or
more, it should be judged as short-circuit malfunction.

1

2

Water temperature input
signal

Short circuit
When no signal is detected for 2seconds continuously with the
ignition ON, it should be judged as signal malfunction.

1

Odo/trip meter switch has
malfunctioned.

1

Reset buttons

Short circuit for reset buttons
When the short circuit is continuously detected for 5 minutes or
more, it should be judged as
short-circuit malfunction.

Clock switch has malfunctioned.

2

Both switch have malfunctioned.

3

When short circuit of the signal line is detected for 4 seconds or
more, it should be judged as short-circuit malfunction.

●

When no signal is detected for 2seconds continuously with the
ignition ON, it should be judged as signal malfunction.

●

When open circuit of the signal line is detected for 4 seconds or
more, it should be judged as open-circuit malfunction.

●

When unusual signal is detected for 2seconds continuously with
the ignition ON, it should be judged as signal malfunction.

OAT input signal

0

0

Open circuit
When open circuit of the signal line is detected for 120 seconds or
more, it should be judged as open-circuit malfunction.

●

No malfunction

0

0

1
5
2

6

—

—

0

0

7

—

—

0

0

DI-12

COMBINATION METERS
Trouble Diagnoses

BKS000ZM

A

PRELIMINARY CHECK

1. CHECK POWER SUPPLY
1. Turn ignition switch ON.
2. Warning lamps should illuminate (seat belt warning or door warning etc.).
Do warning lamps illuminate?
YES >> GO TO 2.
NO
>> Check power supply and ground circuit check. Refer to DI-15, «Check Power Supply and Ground
Circuit» .

2. CHECK OPERATION OF SELF-DIAGNOSIS MODE
Perform self-diagnosis mode. Refer to DI-10, «PERFORMING SELF-DIAGNOSIS MODE» .
Can self-diagnosis mode be activated?
YES >> GO TO 3.
NO
>> Replace combination meter. Refer to DI-20, «Removal and Installation for Combination Meter» .

B

C

D

E

F

3. CHECK OPERATION OF METER/GAUGE
Check meter/gauge operation in self-diagnosis mode (meter/gauge test). Refer to DI-10, «PERFORMING
SELF-DIAGNOSIS MODE» .
Is any malfunction indicated in self-diagnosis mode?
YES >> GO TO “Symptom Chart 1”. Refer to DI-15, «Symptom Chart 1» .
NO
>> GO TO 4.

4. CHECK WATER TEMPERATURE WARNING/INDICATOR

G

H

I

Check water temperature warning/indicator lamp.
1. Turn ignition switch OFF.
J
2. When turn ignition switch ON, water temperature warning/indicator lamp will be ON with red color for 1
second then blue color for 1 second.
●
Check water temperature indicator lamp (blue color)
DI
Check meter/gauge operation in self-diagnosis mode (meter/gauge test). Refer to DI-10, «Combination Meter
Self-Diagnosis» .
Does water temperature warning/lenticular lamp is ON?
L
Yes
>> GO TO 5.
No
>> Replace combination meter.
●

5. CHECK SEGMENTS

M

Check all odo/trip meter segments in self-diagnosis mode (odo/trip meter segment test). Refer to DI-10, «PERFORMING SELF-DIAGNOSIS MODE» .
Do all segments indicate?
YES >> GO TO 6.
NO
>> Replace combination meter.

6. CHECK INPUT SIGNALS
Check input signals from each sensors in self-diagnosis mode (Error 1 and Error E). Refer to DI-12, «Malfunction Chart for “Error 1” and “Error E”» .
OK or NG
OK
>> GO TO 7.
NG
>> GO TO “Symptom Chart 2”. Refer to DI-15, «Symptom Chart 2» .

DI-13

COMBINATION METERS

7. CHECK WARNING INDICATOR LAMP
Check warning lamp in self-diagnosis mode. Refer to DI-10, «PERFORMING SELF-DIAGNOSIS MODE» .
All warning/indicator lamp should turn ON.
OK or NG
OK
>> GO TO 8.
NG
>> Replace combination meter.

8. CHECK OTHER MALFUNCTION
Check each malfunction according to the instruction of the “SYMPTOM CHART 3”. Refer to DI-15, «Symptom
Chart 3» .
OK or NG
OK
>> Combination meter is OK.
NG
>> Check the case of malfunction.

DI-14

COMBINATION METERS
SYMPTOM CHART
Symptom Chart 1

A
Symptom

Possible causes

Repair order

Reference
page

B

Odo/trip meter indicates malfunction in Diagnosis mode.
Multiple meter/gauge indicate malfunction in Diagnosis mode.

Unified meter control unit

Replace combination meter

DI-20

C

One of speedometer/tachometer/fuel gauge/Water temperature lamp. indicates malfunction in Diagnosis mode.

Symptom Chart 2

D

Symptom

Possible causes

Repair order

Reference
page

Speedometer input signal indicates malfunction in
Diagnosis mode.

Speedometer input signal

Check signal for speedometer

DI-16

Tachometer input signal indicates malfunction in
Diagnosis mode.

Tachometer input signal

Check signal for tachometer

DI-17

Fuel level input signal indicates malfunction in Diagnosis mode.

Fuel level input signal

Check fuel level signal

DI-17

Water temperature input signal Indicates malfunction
in Diagnosis mode.

Water temp. warning/indicator lamps input signal

Check water temperature signal

DI-19

Reset buttons indicates malfunction in Diagnosis
mode.

Unified meter control unit

Combination meter

DI-20

CPU indicates malfunction in Diagnosis mode.

Unified meter control unit

Combination meter

DI-20

E

F

G

H

Symptom Chart 3
I
Symptom

Possible
causes

Fuel gauge pointer fluctuates, Indicator wrong value or varies.

—

Check the case of malfunction

DI-19

Fuel gauge does not move to “F” position.

—

Check the case of malfunction

DI-19

Repair order

Check Power Supply and Ground Circuit

Reference
page

BKS0026C

1. CHECK FUSE
Check for blown combination meter fuses.

J

DI

L

Power source

Fuse No.

Battery

7

Ignition switch ON or START

4

OK or NG
OK
>> GO TO 2.
NG
>> Be sure to eliminate cause of malfunction before installing new fuse. Refer toPG-4, «POWER
SUPPLY ROUTING CIRCUIT» .

DI-15

M

COMBINATION METERS

2. CHECK POWER SUPPLY CIRCUIT
Check voltage between combination meter harness connector terminals and ground.
Terminals

Ignition switch position

(+)
Combination meter
connector

Terminal
27

M27

(–)

Ground

OFF

ON

Battery voltage

Battery voltage

0V

Battery voltage

28

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

PKIC0700E

3. CHECK GROUND CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect combination meter connector.
Check continuity between combination meter harness connector terminals and ground.
Combination meter connector

Terminal

Continuity

21
M27

22

Ground

Yes

23

OK or NG
OK
>> Replace combination meter.
NG
>> Repair harness or connector.
PKIC0701E

Check Vehicle Speed Signal

BKS000ZO

1. CHECK ABS ACTUATOR AND ELECTRIC UNIT SYSTEM
Perform ABS actuator and electric unit (control unit) self-diagnosis. Refer to BRC-19, «CONSULT-II Functions
(ABS)» (With ABS models), BRC-62, «CONSULT-II Functions (ABS)» (With ESP/TCS/ABS models).
OK or NG
OK
>> Replace combination meter.
NG
>> Perform “Diagnostic procedure” for displayed self-diagnosis result.

DI-16

COMBINATION METERS
Check Engine Revolution Signal

BKS000ZP

1. CHECK ECM SYSTEM

A

Perform ECM self-diagnosis. Refer to EC-48, «Emission-related Diagnostic Information» (CR engine models
with EURO-OBD), EC-476, «Emission-related Diagnostic Information» (CR engine models without EUROOBD), EC-831, «Emission-related Diagnostic Information» (HR engine models with EURO-OBD), EC-1264,
«Emission-related Diagnostic Information» (HR engine models without EURO-OBD) or Rfer to EC-1628, «ON
BOARD DIAGNOSTIC (OBD) SYSTEM» (K9K engine models).
OK or NG
OK
>> Replace combination meter.
NG
>> Perform “Diagnostic procedure” for displayed DTC.

Check Fuel Level Sensor Signal

B

C

D

BKS0026D

Symptom:
●
Fuel gauge indication is malfunction.
●
Low-fuel warning lamp indication is irregular.
NOTE:
The following symptoms are not malfunction.
Fuel level sensor unit
●
Depending on vehicle position or driving circumstance, the fuel level in the tank varies, and the pointer
may fluctuate.
●
If the vehicle is fueled with the ignition switch ON, the pointer will move slowly.
Low-fuel warning lamp
●
Depending on vehicle position or driving circumstance, the fuel in the tank flows and the warning lamp ON
timing may change.

1. CHECK HARNESS CONNECTOR

E

F

G

H

I

1.
2.

Turn ignition switch OFF.
Check combination meter and fuel level sensor unit terminals (meter-side and harness-side) for poor con- J
nection.
OK or NG
DI
OK
>> GO TO 2.
NG
>> Repair or replace terminals or connectors.
L

M

DI-17

COMBINATION METERS

2. CHECK FUEL LEVEL SENSOR UNIT CIRCUIT
1.
2.

Disconnect combination meter connector and fuel level sensor unit connector.
Check continuity between combination meter harness connector and fuel level sensor unit and fuel pump
harness connector.
A

Combination
meter
connector
M27

3.

B

Terminal

Fuel level
sensor unit
and fuel
pump
connector

Terminal

6

B33

2

Continuity

Yes

Check continuity between combination meter harness connector
and ground.
PKIC0702E

A
Combination
meter
connector

Terminal

M27

6

Continuity

Ground

No

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

3. CHECK FUEL LEVEL SENSOR GROUND CIRCUIT
1.

Check continuity between combination meter harness connector and fuel level sensor unit and fuel pump
harness connector.
A

Combination
meter
connector
M27

2.

B

Terminal

Fuel level
sensor and
fuel pump
connector

Terminal

24

B33

4

Continuity

Yes

Check continuity between combination meter harness connector
(A) and ground.
A

PKIC0725E

Combination
meter
connector

Terminal

M27

24

Ground

Continuity

No

OK or NG
OK
>> GO TO 4.
NG
>> Repair harness or connector.

4. CHECK FUEL LEVEL SENSOR UNIT
Check fuel level sensor unit. Refer to DI-19, «Check Electrical Components»
OK or NG
OK
>> Check fuel level sensor unit installation, and check whether the float arm interferes or binds with
any of the internal components in the fuel tank. Repair or replace malfunctioning part, if necessary.
NG
>> Replace fuel level sensor unit.

DI-18

COMBINATION METERS
Check Water Temperature Warning/indicator Lamp

BKS000ZR

1. CHECK ECM SYSTEM

A

Perform ECM self-diagnosis. Refer to EC-48, «Emission-related Diagnostic Information» (CR engine models
with EURO-OBD), EC-476, «Emission-related Diagnostic Information» (CR engine models without EUROOBD), EC-831, «Emission-related Diagnostic Information» (HR engine models with EURO-OBD), EC-1264,
«Emission-related Diagnostic Information» (HR engine models without EURO-OBD) or Rfer to EC-1628, «ON
BOARD DIAGNOSTIC (OBD) SYSTEM» (K9K engine models).
OK or NG
OK
>> Replace combination meter.
NG
>> Perform “Diagnostic procedure” for displayed DTC.

Check Fuel Gauge Fluctuation

B

C

D

BKS000ZS

1. CHECK FUEL GAUGE FLUCTUATION

E

Test drive vehicle to see if gauge fluctuates only during driving or at the instant of stopping.
Does the indication value vary only during driving or at the instant of stopping?
YES >> The pointer fluctuation may be caused by fuel level change in the fuel tank. Condition is normal.
NO
>> Ask the customer about the situation when the symptom occurs in detail, and perform the trouble
diagnosis.

F

Fuel Gauge Does Not Move to FULL position

G

BKS000ZT

1. QUESTION 1
H

Does it take a long time for the pointer to move to FULL position?
YES or NO
YES >> GO TO 2.
NO
>> GO TO 3.

I

2. QUESTION 2
J
Was the vehicle fueled with the ignition switch ON?
YES or NO
YES >> Be sure to fuel the vehicle with the ignition switch OFF. Otherwise it will take a long time to move DI
to FULL position because of the characteristic of the fuel gauge.
NO
>> GO TO 3.

3. QUESTION 3

L

Is the floor or the vehicle inclined?
YES or NO
YES >> It may not be filled fully.
NO
>> GO TO 4.

M

4. QUESTION 4
During driving, does the fuel gauge pointer move gradually toward EMPTY position?
YES or NO
YES >> Check the components. Refer to DI-19, «Check Electrical Components» .
NO
>> The float arm may interfere or bind with any of the components in the fuel tank.

Check Electrical Components

BKS000ZV

CHECK FUEL LEVEL SENSOR UNIT
For removal, refer to [refer to FL-4, «FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY» (CR engine models), FL-15, «FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY» (HR engine models) or FL-29, «FUEL LEVEL SENSOR UNIT» (K9K engine models)].

DI-19

COMBINATION METERS
Check the resistance between terminals 2 and 4.
Ohmmeter
4

2

Float position

Resistance value

Full

Approx. 46

Empty

Approx. 320

[Ω]

MKIB0432E

Removal and Installation for Combination Meter

BKS000ZW

CAUTION:
Always replace with new* combination meter when the combination meter replacement is required.
*: New one means virgin control unit that has never been energized on-board.

REMOVAL
1.
2.

Remove the cluster lid A. Refer to IP-4, «INSTRUMENT PANEL
ASSEMBLY» .
Remove the screw (A), and metal clip (B), and remove combination meter (1).

PKIB7219J

INSTALLATION
●

Install in the reverse order of removal.

Disassembly and Assembly for Combination Meter

BKS000ZX

1. Front cover
2. Upper housing
3. Unified meter control unit assembly

PKIB7220J

DISASSEMBLY
1.
2.

Disengage the tabs (7) to separate upper housing.
Disengage the tabs (6) to separate front cover.

ASSEMBLY
Assembly is the reverse order of disassembly.

DI-20

DRIVE COMPUTER
DRIVE COMPUTER
Component Parts and Harness Connector Location

PFP:24859

A
BKS000ZY

B

C

D

E

F

G

H

I
MKIB2332E

1.

Combination meter M27

2.

Steering wheel switch M502

4.

Oil level sensor
F44: HR engine model
F126: K9K engine models

5.

Ambient sensor E17

3.

Fuel level sensor unit and fuel pump
B33

J

DI

System Description

BKS000ZZ

Refer to Owner′s Manual for drive computer operating instructions.

L

DRIVE COMPUTER
Drive computer can indicate the following item.
●
Odo
●
Trip A/B
●
Range
●
Average fuel consumption
●
Average speed
●
Journey time
●
Outside temp

M

DI-21

DRIVE COMPUTER
Indication can be changed by in the following order by pushing trip
button (1).
Odo → Trip A → Trip B → Range → Average fuel consumption →
Average speed → Journey time → Outside temp → Odo ······
NOTE:
●
Holding the switch for more than 1 second in each mode (except
odo range and outside temp), the function is reset.
●
Holding the switch for more than 3 seconds (the display flash
one time) in each mode (except odo, trip A, range and outside
temp), all mode are reset at the same time (except odo, trip A,
range and outside temp).

MKIB2321E

Range
●

●

The elapsed time indication provides driver with an estimation of the distance that can be driven before
refuelling. The range is conducted by fuel tank level sensor unit (fuel remaining), ECM pulse signal (fuel
consumption) and vehicle speed signal.
The range is conducted by combination meter and sent to CAN communication line. Combination meter
calculate the range by fuel level sensor unit (fuel remaining), ECM pulse signal (fuel consumption signal)
and vehicle speed signal.

Average Fuel Consumption
●

●
●

The average fuel economy is conducted by combination meter sent to CAN communication line. Combination meter calculate the average fuel economy by fuel consumption signal and vehicle speed signal.
There are two display types, instantaneous and average.
At about 0.5 km and for 30 seconds after resetting, the display shows “– – –”.

Average Speed
●
●

Average vehicle speed indication is conducted by trip distance and trip time.
At about 0.5 km and for 30 seconds after resetting, the display shows “– – –”.

Journey Time
●
●

Trip time is calculated by drive computer as elapsed time since last reset.
It only increases with ignition switch ON.

SERVICE REMINDER
Show the distance to the next maintenance.
For the first 5 seconds after ignition switch ON, the odometer displays distance to service and the maintenance symbol.
●
The interval can be changed.
NOTE:
Refer to owner’s manual for setting.
●
●

OIL LEVEL WARNING
The oil amount is shown on the display 5 to 10 seconds after the ignition is turn ON.
The display changes depending on the oil level.
–
Oil level LOW: “o– – – –”
–
Oil level HI: “ooooo”
●
The indicator flashes when the oil level drop below the limit level.
Combination meter read oil level sensor signal to measure oil level.
The signal is supplied
●
to combination meter terminal 36
●
through oil level sensor terminal 1 and 2
●
through combination meter terminal 37.
●
●

OUTSIDE AIR TEMPERATURE
Outside air temperature is displayed ON when ignition switch ON.

DI-22

DRIVE COMPUTER
When the outside air temperature is lower than -30°C or higher than 60°C the display shows. only “– –”
though it is operating. This is not a malfunction.
●
When the outside air temperature drops below freezing point (Approx. 3°C), it indicator as following. (Low
temperature warning)
–
Outside air temperature is 3°C — −30°C: “3°C” is flushed.
–
Outside air temperature is −30°C — −40°C: “– –°C” is flushed.
–
Outside air temperature is less than −40°C or more than 60°C: “– –” is flushed.
–
Outside air temperature is more than 4°C low temperature warning is canceled.
Combination meter should read ambient sensor.
The ambient sensor is regulated by a variable resistor signal supplied
●
to combination meter terminal 25
●
from ambient sensor terminal 2
●
through ambient sensor terminal 1 and
●
through combination meter terminal 26.
●

CAN Communication

A

B

C

D

E

BKS00100

SYSTEM DESCRIPTION

F

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

G

CAN Communication Unit

H

BKS00101

Refer to LAN-27, «CAN Communication Unit» .
I

J

DI

L

M

DI-23

DRIVE COMPUTER
Wiring Diagram — D/COMP —

BKS00102

MKWA4299E

DI-24

DRIVE COMPUTER
A

B

C

D

E

F

G

H

I

J

DI

L

M

MKWA4300E

DI-25

DRIVE COMPUTER
Terminals and Reference Value for Combination Meter

BKS00103

Condition
Terminal
No.

Wire
color

1

L

CAN- H

2

Y

CAN- L

6

BR

21

B

22

B

23

Signal
Input/Output

Item

Ignition
switch

Operation or condition

Voltage (V)
(Approx.)

Input/Output

—

—

—

Input/Output

—

—

—

Fuel level sensor signal

Refer to (CR engine)FL-4,
«FUEL LEVEL SENSOR UNIT,
FUEL FILTER AND FUEL
PUMP ASSEMBLY»
(HR engine)FL-15, «FUEL
LEVEL SENSOR UNIT, FUEL
FILTER AND FUEL PUMP
ASSEMBLY»
(K9K engine) FL-29, «FUEL
LEVEL SENSOR UNIT» .

Input

—

—

Ground

—

—

—

0

Ground

—

—

—

0

B

Ground

—

—

—

0

24

G

Fuel level sensor ground

—

ON

—

0

—

2.6

25

V

Ambient sensor signal

Input

ON

26

BR

Ambient sensor ground

—

ON

—

0

27

LG

Power source (BAT)

Input

OFF

—

Battery voltage

28

W

Power source (IGN)

Input

ON

—

Battery voltage

Steering switch release

10

29

G

Steering switch signal

Input

ON

Steering switch pushed

0

36

Y

Oil level sensor signal

Input

ON

—

—

37

G

Oil level sensor ground

—

ON

—

0

Disconnect ambient
sensor connector

Check Ambient Sensor Signal

5

BKS0026M

1. CHECK OUTPUT VOLTAGE OF COMBINATION METER
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect ambient sensor harness connector.
Turn ignition switch ON.
Check voltage between ambient sensor harness connector and ground.
Terminals
(+)

Ambient sensor
connector

Terminal

E17

2

(–)

Voltage (V)
(Approx.)

Ground

5

OK or NG
OK
>> GO TO 2.
NG
>> GO TO 4.
MKIB2333E

DI-26

DRIVE COMPUTER

2. CHECK AMBIENT SENSOR
1.
2.

A

Turn ignition switch OFF.
Check ambient sensor.
B

Ambient sensor connector

Terminals

E17

1

Temperature (°C)

Resistance (kΩ)

−15

12.73

−10

9.92

0

6.19

10

3.99

20

2.65

30

1.81

40

1.27

2

C

D

MKIB2335E

OK or NG
OK
>> GO TO 3.
NG
>> Replace ambient sensor.

F

3. CHECK AMBIENT SENSOR CIRCUIT (–)
1.
2.

H

B

Combination
meter
connector

Terminal

Ambient
sensor
connector

Terminal

M27

26

E17

1

3.

G

Disconnect combination meter connector.
Check continuity between combination meter harness connector and ambient sensor harness connector.
A

E

Continuity

I
Yes

J

Check continuity between combination meter harness connector
and ground.
A

Combination
meter
connector

Terminal

M27

26

Ground

Continuity

No

OK or NG
OK
>> Replace combination meter.
NG
>> Repair harness or connector.

MKIB2334E

DI

L

M

DI-27

DRIVE COMPUTER

4. CHECK AMBIENT SENSOR CIRCUIT (+)
1.
2.
3.

Turn ignition switch OFF.
Disconnect combination meter connector.
Check continuity between combination meter harness connector and ambient sensor harness connector.
A

B

Combination
meter
connector

Terminal

ambient
sensor
connector

Terminal

M27

25

E17

2

4.

Continuity

Yes

Check continuity between combination meter harness connector
and ground.
A

Combination
meter
connector

Terminal

M27

25

Continuity
Ground
No

OK or NG
OK
>> Replace combination meter.
NG
>> Repair harness or connector.

DI-28

MKIB2336E

DRIVE COMPUTER
Check Steering Wheel Switch

BKS00106

1. CHECK COMBINATION METER INPUT SIGNAL
1.
2.

A

Turn ignition switch ON.
Check voltage between combination meter harness connector and ground.

Connector
meter
connector

Terminal
(+)

Condition

(-)

B

Voltage (V)
(Approx.)

C

Battery voltage

D

Steering wheel switch is
pushed.
M27

29

Ground

Steering wheel switch is
released.

OK or NG
OK
>> Replace combination meter.
NG
>> GO TO 2.

E
MKIB2337E

2. CHECK STEERING WHEEL SWITCH

F

1.
2.
3.

G

Turn ignition switch OFF.
Disconnect steering wheel switch.
Check steering wheel switch (drive computer).

Steering
wheel
switch
connector

H
Terminal

M502

16

20

Condition

Continuity

Steering wheel switch is
pushed.

No

Steering wheel switch is
released.

Yes

OK or NG
OK
>> GO TO 3.
NG
>> Replace steering wheel switch.

I

J
MKIB2338E

DI

3. CHECK STEERING WHEEL SWITCH CIRCUIT
1.
2.

Disconnect combination meter connector.
Check continuity between combination meter harness connector and combination switch (spiral cable)
harness connector.
A

3.

B

Combination
meter
connector

Terminal

Combination
switch connector

Terminal

M27

29

M42

24

Continuity

Yes

Check continuity between combination meter harness connector
and ground.
A
Combination
meter
connector

Terminal

M27

29

Continuity
Ground
No

OK or NG
OK
>> GO TO 4.
NG
>> Replace harness or connector.

DI-29

MKIB2339E

L

M

DRIVE COMPUTER

4. CHECK STEERING WHEEL SWITCH GROUND CIRCUIT
1.
2.

Disconnect audio unit connector.
Check continuity between combination switch harness connector and audio unit harness connector.
A

3.

B

Combination
meter
connector

Terminal

Audio unit
connector

Terminal

M42

32

M45

12

Continuity

Yes

Check continuity between combination switch harness connector and ground.
A
Combination
switch
connector

Terminal

M42

32

Continuity

MKIB2340E

Ground
No

OK or NG
OK
>> Check audio unit ground circuit. Refer to PG-4, «POWER SUPPLY ROUTING CIRCUIT» .
NG
>> Repair harness or connector.

Check Oil Level sensor

BKS0026N

NOTE:
For engine oil level inspection, refer to LU-6, «ENGINE OIL» (CR engine models), LU-16, «ENGINE OIL» (HR
engine models), LU-23, «ENGINE OIL» (K9K engine models).

1. CHECK OIL LEVEL SENSOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect oil level sensor connector.
Check oil level sensor.
Oil level sensor

M44: HG engine models
F126: K9K engine models

Terminal
1

Resistance value (Ω)
2

3 – 20

OK or NG
OK
>> GO TO 2.
NG
>> Replace oil level sensor.

MKIB2343E

DI-30

DRIVE COMPUTER

2. CHECK OIL LEVEL SENSOR POWER SUPPLY CIRCUIT
1.
2.

A

Disconnect combination meter connector.
Check continuity between combination meter harness connector and oil level sensor harness connector.
B
A

Combination
meter
M27

3.

B
Terminal

Audio unit
connector

Terminal

36

M44: HG engine models
F126: K9K engine models

1

Continuity

C
Yes

Check continuity between combination meter harness connector
and ground.

D

A
Combination
meter

Terminal

M27

36

Continuity

Ground

MKIB2341E

No

E

F

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

G

3. CHECK OIL LEVEL SENSOR GROUND CIRCUIT
1.

Check continuity between combination meter harness connector and oil level sensor harness connector.
A

2.

H

B
Continuity

Combination
meter

Terminal

Audio unit connector

Terminal

M27

37

M44: HG engine models
F126: K9K engine models

2

I

Yes

J

Check continuity between combination meter harness connector
and ground.
A

DI
MKIB2342E

Continuity

Combination
meter

Terminal

M27

37

Ground

L
No

OK or NG
OK
>> Replace combination meter.
NG
>> Repair harness or connector.

M

DI-31

WARNING LAMPS
WARNING LAMPS
System Description

PFP:24814
BKS0026Z

OIL PRESSURE WARNING LAMP
Oil Pressure Warning
Oil pressure warning lamp turns ON when engine oil pressure reducing abnormally.
●
IPDM E/R reads oil pressure switch signal from oil pressure switch, and transmits the signal to combination meter with CAN communication.
●
Combination meter turns oil pressure warning lamp ON with received oil pressure switch signal.

SKIB4797E

Component Parts and Harness Connector Location

BKS00270

MKIB2344E

1.

Combination meter M27

2.

IPDM E/R E5, E12

DI-32

3.

Oil pressure switch
F23: CR engine models
F45: HR engine models
F137 K9K engine models

WARNING LAMPS
Schematic

BKS00271

A

B

C

D

E

F

G

H

I

J

DI

L

M

MKWA4301E

DI-33

WARNING LAMPS
Wiring Diagram — WARN — / With Gasoline Engine Models

BKS00272

MKWA4302E

DI-34

WARNING LAMPS
A

B

C

D

E

F

G

H

I

J

DI

L

M

MKWA4303E

DI-35

WARNING LAMPS

MKWA4304E

DI-36

WARNING LAMPS
A

B

C

D

E

F

G

H

I

J

DI

L

M

MKWA4305E

DI-37

WARNING LAMPS

MKWA4306E

DI-38

WARNING LAMPS
A

B

C

D

E

F

G

H

I

J

DI

L

M

MKWA4307E

DI-39

WARNING LAMPS
Wiring Diagram — WARN — / With Diesel Engine Models

BKS00273

MKWA4308E

DI-40

WARNING LAMPS
A

B

C

D

E

F

G

H

I

J

DI

L

M

MKWA4309E

DI-41

WARNING LAMPS

MKWA4310E

DI-42

WARNING LAMPS
A

B

C

D

E

F

G

H

I

J

DI

L

M

MKWA4311E

DI-43

WARNING LAMPS

MKWA4312E

DI-44

WARNING LAMPS
Oil Pressure Warning Lamp Stays Off (Ignition Switch ON)

BKS00274

1. CHECK IPDM SELF-DIAGNOSIS

A

1. Perform IPDM E/R self-diagnosis. Refer to PG-20, «CONSULT-II Function (IPDM E/R)» .
self-diagnostic results content
NON DTC IS DETECTED >>GO TO 2.
DTC IS DETECTED >>Check IPDM E/R. Refer to PG-33, «Inspection With CONSULT-II (Self-Diagnosis)» .

C

2. CHECK IPDM E/R INPUT SIGNAL
1.
2.
3.

Disconnect oil pressure switch.
Turn the ignition switch ON.
Check voltage between oil pressure switch harness connector and ground.

D

E

Terminals
(+)
Oil pressure switch
connector
F23: CR engine models
F45: HR engine models
F137: K9K engine models

B

Voltage (V)
(Approx.)

(-)

Terminal

F

1

Ground

Battery voltage

G

OK or NG
OK
>> Replace combination meter.
NG
>> GO TO 3.

MKIB2345E

H

3. CHECK OIL PRESSURE SWITCH
I

Check oil pressure switch. Refer to DI-47, «Electrical Components Inspection» .
OK or NG
OK
>> GO TO 4.
NG
>> Replace the oil pressure switch.

J

4. CHECK OIL PRESSURE SWITCH CIRCUIT
1.
2.

DI

Disconnect IPDM E/R connector and oil pressure switch connector.
Check continuity between IPDM E/R harness connector and oil pressure switch harness connector.
L
A

IPDM E/R
connector
E5

B
Continuity

Terminal

Oil pressure switch
connector

Terminal

66

F23: CR engine models
F45: HR engine models
F137: K9K engine models

1

M
Yes

OK or NG
OK
>> Replace IPDM E/R.
NG
>> Repair harness or connector.
MKIB2346E

DI-45

WARNING LAMPS
Oil Pressure Warning Lamp Does Not Turn Off (Oil Pressure Is Normal)

BKS00275

NOTE:
For oil pressure inspection, refer to LU-6, «ENGINE OIL» (CR engine models), LU-16, «ENGINE OIL» (HR
engine models) or LU-23, «ENGINE OIL» (K9K engine models).

1. CHECK OIL PRESSURE SWITCH INPUT
1.
2.
3.

Disconnect oil pressure switch.
Turn the ignition switch ON.
Check voltage between oil pressure switch harness connector and ground.
Terminals
(+)
Oil pressure switch
connector

(-)

Voltage (V)
(Approx.)

Ground

Battery voltage

Terminal

F23: CR engine models
F45: HR engine models
F137: K9K engine models

1

OK or NG
OK
>> GO TO 2.
NG
>> GO TO 3.

MKIB2345E

2. CHECK OIL PRESSURE SWITCH
Check oil pressure switch. Refer to DI-47, «OIL PRESSURE SWITCH CHECK» .
OK or NG
OK
>> Replace combination meter.
NG
>> Replace the oil pressure switch.

3. CHECK OIL PRESSURE SWITCH CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R connector.
Check continuity between IPDM E/R harness connector and ground.

IPDM E/R connector
E5

Terminal
66

Continuity
Ground

No

OK or NG
OK
>> Replace IPDM E/R.
NG
>> Repair harness or connector.

MKIB2347E

DI-46

WARNING LAMPS
Electrical Components Inspection

BKS00276

A

OIL PRESSURE SWITCH CHECK
Oil pressure
kPa (bar, kg/cm2 , psi)

Continuity

B

Engine running

More than 10 — 20 (0.10 0.20, 0.1 — 0.2, 1 — 3)

No

Engine not running

Less than 10 — 20 (0.10 0.20, 0.1 — 0.2, 1 — 3)

Yes

C

Check the continuity between the terminals of oil pressure switch
and body ground.

D
MEL425F

E

F

G

H

I

J

DI

L

M

DI-47

A/T INDICATOR
A/T INDICATOR
System Description

PFP:24814
BKS0026J

A/T position is displayed in the segment display in the combination meter.

FEATURE DESCRIPTION
When TCM detects output A/T position indicator signals (R-range, D-range, 2-range, and 1-range) from PNP
switch and A/T position indicator signals (P-range and N-range) input from combination meter, TCM sends A/
T position indicator signals to combination meter with the CAN communication. Combination meter indicates
received shift position.

PKIC0975E

DI-48

A/T INDICATOR
Wiring Diagram — AT/IND —

BKS0026K

A

B

C

D

E

F

G

H

I

J

DI

L

M

MKWA4380E

DI-49

A/T INDICATOR

MKWA4381E

DI-50

A/T INDICATOR
A/T Indicator Does Not Illuminate

BKS0026L

1. CHECK SEGMENT OF A/T INDICATOR

A

Perform self-diagnosis of combination meter. Refer to DI-10, «Combination Meter Self-Diagnosis» .
Are all segments displayed?
YES >> GO TO 2.
NO
>> Replace combination meter.

B

C

D
SKIB1206J

2. CHECK SELF-DIAGNOSIS RESULTS OF TCM
Perform self-diagnosis of TCM. Refer to AT-83, «CONSULT-II Function (A/T)» .
OK or NG
OK
>> Check TCM input/output signal. Repair of replace malfunctioning part, if necessary. Refer to AT80, «TCM Terminals and Reference Value» .
NG
>> Check applicable part, and repair or replace corresponding parts.

E

F

G

H

I

J

DI

L

M

DI-51

WARNING CHIME
WARNING CHIME
Component Parts and Harness Connector Location

PFP:24814
BKS0010E

MKIB2348E

1.

Combination meter M27

2.

BCM M57,M59

3.

Intelligent Key unit M60

4.

Combination switch M38

5.

Key and ignition knob switch M34
(With Intelligent Key system)

6.

Key switch M33
(Without Intelligent Key system)

7.

Parking break switch M55

8.

Front door switch
B14: LHD models
B29: RHD models

DI-52

WARNING CHIME
System Description

BKS0010F

The warning chime is controlled by the BCM.
The warning chime is located in the combination meter.

POWER SUPPLY AND GROUND CIRCUIT

A

B

Power is supplied at all times
●
through 40A fusible link (letter J , located in fuse and fusible link box)
●
to BCM terminals 74 and 79
●
through 10A fuse [No. 7, located in fuse block (J/B)]
●
to combination meter terminal 27
●
through 10A fuse [No. 9, located in the fuse block (J/B)]
●
to key switch terminal 2 (without Intelligent Key system)
●
through 10A fuse [No. 13, located in the fuse block (J/B)]
●
to key switch and ignition knob terminals 2 and 4 (with Intelligent Key system).
With ignition switch in ON or START position, power is supplied
●
through 10A fuse [No. 5, located in the fuse block (J/B)]
●
to BCM terminal 24.
●
through 10 A fuse [No. 4, located in the fuse block (J/B)]
●
to combination meter terminals 28
Ground is supplied
●
to BCM terminals 2 and 70, and
●
to combination meter terminals 21, 22 and 23,
●
through body grounds, M19 and M20.

IGNITION KEY WARNING CHIME

C

D

E

F

G

H

I
With the key in the ignition key cylinder, the ignition switch in OFF or ACC position, and the driver’s door open,
the warning chime will sound.
Power is supplied
J
●
through key switch terminal 2 (without Intelligent Key system) or
●
through key switch and ignition knob terminal 2 (with Intelligent Key system)
●
to BCM terminal 3.
DI
Ground is supplied
●
from front door switch LH (LHD models) or RH (RHD models) terminal 1
L
●
to BCM terminal 29.
Ground is supplied through the case of the front door switch LH (LHD models) or RH (RHD models).
BCM sends buzzer output signal to combination meter via CAN communication line.
M
When combination meter receives buzzer output signal, it sounds warning chime.

INTELLIGENT KEY SYSTEM WARNING CHIME
For information regarding Intelligent Key system, BL-135, «WARNING AND ALARM FUNCTION» .

LIGHT WARNING CHIME
With ignition switch OFF position, driver’s door open, and lighting switch in 1ST or 2ND position, warning
chime will sound. [Except when headlamp battery saver control operates (for 5 minutes after ignition switch is
turned to OFF or ACC position) and headlamps do not illuminate.]
Signal is supplied
●
from combination switch (lighting switch) terminals 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10
●
to BCM terminals 7, 8, 9, 13, 14, 15, 27, 28, 33 and 34
NOTE:
BCM detection lighting switch in 1st or 2nd position, refer to WW-8, «COMBINATION SWITCH READING
FUNCTION» .
Ground is supplied
●
from front door switch LH (LHD models) or RH (RHD models) terminal 1
●
to BCM terminal 29.

DI-53

WARNING CHIME
Ground is supplied through the case of the front door switch LH (LHD models) or RH (RHD models).
BCM sends buzzer output signal to combination meter via CAN communication line. when combination meter
receives buzzer output signal, it sounds warning chime.

SEAT BELT WARNING CHIME
Seat belt warning chime will sound for approximately 90 seconds, when vehicle speed becomes more than 25
km/h (16 MPH) with driver or passenger seat belt unfastened.
When driver side seat belt is unfastened, ground is supplied as signal
●
to combination meter terminal 9
●
through seat belt buckle switch (driver side) terminals 1 and 2
●
through grounds B13, B28, B38 and B48.
ABS actuator and electric unit (control unit) provides a vehicle speed signal to the combination meter.
Combination meter detects that driver or passenger seat belt is unfastened (seat belt buckle switch ON) and
vehicle speed more than 25 km/h (16 MPH). And then it sounds seat belt warning chime for 90 seconds.
NOTE:
Warning chime should be turned off under the following conditions.
●
Seat belt is fastened (seat belt buckle switch OFF)
●
90 seconds elapsed since warning chime start

PARKING BRAKE WARNING CHIME
Parking break warning chime will sound, when vehicle speed becomes more than 7 km/h with parking break
applied (parking break: ON) until parking break is released or vehicle speed become less than 3km/h.
When parking break is applied, ground is supplied as signal
●
to combination meter terminal 10
●
through parking break switch terminals 1 and ground part of parking break switch.

CAN Communication

BKS0010G

SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

CAN Communication Unit

BKS0010H

Refer to LAN-27, «CAN Communication Unit» .

DI-54

WARNING CHIME
Schematic

BKS0010I

A

B

C

D

E

F

G

H

I

J

DI

L

M

MKWA4313E

DI-55

WARNING CHIME
Wiring Diagram — CHIME —

BKS0010J

MKWA4314E

DI-56

WARNING CHIME
A

B

C

D

E

F

G

H

I

J

DI

L

M

MKWA4315E

DI-57

WARNING CHIME

MKWA4316E

DI-58

WARNING CHIME
A

B

C

D

E

F

G

H

I

J

DI

L

M

MKWA4317E

DI-59

WARNING CHIME
Terminals and Reference Value for BCM

BKS0010K

Condition
Terminal

Wire
color

2

B

3

GR
(O)

Key switch signal

7

BR

Combination switch
input 5

Output

8

L

Combination switch
input 3

Output

9

V

Combination switch
input 1

Output

27

GR

Combination switch
input 4

Output

G

Combination switch
input 2

Item
Ground

Signal Input/
Output

Ignition
switch

Measurement method

Voltage (V)
(Approx.)

—

ON

—

0

Input

OFF

key is withdrawn.
Key is inserted.

0
Battery voltage

—

SKIA2167J

28

13

SB

Combination switch
input 1

Output

15

P

W

Combination switch
input 3

Combination switch
input 5

19

L

CAN H

24

O

Power source (IGN)

OFF

●

Front wiper switch HI
(Wiper intermittent dial
position 4)

●

Rear wiper switch INT
(Wiper intermittent dial
position 4)

●

Wiper intermittent dial
position 1

Input

ON

14

●

Input

●

Wiper intermittent dial
position 2

●

Wiper intermittent dial
position 3

●

Wiper intermittent dial
position 6

●

Wiper intermittent dial
position 7

●

OFF

●

Lighting switch AUTO

●

Rear fog lamp switch

●

Front wiper switch
MIST

●

Front wiper switch INT

●

Front wiper switch LO

●

OFF

●

Lighting switch 1ST

●

Lighting switch 2ND

●

Lighting switch HIGH
beam
(Operates only HIGH
beam switch)

●

Turn signal switch to
right

Input

WW-20, «Reference Values for
BCM (Input)»

WW-20, «Reference Values for
BCM (Input)»

WW-20, «Reference Values for
BCM (Input)»

Input/Output

—

—

—

Input

ON

—

Battery voltage

DI-60

WARNING CHIME
Condition
Terminal

29

33

Wire
color
LG*1
2

BR*

R

Item

Front door switch
(driver side)

Combination switch
input 2

Signal Input/
Output

Input

Ignition
switch
OFF

34

Y

ON (open)

0

OFF (closed)
●

OFF

●

Front washer switch
(Wiper intermittent dial
position 4)

●

Rear wiper switch ON
(Wiper intermittent dial
position 4)

●

Rear washer switch
ON
(Wiper intermittent dial
position 4)

Input

ON

Combination switch
input 4

Measurement method

Input

●

Wiper intermittent dial
position 1

●

Wiper intermittent dial
position 5

●

Wiper intermittent dial
position 6

●

OFF

●

Front fog lamp switch
ON

●

Lighting switch 2ND

●

Lighting switch PASSING
(Operates only PASSING switch)

●

Voltage (V)
(Approx.)

Battery voltage

A

B

C

D

WW-20, «Reference Values for
BCM (Input)»

E

F

G

H

WW-20, «Reference Values for
BCM (Input)»

I

J

Turn signal switch to
left

39

Y

CAN L

Input/Output

—

—

—

70

B

Ground

—

ON

—

0

74

Y

Power source
(BAT)

Input

OFF

—

Battery voltage

79

Y

Power source
(BAT)

Input

OFF

—

Battery voltage

DI

L

M

(): Without Intelligent Key system
*1: LHD models
*2: RHD models

DI-61

WARNING CHIME
Terminals and Reference Value for Combination Meter

BKS0010L

Condition
Measurement method

Voltage (V)
(Approx.)

Input/Output

—

—

—

Input/Output

—

—

—

Seat belt buckle switch
(Driver side)

Input

ON

Unfastened.

0

Fastened.

Battery voltage

Parking brake switch

Input

Applied

0

Release

Battery voltage

Wire color

1

L

CAN H

2

Y

CAN L

9

10

L*1
O

*2

SB

Signal Input/
Output

Ignition
switch

Terminal

Item

ON

21

B

Ground

—

ON

—

0

22

B

Ground

—

ON

—

0

23

B

Ground

—

ON

—

0

27

LG

Battery power supply

Input

OFF

—

Battery voltage

28

W

Ignition switch
(ON or START)

Input

ON

—

Battery voltage

*1 : LHD models
*2 : RHD models

DI-62

WARNING CHIME
Trouble Diagnosis

BKS00277

HOW TO PERFORM TROUBLE DIAGNOSIS

A

1.
2.
3.
4.

B

5.
6.

Confirm the symptom and customer complaint.
Understand the outline of system. Refer to DI-53, «System Description» .
Perform the preliminary inspection. Refer to DI-63, «PRELIMINARY INSPECTION» .
Referring to trouble diagnosis chart, repair or replace the cause of the malfunction. Refer to DI-63,
«SYMPTOM CHART» .
Does warning chime system operate normally? If yes, GO TO 6. If not, GO TO 3.
INSPECTION END

PRELIMINARY INSPECTION

C

D

1. CHECK BCM (CONSULT-II)
Perform self-diagnosis of BCM. Refer to BCS-9, «CONSULT-II Function (BCM)» .
Self-diagnostic results
No malfunction detected>>INSPECTION END
Malfunction detected>>Check applicable parts, and repair or replace corresponding parts.

E

F

SYMPTOM CHART
Symptom

Diagnoses/Service procedure

Key reminder warning chime does
not operate.

Check key reminder system trouble diagnosis.
Refer to the following:
[LHD models]
BL-35, «Work Flow».
[RHD models]
BL-79, «Work Flow».

Intelligent Key system warning
chime does not operate. (With Intelligent Key)

Check Intelligent Key system trouble diagnosis.
Refer to BL-153, «Trouble Diagnosis Procedure» .

G

H

I

Check the following inspection.
Light warning chime does not activate.

J

●

WW-20, «Reference Values for BCM (Input)».

●

DI-63, «Check Front Door Switch (Driver Side) Signal».

Replace combination meter, found normal function in the above inspection.

DI

Check the following inspection.
Seat belt warning chime does not
activate.

●

Confirm speedometer operation

●

DI-64, «Check Seat Belt Buckle Switch Signal».

Parking brake warning chime does
not activate.

Check DI-66, «Check Parking Break Switch Signal» .
Replace combination meter, found normal function in the above inspection.

L

Replace combination meter, found normal function in the above inspection.

Check Front Door Switch (Driver Side) Signal

M
BKS00278

1. CHECK BCM INPUT SIGNAL
Check voltage between BCM harness connector and ground.
Terminal

BCM
connector

(+)

(-)

M57

29

Ground

Condition

Voltage (V)
(Approx.)

Driver side door: CLOSE

Battery voltage

Driver side door: OPEN

0

OK or NG
OK
>> Front door switch (driver side) signal is OK. Return to
DI-63, «SYMPTOM CHART» .
NG
>> GO TO 2.
MKIB2349E

DI-63

WARNING CHIME

2. CHECK FRONT DOOR SWITCH (DRIVER SIDE) CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector and front door switch (driver side) connector.
Check continuity between BCM harness connector and front door switch (driver side) harness connector.
A

4.

B

BCM
connector

Terminal

Front door
switch
(driver side)
connector

Terminal

M57

29

B14: LHD
B29: RHD

1

Continuity

Yes

Check continuity between BCM harness connector and ground.
A

MKIB2350E

Continuity

BCM
connector

Terminal

M57

29

Ground
No

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

3. CHECK FRONT DOOR SWITCH (DRIVER SIDE)
Check front door switch (driver side).
terminal
1

Door switch
case ground

Condition

Continuity

When door switch is released

Yes

When door switch is pressed

No

OK or NG
OK
>> Replace BCM.
NG
>> Replace front door switch (driver side).

MKIB2351E

Check Seat Belt Buckle Switch Signal

1. CHECK OPERATION OF SEAT BELT WARNING LAMP
1.
2.

Turn ignition switch ON.
Check operation of seat belt warning lamp.
When driver seat belt is fastened
When driver seat belt is unfastened

: Seat belt warning lamp OFF
: Seat belt warning lamp ON

OK or NG
OK
>> Seat belt buckle switch signal is OK. Return to DI-63, «SYMPTOM CHART» .
NG
>> GO TO 2.

DI-64

BKS00279

WARNING CHIME

2. CHECK COMBINATION METER INPUT SIGNAL

A

Check voltage between combination meter harness connector and ground.
Terminals

B

(+)
Combination
meter connector

Voltage (V)
(Approx.)

Condition

(–)
Terminal

M27

9

C
Ground

Driver seat belt is fastened

Battery voltage

Driver seat belt is
unfastened

D

0

OK or NG
OK
>> Replace combination meter.
NG
>> GO TO 3.

MKIB2352E

E

3. CHECK SEAT BELT BUCKLE SWITCH CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect combination meter connector and seat belt buckle switch (driver side) connector.
Check continuity between combination meter harness connector and seat belt buckle switch harness connector.
A

Combination
meter
connector

B
Terminal

Seat belt buckle
switch connector

9

B10 (LHD)
B25 (RHD)

H
Terminal

Continuity

1

Yes

Check harness continuity between combination meter harness
connector and ground.
A

J

MKIB2353E

Combination
meter
connector

Terminal

M27

9

Ground

DI

Continuity

L

No

OK or NG
OK
>> GO TO 4.
NG
>> Repair harness or connector.

M

4. CHECK SEAT BELT BUCKLE SWITCH
Check seat belt buckle switch.
terminal
1

G

I

M27

4.

F

Condition
2

Continuity

When seat belt is fastened

No

When seat belt is unfastened

Yes

OK or NG
OK
>> Check seat belt buckle switch (driver side) ground circuit.
NG
>> Replace seat belt buckle switch (driver side).
SKIB4805E

DI-65

WARNING CHIME
Check Parking Break Switch Signal

BKS0027B

1. CHECK OPERATION OF BREAK WARNING LAMP WARNING LAMP
1.
2.

Turn ignition switch ON.
Check operation of break warning lamp.
When parking break is applied
When parking break is released

: Break warning lamp ON
: Break warning lamp OFF

OK or NG
OK
>> Parking break switch signal is OK. Return to DI-63, «SYMPTOM CHART» .
NG
>> GO TO 2.

2. CHECK COMBINATION METER INPUT SIGNAL
Check voltage between combination meter harness connector and ground.
Terminals
(+)
Combination
meter connector

M27

Voltage (V)
(Approx.)

Condition

(–)
Terminal

10

Ground

Parking break is
applied

Battery voltage

Parking break is
released

0

OK or NG
OK
>> Replace combination meter.
NG
>> GO TO 3.

MKIB2354E

3. CHECK PARKING BREAK SWITCH CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect combination meter connector and parking break switch connector.
Check continuity between combination meter harness connector and parking break switch harness connector.
A

B

Combination
meter
connector

Terminal

Parking break
switch connector

Terminal

M27

10

M55

1

4.

Continuity

Yes

Check harness continuity between combination meter harness
connector and ground.
A
Combination
meter
connector

Terminal

M27

10

Ground

Continuity

No

OK or NG
OK
>> GO TO 4.
NG
>> Repair harness or connector.

DI-66

MKIB2355E

WARNING CHIME

4. CHECK PARKING BREAK SWITCH (DRIVER SIDE)

A

Check parking break switch.
Terminal
1

Ground part of parking
break switch

Condition

Continuity

Parking break is released

No

Parking break is applied

Yes

B

C

OK or NG
OK
>> Check parking break switch ground condition.
NG
>> Replace parking break switch.

D
MKIB2356E

E

F

G

H

I

J

DI

L

M

DI-67

WARNING CHIME

DI-68

ENGINE CONTROL SYSTEM

B ENGINE

SECTION

EC

ENGINE CONTROL SYSTEM

A

EC

C

D

CONTENTS
APPLICATION NOTICE …………………………………….. 21
How to Check Vehicle Type …………………………….. 21

CR (WITH EURO-OBD)
INDEX FOR DTC ……………………………………………… 22
DTC No. Index ………………………………………………. 22
Alphabetical Index ………………………………………….. 24
PRECAUTIONS ……………………………………………….. 26
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………. 26
Maintenance Information …………………………………. 26
PrecautionsforProcedureswithoutCowlTopCover… 26
On Board Diagnostic (OBD) System of Engine …… 26
Precaution …………………………………………………….. 27
PREPARATION ………………………………………………… 31
Special Service Tools ……………………………………… 31
Commercial Service Tools ……………………………….. 32
ENGINE CONTROL SYSTEM ……………………………. 33
System Diagram …………………………………………….. 33
Multiport Fuel Injection (MFI) System ……………….. 34
Electronic Ignition (EI) System …………………………. 36
Fuel Cut Control (at No Load and High Engine
Speed) ………………………………………………………….. 36
AIR CONDITIONING CUT CONTROL ………………… 38
Input/Output Signal Chart ………………………………… 38
CAN COMMUNICATION …………………………………… 39
System Description ………………………………………… 39
EVAPORATIVE EMISSION SYSTEM ………………….. 40
Description ……………………………………………………. 40
Component Inspection ……………………………………. 43
NATS (NISSAN ANTI-THEFT SYSTEM) ……………… 44
Description ……………………………………………………. 44
POSITIVE CRANKCASE VENTILATION …………….. 45
Description ……………………………………………………. 45
Component Inspection ……………………………………. 45
ON BOARD DIAGNOSTIC (OBD) SYSTEM ………… 47
Introduction …………………………………………………… 47
Two Trip Detection Logic …………………………………. 47

Emission-related Diagnostic Information ……………. 48
Malfunction Indicator (MI) ………………………………… 58
OBD System Operation Chart ………………………….. 61
BASIC SERVICE PROCEDURE …………………………. 66
Basic Inspection …………………………………………….. 66
Idle Speed Check …………………………………………… 69
Accelerator Pedal Released Position Learning …… 69
Throttle Valve Closed Position Learning …………….. 69
Idle Air Volume Learning …………………………………. 69
Fuel Pressure Check ………………………………………. 71
TROUBLE DIAGNOSIS …………………………………….. 74
Trouble Diagnosis Introduction …………………………. 74
DTC Inspection Priority Chart …………………………… 80
Fail-Safe Chart ………………………………………………. 81
Symptom Matrix Chart …………………………………….. 82
Engine Control Component Parts Location ………… 86
Vacuum Hose Drawing ……………………………………. 92
Circuit Diagram ………………………………………………. 93
ECM Harness Connector Terminal Layout …………. 95
ECM Terminals and Reference Value ………………… 95
CONSULT-II Function (ENGINE) …………………….. 102
Generic Scan Tool (GST) Function ……………………111
CONSULT-IIReferenceValueinDataMonitorMode
. 112
Major Sensor Reference Graph in Data Monitor
Mode …………………………………………………………… 115
TROUBLE DIAGNOSIS — SPECIFICATION VALUE. 117
Description …………………………………………………… 117
Testing Condition ………………………………………….. 117
Inspection Procedure …………………………………….. 117
Diagnostic Procedure ……………………………………. 118
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT …………………………………………………………….. 127
Description …………………………………………………… 127
Diagnostic Procedure ……………………………………. 127
POWER SUPPLY AND GROUND CIRCUIT ……….. 128
Wiring Diagram …………………………………………….. 128
Diagnostic Procedure ……………………………………. 129
Ground Inspection ………………………………………… 133

EC-1

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DTC U1001 CAN COMMUNICATION LINE ………… 134
Description …………………………………………………… 134
On Board Diagnosis Logic ……………………………… 134
DTC Confirmation Procedure …………………………. 134
Wiring Diagram …………………………………………….. 135
Diagnostic Procedure ……………………………………. 136
DTC U1010 CAN COMMUNICATION ………………… 137
Description …………………………………………………… 137
On Board Diagnosis Logic ……………………………… 137
DTC Confirmation Procedure …………………………. 137
Diagnostic Procedure ……………………………………. 138
DTC P0011 IVT CONTROL ………………………………. 139
Description …………………………………………………… 139
CONSULT-IIReferenceValueinDataMonitorMode
. 139
On Board Diagnosis Logic ……………………………… 140
DTC Confirmation Procedure …………………………. 140
Diagnostic Procedure ……………………………………. 141
Component Inspection …………………………………… 142
Removal and Installation ……………………………….. 142
DTC P0031, P0032 HO2S1 HEATER ………………… 143
Description …………………………………………………… 143
CONSULT-IIReferenceValueinDataMonitorMode
. 143
On Board Diagnosis Logic ……………………………… 143
DTC Confirmation Procedure …………………………. 144
Wiring Diagram …………………………………………….. 145
Diagnostic Procedure ……………………………………. 146
Component Inspection …………………………………… 148
Removal and Installation ……………………………….. 148
DTC P0037, P0038 HO2S2 HEATER ………………… 149
Description …………………………………………………… 149
CONSULT-IIReferenceValueinDataMonitorMode
. 149
On Board Diagnosis Logic ……………………………… 149
DTC Confirmation Procedure …………………………. 149
Wiring Diagram …………………………………………….. 151
Diagnostic Procedure ……………………………………. 152
Component Inspection …………………………………… 154
Removal and Installation ……………………………….. 154
DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR ………………………………………………. 155
Component Description …………………………………. 155
On Board Diagnosis Logic ……………………………… 155
DTC Confirmation Procedure …………………………. 155
Wiring Diagram …………………………………………….. 156
Diagnostic Procedure ……………………………………. 157
Component Inspection …………………………………… 159
Removal and Installation ……………………………….. 160
DTC P0112, P0113 IAT SENSOR ……………………… 161
Component Description …………………………………. 161
On Board Diagnosis Logic ……………………………… 161
DTC Confirmation Procedure …………………………. 162
Wiring Diagram …………………………………………….. 163
Diagnostic Procedure ……………………………………. 164
Component Inspection …………………………………… 165
Removal and Installation ……………………………….. 165
DTC P0117, P0118 ECT SENSOR …………………….. 166
Component Description …………………………………. 166

On Board Diagnosis Logic ……………………………… 166
DTC Confirmation Procedure ………………………….. 167
Wiring Diagram …………………………………………….. 168
Diagnostic Procedure …………………………………….. 169
Component Inspection ……………………………………170
Removal and Installation ………………………………… 170
DTC P0122, P0123 TP SENSOR ………………………. 171
Component Description …………………………………. 171
CONSULT-IIReferenceValueinDataMonitorMode
.171
On Board Diagnosis Logic ……………………………… 171
DTC Confirmation Procedure ………………………….. 172
Wiring Diagram …………………………………………….. 173
Diagnostic Procedure …………………………………….. 174
Component Inspection ……………………………………177
Removal and Installation ………………………………… 177
DTC P0132 HO2S1 …………………………………………. 178
Component Description …………………………………. 178
CONSULT-IIReferenceValueinDataMonitorMode
.178
On Board Diagnosis Logic ……………………………… 178
DTC Confirmation Procedure ………………………….. 179
Wiring Diagram …………………………………………….. 180
Diagnostic Procedure …………………………………….. 181
Component Inspection ……………………………………183
Removal and Installation ………………………………… 184
DTC P0133 HO2S1 …………………………………………. 185
Component Description …………………………………. 185
CONSULT-IIReferenceValueinDataMonitorMode
.185
On Board Diagnosis Logic ……………………………… 185
DTC Confirmation Procedure ………………………….. 186
Overall Function Check ………………………………….. 187
Wiring Diagram …………………………………………….. 188
Diagnostic Procedure …………………………………….. 189
Component Inspection ……………………………………193
Removal and Installation ………………………………… 194
DTC P0134 HO2S1 …………………………………………. 195
Component Description …………………………………. 195
CONSULT-IIReferenceValueinDataMonitorMode
.195
On Board Diagnosis Logic ……………………………… 195
DTC Confirmation Procedure ………………………….. 196
Overall Function Check ………………………………….. 197
Wiring Diagram …………………………………………….. 198
Diagnostic Procedure …………………………………….. 199
Component Inspection ……………………………………201
Removal and Installation ………………………………… 202
DTC P0138 HO2S2 …………………………………………. 203
Component Description …………………………………. 203
CONSULT-IIReferenceValueinDataMonitorMode
.203
On Board Diagnosis Logic ……………………………… 203
DTC Confirmation Procedure ………………………….. 204
Wiring Diagram …………………………………………….. 205
Diagnostic Procedure …………………………………….. 206
Component Inspection ……………………………………208
Removal and Installation ………………………………… 209

EC-2

DTC P0139 HO2S2 …………………………………………. 210
Component Description …………………………………. 210
CONSULT-IIReferenceValueinDataMonitorMode
. 210
On Board Diagnosis Logic …………………………….. 210
DTC Confirmation Procedure …………………………..211
Overall Function Check …………………………………. 212
Wiring Diagram ……………………………………………. 213
Diagnostic Procedure ……………………………………. 214
Component Inspection ………………………………….. 216
Removal and Installation ……………………………….. 217
DTCP0171FUELINJECTIONSYSTEMFUNCTION. 218
On Board Diagnosis Logic …………………………….. 218
DTC Confirmation Procedure …………………………. 218
Wiring Diagram ……………………………………………. 220
Diagnostic Procedure ……………………………………. 222
DTCP0172FUELINJECTIONSYSTEMFUNCTION. 226
On Board Diagnosis Logic …………………………….. 226
DTC Confirmation Procedure …………………………. 226
Wiring Diagram ……………………………………………. 228
Diagnostic Procedure ……………………………………. 230
DTC P0222, P0223 TP SENSOR ……………………… 233
Component Description …………………………………. 233
CONSULT-IIReferenceValueinDataMonitorMode
. 233
On Board Diagnosis Logic …………………………….. 233
DTC Confirmation Procedure …………………………. 234
Wiring Diagram ……………………………………………. 235
Diagnostic Procedure ……………………………………. 236
Component Inspection ………………………………….. 239
Removal and Installation ……………………………….. 239
DTC P0300 — P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 — 4 CYLINDER MISFIRE ………………… 240
On Board Diagnosis Logic …………………………….. 240
DTC Confirmation Procedure …………………………. 240
Diagnostic Procedure ……………………………………. 241
DTC P0327, P0328 KS ……………………………………. 246
Component Description …………………………………. 246
On Board Diagnosis Logic …………………………….. 246
DTC Confirmation Procedure …………………………. 246
Wiring Diagram ……………………………………………. 247
Diagnostic Procedure ……………………………………. 248
Component Inspection ………………………………….. 249
Removal and Installation ……………………………….. 249
DTC P0335 CKP SENSOR (POS) …………………….. 250
Component Description …………………………………. 250
CONSULT-IIReferenceValueinDataMonitorMode
. 250
On Board Diagnosis Logic …………………………….. 250
DTC Confirmation Procedure …………………………. 250
Wiring Diagram ……………………………………………. 252
Diagnostic Procedure ……………………………………. 254
Component Inspection ………………………………….. 256
Removal and Installation ……………………………….. 256
DTC P0340 CMP SENSOR (PHASE) ………………… 257
Component Description …………………………………. 257
On Board Diagnosis Logic …………………………….. 257
DTC Confirmation Procedure …………………………. 257
Wiring Diagram ……………………………………………. 259

Diagnostic Procedure ……………………………………. 260
Component Inspection …………………………………… 263
Removal and Installation ……………………………….. 263
DTC P0420 THREE WAY CATALYST FUNCTION. 264
On Board Diagnosis Logic ……………………………… 264
DTC Confirmation Procedure …………………………. 264
Overall Function Check …………………………………. 265
Diagnostic Procedure ……………………………………. 266
DTC P0444 EVAP CANISTER PURGE VOLUME
CONTROL SOLENOID VALVE …………………………. 270
Description …………………………………………………… 270
CONSULT-IIReferenceValueinDataMonitorMode
. 270
On Board Diagnosis Logic ……………………………… 270
DTC Confirmation Procedure …………………………. 271
Wiring Diagram …………………………………………….. 272
Diagnostic Procedure ……………………………………. 274
Component Inspection …………………………………… 275
Removal and Installation ……………………………….. 276
DTC P0500 VSS ……………………………………………… 277
Description …………………………………………………… 277
On Board Diagnosis Logic ……………………………… 277
DTC Confirmation Procedure …………………………. 277
Overall Function Check …………………………………. 278
Diagnostic Procedure ……………………………………. 278
DTC P0605 ECM …………………………………………….. 279
Component Description …………………………………. 279
On Board Diagnosis Logic ……………………………… 279
DTC Confirmation Procedure …………………………. 279
Diagnostic Procedure ……………………………………. 280
DTC P1065 ECM POWER SUPPLY ………………….. 282
Component Description …………………………………. 282
On Board Diagnosis Logic ……………………………… 282
DTC Confirmation Procedure …………………………. 282
Wiring Diagram …………………………………………….. 283
Diagnostic Procedure ……………………………………. 284
DTC P1111 IVT CONTROL SOLENOID VALVE ….. 286
Component Description …………………………………. 286
CONSULT-IIReferenceValueinDataMonitorMode
. 286
On Board Diagnosis Logic ……………………………… 286
DTC Confirmation Procedure …………………………. 286
Wiring Diagram …………………………………………….. 287
Diagnostic Procedure ……………………………………. 289
Component Inspection …………………………………… 290
Removal and Installation ……………………………….. 290
DTC P1121 ELECTRIC THROTTLE CONTROL
ACTUATOR ……………………………………………………. 291
Component Description …………………………………. 291
On Board Diagnosis Logic ……………………………… 291
DTC Confirmation Procedure …………………………. 291
Diagnostic Procedure ……………………………………. 292
DTC P1122 ELECTRIC THROTTLE CONTROL
FUNCTION …………………………………………………….. 293
Description …………………………………………………… 293
On Board Diagnosis Logic ……………………………… 293
DTC Confirmation Procedure …………………………. 293
Wiring Diagram …………………………………………….. 294
Diagnostic Procedure ……………………………………. 295

EC-3

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Component Inspection …………………………………… 298
Removal and Installation ……………………………….. 298
DTC P1124, P1126 THROTTLE CONTROL MOTOR
RELAY …………………………………………………………… 299
Component Description …………………………………. 299
CONSULT-IIReferenceValueinDataMonitorMode
. 299
On Board Diagnosis Logic ……………………………… 299
DTC Confirmation Procedure …………………………. 299
Wiring Diagram …………………………………………….. 301
Diagnostic Procedure ……………………………………. 302
DTC P1128 THROTTLE CONTROL MOTOR ……… 305
Component Description …………………………………. 305
On Board Diagnosis Logic ……………………………… 305
DTC Confirmation Procedure …………………………. 305
Wiring Diagram …………………………………………….. 306
Diagnostic Procedure ……………………………………. 307
Component Inspection …………………………………… 308
Removal and Installation ……………………………….. 309
DTC P1143 HO2S1 …………………………………………. 310
Component Description …………………………………. 310
CONSULT-IIReferenceValueinDataMonitorMode
. 310
On Board Diagnosis Logic ……………………………… 310
DTC Confirmation Procedure …………………………. 311
Overall Function Check …………………………………. 312
Diagnostic Procedure ……………………………………. 312
Component Inspection …………………………………… 314
Removal and Installation ……………………………….. 315
DTC P1144 HO2S1 …………………………………………. 316
Component Description …………………………………. 316
CONSULT-IIReferenceValueinDataMonitorMode
. 316
On Board Diagnosis Logic ……………………………… 316
DTC Confirmation Procedure …………………………. 317
Overall Function Check …………………………………. 318
Diagnostic Procedure ……………………………………. 318
Component Inspection …………………………………… 320
Removal and Installation ……………………………….. 321
DTC P1146 HO2S2 …………………………………………. 322
Component Description …………………………………. 322
CONSULT-IIReferenceValueinDataMonitorMode
. 322
On Board Diagnosis Logic ……………………………… 322
DTC Confirmation Procedure …………………………. 322
Overall Function Check …………………………………. 324
Wiring Diagram …………………………………………….. 325
Diagnostic Procedure ……………………………………. 326
Component Inspection …………………………………… 328
Removal and Installation ……………………………….. 329
DTC P1147 HO2S2 …………………………………………. 330
Component Description …………………………………. 330
CONSULT-IIReferenceValueinDataMonitorMode
. 330
On Board Diagnosis Logic ……………………………… 330
DTC Confirmation Procedure …………………………. 331
Overall Function Check …………………………………. 332
Wiring Diagram …………………………………………….. 333
Diagnostic Procedure ……………………………………. 334

Component Inspection ……………………………………336
Removal and Installation ………………………………… 337
DTC P1171 INTAKE ERROR ……………………………. 338
On Board Diagnosis Logic ……………………………… 338
DTC Confirmation Procedure ………………………….. 338
Wiring Diagram …………………………………………….. 339
Diagnostic Procedure …………………………………….. 340
DTC P1211 TCS CONTROL UNIT …………………….. 343
Description …………………………………………………… 343
On Board Diagnosis Logic ……………………………… 343
DTC Confirmation Procedure ………………………….. 343
Diagnostic Procedure …………………………………….. 343
DTC P1212 TCS COMMUNICATION LINE …………. 344
Description …………………………………………………… 344
On Board Diagnosis Logic ……………………………… 344
DTC Confirmation Procedure ………………………….. 344
Diagnostic Procedure …………………………………….. 344
DTC P1217 ENGINE OVER TEMPERATURE …….. 345
System Description ……………………………………….. 345
CONSULT-IIReferenceValueinDataMonitorMode
.346
On Board Diagnosis Logic ……………………………… 346
Overall Function Check ………………………………….. 347
Wiring Diagram …………………………………………….. 349
Diagnostic Procedure …………………………………….. 351
Main 12 Causes of Overheating ……………………… 357
Component Inspection ……………………………………358
DTC P1225 TP SENSOR …………………………………. 359
Component Description …………………………………. 359
On Board Diagnosis Logic ……………………………… 359
DTC Confirmation Procedure ………………………….. 359
Diagnostic Procedure …………………………………….. 360
Removal and Installation ………………………………… 360
DTC P1226 TP SENSOR …………………………………. 361
Component Description …………………………………. 361
On Board Diagnosis Logic ……………………………… 361
DTC Confirmation Procedure ………………………….. 361
Diagnostic Procedure …………………………………….. 362
Removal and Installation ………………………………… 362
DTC P1229 SENSOR POWER SUPPLY ……………. 363
On Board Diagnosis Logic ……………………………… 363
DTC Confirmation Procedure ………………………….. 363
Wiring Diagram …………………………………………….. 364
Diagnostic Procedure …………………………………….. 368
DTC P1706 PNP SWITCH ………………………………… 371
Component Description …………………………………. 371
CONSULT-IIReferenceValueinDataMonitorMode
.371
On Board Diagnosis Logic ……………………………… 371
DTC Confirmation Procedure ………………………….. 371
Overall Function Check ………………………………….. 372
Wiring Diagram …………………………………………….. 373
Diagnostic Procedure …………………………………….. 374
DTC P1805 BRAKE SWITCH …………………………… 377
Description …………………………………………………… 377
CONSULT-IIReferenceValueinDataMonitorMode
.377
On Board Diagnosis Logic ……………………………… 377
DTC Confirmation Procedure ………………………….. 377

EC-4

Wiring Diagram ……………………………………………. 379
Diagnostic Procedure ……………………………………. 380
Component Inspection ………………………………….. 382
DTC P2122, P2123 APP SENSOR …………………… 383
Component Description …………………………………. 383
CONSULT-IIReferenceValueinDataMonitorMode
. 383
On Board Diagnosis Logic …………………………….. 383
DTC Confirmation Procedure …………………………. 384
Wiring Diagram ……………………………………………. 385
Diagnostic Procedure ……………………………………. 388
Component Inspection ………………………………….. 390
Removal and Installation ……………………………….. 391
DTC P2127, P2128 APP SENSOR …………………… 392
Component Description …………………………………. 392
CONSULT-IIReferenceValueinDataMonitorMode
. 392
On Board Diagnosis Logic …………………………….. 392
DTC Confirmation Procedure …………………………. 393
Wiring Diagram ……………………………………………. 394
Diagnostic Procedure ……………………………………. 397
Component Inspection ………………………………….. 400
Removal and Installation ……………………………….. 401
DTC P2135 TP SENSOR …………………………………. 402
Component Description …………………………………. 402
CONSULT-IIReferenceValueinDataMonitorMode
. 402
On Board Diagnosis Logic …………………………….. 402
DTC Confirmation Procedure …………………………. 403
Wiring Diagram ……………………………………………. 404
Diagnostic Procedure ……………………………………. 405
Component Inspection ………………………………….. 408
Removal and Installation ……………………………….. 408
DTC P2138 APP SENSOR ………………………………. 409
Component Description …………………………………. 409
CONSULT-IIReferenceValueinDataMonitorMode
. 409
On Board Diagnosis Logic …………………………….. 409
DTC Confirmation Procedure …………………………. 410
Wiring Diagram ……………………………………………..411
Diagnostic Procedure ……………………………………. 414
Component Inspection ………………………………….. 418
Removal and Installation ……………………………….. 418
ELECTRICAL LOAD SIGNAL ………………………….. 419
Description ………………………………………………….. 419
CONSULT-IIReferenceValueinDataMonitorMode
. 419
Diagnostic Procedure ……………………………………. 419
FUEL INJECTOR ……………………………………………. 421
Component Description …………………………………. 421
CONSULT-IIReferenceValueinDataMonitorMode
. 421
Wiring Diagram ……………………………………………. 422
Diagnostic Procedure ……………………………………. 423
Component Inspection ………………………………….. 426
Removal and Installation ……………………………….. 426
FUEL PUMP ………………………………………………….. 427
Description ………………………………………………….. 427
CONSULT-IIReferenceValueinDataMonitorMode

. 427
Wiring Diagram …………………………………………….. 428
Diagnostic Procedure ……………………………………. 429
Component Inspection …………………………………… 431
Removal and Installation ……………………………….. 432
IGNITION SIGNAL ………………………………………….. 433
Component Description …………………………………. 433
Wiring Diagram …………………………………………….. 434
Diagnostic Procedure ……………………………………. 437
Component Inspection …………………………………… 441
Removal and Installation ……………………………….. 442
REFRIGERANT PRESSURE SENSOR ……………… 443
Component Description …………………………………. 443
Wiring Diagram …………………………………………….. 444
Diagnostic Procedure ……………………………………. 445
Removal and Installation ……………………………….. 447
MI & DATA LINK CONNECTORS ……………………… 448
Wiring Diagram …………………………………………….. 448
SERVICE DATA AND SPECIFICATIONS (SDS) …. 449
Fuel Pressure ………………………………………………. 449
Idle Speed …………………………………………………… 449
Calculated Load Value …………………………………… 449
Manifold Absolute Pressure Sensor ………………… 449
Intake Air Temperature Sensor ……………………….. 449
Engine Coolant Temperature Sensor ………………. 449
Knock Sensor ………………………………………………. 449
Crankshaft Position Sensor (POS) ………………….. 449
Camshaft Position Sensor (PHASE) ……………….. 449
Heated Oxygen Sensor 1 Heater ……………………. 449
Heated Oxygen Sensor 2 Heater ……………………. 449
Intake Valve Timing Control Solenoid Valve ……… 449
Throttle Control Motor ……………………………………. 450
Fuel Injector …………………………………………………. 450
Fuel Pump …………………………………………………… 450

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CR (WITHOUT EURO-OBD)
INDEX FOR DTC …………………………………………….. 451
DTC No. Index ……………………………………………… 451
Alphabetical Index ………………………………………… 453
PRECAUTIONS ……………………………………………… 455
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ……………………………………………………… 455
Maintenance Information ……………………………….. 455
Precautions forProcedureswithoutCowlTopCover. 455
On Board Diagnostic (OBD) System of Engine …. 455
Precaution …………………………………………………… 456
PREPARATION ………………………………………………. 460
Special Service Tools ……………………………………. 460
Commercial Service Tools ……………………………… 461
ENGINE CONTROL SYSTEM ………………………….. 462
System Diagram …………………………………………… 462
Multiport Fuel Injection (MFI) System ………………. 463
Electronic Ignition (EI) System ……………………….. 465
Fuel Cut Control (at No Load and High Engine
Speed) ………………………………………………………… 465
AIR CONDITIONING CUT CONTROL ……………….. 467
Input/Output Signal Chart ………………………………. 467

EC-5

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CAN COMMUNICATION ………………………………….. 468
System Description ……………………………………….. 468
EVAPORATIVE EMISSION SYSTEM ………………… 469
Description …………………………………………………… 469
Component Inspection …………………………………… 472
NATS (NISSAN ANTI-THEFT SYSTEM) ……………. 473
Description …………………………………………………… 473
POSITIVE CRANKCASE VENTILATION …………… 474
Description …………………………………………………… 474
Component Inspection …………………………………… 474
ON BOARD DIAGNOSTIC (OBD) SYSTEM ………. 476
Introduction ………………………………………………….. 476
Two Trip Detection Logic ……………………………….. 476
Emission-related Diagnostic Information ………….. 476
Malfunction Indicator (MI) ………………………………. 479
BASIC SERVICE PROCEDURE ……………………….. 483
Basic Inspection …………………………………………… 483
Idle Speed Check …………………………………………. 486
Accelerator Pedal Released Position Learning …. 486
Throttle Valve Closed Position Learning …………… 486
Idle Air Volume Learning ……………………………….. 486
Fuel Pressure Check …………………………………….. 488
TROUBLE DIAGNOSIS …………………………………… 491
Trouble Diagnosis Introduction ……………………….. 491
DTC Inspection Priority Chart …………………………. 497
Fail-Safe Chart …………………………………………….. 498
Symptom Matrix Chart …………………………………… 499
Engine Control Component Parts Location ………. 503
Vacuum Hose Drawing ………………………………….. 509
Circuit Diagram …………………………………………….. 510
ECM Harness Connector Terminal Layout ……….. 512
ECM Terminals and Reference Value ………………. 512
CONSULT-II Function (ENGINE) …………………….. 519
CONSULT-IIReferenceValueinDataMonitorMode
. 527
Major Sensor Reference Graph in Data Monitor
Mode …………………………………………………………… 530
TROUBLE DIAGNOSIS — SPECIFICATION VALUE. 532
Description …………………………………………………… 532
Testing Condition ………………………………………….. 532
Inspection Procedure …………………………………….. 532
Diagnostic Procedure ……………………………………. 533
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT …………………………………………………………….. 542
Description …………………………………………………… 542
Diagnostic Procedure ……………………………………. 542
POWER SUPPLY AND GROUND CIRCUIT ……….. 543
Wiring Diagram …………………………………………….. 543
Diagnostic Procedure ……………………………………. 544
Ground Inspection ………………………………………… 548
DTC U1001 CAN COMMUNICATION LINE ………… 549
Description …………………………………………………… 549
On Board Diagnosis Logic ……………………………… 549
DTC Confirmation Procedure …………………………. 549
Wiring Diagram …………………………………………….. 550
Diagnostic Procedure ……………………………………. 551
DTC U1010 CAN COMMUNICATION ………………… 552
Description …………………………………………………… 552
On Board Diagnosis Logic ……………………………… 552

DTC Confirmation Procedure ………………………….. 552
Diagnostic Procedure …………………………………….. 553
DTC P0011 IVT CONTROL ………………………………. 554
Description …………………………………………………… 554
CONSULT-IIReferenceValueinDataMonitorMode
.554
On Board Diagnosis Logic ……………………………… 555
DTC Confirmation Procedure ………………………….. 555
Overall Function Check ………………………………….. 556
Diagnostic Procedure …………………………………….. 556
Component Inspection ……………………………………557
Removal and Installation ………………………………… 558
DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR ………………………………………………. 559
Component Description …………………………………. 559
On Board Diagnosis Logic ……………………………… 559
DTC Confirmation Procedure ………………………….. 559
Wiring Diagram …………………………………………….. 560
Diagnostic Procedure …………………………………….. 561
Component Inspection ……………………………………563
Removal and Installation ………………………………… 564
DTC P0117, P0118 ECT SENSOR …………………….. 565
Component Description …………………………………. 565
On Board Diagnosis Logic ……………………………… 565
DTC Confirmation Procedure ………………………….. 566
Wiring Diagram …………………………………………….. 567
Diagnostic Procedure …………………………………….. 568
Component Inspection ……………………………………569
Removal and Installation ………………………………… 569
DTC P0122, P0123 TP SENSOR ………………………. 570
Component Description …………………………………. 570
CONSULT-IIReferenceValueinDataMonitorMode
.570
On Board Diagnosis Logic ……………………………… 570
DTC Confirmation Procedure ………………………….. 571
Wiring Diagram …………………………………………….. 572
Diagnostic Procedure …………………………………….. 573
Component Inspection ……………………………………576
Removal and Installation ………………………………… 576
DTC P0132 HO2S1 …………………………………………. 577
Component Description …………………………………. 577
CONSULT-IIReferenceValueinDataMonitorMode
.577
On Board Diagnosis Logic ……………………………… 577
DTC Confirmation Procedure ………………………….. 578
Wiring Diagram …………………………………………….. 579
Diagnostic Procedure …………………………………….. 580
Component Inspection ……………………………………582
Removal and Installation ………………………………… 583
DTC P0134 HO2S1 …………………………………………. 584
Component Description …………………………………. 584
CONSULT-IIReferenceValueinDataMonitorMode
.584
On Board Diagnosis Logic ……………………………… 584
Overall Function Check ………………………………….. 585
Wiring Diagram …………………………………………….. 586
Diagnostic Procedure …………………………………….. 587
Component Inspection ……………………………………589
Removal and Installation ………………………………… 590

EC-6

DTC P0138 HO2S2 …………………………………………. 591
Component Description …………………………………. 591
CONSULT-IIReferenceValueinDataMonitorMode
. 591
On Board Diagnosis Logic …………………………….. 591
DTC Confirmation Procedure …………………………. 591
Wiring Diagram ……………………………………………. 593
Diagnostic Procedure ……………………………………. 594
Component Inspection ………………………………….. 596
Removal and Installation ……………………………….. 597
DTC P0222, P0223 TP SENSOR ……………………… 598
Component Description …………………………………. 598
CONSULT-IIReferenceValueinDataMonitorMode
. 598
On Board Diagnosis Logic …………………………….. 598
DTC Confirmation Procedure …………………………. 598
Wiring Diagram ……………………………………………. 600
Diagnostic Procedure ……………………………………. 601
Component Inspection ………………………………….. 604
Removal and Installation ……………………………….. 604
DTC P0327, P0328 KS ……………………………………. 605
Component Description …………………………………. 605
On Board Diagnosis Logic …………………………….. 605
DTC Confirmation Procedure …………………………. 605
Wiring Diagram ……………………………………………. 606
Diagnostic Procedure ……………………………………. 607
Component Inspection ………………………………….. 608
Removal and Installation ……………………………….. 608
DTC P0335 CKP SENSOR (POS) …………………….. 609
Component Description …………………………………. 609
CONSULT-IIReferenceValueinDataMonitorMode
. 609
On Board Diagnosis Logic …………………………….. 609
DTC Confirmation Procedure …………………………. 609
Wiring Diagram ……………………………………………..611
Diagnostic Procedure ……………………………………. 613
Component Inspection ………………………………….. 615
Removal and Installation ……………………………….. 615
DTC P0340 CMP SENSOR (PHASE) ………………… 616
Component Description …………………………………. 616
On Board Diagnosis Logic …………………………….. 616
DTC Confirmation Procedure …………………………. 616
Wiring Diagram ……………………………………………. 618
Diagnostic Procedure ……………………………………. 619
Component Inspection ………………………………….. 622
Removal and Installation ……………………………….. 622
DTC P0605 ECM ……………………………………………. 623
Component Description …………………………………. 623
On Board Diagnosis Logic …………………………….. 623
DTC Confirmation Procedure …………………………. 623
Diagnostic Procedure ……………………………………. 625
DTC P1065 ECM POWER SUPPLY ………………….. 626
Component Description …………………………………. 626
On Board Diagnosis Logic …………………………….. 626
DTC Confirmation Procedure …………………………. 626
Wiring Diagram ……………………………………………. 627
Diagnostic Procedure ……………………………………. 628
DTC P1111 IVT CONTROL SOLENOID VALVE …. 630
Component Description …………………………………. 630

CONSULT-IIReferenceValueinDataMonitorMode
. 630
On Board Diagnosis Logic ……………………………… 630
DTC Confirmation Procedure …………………………. 630
Wiring Diagram …………………………………………….. 631
Diagnostic Procedure ……………………………………. 633
Component Inspection …………………………………… 634
Removal and Installation ……………………………….. 634
DTC P1121 ELECTRIC THROTTLE CONTROL
ACTUATOR ……………………………………………………. 635
Component Description …………………………………. 635
On Board Diagnosis Logic ……………………………… 635
DTC Confirmation Procedure …………………………. 635
Diagnostic Procedure ……………………………………. 636
DTC P1122 ELECTRIC THROTTLE CONTROL
FUNCTION …………………………………………………….. 637
Description …………………………………………………… 637
On Board Diagnosis Logic ……………………………… 637
DTC Confirmation Procedure …………………………. 637
Wiring Diagram …………………………………………….. 638
Diagnostic Procedure ……………………………………. 639
Component Inspection …………………………………… 642
Removal and Installation ……………………………….. 642
DTC P1124, P1126 THROTTLE CONTROL MOTOR
RELAY …………………………………………………………… 643
Component Description …………………………………. 643
CONSULT-IIReferenceValueinDataMonitorMode
. 643
On Board Diagnosis Logic ……………………………… 643
DTC Confirmation Procedure …………………………. 643
Wiring Diagram …………………………………………….. 645
Diagnostic Procedure ……………………………………. 646
DTC P1128 THROTTLE CONTROL MOTOR ……… 649
Component Description …………………………………. 649
On Board Diagnosis Logic ……………………………… 649
DTC Confirmation Procedure …………………………. 649
Wiring Diagram …………………………………………….. 650
Diagnostic Procedure ……………………………………. 651
Component Inspection …………………………………… 652
Removal and Installation ……………………………….. 653
DTC P1171 INTAKE ERROR ……………………………. 654
On Board Diagnosis Logic ……………………………… 654
DTC Confirmation Procedure …………………………. 654
Wiring Diagram …………………………………………….. 656
Diagnostic Procedure ……………………………………. 657
DTC P1211 TCS CONTROL UNIT …………………….. 660
Description …………………………………………………… 660
On Board Diagnosis Logic ……………………………… 660
DTC Confirmation Procedure …………………………. 660
Diagnostic Procedure ……………………………………. 660
DTC P1212 TCS COMMUNICATION LINE ………… 661
Description …………………………………………………… 661
On Board Diagnosis Logic ……………………………… 661
DTC Confirmation Procedure …………………………. 661
Diagnostic Procedure ……………………………………. 661
DTC P1217 ENGINE OVER TEMPERATURE …….. 662
System Description ……………………………………….. 662
CONSULT-IIReferenceValueinDataMonitorMode
. 663

EC-7

A

EC

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On Board Diagnosis Logic ……………………………… 663
Overall Function Check …………………………………. 664
Wiring Diagram …………………………………………….. 666
Diagnostic Procedure ……………………………………. 668
Main 12 Causes of Overheating ……………………… 674
Component Inspection …………………………………… 675
DTC P1225 TP SENSOR …………………………………. 676
Component Description …………………………………. 676
On Board Diagnosis Logic ……………………………… 676
DTC Confirmation Procedure …………………………. 676
Diagnostic Procedure ……………………………………. 677
Removal and Installation ……………………………….. 677
DTC P1226 TP SENSOR …………………………………. 678
Component Description …………………………………. 678
On Board Diagnosis Logic ……………………………… 678
DTC Confirmation Procedure …………………………. 678
Diagnostic Procedure ……………………………………. 679
Removal and Installation ……………………………….. 679
DTC P1229 SENSOR POWER SUPPLY ……………. 680
On Board Diagnosis Logic ……………………………… 680
DTC Confirmation Procedure …………………………. 680
Wiring Diagram …………………………………………….. 681
Diagnostic Procedure ……………………………………. 685
DTC P1706 PNP SWITCH ……………………………….. 688
Component Description …………………………………. 688
CONSULT-IIReferenceValueinDataMonitorMode
. 688
On Board Diagnosis Logic ……………………………… 688
Overall Function Check …………………………………. 688
Wiring Diagram …………………………………………….. 689
Diagnostic Procedure ……………………………………. 690
DTC P1805 BRAKE SWITCH …………………………… 693
Description …………………………………………………… 693
CONSULT-IIReferenceValueinDataMonitorMode
. 693
On Board Diagnosis Logic ……………………………… 693
DTC Confirmation Procedure …………………………. 693
Wiring Diagram …………………………………………….. 695
Diagnostic Procedure ……………………………………. 696
Component Inspection …………………………………… 698
DTC P2122, P2123 APP SENSOR ……………………. 699
Component Description …………………………………. 699
CONSULT-IIReferenceValueinDataMonitorMode
. 699
On Board Diagnosis Logic ……………………………… 699
DTC Confirmation Procedure …………………………. 699
Wiring Diagram …………………………………………….. 701
Diagnostic Procedure ……………………………………. 704
Component Inspection …………………………………… 706
Removal and Installation ……………………………….. 707
DTC P2127, P2128 APP SENSOR ……………………. 708
Component Description …………………………………. 708
CONSULT-IIReferenceValueinDataMonitorMode
. 708
On Board Diagnosis Logic ……………………………… 708
DTC Confirmation Procedure …………………………. 708
Wiring Diagram …………………………………………….. 710
Diagnostic Procedure ……………………………………. 713

Component Inspection ……………………………………716
Removal and Installation ………………………………… 717
DTC P2135 TP SENSOR …………………………………. 718
Component Description …………………………………. 718
CONSULT-IIReferenceValueinDataMonitorMode
.718
On Board Diagnosis Logic ……………………………… 718
DTC Confirmation Procedure ………………………….. 718
Wiring Diagram …………………………………………….. 720
Diagnostic Procedure …………………………………….. 721
Component Inspection ……………………………………724
Removal and Installation ………………………………… 724
DTC P2138 APP SENSOR ……………………………….. 725
Component Description …………………………………. 725
CONSULT-IIReferenceValueinDataMonitorMode
.725
On Board Diagnosis Logic ……………………………… 725
DTC Confirmation Procedure ………………………….. 726
Wiring Diagram …………………………………………….. 727
Diagnostic Procedure …………………………………….. 730
Component Inspection ……………………………………734
Removal and Installation ………………………………… 734
ELECTRICAL LOAD SIGNAL ………………………….. 735
Description …………………………………………………… 735
CONSULT-IIReferenceValueinDataMonitorMode
.735
Diagnostic Procedure …………………………………….. 735
EVAP CANISTER PURGE VOLUME CONTROL
SOLENOID VALVE ………………………………………….. 737
Description …………………………………………………… 737
CONSULT-IIReferenceValueinDataMonitorMode
.737
Wiring Diagram …………………………………………….. 738
Diagnostic Procedure …………………………………….. 740
Component Inspection ……………………………………743
Removal and Installation ………………………………… 743
FUEL INJECTOR …………………………………………….. 744
Component Description …………………………………. 744
CONSULT-IIReferenceValueinDataMonitorMode
.744
Wiring Diagram …………………………………………….. 745
Diagnostic Procedure …………………………………….. 746
Component Inspection ……………………………………749
Removal and Installation ………………………………… 749
FUEL PUMP …………………………………………………… 750
Description …………………………………………………… 750
CONSULT-IIReferenceValueinDataMonitorMode
.750
Wiring Diagram …………………………………………….. 751
Diagnostic Procedure …………………………………….. 752
Component Inspection ……………………………………754
Removal and Installation ………………………………… 755
HO2S1 …………………………………………………………… 756
Component Description …………………………………. 756
CONSULT-IIReferenceValueinDataMonitorMode
.756
Wiring Diagram …………………………………………….. 757
Diagnostic Procedure …………………………………….. 759

EC-8

Component Inspection ………………………………….. 760
Removal and Installation ……………………………….. 762
HO2S1 HEATER …………………………………………….. 763
Description ………………………………………………….. 763
CONSULT-IIReferenceValueinDataMonitorMode
. 763
Wiring Diagram ……………………………………………. 764
Diagnostic Procedure ……………………………………. 765
Component Inspection ………………………………….. 767
Removal and Installation ……………………………….. 767
HO2S2 ………………………………………………………….. 768
Component Description …………………………………. 768
CONSULT-IIReferenceValueinDataMonitorMode
. 768
Wiring Diagram ……………………………………………. 769
Diagnostic Procedure ……………………………………. 770
Component Inspection ………………………………….. 772
Removal and Installation ……………………………….. 773
HO2S2 HEATER …………………………………………….. 774
Description ………………………………………………….. 774
CONSULT-IIReferenceValueinDataMonitorMode
. 774
Wiring Diagram ……………………………………………. 775
Diagnostic Procedure ……………………………………. 776
Component Inspection ………………………………….. 778
Removal and Installation ……………………………….. 778
IAT SENSOR ………………………………………………….. 779
Component Description …………………………………. 779
Wiring Diagram ……………………………………………. 780
Diagnostic Procedure ……………………………………. 781
Component Inspection ………………………………….. 783
Removal and Installation ……………………………….. 783
IGNITION SIGNAL ………………………………………….. 784
Component Description …………………………………. 784
Wiring Diagram ……………………………………………. 785
Diagnostic Procedure ……………………………………. 788
Component Inspection ………………………………….. 792
Removal and Installation ……………………………….. 793
REFRIGERANT PRESSURE SENSOR …………….. 794
Component Description …………………………………. 794
Wiring Diagram ……………………………………………. 795
Diagnostic Procedure ……………………………………. 796
Removal and Installation ……………………………….. 798
VSS ………………………………………………………………. 799
Description ………………………………………………….. 799
Diagnostic Procedure ……………………………………. 799
MI & DATA LINK CONNECTORS …………………….. 800
Wiring Diagram ……………………………………………. 800
SERVICE DATA AND SPECIFICATIONS (SDS) …. 801
Fuel Pressure ………………………………………………. 801
Idle Speed …………………………………………………… 801
Manifold Absolute Pressure Sensor ………………… 801
Intake Air Temperature Sensor ………………………. 801
Engine Coolant Temperature Sensor ………………. 801
Knock Sensor ………………………………………………. 801
Crankshaft Position Sensor (POS) ………………….. 801
Camshaft Position Sensor (PHASE) ……………….. 801
Heated Oxygen Sensor 1 Heater ……………………. 801
Heated Oxygen Sensor 2 Heater ……………………. 801

Intake Valve Timing Control Solenoid Valve ……… 801
Throttle Control Motor ……………………………………. 801
Fuel Injector …………………………………………………. 801
Fuel Pump …………………………………………………… 802

A

EC

HR (WITH EURO-OBD)
INDEX FOR DTC …………………………………………….. 803
DTC No. Index ……………………………………………… 803
Alphabetical Index ………………………………………… 806
PRECAUTIONS ……………………………………………… 809
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ……………………………………………………… 809
Maintenance Information ……………………………….. 809
Precautions forProcedureswithoutCowlTopCover. 809
On Board Diagnostic (OBD) System of Engine and
A/T ……………………………………………………………… 809
Precaution …………………………………………………… 810
PREPARATION ………………………………………………. 814
Special Service Tools ……………………………………. 814
Commercial Service Tools ……………………………… 815
ENGINE CONTROL SYSTEM ………………………….. 816
System Diagram …………………………………………… 816
Multiport Fuel Injection (MFI) System ………………. 817
Electronic Ignition (EI) System ……………………….. 819
Fuel Cut Control (at No Load and High Engine
Speed) ………………………………………………………… 820
AIR CONDITIONING CUT CONTROL ……………….. 821
Input/Output Signal Chart ………………………………. 821
System Description ……………………………………….. 821
CAN COMMUNICATION ………………………………….. 822
System Description ……………………………………….. 822
EVAPORATIVE EMISSION SYSTEM ………………… 823
Description …………………………………………………… 823
Component Inspection …………………………………… 826
NATS (NISSAN ANTI-THEFT SYSTEM) ……………. 827
Description …………………………………………………… 827
POSITIVE CRANKCASE VENTILATION …………… 828
Description …………………………………………………… 828
Component Inspection …………………………………… 828
ON BOARD DIAGNOSTIC (OBD) SYSTEM ………. 830
Introduction ………………………………………………….. 830
Two Trip Detection Logic ……………………………….. 830
Emission-related Diagnostic Information ………….. 831
Malfunction Indicator (MI) ………………………………. 843
OBD System Operation Chart ………………………… 846
BASIC SERVICE PROCEDURE ……………………….. 851
Basic Inspection …………………………………………… 851
Idle Speed and Ignition Timing Check ……………… 856
Accelerator Pedal Released Position Learning …. 857
Throttle Valve Closed Position Learning …………… 857
Idle Air Volume Learning ……………………………….. 858
Fuel Pressure Check …………………………………….. 860
TROUBLE DIAGNOSIS …………………………………… 863
Trouble Diagnosis Introduction ……………………….. 863
DTC Inspection Priority Chart …………………………. 869
Fail-Safe Chart …………………………………………….. 870
Symptom Matrix Chart …………………………………… 871

EC-9

C

D

E

F

G

H

I

J

K

L

M

Engine Control Component Parts Location ………. 875
Vacuum Hose Drawing ………………………………….. 880
Circuit Diagram …………………………………………….. 881
ECM Harness Connector Terminal Layout ……….. 883
ECM Terminals and Reference Value ………………. 883
CONSULT-II Function (ENGINE) …………………….. 891
Generic Scan Tool (GST) Function ………………….. 900
CONSULT-II Reference Value in Data Monitor ….. 902
Major Sensor Reference Graph in Data Monitor
Mode …………………………………………………………… 905
TROUBLE DIAGNOSIS — SPECIFICATION VALUE. 907
Description …………………………………………………… 907
Testing Condition ………………………………………….. 907
Inspection Procedure …………………………………….. 907
Diagnostic Procedure ……………………………………. 908
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT …………………………………………………………….. 917
Description …………………………………………………… 917
Diagnostic Procedure ……………………………………. 917
POWER SUPPLY AND GROUND CIRCUIT ……….. 918
Wiring Diagram …………………………………………….. 918
Diagnostic Procedure ……………………………………. 919
Ground Inspection ………………………………………… 924
DTC U1000, U1001 CAN COMMUNICATION LINE. 925
Description …………………………………………………… 925
On Board Diagnosis Logic ……………………………… 925
DTC Confirmation Procedure …………………………. 925
Wiring Diagram …………………………………………….. 926
Diagnostic Procedure ……………………………………. 927
DTC U1010 CAN COMMUNICATION ………………… 928
Description …………………………………………………… 928
On Board Diagnosis Logic ……………………………… 928
DTC Confirmation Procedure …………………………. 928
Diagnostic Procedure ……………………………………. 929
DTC P0011 IVT CONTROL ………………………………. 930
Description …………………………………………………… 930
CONSULT-IIReferenceValueinDataMonitorMode
. 930
On Board Diagnosis Logic ……………………………… 931
DTC Confirmation Procedure …………………………. 931
Diagnostic Procedure ……………………………………. 932
Component Inspection …………………………………… 933
Removal and Installation ……………………………….. 934
DTC P0102, P0103 MAF SENSOR ……………………. 935
Component Description …………………………………. 935
CONSULT-IIReferenceValueinDataMonitorMode
. 935
On Board Diagnosis Logic ……………………………… 935
DTC Confirmation Procedure …………………………. 936
Wiring Diagram …………………………………………….. 937
Diagnostic Procedure ……………………………………. 938
Component Inspection …………………………………… 940
Removal and Installation ……………………………….. 941
DTC P0112, P0113 IAT SENSOR ……………………… 942
Component Description …………………………………. 942
On Board Diagnosis Logic ……………………………… 942
DTC Confirmation Procedure …………………………. 942
Wiring Diagram …………………………………………….. 944
Diagnostic Procedure ……………………………………. 945

Component Inspection ……………………………………946
Removal and Installation ………………………………… 946
DTC P0117, P0118 ECT SENSOR …………………….. 947
Component Description …………………………………. 947
On Board Diagnosis Logic ……………………………… 947
DTC Confirmation Procedure ………………………….. 948
Wiring Diagram …………………………………………….. 949
Diagnostic Procedure …………………………………….. 950
Component Inspection ……………………………………951
Removal and Installation ………………………………… 952
DTC P0122, P0123 TP SENSOR ………………………. 953
Component Description …………………………………. 953
CONSULT-IIReferenceValueinDataMonitorMode
.953
On Board Diagnosis Logic ……………………………… 953
DTC Confirmation Procedure ………………………….. 954
Wiring Diagram …………………………………………….. 955
Diagnostic Procedure …………………………………….. 956
Component Inspection ……………………………………958
Removal and Installation ………………………………… 958
DTC P0132 HO2S1 …………………………………………. 959
Component Description …………………………………. 959
CONSULT-IIReferenceValueinDataMonitorMode
.959
On Board Diagnosis Logic ……………………………… 959
DTC Confirmation Procedure ………………………….. 960
Wiring Diagram …………………………………………….. 961
Diagnostic Procedure …………………………………….. 962
Component Inspection ……………………………………965
Removal and Installation ………………………………… 966
DTC P0133 HO2S1 …………………………………………. 967
Component Description …………………………………. 967
CONSULT-IIReferenceValueinDataMonitorMode
.967
On Board Diagnosis Logic ……………………………… 967
DTC Confirmation Procedure ………………………….. 968
Overall Function Check ………………………………….. 969
Wiring Diagram …………………………………………….. 970
Diagnostic Procedure …………………………………….. 971
Component Inspection ……………………………………975
Removal and Installation ………………………………… 976
DTC P0134 HO2S1 …………………………………………. 977
Component Description …………………………………. 977
CONSULT-IIReferenceValueinDataMonitorMode
.977
On Board Diagnosis Logic ……………………………… 977
DTC Confirmation Procedure ………………………….. 978
Overall Function Check ………………………………….. 979
Wiring Diagram …………………………………………….. 980
Diagnostic Procedure …………………………………….. 981
Component Inspection ……………………………………983
Removal and Installation ………………………………… 984
DTC P0135 HO2S1 HEATER ……………………………. 985
Description …………………………………………………… 985
CONSULT-IIReferenceValueinDataMonitorMode
.985
On Board Diagnosis Logic ……………………………… 985
DTC Confirmation Procedure ………………………….. 986
Wiring Diagram …………………………………………….. 987

EC-10

Diagnostic Procedure ……………………………………. 988
Component Inspection ………………………………….. 990
Removal and Installation ……………………………….. 990
DTC P0138 HO2S2 …………………………………………. 991
Component Description …………………………………. 991
CONSULT-IIReferenceValueinDataMonitorMode
. 991
On Board Diagnosis Logic …………………………….. 991
DTC Confirmation Procedure …………………………. 992
Wiring Diagram ……………………………………………. 993
Diagnostic Procedure ……………………………………. 994
Component Inspection ………………………………….. 995
Removal and Installation ……………………………….. 997
DTC P0139 HO2S2 …………………………………………. 998
Component Description …………………………………. 998
CONSULT-IIReferenceValueinDataMonitorMode
. 998
On Board Diagnosis Logic …………………………….. 998
DTC Confirmation Procedure …………………………. 999
Overall Function Check …………………………………1000
Wiring Diagram ……………………………………………1001
Diagnostic Procedure ……………………………………1002
Component Inspection ………………………………….1004
Removal and Installation ……………………………….1005
DTC P0141 HO2S2 HEATER …………………………..1006
Description ………………………………………………….1006
CONSULT-IIReferenceValueinDataMonitorMode
1006
On Board Diagnosis Logic …………………………….1006
DTC Confirmation Procedure …………………………1007
Wiring Diagram ……………………………………………1008
Diagnostic Procedure ……………………………………1009
Component Inspection ………………………………….1011
Removal and Installation ……………………………….1011
DTCP0171FUELINJECTIONSYSTEMFUNCTION1012
On Board Diagnosis Logic …………………………….1012
DTC Confirmation Procedure …………………………1012
Wiring Diagram ……………………………………………1014
Diagnostic Procedure ……………………………………1016
DTCP0172FUELINJECTIONSYSTEMFUNCTION1019
On Board Diagnosis Logic …………………………….1019
DTC Confirmation Procedure …………………………1019
Wiring Diagram ……………………………………………1021
Diagnostic Procedure ……………………………………1023
DTC P0222, P0223 TP SENSOR ……………………..1026
Component Description …………………………………1026
CONSULT-IIReferenceValueinDataMonitorMode
1026
On Board Diagnosis Logic …………………………….1026
DTC Confirmation Procedure …………………………1027
Wiring Diagram ……………………………………………1028
Diagnostic Procedure ……………………………………1029
Component Inspection ………………………………….1031
Removal and Installation ……………………………….1031
DTC P0300 — P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 — 4 CYLINDER MISFIRE ………………..1032
On Board Diagnosis Logic …………………………….1032
DTC Confirmation Procedure …………………………1033
Diagnostic Procedure ……………………………………1033

DTC P0327, P0328 KS ……………………………………1038
Component Description …………………………………1038
On Board Diagnosis Logic ……………………………..1038
DTC Confirmation Procedure …………………………1038
Wiring Diagram …………………………………………….1039
Diagnostic Procedure ……………………………………1040
Component Inspection …………………………………..1041
Removal and Installation ……………………………….1041
DTC P0335 CKP SENSOR (POS) …………………….1042
Component Description …………………………………1042
CONSULT-IIReferenceValueinDataMonitorMode
1042
On Board Diagnosis Logic ……………………………..1042
DTC Confirmation Procedure …………………………1043
Wiring Diagram …………………………………………….1044
Diagnostic Procedure ……………………………………1046
Component Inspection …………………………………..1048
Removal and Installation ……………………………….1048
DTC P0340 CMP SENSOR (PHASE) ………………..1049
Component Description …………………………………1049
On Board Diagnosis Logic ……………………………..1049
DTC Confirmation Procedure …………………………1050
Wiring Diagram …………………………………………….1051
Diagnostic Procedure ……………………………………1052
Component Inspection …………………………………..1054
Removal and Installation ……………………………….1055
DTC P0420 THREE WAY CATALYST FUNCTION1056
On Board Diagnosis Logic ……………………………..1056
DTC Confirmation Procedure …………………………1056
Overall Function Check …………………………………1057
Diagnostic Procedure ……………………………………1059
DTC P0444 EVAP CANISTER PURGE VOLUME
CONTROL SOLENOID VALVE …………………………1063
Description …………………………………………………..1063
CONSULT-IIReferenceValueinDataMonitorMode
1063
On Board Diagnosis Logic ……………………………..1063
DTC Confirmation Procedure …………………………1064
Wiring Diagram …………………………………………….1065
Diagnostic Procedure ……………………………………1067
Component Inspection …………………………………..1068
Removal and Installation ……………………………….1069
DTC P0500 VSS ……………………………………………..1070
Description …………………………………………………..1070
On Board Diagnosis Logic ……………………………..1070
DTC Confirmation Procedure …………………………1070
Overall Function Check …………………………………1071
Diagnostic Procedure ……………………………………1071
DTC P0605 ECM …………………………………………….1072
Component Description …………………………………1072
On Board Diagnosis Logic ……………………………..1072
DTC Confirmation Procedure …………………………1072
Diagnostic Procedure ……………………………………1073
DTC P1065 ECM …………………………………………….1075
Component Description …………………………………1075
On Board Diagnosis Logic ……………………………..1075
DTC Confirmation Procedure …………………………1075
Diagnostic Procedure ……………………………………1076

EC-11

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EC

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DTC P1111 IVT CONTROL SOLENOID VALVE ….1077
Component Description …………………………………1077
CONSULT-IIReferenceValueinDataMonitorMode
1077
On Board Diagnosis Logic ……………………………..1077
DTC Confirmation Procedure …………………………1077
Wiring Diagram …………………………………………….1078
Diagnostic Procedure ……………………………………1080
Component Inspection …………………………………..1081
Removal and Installation ……………………………….1081
DTC P1121 ELECTRIC THROTTLE CONTROL
ACTUATOR ……………………………………………………1082
Component Description …………………………………1082
On Board Diagnosis Logic ……………………………..1082
DTC Confirmation Procedure …………………………1082
Diagnostic Procedure ……………………………………1083
Removal and Installation ……………………………….1083
DTC P1122 ELECTRIC THROTTLE CONTROL
FUNCTION …………………………………………………….1084
Description …………………………………………………..1084
On Board Diagnosis Logic ……………………………..1084
DTC Confirmation Procedure …………………………1084
Wiring Diagram …………………………………………….1085
Diagnostic Procedure ……………………………………1086
Component Inspection …………………………………..1089
Removal and Installation ……………………………….1089
DTC P1124, P1126 THROTTLE CONTROL MOTOR
RELAY …………………………………………………………..1090
Component Description …………………………………1090
CONSULT-IIReferenceValueinDataMonitorMode
1090
On Board Diagnosis Logic ……………………………..1090
DTC Confirmation Procedure …………………………1090
Wiring Diagram …………………………………………….1092
Diagnostic Procedure ……………………………………1093
DTC P1128 THROTTLE CONTROL MOTOR ……..1096
Component Description …………………………………1096
On Board Diagnosis Logic ……………………………..1096
DTC Confirmation Procedure …………………………1096
Wiring Diagram …………………………………………….1097
Diagnostic Procedure ……………………………………1098
Component Inspection …………………………………..1100
Removal and Installation ……………………………….1100
DTC P1143 HO2S1 …………………………………………1101
Component Description …………………………………1101
CONSULT-IIReferenceValueinDataMonitorMode
1101
On Board Diagnosis Logic ……………………………..1101
DTC Confirmation Procedure …………………………1102
Overall Function Check …………………………………1103
Diagnostic Procedure ……………………………………1103
Component Inspection …………………………………..1105
Removal and Installation ……………………………….1106
DTC P1144 HO2S1 …………………………………………1107
Component Description …………………………………1107
CONSULT-IIReferenceValueinDataMonitorMode
1107
On Board Diagnosis Logic ……………………………..1107
DTC Confirmation Procedure …………………………1108

Overall Function Check ………………………………….1109
Diagnostic Procedure …………………………………….1109
Component Inspection …………………………………..1111
Removal and Installation ………………………………..1112
DTC P1146 HO2S2 ………………………………………….1113
Component Description …………………………………1113
CONSULT-IIReferenceValueinDataMonitorMode
1113
On Board Diagnosis Logic ……………………………..1113
DTC Confirmation Procedure ………………………….1114
Overall Function Check ………………………………….1115
Wiring Diagram …………………………………………….1116
Diagnostic Procedure …………………………………….1117
Component Inspection …………………………………..1119
Removal and Installation ………………………………..1120
DTC P1147 HO2S2 ………………………………………….1121
Component Description …………………………………1121
CONSULT-IIReferenceValueinDataMonitorMode
1121
On Board Diagnosis Logic ……………………………..1121
DTC Confirmation Procedure ………………………….1122
Overall Function Check ………………………………….1123
Wiring Diagram …………………………………………….1124
Diagnostic Procedure …………………………………….1125
Component Inspection …………………………………..1127
Removal and Installation ………………………………..1128
DTC P1212 TCS COMMUNICATION LINE …………1129
Description …………………………………………………..1129
On Board Diagnosis Logic ……………………………..1129
DTC Confirmation Procedure ………………………….1129
Diagnostic Procedure …………………………………….1129
DTC P1217 ENGINE OVER TEMPERATURE …….1130
System Description ……………………………………….1130
CONSULT-IIReferenceValueinDataMonitorMode
1131
On Board Diagnosis Logic ……………………………..1131
Overall Function Check ………………………………….1132
Wiring Diagram …………………………………………….1135
Diagnostic Procedure …………………………………….1137
Main 12 Causes of Overheating ……………………..1144
Component Inspection …………………………………..1145
DTC P1225 TP SENSOR …………………………………1146
Component Description …………………………………1146
On Board Diagnosis Logic ……………………………..1146
DTC Confirmation Procedure ………………………….1146
Diagnostic Procedure …………………………………….1147
Removal and Installation ………………………………..1147
DTC P1226 TP SENSOR …………………………………1148
Component Description …………………………………1148
On Board Diagnosis Logic ……………………………..1148
DTC Confirmation Procedure ………………………….1148
Diagnostic Procedure …………………………………….1149
Removal and Installation ………………………………..1149
DTC P1229 SENSOR POWER SUPPLY ……………1150
On Board Diagnosis Logic ……………………………..1150
DTC Confirmation Procedure ………………………….1150
Wiring Diagram …………………………………………….1151
Diagnostic Procedure …………………………………….1155

EC-12

DTC P1706 PNP SWITCH ……………………………….1158
Component Description …………………………………1158
CONSULT-IIReferenceValueinDataMonitorMode
1158
On Board Diagnosis Logic …………………………….1158
DTC Confirmation Procedure …………………………1158
Overall Function Check …………………………………1159
Wiring Diagram ……………………………………………1160
Diagnostic Procedure ……………………………………1163
DTC P1805 BRAKE SWITCH ………………………….1167
Description ………………………………………………….1167
CONSULT-IIReferenceValueinDataMonitorMode
1167
On Board Diagnosis Logic …………………………….1167
FAIL-SAFE MODE ……………………………………….1167
DTC Confirmation Procedure …………………………1167
Wiring Diagram ……………………………………………1168
Diagnostic Procedure ……………………………………1169
Component Inspection ………………………………….1171
DTC P2122, P2123 APP SENSOR …………………..1172
Component Description …………………………………1172
CONSULT-IIReferenceValueinDataMonitorMode
1172
On Board Diagnosis Logic …………………………….1172
DTC Confirmation Procedure …………………………1173
Wiring Diagram ……………………………………………1174
Diagnostic Procedure ……………………………………1177
Component Inspection ………………………………….1180
Removal and Installation ……………………………….1180
DTC P2127, P2128 APP SENSOR …………………..1181
Component Description …………………………………1181
CONSULT-IIReferenceValueinDataMonitorMode
1181
On Board Diagnosis Logic …………………………….1181
DTC Confirmation Procedure …………………………1182
Wiring Diagram ……………………………………………1183
Diagnostic Procedure ……………………………………1187
Component Inspection ………………………………….1190
Removal and Installation ……………………………….1190
DTC P2135 TP SENSOR …………………………………1191
Component Description …………………………………1191
CONSULT-IIReferenceValueinDataMonitorMode
1191
On Board Diagnosis Logic …………………………….1191
DTC Confirmation Procedure …………………………1192
Wiring Diagram ……………………………………………1193
Diagnostic Procedure ……………………………………1194
Component Inspection ………………………………….1196
Removal and Installation ……………………………….1196
DTC P2138 APP SENSOR ………………………………1197
Component Description …………………………………1197
CONSULT-IIReferenceValueinDataMonitorMode
1197
On Board Diagnosis Logic …………………………….1197
DTC Confirmation Procedure …………………………1198
Wiring Diagram ……………………………………………1199
Diagnostic Procedure ……………………………………1203
Component Inspection ………………………………….1206
Removal and Installation ……………………………….1206

ELECTRICAL LOAD SIGNAL ………………………….1207
CONSULT-IIReferenceValueinDataMonitorMode
1207
Diagnostic Procedure ……………………………………1207
FUEL INJECTOR ……………………………………………1209
Component Description …………………………………1209
CONSULT-IIReferenceValueinDataMonitorMode
1209
Wiring Diagram …………………………………………….1210
Diagnostic Procedure ……………………………………1211
Component Inspection …………………………………..1214
Removal and Installation ……………………………….1214
FUEL PUMP …………………………………………………..1215
Description …………………………………………………..1215
CONSULT-IIReferenceValueinDataMonitorMode
1215
Wiring Diagram …………………………………………….1216
Diagnostic Procedure ……………………………………1217
Component Inspection …………………………………..1220
Removal and Installation ……………………………….1220
IGNITION SIGNAL ………………………………………….1221
Component Description …………………………………1221
Wiring Diagram …………………………………………….1222
Diagnostic Procedure ……………………………………1225
Component Inspection …………………………………..1229
Removal and Installation ……………………………….1230
REFRIGERANT PRESSURE SENSOR ……………..1231
Component Description …………………………………1231
Wiring Diagram …………………………………………….1232
Diagnostic Procedure ……………………………………1233
Removal and Installation ……………………………….1235
MI & DATA LINK CONNECTORS ……………………..1236
Wiring Diagram …………………………………………….1236
SERVICE DATA AND SPECIFICATIONS (SDS) …1237
Fuel Pressure ………………………………………………1237
Idle Speed and Ignition Timing ……………………….1237
Calculated Load Value …………………………………..1237
Mass Air Flow Sensor ……………………………………1237
Intake Air Temperature Sensor ……………………….1237
Engine Coolant Temperature Sensor ………………1237
Knock Sensor ………………………………………………1237
Heated Oxygen Sensor 1 Heater ……………………1237
Heated Oxygen sensor 2 Heater …………………….1237
Crankshaft Position Sensor (POS) ………………….1238
Camshaft Position Sensor (PHASE) ……………….1238
Intake Valve Timing Control Solenoid Valve ……..1238
Throttle Control Motor ……………………………………1238
Fuel Injector …………………………………………………1238
Fuel Pump …………………………………………………..1238

HR (WITHOUT EURO-OBD)
INDEX FOR DTC …………………………………………….1239
DTC No. Index ……………………………………………..1239
Alphabetical Index ………………………………………..1241
PRECAUTIONS ……………………………………………..1243
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ……………………………………………………..1243

EC-13

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Maintenance Information ……………………………….1243
Precautions for ProcedureswithoutCowlTopCover1243
On Board Diagnostic (OBD) System of Engine …1243
Precaution …………………………………………………..1244
PREPARATION ………………………………………………1248
Special Service Tools ……………………………………1248
Commercial Service Tools ……………………………..1249
ENGINE CONTROL SYSTEM ………………………….1250
System Diagram …………………………………………..1250
Multiport Fuel Injection (MFI) System ………………1251
Electronic Ignition (EI) System ……………………….1253
Fuel Cut Control (at No Load and High Engine
Speed) ………………………………………………………..1254
AIR CONDITIONING CUT CONTROL ……………….1255
Input/Output Signal Chart ………………………………1255
System Description ……………………………………….1255
CAN COMMUNICATION ………………………………….1256
System Description ……………………………………….1256
EVAPORATIVE EMISSION SYSTEM ………………..1257
Description …………………………………………………..1257
Component Inspection …………………………………..1260
NATS (NISSAN ANTI-THEFT SYSTEM) ……………1261
Description …………………………………………………..1261
POSITIVE CRANKCASE VENTILATION …………..1262
Description …………………………………………………..1262
Component Inspection …………………………………..1262
ON BOARD DIAGNOSTIC (OBD) SYSTEM ………1264
Introduction ………………………………………………….1264
Two Trip Detection Logic ……………………………….1264
Emission-related Diagnostic Information ………….1264
Malfunction Indicator (MI) ………………………………1268
BASIC SERVICE PROCEDURE ……………………….1272
Basic Inspection …………………………………………..1272
Idle Speed and Ignition Timing Check ……………..1277
Accelerator Pedal Released Position Learning …1278
Throttle Valve Closed Position Learning …………..1279
Idle Air Volume Learning ……………………………….1279
Fuel Pressure Check …………………………………….1281
TROUBLE DIAGNOSIS …………………………………..1284
Trouble Diagnosis Introduction ……………………….1284
DTC Inspection Priority Chart …………………………1290
Fail-Safe Chart …………………………………………….1291
Symptom Matrix Chart …………………………………..1292
Engine Control Component Parts Location ………1296
Vacuum Hose Drawing ………………………………….1301
Circuit Diagram …………………………………………….1302
ECM Harness Connector Terminal Layout ……….1304
ECM Terminals and Reference Value ………………1304
CONSULT-II Function (ENGINE) …………………….1312
CONSULT-II Reference Value in Data Monitor ….1321
Major Sensor Reference Graph in Data Monitor
Mode …………………………………………………………..1324
TROUBLE DIAGNOSIS — SPECIFICATION VALUE1326
Description …………………………………………………..1326
Testing Condition ………………………………………….1326
Inspection Procedure …………………………………….1326
Diagnostic Procedure ……………………………………1327
TROUBLE DIAGNOSIS FOR INTERMITTENT INCI-

DENT …………………………………………………………….1336
Description …………………………………………………..
1336
Diagnostic Procedure …………………………………….
1336
POWER SUPPLY AND GROUND CIRCUIT ……….1337
Wiring Diagram …………………………………………….1337
Diagnostic Procedure …………………………………….
1338
Ground Inspection …………………………………………
1342
DTC U1000, U1001 CAN COMMUNICATION LINE1344
Description …………………………………………………..
1344
On Board Diagnosis Logic ……………………………..1344
DTC Confirmation Procedure ………………………….
1344
Wiring Diagram …………………………………………….1345
Diagnostic Procedure …………………………………….
1346
DTC U1010 CAN COMMUNICATION ………………..1347
Description …………………………………………………..
1347
On Board Diagnosis Logic ……………………………..1347
DTC Confirmation Procedure ………………………….
1347
Diagnostic Procedure …………………………………….
1348
DTC P0011 IVT CONTROL ………………………………1349
Description …………………………………………………..
1349
CONSULT-IIReferenceValueinDataMonitorMode
1349
On Board Diagnosis Logic ……………………………..1350
DTC Confirmation Procedure ………………………….
1350
Overall Function Check ………………………………….
1351
Diagnostic Procedure …………………………………….
1352
Component Inspection …………………………………..
1353
Removal and Installation ………………………………..1353
DTC P0102, P0103 MAF SENSOR ……………………
1354
Component Description …………………………………
1354
CONSULT-IIReferenceValueinDataMonitorMode
1354
On Board Diagnosis Logic ……………………………..1354
DTC Confirmation Procedure ………………………….
1355
Wiring Diagram …………………………………………….1356
Diagnostic Procedure …………………………………….
1357
Component Inspection …………………………………..
1359
Removal and Installation ………………………………..1360
DTC P0117, P0118 ECT SENSOR …………………….
1361
Component Description …………………………………
1361
On Board Diagnosis Logic ……………………………..1361
DTC Confirmation Procedure ………………………….
1362
Wiring Diagram …………………………………………….1363
Diagnostic Procedure …………………………………….
1364
Component Inspection …………………………………..
1365
Removal and Installation ………………………………..1366
DTC P0122, P0123 TP SENSOR ………………………
1367
Component Description …………………………………
1367
CONSULT-IIReferenceValueinDataMonitorMode
1367
On Board Diagnosis Logic ……………………………..1367
DTC Confirmation Procedure ………………………….
1368
Wiring Diagram …………………………………………….1369
Diagnostic Procedure …………………………………….
1370
Component Inspection …………………………………..
1372
Removal and Installation ………………………………..1372
DTC P0132 HO2S1 …………………………………………
1373
Component Description …………………………………
1373
CONSULT-IIReferenceValueinDataMonitorMode

EC-14

1373
On Board Diagnosis Logic …………………………….1373
DTC Confirmation Procedure …………………………1374
Wiring Diagram ……………………………………………1375
Diagnostic Procedure ……………………………………1376
Component Inspection ………………………………….1379
Removal and Installation ……………………………….1380
DTC P0134 HO2S1 …………………………………………1381
Component Description …………………………………1381
CONSULT-IIReferenceValueinDataMonitorMode
1381
On Board Diagnosis Logic …………………………….1381
Overall Function Check …………………………………1382
Wiring Diagram ……………………………………………1383
Diagnostic Procedure ……………………………………1384
Component Inspection ………………………………….1385
Removal and Installation ……………………………….1387
DTC P0138 HO2S2 …………………………………………1388
Component Description …………………………………1388
CONSULT-IIReferenceValueinDataMonitorMode
1388
On Board Diagnosis Logic …………………………….1388
DTC Confirmation Procedure …………………………1389
Wiring Diagram ……………………………………………1390
Diagnostic Procedure ……………………………………1391
Component Inspection ………………………………….1392
Removal and Installation ……………………………….1394
DTC P0222, P0223 TP SENSOR ……………………..1395
Component Description …………………………………1395
CONSULT-IIReferenceValueinDataMonitorMode
1395
On Board Diagnosis Logic …………………………….1395
DTC Confirmation Procedure …………………………1396
Wiring Diagram ……………………………………………1397
Diagnostic Procedure ……………………………………1398
Component Inspection ………………………………….1400
Removal and Installation ……………………………….1400
DTC P0327, P0328 KS ……………………………………1401
Component Description …………………………………1401
On Board Diagnosis Logic …………………………….1401
DTC Confirmation Procedure …………………………1401
Wiring Diagram ……………………………………………1402
Diagnostic Procedure ……………………………………1403
Component Inspection ………………………………….1404
Removal and Installation ……………………………….1404
DTC P0335 CKP SENSOR (POS) …………………….1405
Component Description …………………………………1405
CONSULT-IIReferenceValueinDataMonitorMode
1405
On Board Diagnosis Logic …………………………….1405
DTC Confirmation Procedure …………………………1406
Wiring Diagram ……………………………………………1407
Diagnostic Procedure ……………………………………1409
Component Inspection ………………………………….1412
Removal and Installation ……………………………….1412
DTC P0340 CMP SENSOR (PHASE) ………………..1413
Component Description …………………………………1413
On Board Diagnosis Logic …………………………….1413
DTC Confirmation Procedure …………………………1414

Wiring Diagram …………………………………………….1415
Diagnostic Procedure ……………………………………1416
Component Inspection …………………………………..1418
Removal and Installation ……………………………….1419
DTC P0605 ECM …………………………………………….1420
Component Description …………………………………1420
On Board Diagnosis Logic ……………………………..1420
DTC Confirmation Procedure …………………………1420
Diagnostic Procedure ……………………………………1422
DTC P1065 ECM …………………………………………….1423
Component Description …………………………………1423
On Board Diagnosis Logic ……………………………..1423
DTC Confirmation Procedure …………………………1423
Diagnostic Procedure ……………………………………1424
DTC P1111 IVT CONTROL SOLENOID VALVE ….1425
Component Description …………………………………1425
CONSULT-IIReferenceValueinDataMonitorMode
1425
On Board Diagnosis Logic ……………………………..1425
DTC Confirmation Procedure …………………………1425
Wiring Diagram …………………………………………….1426
Diagnostic Procedure ……………………………………1428
Component Inspection …………………………………..1429
Removal and Installation ……………………………….1429
DTC P1121 ELECTRIC THROTTLE CONTROL
ACTUATOR ……………………………………………………1430
Component Description …………………………………1430
On Board Diagnosis Logic ……………………………..1430
DTC Confirmation Procedure …………………………1430
Diagnostic Procedure ……………………………………1431
Removal and Installation ……………………………….1432
DTC P1122 ELECTRIC THROTTLE CONTROL
FUNCTION …………………………………………………….1433
Description …………………………………………………..1433
On Board Diagnosis Logic ……………………………..1433
DTC Confirmation Procedure …………………………1433
Wiring Diagram …………………………………………….1434
Diagnostic Procedure ……………………………………1435
Component Inspection …………………………………..1438
Removal and Installation ……………………………….1438
DTC P1124, P1126 THROTTLE CONTROL MOTOR
RELAY …………………………………………………………..1439
Component Description …………………………………1439
CONSULT-IIReferenceValueinDataMonitorMode
1439
On Board Diagnosis Logic ……………………………..1439
DTC Confirmation Procedure …………………………1439
Wiring Diagram …………………………………………….1441
Diagnostic Procedure ……………………………………1442
DTC P1128 THROTTLE CONTROL MOTOR ……..1445
Component Description …………………………………1445
On Board Diagnosis Logic ……………………………..1445
DTC Confirmation Procedure …………………………1445
Wiring Diagram …………………………………………….1446
Diagnostic Procedure ……………………………………1447
Component Inspection …………………………………..1449
Removal and Installation ……………………………….1449
DTC P1212 TCS COMMUNICATION LINE ………..1450
Description …………………………………………………..1450

EC-15

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On Board Diagnosis Logic ……………………………..1450
DTC Confirmation Procedure …………………………1450
Diagnostic Procedure ……………………………………1450
DTC P1217 ENGINE OVER TEMPERATURE …….1451
System Description ……………………………………….1451
CONSULT-IIReferenceValueinDataMonitorMode
1452
On Board Diagnosis Logic ……………………………..1452
Overall Function Check …………………………………1453
Wiring Diagram …………………………………………….1456
Diagnostic Procedure ……………………………………1458
Main 12 Causes of Overheating ……………………..1465
Component Inspection …………………………………..1466
DTC P1225 TP SENSOR …………………………………1467
Component Description …………………………………1467
On Board Diagnosis Logic ……………………………..1467
DTC Confirmation Procedure …………………………1467
Diagnostic Procedure ……………………………………1468
Removal and Installation ……………………………….1468
DTC P1226 TP SENSOR …………………………………1469
Component Description …………………………………1469
On Board Diagnosis Logic ……………………………..1469
DTC Confirmation Procedure …………………………1469
Diagnostic Procedure ……………………………………1470
Removal and Installation ……………………………….1470
DTC P1229 SENSOR POWER SUPPLY ……………1471
On Board Diagnosis Logic ……………………………..1471
DTC Confirmation Procedure …………………………1471
Wiring Diagram …………………………………………….1472
Diagnostic Procedure ……………………………………1476
DTC P1706 PNP SWITCH ……………………………….1479
Component Description …………………………………1479
CONSULT-IIReferenceValueinDataMonitorMode
1479
On Board Diagnosis Logic ……………………………..1479
Overall Function Check …………………………………1479
Wiring Diagram …………………………………………….1480
Diagnostic Procedure ……………………………………1483
DTC P1805 BRAKE SWITCH …………………………..1487
Description …………………………………………………..1487
CONSULT-IIReferenceValueinDataMonitorMode
1487
On Board Diagnosis Logic ……………………………..1487
FAIL-SAFE MODE ………………………………………..1487
DTC Confirmation Procedure …………………………1487
Wiring Diagram …………………………………………….1488
Diagnostic Procedure ……………………………………1489
Component Inspection …………………………………..1491
DTC P2122, P2123 APP SENSOR ……………………1492
Component Description …………………………………1492
CONSULT-IIReferenceValueinDataMonitorMode
1492
On Board Diagnosis Logic ……………………………..1492
DTC Confirmation Procedure …………………………1493
Wiring Diagram …………………………………………….1494
Diagnostic Procedure ……………………………………1497
Component Inspection …………………………………..1499
Removal and Installation ……………………………….1500

DTC P2127, P2128 APP SENSOR ……………………
1501
Component Description …………………………………
1501
CONSULT-IIReferenceValueinDataMonitorMode
1501
On Board Diagnosis Logic ……………………………..1501
DTC Confirmation Procedure ………………………….
1502
Wiring Diagram …………………………………………….1503
Diagnostic Procedure …………………………………….
1507
Component Inspection …………………………………..
1509
Removal and Installation ………………………………..1510
DTC P2135 TP SENSOR …………………………………1511
Component Description …………………………………1511
CONSULT-IIReferenceValueinDataMonitorMode
1511
On Board Diagnosis Logic ……………………………..1511
DTC Confirmation Procedure ………………………….
1512
Wiring Diagram …………………………………………….1513
Diagnostic Procedure …………………………………….
1514
Component Inspection …………………………………..
1516
Removal and Installation ………………………………..1516
DTC P2138 APP SENSOR ……………………………….1517
Component Description …………………………………
1517
CONSULT-IIReferenceValueinDataMonitorMode
1517
On Board Diagnosis Logic ……………………………..1517
DTC Confirmation Procedure ………………………….
1518
Wiring Diagram …………………………………………….1519
Diagnostic Procedure …………………………………….
1523
Component Inspection …………………………………..
1527
Removal and Installation ………………………………..1527
ELECTRICAL LOAD SIGNAL ………………………….
1528
CONSULT-IIReferenceValueinDataMonitorMode
1528
Diagnostic Procedure …………………………………….
1528
EVAP CANISTER PURGE VOLUME CONTROL
SOLENOID VALVE ………………………………………….
1530
Description …………………………………………………..
1530
CONSULT-IIReferenceValueinDataMonitorMode
1530
Wiring Diagram …………………………………………….1531
Diagnostic Procedure …………………………………….
1533
Component Inspection …………………………………..
1536
Removal and Installation ………………………………..1536
FUEL INJECTOR …………………………………………….1537
Component Description …………………………………
1537
CONSULT-IIReferenceValueinDataMonitorMode
1537
Wiring Diagram …………………………………………….1538
Diagnostic Procedure …………………………………….
1539
Component Inspection …………………………………..
1542
Removal and Installation ………………………………..1542
FUEL PUMP …………………………………………………..
1543
Description …………………………………………………..
1543
CONSULT-IIReferenceValueinDataMonitorMode
1543
Wiring Diagram …………………………………………….1544
Diagnostic Procedure …………………………………….
1545
Component Inspection …………………………………..
1548
Removal and Installation ………………………………..1548

EC-16

HO2S1 ………………………………………………………….1549
Component Description …………………………………1549
CONSULT-IIReferenceValueinDataMonitorMode
1549
Wiring Diagram ……………………………………………1550
Diagnostic Procedure ……………………………………1552
Component Inspection ………………………………….1555
Removal and Installation ……………………………….1556
HO2S1 HEATER …………………………………………….1557
Description ………………………………………………….1557
CONSULT-IIReferenceValueinDataMonitorMode
1557
Wiring Diagram ……………………………………………1558
Diagnostic Procedure ……………………………………1560
Component Inspection ………………………………….1562
Removal and Installation ……………………………….1562
HO2S2 ………………………………………………………….1563
Component Description …………………………………1563
CONSULT-IIReferenceValueinDataMonitorMode
1563
Wiring Diagram ……………………………………………1564
Diagnostic Procedure ……………………………………1565
Component Inspection ………………………………….1567
Removal and Installation ……………………………….1568
HO2S2 HEATER …………………………………………….1569
Description ………………………………………………….1569
CONSULT-IIReferenceValueinDataMonitorMode
1569
Wiring Diagram ……………………………………………1570
Diagnostic Procedure ……………………………………1572
Component Inspection ………………………………….1574
Removal and Installation ……………………………….1574
IAT SENSOR ………………………………………………….1575
Component Description …………………………………1575
Wiring Diagram ……………………………………………1576
Diagnostic Procedure ……………………………………1577
Component Inspection ………………………………….1579
Removal and Installation ……………………………….1579
IGNITION SIGNAL ………………………………………….1580
Component Description …………………………………1580
Wiring Diagram ……………………………………………1581
Diagnostic Procedure ……………………………………1584
Component Inspection ………………………………….1588
Removal and Installation ……………………………….1589
REFRIGERANT PRESSURE SENSOR …………….1590
Component Description …………………………………1590
Wiring Diagram ……………………………………………1591
Diagnostic Procedure ……………………………………1592
Removal and Installation ……………………………….1594
VSS ………………………………………………………………1595
Description ………………………………………………….1595
Diagnostic Procedure ……………………………………1595
MI & DATA LINK CONNECTORS …………………….1596
Wiring Diagram ……………………………………………1596
SERVICE DATA AND SPECIFICATIONS (SDS) …1597
Fuel Pressure ………………………………………………1597
Idle Speed and Ignition Timing ……………………….1597
Mass Air Flow Sensor …………………………………..1597
Intake Air Temperature Sensor ………………………1597

Engine Coolant Temperature Sensor ………………1597
Knock Sensor ………………………………………………1597
Heated Oxygen Sensor 1 Heater ……………………1597
Heated Oxygen sensor 2 Heater …………………….1597
Crankshaft Position Sensor (POS) ………………….1597
Camshaft Position Sensor (PHASE) ……………….1597
Intake Valve Timing Control Solenoid Valve ……..1597
Throttle Control Motor ……………………………………1598
Fuel Injector …………………………………………………1598
Fuel Pump …………………………………………………..1598

K9K
INDEX FOR DTC …………………………………………….1599
DTC No. Index ……………………………………………..1599
Alphabetical Index ………………………………………..1601
PRECAUTIONS ……………………………………………..1603
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ……………………………………………………..1603
Maintenance Information ……………………………….1603
Precautions forProcedureswithoutCowlTopCover1603
On Board Diagnostic (OBD) System of Engine …1603
Precautions ………………………………………………….1604
Cleanliness ………………………………………………….1606
ENGINE CONTROL SYSTEM ………………………….1609
System Diagram …………………………………………..1609
Vacuum Hose Drawing ………………………………….1611
System Overview ………………………………………….1612
Fuel Injection Control …………………………………….1612
Functions Performed …………………………………….1613
Idle Speed Control ………………………………………..1616
Air Conditioning Control …………………………………1618
Pre/Postheating (Glow Plug) Control ……………….1619
Glow Plugs ………………………………………………….1620
Cooling Fan Control ………………………………………1620
Oil Vapour Rebreathing …………………………………1622
Exhaust Gas Recirculation (EGR) …………………..1622
CAN Communication …………………………………….1624
BASIC SERVICE PROCEDURE ……………………….1625
Fuel Filter …………………………………………………….1625
Injector Adjustment Value Registration …………….1625
Tightening The High Pressure Pipes ……………….1626
Checking Sealing After Repair ……………………….1626
Replacing ECM …………………………………………….1626
Replacing Fuel Injectors ………………………………..1627
ON BOARD DIAGNOSTIC (OBD) SYSTEM ………1628
Introduction ………………………………………………….1628
How to Erase DTC ………………………………………..1628
NATS (Nissan Anti-Theft System) …………………..1629
TROUBLE DIAGNOSIS …………………………………..1630
Trouble Diagnosis Introduction ……………………….1630
Trouble Diagnosis — Symptom ………………………..1634
Trouble Diagnosis — Basic Test Procedure ……….1660
Engine Control Component Parts Location ………1668
Wiring Diagram — ECM — …………………………….1671
ECM Harness Connector Terminal Layout ……….1673
ECM Terminals And Reference Value ……………..1673

EC-17

A

EC

C

D

E

F

G

H

I

J

K

L

M

Conformity Check …………………………………………1680
CONSULT-IIReferenceValueinDataMonitorMode
1694
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT …………………………………………………………….1697
Description …………………………………………………..1697
Diagnostic Procedure ……………………………………1697
POWER SUPPLY AND GROUND CIRCUIT ……….1698
Wiring Diagram …………………………………………….1698
Diagnostic Procedure ……………………………………1699
Ground Inspection ………………………………………..1703
DTC PC001 CAN COMMUNICATION LINE ……….1705
Description …………………………………………………..1705
On Board Diagnosis Logic ……………………………..1705
Wiring Diagram …………………………………………….1706
Diagnostic Procedure ……………………………………1707
DTC P0016 CKP — CMP CORRELATION …………..1708
On Board Diagnosis Logic ……………………………..1708
Diagnostic Procedure ……………………………………1708
DTC P0045 TC BOOST CONTROL SORENOID
VALVE …………………………………………………………..1710
Description …………………………………………………..1710
On Board Diagnosis Logic ……………………………..1710
Wiring Diagram …………………………………………….1711
Diagnostic Procedure ……………………………………1713
Component Inspection …………………………………..1714
DTC P0070 IAT SENSOR ………………………………..1715
Component Description …………………………………1715
On Board Diagnosis Logic ……………………………..1715
Wiring Diagram …………………………………………….1716
Diagnostic Procedure ……………………………………1717
Component Inspection …………………………………..1718
Removal and Installation ……………………………….1718
DTC P0087 FUEL SYSTEM ……………………………..1719
On Board Diagnosis Logic ……………………………..1719
Diagnostic Procedure ……………………………………1719
Removal and Installation ……………………………….1720
DTC P0089 FUEL PUMP …………………………………1721
On Board Diagnosis Logic ……………………………..1721
Diagnostic Procedure ……………………………………1721
Removal and Installation ……………………………….1721
DTC P0100 MAF SENSOR ………………………………1722
Component Description …………………………………1722
CONSULT-IIReferenceValueinDataMonitorMode
1722
On Board Diagnosis Logic ……………………………..1722
Wiring Diagram …………………………………………….1723
Diagnostic Procedure ……………………………………1724
Component Inspection …………………………………..1726
Removal and Installation ……………………………….1726
DTC P0115 ECT SENSOR ……………………………….1727
Description …………………………………………………..1727
On Board Diagnosis Logic ……………………………..1727
Wiring Diagram …………………………………………….1728
Diagnostic Procedure ……………………………………1729
Component Inspection …………………………………..1730
Removal and Installation ……………………………….1730
DTC P0170 FUEL INJECTOR ADJUSTMENT

VALUE …………………………………………………………..1731
On Board Diagnosis Logic ……………………………..1731
Diagnostic Procedure …………………………………….
1731
DTCP0180FUELPUMPTEMPERATURESENSOR
1732
Description …………………………………………………..
1732
CONSULT-IIReferenceValueinDataMonitorMode
1732
On Board Diagnosis Logic ……………………………..1732
Wiring Diagram …………………………………………….1733
Diagnostic Procedure …………………………………….
1734
Component Inspection …………………………………..
1735
Removal and Installation ………………………………..1735
DTC P0190 FRP SENSOR ……………………………….1736
CONSULT-IIReferenceValueinDataMonitorMode
1736
On Board Diagnosis Logic ……………………………..1736
Wiring Diagram …………………………………………….1737
Diagnostic Procedure …………………………………….
1738
Component Inspection …………………………………..
1739
Removal and Installation ………………………………..1739
DTC P0200 FUEL INJECTOR …………………………..1740
Component Description …………………………………
1740
CONSULT-IIReferenceValueinDataMonitorMode
1740
On Board Diagnosis Logic ……………………………..1740
Wiring Diagram …………………………………………….1741
Diagnostic Procedure …………………………………….
1743
Removal and Installation ………………………………..1744
DTC P0201 — P0204 FUEL INJECTOR ………………
1745
Component Description …………………………………
1745
CONSULT-IIReferenceValueinDataMonitorMode
1745
On Board Diagnosis Logic ……………………………..1745
Wiring Diagram …………………………………………….1746
Diagnostic Procedure …………………………………….
1747
Component Inspection …………………………………..
1750
Removal and Installation ………………………………..1750
DTC P0225 APP SENSOR ……………………………….1751
Description …………………………………………………..
1751
CONSULT-IIReferenceValueinDataMonitorMode
1751
On Board Diagnosis Logic ……………………………..1751
Wiring Diagram …………………………………………….1752
Diagnostic Procedure …………………………………….
1755
Component Inspection …………………………………..
1757
Removal and Installation ………………………………..1758
DTC P0231 FUEL PUMP …………………………………1759
Description …………………………………………………..
1759
CONSULT-IIReferenceValueinDataMonitorMode
1759
On Board Diagnosis Logic ……………………………..1759
Wiring Diagram …………………………………………….1760
Diagnostic Procedure …………………………………….
1761
Component Inspection …………………………………..
1762
Removal and Installation ………………………………..1762
DTC P0235 TC BOOST SENSOR …………………….1763
Component Description …………………………………
1763
CONSULT-IIReferenceValueinDataMonitorMode

EC-18

1763
On Board Diagnosis Logic …………………………….1763
Wiring Diagram ……………………………………………1764
Diagnostic Procedure ……………………………………1765
Removal and Installation ……………………………….1767
DTC P0263, P0266, P0269, P0272 NO.1 — 4 CYLINDER MISFIRE …………………………………………….1768
On Board Diagnosis Logic …………………………….1768
Diagnostic Procedure ……………………………………1769
DTC P0325 KNOCK SENSOR (KS) ………………….1770
Component Description …………………………………1770
On Board Diagnosis Logic …………………………….1770
Wiring Diagram ……………………………………………1771
Diagnostic Procedure ……………………………………1772
Removal and Installation ……………………………….1773
DTC P0335 CKP SENSOR ………………………………1774
Description ………………………………………………….1774
CONSULT-IIReferenceValueinDataMonitorMode
1774
On Board Diagnosis Logic …………………………….1774
Wiring Diagram ……………………………………………1775
Diagnostic Procedure ……………………………………1776
Component Inspection ………………………………….1777
Removal and Installation ……………………………….1777
DTC P0340 CMP SENSOR ……………………………..1778
Description ………………………………………………….1778
On Board Diagnosis Logic …………………………….1778
Wiring Diagram ……………………………………………1779
Diagnostic Procedure ……………………………………1780
Component Inspection ………………………………….1783
Removal and Installation ……………………………….1783
DTC P0380 GLOW CONTROL UNIT ………………..1784
On Board Diagnosis Logic …………………………….1784
Wiring Diagram ……………………………………………1785
Diagnostic Procedure ……………………………………1786
DTC P0382 GLOW CONTROL UNIT ………………..1788
On Board Diagnosis Logic …………………………….1788
Wiring Diagram ……………………………………………1789
Diagnostic Procedure ……………………………………1790
DTC P0400 EGR FUNCTION …………………………..1791
CONSULT-IIReferenceValueinDataMonitorMode
1791
On Board Diagnosis Logic …………………………….1791
Wiring Diagram ……………………………………………1792
Diagnostic Procedure ……………………………………1794
DTC P0403 EGR VOLUME CONTROL VALVE ….1795
CONSULT-IIReferenceValueinDataMonitorMode
1795
On Board Diagnosis Logic …………………………….1795
Wiring Diagram ……………………………………………1796
Diagnostic Procedure ……………………………………1798
Component Inspection ………………………………….1799
Removal and Installation ……………………………….1799
DTC P0409 EGRVOLUME CONTROL VALVE CONTROL POSITION SENSOR ……………………………..1800
CONSULT-IIReferenceValueinDataMonitorMode
1800
On Board Diagnosis Logic …………………………….1800
Wiring Diagram ……………………………………………1801

Diagnostic Procedure ……………………………………1803
Component Inspection …………………………………..1804
Removal and Installation ……………………………….1804
DTC P0487EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR ……………………………..1805
CONSULT-IIReferenceValueinDataMonitorMode
1805
On Board Diagnosis Logic ……………………………..1805
Wiring Diagram …………………………………………….1806
Diagnostic Procedure ……………………………………1808
Component Inspection …………………………………..1809
Removal and Installation ……………………………….1809
DTC P0500 VSS ……………………………………………..1810
Description …………………………………………………..1810
On Board Diagnosis Logic ……………………………..1810
Diagnostic Procedure ……………………………………1810
DTC P0530 REFRIGERANT PRESSURE SENSOR1811
Component Description …………………………………1811
CONSULT-IIReferenceValueinDataMonitorMode
1811
On Board Diagnosis Logic ……………………………..1811
Wiring Diagram …………………………………………….1812
Diagnostic Procedure ……………………………………1813
Removal and Installation ……………………………….1815
DTC P0560 BATTERY VOLTAGE …………………….1816
On Board Diagnosis Logic ……………………………..1816
Wiring Diagram …………………………………………….1817
Diagnostic Procedure ……………………………………1818
DTC P0571 BRAKE SWITCH …………………………..1820
Description …………………………………………………..1820
On Board Diagnosis Logic ……………………………..1820
Wiring Diagram …………………………………………….1821
Diagnostic Procedure ……………………………………1822
Component Inspection …………………………………..1824
DTC P0604 ECM …………………………………………….1825
Description …………………………………………………..1825
On Board Diagnosis Logic ……………………………..1825
Diagnostic Procedure ……………………………………1825
DTC P0606 ECM …………………………………………….1826
Description …………………………………………………..1826
On Board Diagnosis Logic ……………………………..1826
Diagnostic Procedure ……………………………………1826
DTC P062F ECM …………………………………………….1828
Description …………………………………………………..1828
On Board Diagnosis Logic ……………………………..1828
Diagnostic Procedure ……………………………………1828
DTC P0641 SENSOR POWER SUPPLY ……………1830
On Board Diagnosis Logic ……………………………..1830
Wiring Diagram …………………………………………….1831
Diagnostic Procedure ……………………………………1835
DTC P0651 APP SENSOR ………………………………1837
Description …………………………………………………..1837
CONSULT-IIReferenceValueinDataMonitorMode
1837
On Board Diagnosis Logic ……………………………..1837
Wiring Diagram …………………………………………….1838
Diagnostic Procedure ……………………………………1841
Component Inspection …………………………………..1843
Removal and Installation ……………………………….1844

EC-19

A

EC

C

D

E

F

G

H

I

J

K

L

M

DTC P0685 ECM RELAY …………………………………1845
On Board Diagnosis Logic ……………………………..1845
Wiring Diagram …………………………………………….1846
Diagnostic Procedure ……………………………………1847
DTC P0703 BRAKE SWITCH …………………………..1850
Description …………………………………………………..1850
On Board Diagnosis Logic ……………………………..1850
Wiring Diagram …………………………………………….1851
Diagnostic Procedure ……………………………………1852
Component Inspection …………………………………..1854
DTC P2120 APP SENSOR ………………………………1855
Description …………………………………………………..1855
CONSULT-IIReferenceValueinDataMonitorMode
1855
On Board Diagnosis Logic ……………………………..1855
Wiring Diagram …………………………………………….1856

Diagnostic Procedure …………………………………….
1859
Component Inspection …………………………………..
1861
Removal and Installation ………………………………..1862
DTC P2226 BARO SENSOR ……………………………
1863
Description …………………………………………………..
1863
On Board Diagnosis Logic ……………………………..1863
Diagnostic Procedure …………………………………….
1863
COOLING FAN ……………………………………………….1864
System Description ……………………………………….
1864
Wiring Diagram …………………………………………….1866
Diagnostic Procedure …………………………………….
1867
Component Inspection …………………………………..
1868
MI & DATA LINK CONNECTORS ……………………..1869
Wiring Diagram …………………………………………….1869
SERVICE DATA AND SPECIFICATIONS (SDS) …
1870
…………………………………………………………………..1870

EC-20

APPLICATION NOTICE
APPLICATION NOTICE
How to Check Vehicle Type

PFP:00000

A
BBS002T8

CR ENGINE AND HR ENGINE
Check the Euro-OBD (E-OBD) discrimination of the vehicle (refer to GI-45, «IDENTIFICATION INFORMA- EC
TION» ) to confirm the service information in EC section.

K9K ENGINE
Confirm K9K engine type with “Model” written on the “IDENTIFICATION PLATE” (Refe to GI-45, «IDENTIFICATION INFORMATION» ), then refer to service information in EC section.
Vehicle type

C

Engine type

xTKxxxxE11xxE

50kw

xTKxxxxE11xxA

63kw

D

E

F

G

H

I

J

K

L

M

EC-21

INDEX FOR DTC
[CR (WITH EURO-OBD)]

INDEX FOR DTC
DTC No. Index
[CR (WITH EURO-OBD)]

PFP:00024
BBS002TA

NOTE:
●
If DTC U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1001. Refer
to EC-134, «DTC U1001 CAN COMMUNICATION LINE» .
●
If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer
to EC-137, «DTC U1010 CAN COMMUNICATION» .
DTC*1
CONSULT-II
2

GST*

ECM*3

Items
(CONSULT-II screen terms)

Reference page

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

EC-59

1001*5

CAN COMM CIRCUIT

EC-134

U1010

1010

CONTROL UNIT(CAN)

EC-137

P0000

0000

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

P0011

0011

INT/V TIM CONT-B1

EC-139

P0031

0031

HO2S1 HTR (B1)

EC-143

P0032

0032

HO2S1 HTR (B1)

EC-143

P0037

0037

HO2S2 HTR (B1)

EC-149

P0038

0038

HO2S2 HTR (B1)

EC-149

P0107

0107

ABSL PRES SEN/CIRC

EC-155

P0108

0108

ABSL PRES SEN/CIRC

EC-155

P0112

0112

IAT SEN/CIRCUIT

EC-161

P0113

0113

IAT SEN/CIRCUIT

EC-161

P0117

0117

ECT SEN/CIRC

EC-166

P0118

0118

ECT SEN/CIRC

EC-166

P0122

0122

TP SEN 2/CIRC

EC-171

P0123

0123

TP SEN 2/CIRC

EC-171

P0132

0132

HO2S1 (B1)

EC-178

P0133

0133

HO2S1 (B1)

EC-185

P0134

0134

HO2S1 (B1)

EC-195

P0138

0138

HO2S2 (B1)

EC-203

P0139

0139

HO2S2 (B1)

EC-210

P0171

0171

FUEL SYS-LEAN-B1

EC-218

P0172

0172

FUEL SYS-RICH-B1

EC-226

P0222

0222

TP SEN 1/CIRC

EC-233

No DTC

Flashing*4

U1001

—

P0223

0223

TP SEN 1/CIRC

EC-233

P0300

0300

MULTI CYL MISFIRE

EC-240

P0301

0301

CYL 1 MISFIRE

EC-240

P0302

0302

CYL 2 MISFIRE

EC-240

P0303

0303

CYL 3 MISFIRE

EC-240

P0304

0304

CYL 4 MISFIRE

EC-240

P0327

0327

KNOCK SEN/CIRC-B1

EC-246

P0328

0328

KNOCK SEN/CIRC-B1

EC-246

EC-22

INDEX FOR DTC
[CR (WITH EURO-OBD)]
DTC*1
CONSULT-II

Items
(CONSULT-II screen terms)

3

Reference page

GST*2

ECM*

P0335

0335

CKP SEN/CIRCUIT

EC-250

P0340

0340

CMP SEN/CIRC-B1

EC-257

P0420

0420

TW CATALYST SYS-B1

EC-264

P0444

0444

PURG VOLUME CONT/V

EC-270

P0500

0500

VEH SPEED SEN/CIRC

EC-277

P0605

0605

ECM

EC-279

P1065

1065

ECM BACK UP/CIRCUIT

EC-282

P1111

1111

INT/V TIM V/CIR-B1

EC-286

P1121

1121

ETC ACTR

EC-291

P1122

1122

ETC FUNCTION/CIRC

EC-293

P1124

1124

ETC MOT PWR

EC-299

P1126

1126

ETC MOT PWR

EC-299

P1128

1128

ETC MOT

EC-305

P1143

1143

HO2S1 (B1)

EC-310

P1144

1144

HO2S1 (B1)

EC-316

P1146

1146

HO2S2 (B1)

EC-322

P1147

1147

HO2S2 (B1)

EC-330

P1171

1171

INTAKE ERROR

EC-338

P1211

1211

TCS C/U FUNCTN

EC-343

P1212

1212

TCS/CIRC

EC-344

P1217

1217

ENG OVER TEMP

EC-345

P1225

1225

CTP LEARNING

EC-359

P1226

1226

CTP LEARNING

EC-361

P1229

1229

SENSOR POWER/CIRC

EC-363

P1610 — P1615

1610 — 1615

NATS MALFUNCTION

EC-44

P1706

1706

P-N POS SW/CIRCUIT

EC-371

P1805

1805

BRAKE SW/CIRCUIT

EC-377

P2122

2122

APP SEN 1/CIRC

EC-383

P2123

2123

APP SEN 1/CIRC

EC-383

P2127

2127

APP SEN 2/CIRC

EC-392

P2128

2128

APP SEN 2/CIRC

EC-392

P2135

2135

TP SENSOR

EC-402

P2138

2138

APP SENSOR

EC-409

*1: 1st trip DTC No. is the same as DTC No.
*2: This number is prescribed by ISO 15031-5.
*3: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN.
*4: When engine is running.
*5: The troubleshooting for this DTC needs CONSULT-II.

EC-23

A

EC

C

D

E

F

G

H

I

J

K

L

M

INDEX FOR DTC
[CR (WITH EURO-OBD)]

Alphabetical Index

BBS002T9

NOTE:
●
If DTC U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1001. Refer
to EC-134, «DTC U1001 CAN COMMUNICATION LINE» .
●
If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer
to EC-137, «DTC U1010 CAN COMMUNICATION» .
Items
(CONSULT-II screen terms)

DTC*1
CONSULT-II
GST*

2

Reference page
ECM*3

ABSL PRES SEN/CIRC

P0107

0107

EC-155

ABSL PRES SEN/CIRC

P0108

0108

EC-155

APP SEN 1/CIRC

P2122

2122

EC-383

APP SEN 1/CIRC

P2123

2123

EC-383

APP SEN 2/CIRC

P2127

2127

EC-392

APP SEN 2/CIRC

P2128

2128

EC-392

APP SENSOR

P2138

2138

EC-409

BRAKE SW/CIRCUIT

P1805

1805

EC-377

CAN COMM CIRCUIT

U1001

1001*5

EC-134

CKP SEN/CIRCUIT

P0335

0335

EC-250

CMP SEN/CIRC-B1

P0340

0340

EC-257

CONTROL UNIT(CAN)

U1010

1010

EC-137

CTP LEARNING

P1225

1225

EC-359

CTP LEARNING

P1226

1226

EC-361

CYL 1 MISFIRE

P0301

0301

EC-240

CYL 2 MISFIRE

P0302

0302

EC-240

CYL 3 MISFIRE

P0303

0303

EC-240

CYL 4 MISFIRE

P0304

0304

EC-240

ECM

P0605

0605

EC-279

ECM BACK UP/CIRCUIT

P1065

1065

EC-282

ECT SEN/CIRC

P0117

0117

EC-166

ECT SEN/CIRC

P0118

0118

EC-166

ENG OVER TEMP

P1217

1217

EC-345

ETC ACTR

P1121

1121

EC-291

ETC FUNCTION/CIRC

P1122

1122

EC-293

ETC MOT

P1128

1128

EC-305

ETC MOT PWR

P1124

1124

EC-299

ETC MOT PWR

P1126

1126

EC-299

FUEL SYS-LEAN-B1

P0171

0171

EC-218

FUEL SYS-RICH-B1

P0172

0172

EC-226

HO2S1 (B1)

P0132

0132

EC-178

HO2S1 (B1)

P0133

0133

EC-185

HO2S1 (B1)

P0134

0134

EC-195

HO2S1 (B1)

P1143

1143

EC-310

HO2S1 (B1)

P1144

1144

EC-316

HO2S1 HTR (B1)

P0031

0031

EC-143

HO2S1 HTR (B1)

P0032

0032

EC-143

EC-24

INDEX FOR DTC
[CR (WITH EURO-OBD)]
DTC*1
Items
(CONSULT-II screen terms)

CONSULT-II

Reference page

A

3

GST*2

ECM*

HO2S2 (B1)

P0138

0138

EC-203

HO2S2 (B1)

P0139

0139

EC-210

HO2S2 (B1)

P1146

1146

EC-322

HO2S2 (B1)

P1147

1147

EC-330

HO2S2 HTR (B1)

P0037

0037

EC-149

HO2S2 HTR (B1)

P0038

0038

EC-149

IAT SEN/CIRCUIT

P0112

0112

EC-161

IAT SEN/CIRCUIT

P0113

0113

EC-161

INTAKE ERROR

P1171

1171

EC-338

INT/V TIM CONT-B1

P0011

0011

EC-139

EC

C

D

E

INT/V TIM V/CIR-B1

P1111

1111

EC-286

KNOCK SEN/CIRC-B1

P0327

0327

EC-246

KNOCK SEN/CIRC-B1

P0328

0328

EC-246

MULTI CYL MISFIRE

P0300

0300

EC-240

NATS MALFUNCTION

P1610 — P1615

1610 — 1615

EC-44

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

No DTC

Flashing*4

EC-59

H

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

P0000

0000

—

I

P-N POS SW/CIRCUIT

P1706

1706

EC-371

PURG VOLUME CONT/V

P0444

0444

EC-270

SENSOR POWER/CIRC

P1229

1229

EC-363

TCS C/U FUNCTN

P1211

1211

EC-343

TCS/CIRC

P1212

1212

EC-344

TP SEN 1/CIRC

P0222

0222

EC-233

TP SEN 1/CIRC

P0223

0223

EC-233

TP SEN 2/CIRC

P0122

0122

EC-171

TP SEN 2/CIRC

P0123

0123

EC-171

TP SENSOR

P2135

2135

EC-402

TW CATALYST SYS-B1

P0420

0420

EC-264

VEH SPEED SEN/CIRC

P0500

0500

EC-277

*1: 1st trip DTC No. is the same as DTC No.
*2: This number is prescribed by ISO 15031-5.
*3: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN.
*4: When engine is running.
*5: The troubleshooting for this DTC needs CONSULT-II.

EC-25

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PRECAUTIONS
[CR (WITH EURO-OBD)]
PFP:00001
PRECAUTIONS
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

BBS003ZU

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Maintenance Information

BBS005AP

If any of following part is replaced, always replace with new* one.
If it’s not (or fail to do so), the electrical system may not be operated properly.
*: New one means a virgin control unit that has never been energized on-board.

RHD MODELS
●
●
●
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM
IPDM E/R
Combination meter
EPS control unit

LHD MODELS
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM

Precautions for Procedures without Cowl Top Cover

BBS003ZV

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

PIIB3706J

On Board Diagnostic (OBD) System of Engine

BBS002TD

The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of
a malfunction causing emission deterioration.
CAUTION:
●
Be sure to turn the ignition switch OFF and disconnect the battery ground cable before any repair
or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will
cause the MI to light up.

EC-26

PRECAUTIONS
[CR (WITH EURO-OBD)]
●

●

●

●

●

Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease, A
dirt, bent terminals, etc.)
Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to PG-88, «HAR- EC
NESS CONNECTOR» .
Be sure to route and secure the harnesses properly after work. The interference of the harness
with a bracket, etc. may cause the MI to light up due to the short circuit.
C
Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MI to light up due to the malfunction of the fuel injection system, etc.
Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM D
before returning the vehicle to the customer.

Precaution
●
●

●

●

BBS002TE

E

Always use a 12 volt battery as power source.
Do not attempt to disconnect battery cables while engine is
running.
Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect negative
battery cable. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned off.
Before removing parts, turn ignition switch OFF and then
disconnect negative battery cable.

F

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SEF289H

●
●

●

–
–
–
–
–
–

●

Do not disassemble ECM.
If battery cable is disconnected, the memory will return to
the initial ECM values.
The ECM will now start to self-control at its initial values.
Engine operation can vary slightly when the cable is disconnected. However, this is not an indication of a malfunction. Do not replace parts because of a slight variation.
If the battery is disconnected, the following emission
related diagnostic information will be lost within 24 hours.
Diagnostic trouble codes
1st trip diagnostic trouble codes
Freeze frame data
1st freeze frame data
System readiness test (SRT) codes
Test values

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PBIB1164E

M

When connecting ECM harness connector, fasten it
securely with levers as far as they will go as shown in the
figure.

PBIB1512E

EC-27

L

PRECAUTIONS
[CR (WITH EURO-OBD)]
●

●

●

●
●

●

●
●
●

●

●

When connecting or disconnecting pin connectors into or
from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.
Securely connect ECM harness connectors.
A poor connection can cause an extremely high (surge)
voltage to develop in coil and condenser, thus resulting in
damage to ICs.
Keep engine control system harness at least 10 cm (4 in)
away from adjacent harness, to prevent engine control system malfunctions due to receiving external noise, degraded
operation of ICs, etc.
Keep engine control system parts and harness dry.
Before replacing ECM, perform ECM Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-95, «ECM Terminals and Reference Value» .
Handle manifold absolute pressure sensor carefully to
avoid damage.
Do not clean air clear element with any type of detergent.
Do not disassemble electric throttle control actuator.
Even a slight leak in the air intake system can cause serious incidents.
Do not shock or jar the camshaft position sensor (PHASE),
crankshaft position sensor (POS).
After performing each TROUBLE DIAGNOSIS, perform DTC
Confirmation Procedure or Overall Function Check.
The DTC should not be displayed in the DTC Confirmation
Procedure if the repair is completed. The Overall Function
Check should be a good result if the repair is completed.

PBIB0090E

MEF040D

SAT652J

EC-28

PRECAUTIONS
[CR (WITH EURO-OBD)]
●

●

●

When measuring ECM signals with a circuit tester, connect
a break-out box (SST) and Y-cable adapter (SST) between
the ECM and ECM harness connector.
When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact.
Accidental contact of probes will cause a short circuit and
damage the ECM power transistor.
Do not use ECM ground terminals when measuring input/
output voltage. Doing so may result in damage to the ECM’s
transistor. Use a ground other than ECM terminals, such as
the ground.

A

EC

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SEF348N

●
●

Do not operate fuel pump when there is no fuel in lines.
Tighten fuel hose clamps to the specified torque.

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MBIB0291E

●
●

●

Do not depress accelerator pedal when starting.
Immediately after starting, do not rev up engine unnecessarily.
Do not rev up engine just prior to shutdown.

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SEF709Y

EC-29

PRECAUTIONS
[CR (WITH EURO-OBD)]
●

–

–

–

–

When installing C.B. ham radio or a mobile phone, be sure
to observe the following as it may adversely affect electronic control systems depending on installation location.
Keep the antenna as far as possible from the electronic
control units.
Keep the antenna feeder line more than 20 cm (8 in) away
from the harness of electronic controls.
Do not let them run parallel for a long distance.
Adjust the antenna and feeder line so that the standingwave radio can be kept smaller.
Be sure to ground the radio to vehicle body.

EC-30

SEF708Y

PREPARATION
[CR (WITH EURO-OBD)]

PREPARATION
Special Service Tools

PFP:00002

A
BBS002TG

Tool number
Tool name

Description

EG17650301
Radiator cap tester
adapter

Adapting radiator cap tester to radiator cap and
radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)

EC

C

D

S-NT564

KV10117100
Heated oxygen
sensor wrench

Loosening or tightening heated oxygen sensors
with 22 mm (0.87 in) hexagon nut

E

F
S-NT379

KV10114400
Heated oxygen
sensor wrench

Loosening or tightening heated oxygen sensors
a: 22 mm (0.87 in)

G

H

S-NT636

KV109E0010
Break-out box

Measuring ECM signals with a circuit tester

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NT825

KV109E0080
Y-cable adapter

Measuring ECM signals with a circuit tester

L

M
NT826

EC-31

PREPARATION
[CR (WITH EURO-OBD)]

Commercial Service Tools

BBS002TH

Tool name

Description

Quick connector
release

Removing fuel tube quick connectors in engine
room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210)

PBIC0198E

Fuel filler cap adapter

Checking fuel tank vacuum relief valve opening
pressure

S-NT653

Socket wrench

Removing and installing engine coolant
temperature sensor

S-NT705

Oxygen sensor thread
cleaner

Reconditioning the exhaust system threads
before installing a new oxygen sensor. Use with
anti-seize lubricant shown below.
a: 18 mm diameter with pitch 1.5 mm for
Zirconia Oxygen Sensor
b: 12 mm diameter with pitch 1.25 mm for
Titania Oxygen Sensor
AEM488

Lubricating oxygen sensor thread cleaning tool
when reconditioning exhaust system threads.

Anti-seize lubricant
i.e.: (PermatexTM
133AR or equivalent
meeting MIL
specification MIL-A907)
S-NT779

EC-32

ENGINE CONTROL SYSTEM
[CR (WITH EURO-OBD)]

ENGINE CONTROL SYSTEM
System Diagram

PFP:23710

A
BBS002TI

EC

C

D

E

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MBIB1551E

EC-33

ENGINE CONTROL SYSTEM
[CR (WITH EURO-OBD)]

Multiport Fuel Injection (MFI) System

BBS002TL

INPUT/OUTPUT SIGNAL CHART
Sensor

Input Signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*3
Piston position

Manifold absolute pressure sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Heated oxygen sensor 1

Density of oxygen in exhaust gas

Throttle position sensor

Throttle position

Accelerator pedal position sensor

Accelerator pedal position

Park/neutral position (PNP) switch

Gear position

Knock sensor

Engine knocking condition

Battery

Battery voltage*3

EPS control unit

Power steering operation*2

Heated oxygen sensor 2*1

Density of oxygen in exhaust gas

Wheel sensor

Vehicle speed*2

Air conditioner switch

Air conditioner operation*2

ECM Function

Fuel injection &
mixture ratio
control

Actuator

Fuel injector

*1: This sensor is not used to control the engine system under normal conditions.
*2: This signal is sent to the ECM through CAN communication line.
*3: ECM determines the start signal status by the signals of engine speed and battery voltage.

SYSTEM DESCRIPTION
The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of
time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the
ECM memory. The program value is preset by engine operating conditions. These conditions are determined
by input signals (for engine speed and intake air volume) from the crankshaft position sensor (POS), camshaft
position sensor (PHASE) and the manifold absolute pressure sensor.

VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION
In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below.

●
During warm-up
●
When starting the engine
●
During acceleration
●
Hot-engine operation
●
High-load, high-speed operation

●
During deceleration
●
During high engine speed operation

MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL)

PBIB2938E

EC-34

ENGINE CONTROL SYSTEM
[CR (WITH EURO-OBD)]
The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control.
The three way catalyst (manifold) can then better reduce CO, HC and NOx emissions. This system uses A
heated oxygen sensor 1 in the exhaust manifold to monitor whether the engine operation is rich or lean. The
ECM adjusts the injection pulse width according to the sensor voltage signal. For more information about
heated oxygen sensor 1, refer to EC-178 . This maintains the mixture ratio within the range of stoichiometric
EC
(ideal air-fuel mixture).
This stage is referred to as the closed loop control condition.
Heated oxygen sensor 2 is located downstream of the three way catalyst (manifold). Even if the switching
characteristics of heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal C
from heated oxygen sensor 2.

Open Loop Control
D

The open loop system condition refers to when the ECM detects any of the following conditions.
Feedback control stops in order to maintain stabilized fuel combustion.
●
Deceleration and acceleration
●
High-load, high-speed operation
●
Malfunction of heated oxygen sensor 1 or its circuit
●
Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature
●
High engine coolant temperature
●
During warm-up
●
When starting the engine

E

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MIXTURE RATIO SELF-LEARNING CONTROL
The mixture ratio feedback control system monitors the mixture ratio signal transmitted from heated oxygen
sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to
the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. Both manufacturing differences (i.e., manifold absolute pressure sensor silicon diaphragm)
and characteristic changes during operation (i.e., fuel injector clogging) directly affect mixture ratio.
Accordingly, the difference between the basic and theoretical mixture ratios is monitored in this system. This is
then computed in terms of “injection pulse duration” to automatically compensate for the difference between
the two ratios.
“Fuel trim” refers to the feedback compensation value compared against the basic injection duration. Fuel trim
includes short term fuel trim and long term fuel trim.
“Short term fuel trim” is the short-term fuel compensation used to maintain the mixture ratio at its theoretical
value. The signal from heated oxygen sensor 1 indicates whether the mixture ratio is RICH or LEAN compared
to the theoretical value. The signal then triggers a reduction in fuel volume if the mixture ratio is rich, and an
increase in fuel volume if it is lean.
“Long term fuel trim” is overall fuel compensation carried out long-term to compensate for continual deviation
of the short term fuel trim from the central value. Such deviation will occur due to individual engine differences,
wear over time and changes in the usage environment.

FUEL INJECTION TIMING

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SEF337W

Two types of systems are used.

Sequential Multiport Fuel Injection System
Fuel is injected into each cylinder during each engine cycle according to the firing order. This system is used
when the engine is running.

EC-35

ENGINE CONTROL SYSTEM
[CR (WITH EURO-OBD)]
Simultaneous Multiport Fuel Injection System
Fuel is injected simultaneously into all four cylinders twice each engine cycle. In other words, pulse signals of
the same width are simultaneously transmitted from the ECM.
The four fuel injectors will then receive the signals two times for each engine cycle.
This system is used when the engine is being started and/or if the fail-safe system (CPU) is operating.

FUEL SHUT-OFF
Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds or
operation of the vehicle at excessively high speeds.

Electronic Ignition (EI) System

BBS002TM

INPUT/OUTPUT SIGNAL CHART
Sensor

Input Signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*2
Piston position

Manifold absolute pressure sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Throttle position sensor

Throttle position

Accelerator pedal position sensor

Accelerator pedal position

Knock sensor

Engine knocking

Park/neutral position (PNP) switch

Gear position

Battery

Battery voltage*2

Wheel sensor

Vehicle speed*1

ECM Function

Ignition timing
control

Actuator

Power transistor

*1: This signal is sent to the ECM through CAN communication line.
*2: ECM determines the start signal status by the signals of engine speed and battery voltage.

SYSTEM DESCRIPTION
Firing order: 1 — 3 — 4 — 2
The ignition timing is controlled by the ECM to maintain the best air-fuel ratio for every running condition of the
engine. The ignition timing data is stored in the ECM.
The ECM receives information such as the injection pulse width and camshaft position sensor signal. Computing this information, ignition signals are transmitted to the power transistor.
During the following conditions, the ignition timing is revised by the ECM according to the other data stored in
the ECM.
●
At starting
●
During warm-up
●
At idle
●
At low battery voltage
●
During acceleration
The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed
within the anti-knocking zone, if recommended fuel is used under dry conditions. The retard system does not
operate under normal driving conditions. If engine knocking occurs, the knock sensor monitors the condition.
The signal is transmitted to the ECM. The ECM retards the ignition timing to eliminate the knocking condition.

Fuel Cut Control (at No Load and High Engine Speed)

BBS002TO

INPUT/OUTPUT SIGNAL CHART
Sensor
Park/neutral position (PNP) switch

Input Signal to ECM

ECM Function

Actuator

Neutral position

Accelerator pedal position sensor

Accelerator pedal position

Engine coolant temperature sensor

Engine coolant temperature

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed

Wheel sensor

Vehicle speed*

EC-36

Fuel cut control

Fuel injector

ENGINE CONTROL SYSTEM
[CR (WITH EURO-OBD)]
*: This signal is sent to the ECM through CAN communication line.

A

SYSTEM DESCRIPTION

If the engine speed is above 2,500 rpm with no load (for example, the shift position is neutral and engine
speed is over 2,500 rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies
EC
based on engine speed.
Fuel cut will operate until the engine speed reaches 2,000 rpm, then fuel cut is cancelled.
NOTE:
This function is different from deceleration control listed under EC-34, «Multiport Fuel Injection (MFI) System» . C

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EC-37

AIR CONDITIONING CUT CONTROL
[CR (WITH EURO-OBD)]

AIR CONDITIONING CUT CONTROL
Input/Output Signal Chart
Sensor

PFP:23710
BBS003ZD

Input Signal to ECM

ECM Function

Actuator

1

Air conditioner switch

Air conditioner ON signal*

Accelerator pedal position sensor

Accelerator pedal position

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*2

Engine coolant temperature sensor

Engine coolant temperature

Refrigerant pressure sensor

Refrigerant pressure

EPS control unit

Power steering operation*1

Wheel sensor

Vehicle speed*1

Battery

Battery voltage*2

Air conditioner
cut control

*1: This signal is sent to the ECM through CAN communication line.
*2: ECM determines the start signal status by the signals of engine speed and battery voltage.

SYSTEM DESCRIPTION
This system improves engine operation when the air conditioner is used.
Under the following conditions, the air conditioner is turned OFF.
●
When the accelerator pedal is fully depressed.
●
When cranking the engine.
●
At high engine speeds.
●
When the engine coolant temperature becomes excessively high.
●
When operating power steering during low engine speed or low vehicle speed.
●
When engine speed is excessively low.
●
When refrigerant pressure is excessively low or high.

EC-38

Air conditioner relay

CAN COMMUNICATION
[CR (WITH EURO-OBD)]

CAN COMMUNICATION
System Description

PFP:23710

A
BBS003ZE

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- EC
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
C
Each control unit transmits/receives data but selectively reads required data only.
Refer to LAN-21, «CAN COMMUNICATION» , about CAN communication for detail.
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EC-39

EVAPORATIVE EMISSION SYSTEM
[CR (WITH EURO-OBD)]

EVAPORATIVE EMISSION SYSTEM
Description

PFP:14950
BBS00343

SYSTEM DESCRIPTION

PBIB0491E

The evaporative emission system is used to reduce hydrocarbons emitted into the atmosphere from the fuel
system. This reduction of hydrocarbons is accomplished by activated charcoals in the EVAP canister.
The fuel vapor in the sealed fuel tank is led into the EVAP canister which contains activated carbon and the
vapor is stored there when the engine is not operating or when refueling to the fuel tank.
The vapor in the EVAP canister is purged by the air through the purge line to the intake manifold when the
engine is operating. EVAP canister purge volume control solenoid valve is controlled by ECM. When the
engine operates, the flow rate of vapor controlled by EVAP canister purge volume control solenoid valve is
proportionally regulated as the air flow increases.
EVAP canister purge volume control solenoid valve also shuts off the vapor purge line during decelerating and
idling.

EC-40

EVAPORATIVE EMISSION SYSTEM
[CR (WITH EURO-OBD)]
EVAPORATIVE EMISSION LINE DRAWING
A

EC

C

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MBIB0544E

EC-41

EVAPORATIVE EMISSION SYSTEM
[CR (WITH EURO-OBD)]

MBIB1450E

: Vehicle front
1.

: To previous page

EVAP canister

EC-42

EVAPORATIVE EMISSION SYSTEM
[CR (WITH EURO-OBD)]

Component Inspection

BBS00344

A

EVAP CANISTER
Check EVAP canister as follows:
1. Block port (B).
2. Blow air into port (A) and check that it flows freely out of port (C).
3. Release blocked port (B).
4. Apply vacuum pressure to port (B) and check that vacuum pressure exists at the ports (A) and (C).
5. Block port (A) and (B).
6. Apply pressure to port (C) and check that there is no leakage.

EC

C

D
PBIB2961E

FUEL CHECK VALVE
1.

2.
3.

E

Blow air through connector on fuel tank side.
A considerable resistance should be felt and a portion of air flow
should be directed toward the EVAP canister side.
Blow air through connector on EVAP canister side.
Air flow should be smoothly directed toward fuel tank side.
If fuel check valve is suspected of not properly functioning in
steps 1 and 2 above, replace it.

F

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H
SEF552Y

FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP)
1.

I

Wipe clean valve housing.

J

K

SEF989X

2.

Check valve opening pressure and vacuum.
Pressure:
Vacuum:

3.

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M

15.3 — 20.0 kPa (0.153 — 0.200 bar,
0.156 — 0.204 kg/cm2 , 2.22 — 2.90 psi)
−6.0 to −3.4 kPa (−0.060 to −0.034 bar,
−0.061 to −0.035 kg/cm2 , −0.87 to −0.49 psi)

If out of specification, replace fuel filler cap as an assembly.

SEF943S

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
Refer to EC-275, «Component Inspection» .

EC-43

NATS (NISSAN ANTI-THEFT SYSTEM)
[CR (WITH EURO-OBD)]

NATS (NISSAN ANTI-THEFT SYSTEM)
Description
●

●

●

PFP:25386
BBS003ZF

If the security indicator lights up with the ignition switch in
the ON position or “NATS MALFUNCTION” is displayed on
“SELF-DIAG RESULTS” screen, perform self-diagnostic
results mode with CONSULT-II using NATS program card.
Refer to BL-215, «NATS (Nissan Anti-Theft System)» .
Confirm no self-diagnostic results of NATS is displayed
before touching “ERASE” in “SELF-DIAG RESULTS” mode
with CONSULT-II.
When replacing ECM, initialization of NATS system and registration of all NATS ignition key IDs must be carried out
SEF515Y
with CONSULT-II using NATS program card.
Therefore, be sure to receive all keys from vehicle owner.
Regarding the procedures of NATS initialization and all NATS ignition key ID registration, refer to
CONSULT-II Operation Manual, NATS.

EC-44

POSITIVE CRANKCASE VENTILATION
[CR (WITH EURO-OBD)]

POSITIVE CRANKCASE VENTILATION
Description

PFP:11810

A
BBS00345

SYSTEM DESCRIPTION
EC

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E

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PBIB0492E

This system returns blow-by gas to the intake manifold.
The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake
manifold. During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the
PCV valve. Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air. The ventilating air is then drawn from the air inlet tubes into the crankcase. In this process the air
passes through the hose connecting air inlet tubes to rocker cover. Under full-throttle condition, the manifold
vacuum is insufficient to draw the blow-by flow through the valve. The flow goes through the hose connection
in the reverse direction.
On vehicles with an excessively high blow-by, the valve does not
meet the requirement. This is because some of the flow will go
through the hose connection to the air inlet tubes under all conditions.

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PBIB1588E

Component Inspection

BBS00346

PCV (POSITIVE CRANKCASE VENTILATION) VALVE
With engine running at idle, remove PCV valve from rocker cover. A
properly working valve makes a hissing noise as air passes through
it. A strong vacuum should be felt immediately when a finger is
placed over valve inlet.

PBIB1589E

EC-45

M

POSITIVE CRANKCASE VENTILATION
[CR (WITH EURO-OBD)]
PCV VALVE VENTILATION HOSE
1.
2.

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

S-ET277

EC-46

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]

ON BOARD DIAGNOSTIC (OBD) SYSTEM
Introduction

PFP:00028

A
BBS002TV

The ECM has an on board diagnostic system, which detects malfunctions related to engine sensors or actuators. The ECM also records various emission-related diagnostic information including:
EC
Emission-related diagnostic information

ISO Standard

Diagnostic Trouble Code (DTC)

Service $03 of ISO 15031-5

Freeze Frame data

Service $02 of ISO 15031-5

System Readiness Test (SRT) code

Service $01 of ISO 15031-5

1st Trip Diagnostic Trouble Code (1st Trip DTC)

Service $07 of ISO 15031-5

C

D

1st Trip Freeze Frame data
Test values and Test limits

Service $06 of ISO 15031-5

Calibration ID

Service $09 of ISO 15031-5

The above information can be checked using procedures listed in the table below.

E

×: Applicable

—: Not applicable

DTC

1st trip DTC

Freeze Frame
data

1st trip Freeze
Frame data

SRT code

Test value

CONSULT-II

×

×

×

×

×

—

GST

×

×

×

—

×

×

ECM

×

×*

—

—

—

—

G

H

*: When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other.

The malfunction indicator (MI) on the instrument panel lights up when the same malfunction is detected in two
consecutive trips (Two trip detection logic), or when the ECM enters fail-safe mode. (Refer to EC-81 .)

Two Trip Detection Logic

F

I

BBS002TW

When a malfunction is detected for the first time, 1st trip DTC and 1st trip Freeze Frame data are stored in the
ECM memory. The MI will not light up at this stage. <1st trip>
If the same malfunction is detected again during the next drive, the DTC and Freeze Frame data are stored in
the ECM memory, and the MI lights up. The MI lights up at the same time when the DTC is stored. <2nd trip>
The “trip” in the “Two Trip Detection Logic” means a driving mode in which self-diagnosis is performed during
vehicle operation. Specific on board diagnostic items will cause the ECM to light up or blink the MI, and store
DTC and Freeze Frame data, even in the 1st trip, as shown below.
×: Applicable

MI

DTC

1st trip

Items

2nd trip

1st trip DTC

2nd trip
displaying

1st trip
displaying

2nd trip
displaying

—

—

—

×

—

×

—

—

×

—

—

×

—

—

×

—

—

—

—

—

×

—

×

×

—

Blinking

Blinking

Lighting
up

Misfire (Possible three way catalyst
damage) — DTC: P0300 — P0304 is
being detected

×

—

—

Misfire (Possible three way catalyst
damage) — DTC: P0300 — P0304 is
being detected

—

—

One trip detection diagnoses (Refer
to EC-48 )

—

Except above

—

When there is an open circuit on MI circuit, the ECM can not warn the driver by lighting up MI when there is a
malfunction on engine control system.
Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as
NG for 5 trips, ECM warns the driver that engine control system has malfunction and MI circuit is open by
means of operating fail-safe function.

EC-47

K

—: Not applicable

1st trip
displaying

Lighting
up

J

L

M

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
The fail-safe function also operate when above diagnoses except MI circuit are detected and demands the
driver to repair the malfunction.
Engine operating condition in fail-safe mode

Engine speed will not rise more than 2,500 rpm due to the fuel cut

Emission-related Diagnostic Information

BBS002TX

EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS
1

DTC*
Items
(CONSULT-II screen terms)

CONSULT-II
GST*2

×: Applicable —: Not applicable

SRT code

Test Valve/
Test Limit
(GST only)

Trip

MI lighting
up

Reference
page

ECM*3

CAN COMM CIRCUIT

U1001

1001*4

—

—

2

—

EC-134

CONTROL UNIT(CAN)

U1010

1010

—

—

2

—

EC-137

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

P0000

0000

—

—

—

—

—

INT/V TIM CONT-B1

P0011

0011

—

—

2

—

EC-139

HO2S1 HTR (B1)

P0031

0031

×

×

2

×

EC-143

HO2S1 HTR (B1)

P0032

0032

×

×

2

×

EC-143

HO2S2 HTR (B1)

P0037

0037

×

×

2

×

EC-149

HO2S2 HTR (B1)

P0038

0038

×

×

2

×

EC-149

ABSL PRES SEN/CIRC

P0107

0107

—

—

2

×

EC-155

ABSL PRES SEN/CIRC

P0108

0108

—

—

2

×

EC-155

IAT SEN/CIRCUIT

P0112

0112

—

—

2

×

EC-161

IAT SEN/CIRCUIT

P0113

0113

—

—

2

×

EC-161

ECT SEN/CIRC

P0117

0117

—

—

1

×

EC-166

ECT SEN/CIRC

P0118

0118

—

—

1

×

EC-166

TP SEN 2/CIRC

P0122

0122

—

—

1

×

EC-171

TP SEN 2/CIRC

P0123

0123

—

—

1

×

EC-171

HO2S1 (B1)

P0132

0132

×

×

2

×

EC-178

HO2S1 (B1)

P0133

0133

×

×

2

×

EC-185

HO2S1 (B1)

P0134

0134

×

×

2

×

EC-195

HO2S2 (B1)

P0138

0138

×

×

2

×

EC-203

HO2S2 (B1)

P0139

0139

×

×

2

×

EC-210

FUEL SYS-LEAN-B1

P0171

0171

—

—

2

×

EC-218

FUEL SYS-RICH-B1

P0172

0172

—

—

2

×

EC-226

TP SEN 1/CIRC

P0222

0222

—

—

1

×

EC-233

TP SEN 1/CIRC

P0223

0223

—

—

1

×

EC-233

MULTI CYL MISFIRE

P0300

0300

—

—

2

×

EC-240

CYL 1 MISFIRE

P0301

0301

—

—

2

×

EC-240

CYL 2 MISFIRE

P0302

0302

—

—

2

×

EC-240

CYL 3 MISFIRE

P0303

0303

—

—

2

×

EC-240

CYL 4 MISFIRE

P0304

0304

—

—

2

×

EC-240

KNOCK SEN/CIRC-B1

P0327

0327

—

—

2

—

EC-246

KNOCK SEN/CIRC-B1

P0328

0328

—

—

2

—

EC-246

CKP SEN/CIRCUIT

P0335

0335

—

—

2

×

EC-250

CMP SEN/CIRC-B1

P0340

0340

—

—

2

×

EC-257

TW CATALYST SYS-B1

P0420

0420

×

×

2

×

EC-264

PURG VOLUME CONT/V

P0444

0444

—

—

2

×

EC-270

EC-48

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
DTC*1
Items
(CONSULT-II screen terms)

CONSULT-II

SRT code

Test Valve/
Test Limit
(GST only)

Trip

MI lighting
up

Reference
page

A

EC

3

GST*2

ECM*

VEH SPEED SEN/CIRC

P0500

0500

—

—

2

×

EC-277

ECM

P0605

0605

—

—

1 or 2

× or —

EC-279

ECM BACK UP/CIRCUIT

P1065

1065

—

—

2

×

EC-282

INT/V TIM V/CIR-B1

P1111

1111

—

—

2

×

EC-286

ETC ACTR

P1121

1121

—

—

1

×

EC-291

ETC FUNCTION/CIRC

P1122

1122

—

—

1

×

EC-293

ETC MOT PWR

P1124

1124

—

—

1

×

EC-299

ETC MOT PWR

P1126

1126

—

—

1

×

EC-299

ETC MOT

P1128

1128

—

—

1

×

EC-305

HO2S1 (B1)

P1143

1143

×

×

2

×

EC-310

HO2S1 (B1)

P1144

1144

×

×

2

×

EC-316

HO2S2 (B1)

P1146

1146

×

×

2

×

EC-322

HO2S2 (B1)

P1147

1147

×

×

2

×

EC-330

INTAKE ERROR

P1171

1171

—

—

1

×

EC-338

TCS C/U FUNCTN

P1211

1211

—

—

2

—

EC-343

TCS/CIRC

P1212

1212

—

—

2

—

EC-344

ENG OVER TEMP

P1217

1217

—

—

1

×

EC-345

CTP LEARNING

P1225

1225

—

—

2

—

EC-359

CTP LEARNING

P1226

1226

—

—

2

—

EC-361

SENSOR POWER/CIRC

P1229

1229

—

—

1

×

EC-363

NATS MALFUNCTION

P1610 P1615

1610 — 1615

—

—

2

—

EC-44

P-N POS SW/CIRCUIT

P1706

1706

—

—

2

×

EC-371

BRAKE SW/CIRCUIT

P1805

1805

—

—

2

—

EC-377

APP SEN 1/CIRC

P2122

2122

—

—

1

×

EC-383

APP SEN 1/CIRC

P2123

2123

—

—

1

×

EC-383

APP SEN 2/CIRC

P2127

2127

—

—

1

×

EC-392

APP SEN 2/CIRC

P2128

2128

—

—

1

×

EC-392

TP SENSOR

P2135

2135

—

—

1

×

EC-402

APP SENSOR

P2138

2138

—

—

1

×

EC-409

*1: 1st trip DTC No. is the same as DTC No.
*2: This number is prescribed by ISO 15031-5.
*3: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN.
*4: The troubleshooting for this DTC needs CONSULT-II.

DTC AND 1ST TRIP DTC
The 1st trip DTC (whose number is the same as the DTC number) is displayed for the latest self-diagnostic
result obtained. If the ECM memory was cleared previously, and the 1st trip DTC did not reoccur, the 1st trip
DTC will not be displayed.
If a malfunction is detected during the 1st trip, the 1st trip DTC is stored in the ECM memory. The MI will not
light up (two trip detection logic). If the same malfunction is not detected in the 2nd trip (meeting the required
driving pattern), the 1st trip DTC is cleared from the ECM memory. If the same malfunction is detected in the
2nd trip, both the 1st trip DTC and DTC are stored in the ECM memory and the MI lights up. In other words,
the DTC is stored in the ECM memory and the MI lights up when the same malfunction occurs in two consecutive trips. If a 1st trip DTC is stored and a non-diagnostic operation is performed between the 1st and 2nd
trips, only the 1st trip DTC will continue to be stored. For malfunctions that blink or light up the MI during the
1st trip, the DTC and 1st trip DTC are stored in the ECM memory.

EC-49

C

D

E

F

G

H

I

J

K

L

M

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
Procedures for clearing the DTC and the 1st trip DTC from the ECM memory are described in EC-57, «HOW
TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .
For malfunctions in which 1st trip DTCs are displayed, refer to EC-48, «EMISSION-RELATED DIAGNOSTIC
INFORMATION ITEMS» . These items are required by legal regulations to continuously monitor the system/
component. In addition, the items monitored non-continuously are also displayed on CONSULT-II.
1st trip DTC is specified in Service $07 of ISO 15031-5. 1st trip DTC detection occurs without lighting up the
MI and therefore does not warn the driver of a malfunction. However, 1st trip DTC detection will not prevent
the vehicle from being tested, for example during Inspection/Maintenance (I/M) tests.
When a 1st trip DTC is detected, check, print out or write down and erase (1st trip) DTC and Freeze Frame
data as specified in Work Flow procedure Step 2, refer to EC-75, «WORK FLOW» . Then perform DTC Confirmation Procedure or Overall Function Check to try to duplicate the malfunction. If the malfunction is duplicated, the item requires repair.

How to Read DTC and 1st Trip DTC
DTC and 1st trip DTC can be read by the following methods.
With CONSULT-II
With GST
CONSULT-II or GST (Generic Scan Tool) Examples: P0112, P1217, P1805, etc.
These DTCs are prescribed by ISO 15031-5.
(CONSULT-II also displays the malfunctioning component or system.)
No Tools
The number of blinks of the MI in the Diagnostic Test Mode II (Self-Diagnostic Results) indicates the DTC.
Example: 0112, 1217, 1805 etc.
These DTCs are controlled by NISSAN.
●
1st trip DTC No. is the same as DTC No.
●
Output of a DTC indicates a malfunction. However, GST or the Diagnostic Test Mode II do not indicate whether the malfunction is still occurring or has occurred in the past and has returned to normal. CONSULT-II can identify malfunction status as shown below. Therefore, using CONSULT-II (if
available) is recommended.
A sample of CONSULT-II display for DTC and 1st trip DTC is shown below. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many times
the vehicle was driven after the last detection of a DTC.
If the DTC is being detected currently, the time data will be [0].
If a 1st trip DTC is stored in the ECM, the time data will be [1t].

PBIB0911E

FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA
The ECM records the driving conditions such as fuel system status, calculated load value, engine coolant temperature, short term fuel trim, long term fuel trim, engine speed, vehicle speed, base fuel schedule and intake
air temperature at the moment a malfunction is detected.
Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data.
The data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II or
GST. The 1st trip freeze frame data can only be displayed on the CONSULT-II screen, not on the GST. For
details, see EC-104, «Freeze Frame Data and 1st Trip Freeze Frame Data» .
Only one set of freeze frame data (either 1st trip freeze frame data or freeze frame data) can be stored in the
ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no priority
for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once
freeze frame data (2nd trip detection/MI on) is stored in the ECM memory, 1st trip freeze frame data is no
longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the following priorities to update the data.

EC-50

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
Priority
1

Items
Freeze frame data

2
3

A

Misfire — DTC: P0300 — P0304
Fuel Injection System Function — DTC: P0171, P0172
Except the above items

EC

1st trip freeze frame data

For example, the EGR malfunction (Priority: 2) was detected and the freeze frame data was stored in the 2nd
trip. After that when the misfire (Priority: 1) is detected in another trip, the freeze frame data will be updated
from the EGR malfunction to the misfire. The 1st trip freeze frame data is updated each time a different malfunction is detected. There is no priority for 1st trip freeze frame data. However, once freeze frame data is
stored in the ECM memory, 1st trip freeze data is no longer stored (because only one freeze frame data or 1st
trip freeze frame data can be stored in the ECM). If freeze frame data is stored in the ECM memory and freeze
frame data with the same priority occurs later, the first (original) freeze frame data remains unchanged in the
ECM memory.
Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased. Procedures for clearing the ECM memory are described in EC-57, «HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .
System Readiness Test (SRT) code is specified in Service $01 of ISO 15031-5.
As part of an enhanced emissions test for Inspection & Maintenance (I/M), certain states require the status of
SRT be used to indicate whether the ECM has completed self-diagnosis of major emission systems and components. Completion must be verified in order for the emissions inspection to proceed.
If a vehicle is rejected for a State emissions inspection due to one or more SRT items indicating “INCMP”, use
the information in this Service Manual to set the SRT to “CMPLT”.
In most cases the ECM will automatically complete its self-diagnosis cycle during normal usage, and the SRT
status will indicate “CMPLT” for each application system. Once set as “CMPLT”, the SRT status remains
“CMPLT” until the self-diagnosis memory is erased.
Occasionally, certain portions of the self-diagnostic test may not be completed as a result of the customer’s
normal driving pattern; the SRT will indicate “INCMP” for these items.
NOTE:
The SRT will also indicate “INCMP” if the self-diagnosis memory is erased for any reason or if the ECM memory power supply is interrupted for several hours.
If, during the state emissions inspection, the SRT indicates “CMPLT” for all test items, the inspector will continue with the emissions test. However, if the SRT indicates “INCMP” for one or more of the SRT items the
vehicle is returned to the customer untested.
NOTE:
If MI is ON during the state emissions inspection, the vehicle is also returned to the customer untested even
though the SRT indicates “CMPLT” for all test items. Therefore, it is important to check SRT (“CMPLT”) and
DTC (No DTCs) before the inspection.

SRT Item

E

Required self-diagnostic items to set the SRT to “CMPLT”

Corresponding DTC No.

CATALYST

2

Three way catalyst function

P0420

HO2S

1

Heated oxygen sensor 1

P0132

Heated oxygen sensor 1

P0133

Heated oxygen sensor 1

P0134

Heated oxygen sensor 1

P1143

Heated oxygen sensor 1

P1144

Heated oxygen sensor 2

P0138

Heated oxygen sensor 2

P0139

Heated oxygen sensor 2

P1146

Heated oxygen sensor 2

P1147

EC-51

G

H

I

J

K

L

M

The table below shows required self-diagnostic items to set the SRT to “CMPLT”.
Performance
Priority*

D

F

SYSTEM READINESS TEST (SRT) CODE

SRT item
(CONSULT-II
indication)

C

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
SRT item
(CONSULT-II
indication)

Performance
Priority*

HO2S HTR

1

Required self-diagnostic items to set the SRT to “CMPLT”

Corresponding DTC No.

Heated oxygen sensor 1 heater

P0031, P0032

Heated oxygen sensor 2 heater

P0037, P0038

*: If completion of several SRTs is required, perform driving patterns (DTC confirmation procedure), one by one based on the priority for
models with CONSULT-II.

SRT Set Timing
SRT is set as “CMPLT” after self-diagnosis has been performed one or more times. Completion of SRT is
done regardless of whether the result is OK or NG. The set timing is different between OK and NG results and
is shown in the table below.
Example
Self-diagnosis result
All OK

Case 1

Case 2

NG exists

Case 3

Ignition cycle
← ON → OFF ← ON →

Diagnosis

← ON →

P0400

OK (1)

— (1)

OK (2)

— (2)

P0402

OK (1)

— (1)

— (1)

OK (2)

P1402

OK (1)

OK (2)

— (2)

— (2)

SRT of EGR

“CMPLT”

“CMPLT”

“CMPLT”

“CMPLT”

P0400

OK (1)

— (1)

— (1)

— (1)

P0402

— (0)

— (0)

OK (1)

— (1)

P1402

OK (1)

OK (2)

— (2)

— (2)

SRT of EGR

“INCMP”

“INCMP”

“CMPLT”

“CMPLT”

P0400

OK

OK

—

—

P0402

—

—

—

—

P1402

NG

—

NG

NG
(Consecutive
NG)

(1st trip)
DTC

1st trip DTC

—

1st trip DTC

DTC
(= MI “ON”)

SRT of EGR

“INCMP”

“INCMP”

“INCMP”

“CMPLT”

OFF

OFF

← ON →

OK: Self-diagnosis is carried out and the result is OK.
NG: Self-diagnosis is carried out and the result is NG.
—: Self-diagnosis is not carried out.

When all SRT related self-diagnoses showed OK results in a single cycle (Ignition OFF-ON-OFF), the SRT will
indicate “CMPLT”. → Case 1 above
When all SRT related self-diagnoses showed OK results through several different cycles, the SRT will indicate
“CMPLT” at the time the respective self-diagnoses have at least one OK result. → Case 2 above
If one or more SRT related self-diagnoses showed NG results in 2 consecutive cycles, the SRT will also indicate “CMPLT”. → Case 3 above
The table above shows that the minimum number of cycles for setting SRT as “INCMP” is one (1) for each
self-diagnosis (Case 1 & 2) or two (2) for one of self-diagnoses (Case 3). However, in preparation for the state
emissions inspection, it is unnecessary for each self-diagnosis to be executed twice (Case 3) for the following
reasons:
●
The SRT will indicate “CMPLT” at the time the respective self-diagnoses have one (1) OK result.
●
The emissions inspection requires “CMPLT” of the SRT only with OK self-diagnosis results.
●
When, during SRT driving pattern, 1st trip DTC (NG) is detected prior to “CMPLT” of SRT, the self-diagnosis memory must be erased from ECM after repair.
●
If the 1st trip DTC is erased, all the SRT will indicate “INCMP”.
NOTE:
SRT can be set as “CMPLT” together with the DTC (s). Therefore, DTC check must always be carried out
prior to the state emission inspection even though the SRT indicates “CMPLT”.

EC-52

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
SRT Service Procedure
If a vehicle has failed the state emissions inspection due to one or more SRT items indicating “INCMP”, review
the flowchart diagnostic sequence on the next page.

A

EC

C

D

E

F

G

H

I

J

K

L

M

SEF573XB

*1

EC-50

*2

EC-54

*3

EC-53

EC-54

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
How to Display SRT Code
WITH CONSULT-II
Selecting “SRT STATUS” in “DTC & SRT CONFIRMATION” mode
with CONSULT-II.
For items whose SRT codes are set, a “CMPLT” is displayed on the
CONSULT-II screen; for items whose SRT codes are not set,
“INCMP” is displayed.
A sample of CONSULT-II display for SRT code is shown at right.
“INCMP” means the self-diagnosis is incomplete and SRT is not set.
“CMPLT” means the self-diagnosis is complete and SRT is set.
WITH GST
Selecting Service $01 with GST (Generic Scan Tool)

PBIB0666E

How to Set SRT Code
To set all SRT codes, self-diagnosis for the items indicated above must be performed one or more times. Each
diagnosis may require a long period of actual driving under various conditions.
WITH CONSULT-II
Perform corresponding DTC Confirmation Procedure one by one based on Performance Priority in the table
on EC-51 .
WITHOUT CONSULT-II
The most efficient driving pattern in which SRT codes can be properly set is explained on the next page. The
driving pattern should be performed one or more times to set all SRT codes.

EC-54

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
Driving Pattern
A

EC

C

D

E

F

G

H

I

J

K

L

M

PBIB2451E

EC-55

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
The time required for each diagnosis varies with road surface conditions, weather, altitude, individual driving habits, etc.
Zone A refers to the range where the time, required for the diagnosis under normal conditions*, is the
shortest.
Zone B refers to the range where the diagnosis can still be performed if the diagnosis is not completed
within zone A.
*: Normal conditions refer to the following:
●
Sea level
●
Flat road
●
Ambient air temperature: 20 — 30°C (68 — 86°F)
●
Diagnosis is performed as quickly as possible under normal conditions.
Under different conditions [For example: ambient air temperature other than 20 — 30°C (68 — 86°F)], diagnosis may also be performed.
Pattern 1:
●
The engine is started at the engine coolant temperature of −10 to 35°C (14 to 95°F)
(where the voltage between the ECM terminal 72 and ground is 3.0 — 4.3V).
●
The engine must be operated at idle speed until the engine coolant temperature is greater than
70°C (158°F) (where the voltage between the ECM terminal 72 and ground is lower than 1.4V).
Pattern 2:
●
When steady-state driving is performed again even after it is interrupted, each diagnosis can be conducted. In this case, the time required for diagnosis may be extended.
*1: Depress the accelerator pedal until vehicle speed is 90 km/h (56 MPH), then release the accelerator pedal
and keep it released for more than 10 seconds. Depress the accelerator pedal until vehicle speed is 90 km/h
(56 MPH) again.
*2: Checking the vehicle speed with GST is advised.
●

TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II)
The following is the information specified in Service $06 of ISO 15031-5.
The test value is a parameter used to determine whether a system/circuit diagnostic test is OK or NG while
being monitored by the ECM during self-diagnosis. The test limit is a reference value which is specified as the
maximum or minimum value and is compared with the test value being monitored.
These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be displayed on the GST screen.
SRT item

CATALYST

Self-diagnostic test item

Three way catalyst function

Heated oxygen sensor 1

HO2S

Heated oxygen sensor 2

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

Test value
(GST display)

DTC

Test limit

TID

CID

P0420

01H

01H

Max.

P0420

02H

81H

Min.

P0133

09H

04H

Max.

P1143

0AH

84H

Min.

P1144

0BH

04H

Max.

P0132

0CH

04H

Max.

P0134

0DH

04H

Max.

P0139

19H

86H

Min.

P1147

1AH

86H

Min.

P1146

1BH

06H

Max.

P0138

1CH

06H

Max.

P0032

29H

08H

Max.

P0031

2AH

88H

Min.

P0038

2DH

0AH

Max.

P0037

2EH

8AH

Min.

EC-56

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION
How to Erase DTC

A

With CONSULT-II
The emission related diagnostic information in the ECM can be erased by selecting “ERASE” in the “SELFEC
DIAG RESULTS” mode with CONSULT-II.
1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once.
Wait at least 10 seconds and then turn it ON (engine stopped) again.
C
2. Touch “ENGINE”.
3. Touch “SELF-DIAG RESULTS”.
4. Touch “ERASE”. (The DTC in the ECM will be erased.)
D

E

F

G

H

I
MBIB1303E

With GST
The emission related diagnostic information in the ECM can be erased by selecting Service $04 with GST.
1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once.
Wait at least 10 seconds and then turn it ON (engine stopped) again.
2. Select Service $04 with GST (Generic Scan Tool).
No Tools
If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once.
Wait at least 10 seconds and then turn it ON (engine stopped) again.
Change the diagnostic test mode from Mode II to Mode I by depressing the accelerator pedal. Refer to
EC-59, «HOW TO SWITCH DIAGNOSTIC TEST MODE» .
●
If the battery is disconnected, the emission-related diagnostic information will be lost within 24
hours.
●
The following data are cleared when the ECM memory is erased.
–
Diagnostic trouble codes
–
1st trip diagnostic trouble codes
–
Freeze frame data
–
1st trip freeze frame data
–
System readiness test (SRT) codes
–
Test values
Actual work procedures are explained using a DTC as an example. Be careful so that not only the DTC, but all
of the data listed above, are cleared from the ECM memory during work procedures.
1.
2.
3.

EC-57

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ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]

Malfunction Indicator (MI)

BBS002TZ

DESCRIPTION
The MI is located on the instrument panel.
1. The MI will light up when the ignition switch is turned ON without
the engine running. This is a bulb check.
If the MI does not light up, refer to DI-32, «WARNING LAMPS»
or see EC-448 .
2. When the engine is started, the MI should go off.
If the MI remains on, the on board diagnostic system has
detected an engine system malfunction.

SAT652J

ON BOARD DIAGNOSTIC SYSTEM FUNCTION
The on board diagnostic system has the following four functions.
Diagnostic Test
Mode

KEY and ENG.
Status

Function

Explanation of Function

Mode I

Ignition switch in
ON position

BULB CHECK

This function checks the MI bulb for damage (blown, open
circuit, etc.).
If the MI does not come on, check MI circuit.

MALFUNCTION
WARNING

This is a usual driving condition. When a malfunction is
detected twice in two consecutive driving cycles (two trip
detection logic), the MI will light up to inform the driver that
a malfunction has been detected.
The following malfunctions will light up or blink the MI in
the 1st trip.

Engine stopped

Engine running

Mode II

Ignition switch in
ON position

●

Misfire (Possible three way catalyst damage)

●

One trip detection diagnoses

SELF-DIAGNOSTIC
RESULTS

This function allows DTCs and 1st trip DTCs to be read.

HEATED OXYGEN SENSOR 1
MONITOR

This function allows the fuel mixture condition (lean or
rich), monitored by heated oxygen sensor 1, to be read.

Engine stopped

Engine running

When there is an open circuit on MI circuit, the ECM can not warn the driver by lighting up MI when there is
malfunction on engine control system.
Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as
NG for 5 trips, ECM warns the driver that engine control system has a malfunction and MI circuit is open by
means of operating fail-safe function.
The fail-safe function also operate when above diagnoses except MI circuit are detected and demands the
driver to repair the a malfunction.
Engine operating condition in fail-safe mode

Engine speed will not rise more than 2,500 rpm due to the fuel cut

EC-58

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
MI Flashing without DTC
If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM diag- A
nostic test mode. EC-59, «HOW TO SWITCH DIAGNOSTIC TEST MODE» .
How to switch the diagnostic test (function) modes, and details of the above functions are described later, EC59, «HOW TO SWITCH DIAGNOSTIC TEST MODE» .
EC
The following emission-related diagnostic information is cleared when the ECM memory is erased.
●
Diagnostic trouble codes
●
1st trip diagnostic trouble codes
C
●
Freeze frame data
●
1st trip freeze frame data
D
●
System readiness test (SRT) codes
●
Test values

HOW TO SWITCH DIAGNOSTIC TEST MODE

E

NOTE:
●
It is better to count the time accurately with a clock.
●
It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit
has a malfunction.
●
Always ECM returns to Diagnostic Test Mode I after ignition switch is turned OFF.

F

How to Set Diagnostic Test Mode II (Self-diagnostic Results)

G

1.
2.
a.
b.
3.

H

4.

Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds.
Repeat the following procedure quickly five times within 5 seconds.
Fully depress the accelerator pedal.
Fully release the accelerator pedal.
Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 10 seconds until the MI starts
blinking.
Fully release the accelerator pedal.
ECM has entered to Diagnostic Test Mode II (Self-diagnostic results).

I

J

K

L

PBIB0092E

How to Set Diagnostic Test Mode II (Heated Oxygen Sensor 1 Monitor)
1.
2.

Set the ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-59, «How to Set Diagnostic
Test Mode II (Self-diagnostic Results)» .
Start Engine.
ECM has entered to Diagnostic Test Mode II (Heated oxygen sensor 1 monitor).

How to Erase Diagnostic Test Mode II (Self-diagnostic Results)
1.
2.
3.

Set ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-59, «How to Erase Diagnostic
Test Mode II (Self-diagnostic Results)» .
Fully depress the accelerator pedal and keep it for more than 10 seconds.
The emission-related diagnostic information has been erased from the backup memory in the ECM.
Fully release the accelerator pedal, and confirm the DTC 0000 is displayed.

DIAGNOSTIC TEST MODE I — BULB CHECK
In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to DI-32,
«WARNING LAMPS» or see EC-448 .

EC-59

M

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
DIAGNOSTIC TEST MODE I — MALFUNCTION WARNING
MI

●

Condition

ON

When the malfunction is detected.

OFF

No malfunction.

These DTC numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS)

DIAGNOSTIC TEST MODE II — SELF-DIAGNOSTIC RESULTS
In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI as shown below.
The DTC and 1st trip DTC are displayed at the same time. If the MI does not illuminate in diagnostic test mode
I (Malfunction warning), all displayed items are 1st trip DTCs. If only one code is displayed when the MI illuminates in diagnostic test mode II (SELF-DIAGNOSTIC RESULTS), it is a DTC; if two or more codes are displayed, they may be either DTCs or 1st trip DTCs. DTC No. is same as that of 1st trip DTC. These unidentified
codes can be identified by using the CONSULT-II or GST. A DTC will be used as an example for how to read a
code.

PBIA3905E

A particular trouble code can be identified by the number of four-digit numeral flashes. The “zero” is indicated
by the number of ten flashes. The length of time the 1,000th-digit numeral flashes on and off is 1.2 seconds
consisting of an ON (0.6-second) — OFF (0.6-second) cycle.
The 100th-digit numeral and lower digit numerals consist of a 0.3-second ON and 0.3-second OFF cycle.
A change from one digit numeral to another occurs at an interval of 1.0-second OFF. In other words, the later
numeral appears on the display 1.3 seconds after the former numeral has disappeared.
A change from one trouble code to another occurs at an interval of 1.8-second OFF.
In this way, all the detected malfunctions are classified by their DTC numbers. The DTC 0000 refers to no malfunction. (See EC-22, «INDEX FOR DTC» )

How to Erase Diagnostic Test Mode II (Self-diagnostic Results)
The DTC can be erased from the back up memory in the ECM by depressing accelerator pedal. Refer to EC59, «HOW TO SWITCH DIAGNOSTIC TEST MODE» .
●
If the battery is disconnected, the DTC will be lost from the backup memory within 24 hours.
●
Be careful not to erase the stored memory before starting trouble diagnoses.

DIAGNOSTIC TEST MODE II — HEATED OXYGEN SENSOR 1 MONITOR
In this mode, the MI displays the condition of the fuel mixture (lean or rich) which is monitored by the heated
oxygen sensor 1.
MI

Fuel mixture condition in the exhaust gas

ON

Lean

OFF

Rich

*Remains ON or OFF

Any condition

EC-60

Air-fuel ratio feedback control condition
Closed loop system
Open loop system

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
*: Maintains conditions just before switching to open loop.

A
To check the heated oxygen sensor 1 function, start engine in the Diagnostic Test Mode II and warm it up until
engine coolant temperature indicator points to the middle of the gauge.
Next run engine at about 2,000 rpm for about 2 minutes under no load conditions. Then make sure that the MI
EC
comes ON more than 5 times within 10 seconds with engine running at 2,000 rpm under no load.

OBD System Operation Chart

BBS002U0

RELATIONSHIP BETWEEN MI, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS
●

●

●

●

●

When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data are
stored in the ECM memory.
When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data are
stored in the ECM memory, and the MI will come on. For details, refer to EC-47, «Two Trip Detection
Logic» .
The MI will go off after the vehicle is driven 3 times (driving pattern B) with no malfunction. The drive is
counted only when the recorded driving pattern is met (as stored in the ECM). If another malfunction
occurs while counting, the counter will reset.
The DTC and the freeze frame data will be stored until the vehicle is driven 40 times (driving pattern A)
without the same malfunction recurring (except for Misfire and Fuel Injection System). For Misfire and
Fuel Injection System, the DTC and freeze frame data will be stored until the vehicle is driven 80 times
(driving pattern C) without the same malfunction recurring. The “TIME” in “SELF-DIAGNOSTIC
RESULTS” mode of CONSULT-II will count the number of times the vehicle is driven.
The 1st trip DTC is not displayed when the self-diagnosis results in OK for the 2nd trip.

C

D

E

F

G

SUMMARY CHART
Items
MI (goes off)
DTC, Freeze Frame Data (no
display)
1st Trip DTC (clear)
1st Trip Freeze Frame Data
(clear)

Fuel Injection System

Misfire

Other

3 (pattern B)

3 (pattern B)

3 (pattern B)

80 (pattern C)

80 (pattern C)

40 (pattern A)

1 (pattern C), *1

1 (pattern C), *1

1 (pattern B)

*1 , *2

*1 , *2

1 (pattern B)

For details about patterns “B” and “C” under “Fuel Injection System” and “Misfire”, see EC-63 .
For details about patterns “A” and “B” under “Other”, see EC-65 .
*1: Clear timing is at the moment OK is detected.
*2: Clear timing is when the same malfunction is detected in the 2nd trip.

H

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EC-61

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS FOR “MISFIRE”
, “FUEL INJECTION SYSTEM”

SEF392SA

*1: When the same malfunction is
detected in two consecutive trips, MI
will light up.

*2: MI will go off after vehicle is driven 3
times (pattern B) without any malfunctions.

*4: The DTC and the freeze frame data *5: When a malfunction is detected for
will not be displayed any longer after
the first time, the 1st trip DTC and
vehicle is driven 80 times (pattern C)
the 1st trip freeze frame data will be
without the same malfunction. (The
stored in ECM.
DTC and the freeze frame data still
remain in ECM.)
*7: When the same malfunction is
detected in the 2nd trip, the 1st trip
freeze frame data will be cleared.

*8: 1st trip DTC will be cleared when
vehicle is driven once (pattern C)
without the same malfunction after
DTC is stored in ECM.

EC-62

*3: When the same malfunction is
detected in two consecutive trips, the
DTC and the freeze frame data will
be stored in ECM.
*6: The 1st trip DTC and the 1st trip
freeze frame data will be cleared at
the moment OK is detected.

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
EXPLANATION FOR DRIVING PATTERNS FOR “MISFIRE ”, “FUEL INJECTION SYSTEM”

Driving pattern B means the vehicle operation as follows:
All components and systems should be monitored at least once by the OBD system.
●
The B counter will be cleared when the malfunction is detected once regardless of the driving pattern.
●
The B counter will be counted up when driving pattern B is satisfied without any malfunction.
●
The MI will go off when the B counter reaches 3. (*2 in OBD SYSTEM OPERATION CHART)

A

EC

C

Driving pattern C means the vehicle operation as follows:
1. The following conditions should be satisfied at the same time:
Engine speed: (Engine speed in the freeze frame data) ±375 rpm
Calculated load value: (Calculated load value in the freeze frame data) x (1±0.1) [%]
Engine coolant temperature (T) condition:
●
When the freeze frame data shows lower than 70°C (158°F), T should be lower than 70°C (158°F).
●
When the freeze frame data shows higher than or equal to 70°C (158°F), T should be higher than or equal
to 70°C (158°F).
Example:
If the stored freeze frame data is as follows:
Engine speed: 850 rpm, Calculated load value: 30%, Engine coolant temperature: 80°C (176°F)
To be satisfied with driving pattern C, the vehicle should run under the following conditions:
Engine speed: 475 — 1,225 rpm, Calculated load value: 27 — 33%, Engine coolant temperature: more than 70°C
(158°F)
●
The C counter will be cleared when the malfunction is detected regardless of vehicle conditions above.
●
The C counter will be counted up when vehicle conditions above is satisfied without the same malfunction.
●
The DTC will not be displayed after C counter reaches 80.
●
The 1st trip DTC will be cleared when C counter is counted once without the same malfunction after DTC
is stored in ECM.

D

E

F

G

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EC-63

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS EXCEPT FOR
“MISFIRE ”, “FUEL INJECTION SYSTEM”

PBIB2551E

*1: When the same malfunction is
detected in two consecutive trips, MI
will light up.

*2: MI will go off after vehicle is driven 3
times (pattern B) without any malfunctions.

*3: When the same malfunction is
detected in two consecutive trips, the
DTC and the freeze frame data will
be stored in ECM.

*4: The DTC and the freeze frame data
will not be displayed any longer after
vehicle is driven 40 times (pattern A)
without the same malfunction.
(The DTC and the freeze frame data
still remain in ECM.)

*5: When a malfunction is detected for
the first time, the 1st trip DTC and
the 1st trip freeze frame data will be
stored in ECM.

*6: 1st trip DTC will be cleared after
vehicle is driven once (pattern B)
without the same malfunction.

*7: When the same malfunction is
detected in the 2nd trip, the 1st trip
freeze frame data will be cleared.

EC-64

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITH EURO-OBD)]
EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR “MISFIRE ”, “FUEL INJECTION SYSTEM”

A

EC

C

D

E

F

G
AEC574

●
●
●

The A counter will be cleared when the malfunction is detected regardless of (1) — (4).
The A counter will be counted up when (1) — (4) are satisfied without the same malfunction.
The DTC will not be displayed after the A counter reaches 40.

Driving pattern B means the vehicle operation as follows:
All components and systems should be monitored at least once by the OBD system.
●
The B counter will be cleared when the malfunction is detected once regardless of the driving pattern.
●
The B counter will be counted up when driving pattern B is satisfied without any malfunctions.
●
The MI will go off when the B counter reaches 3 (*2 in OBD SYSTEM OPERATION CHART).

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EC-65

BASIC SERVICE PROCEDURE
[CR (WITH EURO-OBD)]

BASIC SERVICE PROCEDURE
Basic Inspection

PFP:00018
BBS002U4

1. INSPECTION START
1.
2.
–
–
–
–
–
–

3.
–
–
–
–

4.

Check service records for any recent repairs that may indicate a related malfunction, or a current need for
scheduled maintenance.
Open engine hood and check the following:
Harness connectors for improper connections
Wiring harness for improper connections, pinches and cut
Vacuum hoses for splits, kinks and improper connections
Hoses and ducts for leaks
Air cleaner clogging
Gasket
Confirm that electrical or mechanical loads are not applied.
Headlamp switch is OFF.
SEF983U
Air conditioner switch is OFF.
Rear window defogger switch is OFF.
Steering wheel is in the straight-ahead position, etc.
Start engine and warm it up until engine coolant temperature
indicator points the middle of gauge.
Ensure engine stays below 1,000 rpm.

SEF976U

5.

Run engine at about 2,000 rpm for about 2 minutes under no
load.
6. Make sure that no DTC is displayed with CONSULT-II or GST.
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

SEF977U

2. REPAIR OR REPLACE
Repair or replace components as necessary according to corresponding Diagnostic Procedure.
>> GO TO 3

EC-66

BASIC SERVICE PROCEDURE
[CR (WITH EURO-OBD)]

3. CHECK TARGET IDLE SPEED
1.
2.

A

With CONSULT-II
Run engine at about 2,000 rpm for about 2 minutes under no load.
Rev engine (2,000 to 3,000 rpm) two or three times under no
load, then run engine at idle speed for about 1 minute.

EC

C

D

E
PBIA8513J

3.

Read idle speed in “DATA MONITOR” mode with CONSULT-II.
Refer to EC-69, «IDLE SPEED» .

F

650 ± 50 rpm (in Neutral position)
G

H
SEF058Y

I

Without CONSULT-II
1. Run engine at about 2,000 rpm for about 2 minutes under no load.
2. Rev engine (2,000 to 3,000 rpm) two or three times under no load, then run engine at idle speed for about
1 minute.
3. Check idle speed. Refer to EC-69, «IDLE SPEED» .

K

650 ± 50 rpm (in Neutral position)
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 4.

L

4. PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING
1.
2.

J

Stop engine.
Perform EC-69, «Accelerator Pedal Released Position Learning» .
>> GO TO 5.

5. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING
Perform EC-69, «Throttle Valve Closed Position Learning» .
>> GO TO 6.

EC-67

M

BASIC SERVICE PROCEDURE
[CR (WITH EURO-OBD)]

6. PERFORM IDLE AIR VOLUME LEARNING
Refer to EC-69, «Idle Air Volume Learning» .
Is Idle Air Volume Learning carried out successfully?
Yes or No
Yes
>> GO TO 7.
No
>> 1. Follow the instruction of Idle Air Volume Learning.
2. GO TO 4.

7. CHECK TARGET IDLE SPEED AGAIN
1.
2.

With CONSULT-II
Start engine and warm it up to normal operating temperature.
Read idle speed in “DATA MONITOR” mode with CONSULT-II.
Refer to EC-69, «IDLE SPEED» .
650 ± 50 rpm (in Neutral position)

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Check idle speed. Refer to EC-69, «IDLE SPEED» .
650 ± 50 rpm (in Neutral position)
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 8.

8. DETECT MALFUNCTIONING PART
Check the following.
●
Check camshaft position sensor (PHASE) and circuit. Refer to EC-257 .
●
Check crankshaft position sensor (POS) and circuit. Refer to EC-250 .
OK or NG
OK
>> GO TO 9.
NG
>> 1. Repair or replace.
2. GO TO 4.

9. CHECK ECM FUNCTION
1.
2.

Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but
this is a rare case.)
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
>> GO TO 4.

EC-68

BASIC SERVICE PROCEDURE
[CR (WITH EURO-OBD)]

Idle Speed Check

BBS002TQ

A

IDLE SPEED
With CONSULT-II
Check idle speed in “DATA MONITOR” mode with CONSULT-II.

EC

C

D

SEF058Y

E

With GST
Check idle speed with GST.

Accelerator Pedal Released Position Learning

BBS002TR

F

DESCRIPTION
Accelerator Pedal Released Position Learning is an operation to learn the fully released position of the accelerator pedal by monitoring the accelerator pedal position sensor output signal. It must be performed each time
harness connector of accelerator pedal position sensor or ECM is disconnected.

OPERATION PROCEDURE
1.
2.
3.
4.
5.

H

Make sure that accelerator pedal is fully released.
Turn ignition switch ON and wait at least 2 seconds.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON and wait at least 2 seconds.
Turn ignition switch OFF and wait at least 10 seconds.

Throttle Valve Closed Position Learning

G

I

BBS002TS

J

DESCRIPTION
Throttle Valve Closed Position Learning is an operation to learn the fully closed position of the throttle valve by
monitoring the throttle position sensor output signal. It must be performed each time harness connector of
electric throttle control actuator or ECM is disconnected.

OPERATION PROCEDURE
1.
2.
3.

L

Make sure that accelerator pedal is fully released.
Turn ignition switch ON.
Turn ignition switch OFF and wait at least 10 seconds.
Make sure that throttle valve moves during above 10 seconds by confirming the operating sound.

Idle Air Volume Learning

M
BBS002TT

DESCRIPTION
Idle Air Volume Learning is an operation to learn the idle air volume that keeps each engine within the specific
range. It must be performed under any of the following conditions:
●
Each time electric throttle control actuator or ECM is replaced.
●
Idle speed is out of specification.

PREPARATION
Before performing Idle Air Volume Learning, make sure that all of the following conditions are satisfied.
Learning will be cancelled if any of the following conditions are missed for even a moment.
●
Battery voltage: More than 12.9V (At idle)
●
Engine coolant temperature: 70 — 100°C (158 — 212°F)
●
PNP switch: ON
●
Electric load switch: OFF
(Air conditioner, headlamp, rear window defogger)

EC-69

K

BASIC SERVICE PROCEDURE
[CR (WITH EURO-OBD)]
On vehicles equipped with daytime light systems, set lighting switch to the 1st position to light
only small lamps.
Steering wheel: Neutral (Straight-ahead position)
Vehicle speed: Stopped
Transmission: Warmed-up
Drive vehicle for 10 minutes.

●
●
●
–

OPERATION PROCEDURE
With CONSULT-II
1.
2.
3.
4.
5.

Perform EC-69, «Accelerator Pedal Released Position Learning» .
Perform EC-69, «Throttle Valve Closed Position Learning» .
Start engine and warm it up to normal operating temperature.
Check that all items listed under the topic PREPARATION (previously mentioned) are in good order.
Select “IDLE AIR VOL LEARN” in “WORK SUPPORT” mode.

SEF217Z

6.

Touch “START” and wait 20 seconds.

SEF454Y

7.

8.

Make sure that “CMPLT” is displayed on CONSULT-II screen. If
“CMPLT” is not displayed, Idle Air Volume Learning will not be
carried out successfully. In this case, find the cause of the incident by referring to the Diagnostic Procedure below.
Rev up the engine two or three times and make sure that idle
speed is within the specification.

ITEM

SPECIFICATION

Idle speed

650 ± 50 rpm (in Neutral position)
MBIB0238E

Without CONSULT-II
NOTE:
●
It is better to count the time accurately with a clock.
●
It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit
has a malfunction.
1. Perform EC-69, «Accelerator Pedal Released Position Learning» .
2. Perform EC-69, «Throttle Valve Closed Position Learning» .

EC-70

BASIC SERVICE PROCEDURE
[CR (WITH EURO-OBD)]
3.
4.
5.
6.
7.
a.
b.
8.

Start engine and warm it up to normal operating temperature.
A
Check that all items listed under the topic PREPARATION (previously mentioned) are in good order.
Turn ignition switch OFF and wait at least 10 seconds.
Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds.
EC
Repeat the following procedure quickly five times within 5 seconds.
Fully depress the accelerator pedal.
Fully release the accelerator pedal.
C
Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 20 seconds until the MI stops
blinking and turned ON.
9. Fully release the accelerator pedal within 3 seconds after the MI turned ON.
D
10. Start engine and let it idle.
11. Wait 20 seconds.
E

F

G

PBIB0665E

H

12. Rev up the engine two or three times and make sure that idle speed is within the specification.
ITEM

SPECIFICATION

Idle speed

650 ± 50 rpm (in Neutral position)

I

13. If idle speed is not within the specification, Idle Air Volume Learning will not be carried out successfully. In
this case, find the cause of the incident by referring to the Diagnostic Procedure below.

J

DIAGNOSTIC PROCEDURE
If idle air volume learning cannot be performed successfully, proceed as follows:
1. Check that throttle valve is fully closed.
2. Check PCV valve operation.
3. Check that downstream of throttle valve is free from air leakage.
4. When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the incident.
It is useful to perform EC-117, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .
5. If any of the following conditions occur after the engine has started, eliminate the cause of the
incident and perform Idle Air Volume Learning all over again:
● Engine stalls.
● Erroneous idle.

Fuel Pressure Check

BBS002TU

FUEL PRESSURE RELEASE
With CONSULT-II
1.

Turn ignition switch ON.

EC-71

K

L

M

BASIC SERVICE PROCEDURE
[CR (WITH EURO-OBD)]
2.
3.
4.
5.

Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT”
mode with CONSULT-II.
Start engine.
After engine stalls, crank it 2 or 3 times to release all fuel pressure.
Turn ignition switch OFF.

SEF214Y

Without CONSULT-II
1.
2.
3.
4.
5.

Remove fuel pump fuse located in IPDM E/R.
Start engine.
After engine stalls, crank it 2 or 3 times to release all fuel pressure.
Turn ignition switch OFF.
Reinstall fuel pump fuse after servicing fuel system.

MBIB0277E

FUEL PRESSURE CHECK
CAUTION:
●
Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger.
●
The fuel hose connection method used when taking fuel pressure check must not be used for
other purposes.
●
Be careful not to scratch or put debris around connection area when servicing, so that the quick
connector maintains sealability with O-rings inside.
●
When installing fuel hose quick connector, refer to EM-18, «AIR CLEANER AND AIR DUCT» .
NOTE:
Prepare pans or saucers under the disconnected fuel line because the fuel may spill out. The fuel pressure cannot be completely released because E11 models do not have fuel return system.
1. Release fuel pressure to zero. Refer to EC-71, «FUEL PRESSURE RELEASE» .
2. Prepare fuel hose and fuel hose clamp for fuel pressure check, and connect fuel pressure gauge.
● Use suitable fuel hose for fuel pressure check (genuine NISSAN fuel hose without quick connector).
● To avoid unnecessary force or tension to hose, use moderately long fuel hose for fuel pressure check.
● Do not use the fuel hose for checking fuel pressure with damage or cracks on it.
● Use Pressure Gauge to check fuel pressure.
3. Remove fuel hose. Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
● Do not twist or kink fuel hose because it is plastic hose.
● Do not remove fuel hose from quick connector.
● Keep the original fuel hose to be free from intrusion of dust or foreign substances with a suitable cover.

EC-72

BASIC SERVICE PROCEDURE
[CR (WITH EURO-OBD)]
4.

Install the fuel pressure gauge as shown in the figure.
● Wipe off oil or dirt from hose insertion part using cloth moistened with gasoline.
● Apply proper amount of gasoline between top of the fuel tube
and No.1 spool.
● Insert fuel hose for fuel pressure check until it touches the
No.1 spool on fuel tube.
● Use NISSAN genuine hose clamp (part number: 16439
N4710 or 16439 40U00).
● When reconnecting fuel line, always use new clamps.
● When reconnecting fuel hose, check the original fuel hose for
damage and abnormality.
● Use a torque driver to tighten clamps.
● Install hose clamp to the position within 1 — 2 mm (0.04 — 0.08
in).
– A: Fuel pressure gauge
Tightening torque:

6.
7.
8.

EC

C
PBIB0669E

1 — 1.5 N·m (0.1 — 0.15 kg-m,
9 — 13 in-lb)

Make sure that clamp screw does not contact adjacent parts.
After connecting fuel hose for fuel pressure check, pull the hose
with a force of approximately 98 N (10 kg, 22 lb) to confirm fuel
tube does not come off.
MBIB1495E
Turn ignition switch ON, and check for fuel leakage.
Start engine and check for fuel leakage.
Read the indication of fuel pressure gauge.
● Do not perform fuel pressure check with system operating. Fuel pressure gauge may indicate false
readings.
● During fuel pressure check, confirm for fuel leakage from fuel connection every 3 minutes.
●

5.

A

At idling:

D

E

F

G

H

I

J

Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi)
K

9. If result is unsatisfactory, go to next step.
10. Check the following.
● Fuel hoses and fuel tubes for clogging
● Fuel filter for clogging
● Fuel pump
● Fuel pressure regulator for clogging
If OK, replace fuel pressure regulator.
If NG, repair or replace.

L

M

EC-73

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

TROUBLE DIAGNOSIS
Trouble Diagnosis Introduction

PFP:00004
BBS002U1

INTRODUCTION
The engine has an ECM to control major systems such as fuel control, ignition control, idle air control system, etc. The ECM accepts
input signals from sensors and instantly drives actuators. It is essential that both input and output signals are proper and stable. At the
same time, it is important that there are no malfunctions such as vacuum leaks, fouled spark plugs, or other malfunctions with the engine.

MEF036D

It is much more difficult to diagnose an incident that occurs intermittently rather than continuously. Most intermittent incidents are
caused by poor electric connections or improper wiring. In this case,
careful checking of suspected circuits may help prevent the replacement of good parts.

SEF233G

A visual check only may not find the cause of the incidents. A road
test with CONSULT-II (or GST) or a circuit tester connected should
be performed. Follow the Work Flow on EC-75 .
Before undertaking actual checks, take a few minutes to talk with a
customer who approaches with a driveability complaint. The customer can supply good information about such incidents, especially
intermittent ones. Find out what symptoms are present and under
what conditions they occur. A Diagnostic Worksheet like the example
on EC-79 should be used.
Start your diagnosis by looking for conventional malfunctions first.
This will help troubleshoot driveability malfunctions on an electronically controlled engine vehicle.

EC-74

SEF234G

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
WORK FLOW
Overall Sequence

A

EC

C

D

E

F

G

H

I

J

K

L

M

PBIB2267E

EC-75

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
Detailed Flow

1. GET INFORMATION FOR SYMPTOM
Get the detailed information from the customer about the symptom (the condition and the environment when
the incident/malfunction occurred) using the EC-78, «DIAGNOSTIC WORKSHEET» .
>> GO TO 2.

2. CHECK DTC*1
1.

Check DTC*1 .

2.

Perform the following procedure if DTC*1 is displayed.

–

Record DTC*1 and freeze frame data*2 . (Print them out with CONSULT-II or GST.)

–

Erase DTC*1 . (Refer to EC-57, «HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION»
.)

Study the relationship between the cause detected by DTC*1 and the symptom described by the customer. (Symptom Matrix Chart is useful. Refer to EC-82, «Symptom Matrix Chart» .)
3. Check related service bulletins for information.
Is any symptom described and any DTC detected?

–

Symptom is described, DTC*1 is displayed>>GO TO 3.
Symptom is described, DTC*1 is not displayed>>GO TO 4.
Symptom is not described, DTC*1 is displayed>>GO TO 5.

3. CONFIRM THE SYMPTOM
Try to confirm the symptom described by the customer (except MI ON).
DIAGNOSIS WORK SHEET is useful to verify the incident.
Connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis
results.
Verify relation between the symptom and the condition when the symptom is detected.
>> GO TO 5.

4. CONFIRM THE SYMPTOM
Try to confirm the symptom described by the customer.
DIAGNOSIS WORK SHEET is useful to verify the incident.
Connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis
results.
Verify relation between the symptom and the condition when the symptom is detected.
>> GO TO 6.

EC-76

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

5. PERFORM DTC CONFIRMATION PROCEDURE

A
1

1

Perform DTC Confirmation Procedure for the displayed DTC* , and then make sure that DTC* is detected
again.
At this time, always connect CONSULT-II to the vehicle, and check diagnostic results in real time on “DATA EC
MONITOR (AUTO TRIG)”.
If two or more DTCs*1 are detected, refer to EC-80, «DTC Inspection Priority Chart» and determine trouble
diagnosis order.
C
NOTE:
●
Freeze frame data*2 is useful if the DTC*1 is not detected.
●
Perform Overall Function Check if DTC Confirmation Procedure is not included on Service Manual. This D
simplified check procedure is an effective alternative though DTC*1 cannot be detected during this check.
If the result of Overall Function Check is NG, it is the same as the detection of DTC*1 by DTC ConfirmaE
tion Procedure.
Is DTC*1 detected?
Yes
>> GO TO 10.
No
>> Check according to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

F

6. PERFORM BASIC INSPECTION
G

Perform EC-66, «Basic Inspection» .
With CONSULT-II>>GO TO 7.
Without CONSULT-II>>GO TO 9.

H

7. PERFORM DATA MONITOR (SPEC) MODE

I

With CONSULT-II
Make sure that “B/FUEL SCHDL”, and “A/F ALPHA-B1” are within
the SP value using CONSULT-II “DATA MONITOR (SPEC)” mode.
Refer to EC-118, «Diagnostic Procedure» .
Are they within the SP value?
Yes
>> GO TO 9.
No
>> GO TO 8.

J

K

L

SEF601Z

8. DETECT MALFUNCTIONING PART BY TROUBLE DIAGNOSIS — SPECIFICATION VALUE
Detect malfunctioning part according to EC-117, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .
Is malfunctioning part detected?
Yes
>> GO TO 11.
No
>> GO TO 9.

9. DETECT MALFUNCTIONING SYSTEM BY SYMPTOM MATRIX CHART
Detect malfunctioning system according to EC-82, «Symptom Matrix Chart» based on the confirmed symptom
in step 4, and determine the trouble diagnosis order based on possible causes and symptom.
>> GO TO 10.

EC-77

M

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

10. DETECT MALFUNCTIONING PART BY DIAGNOSTIC PROCEDURE
Inspect according to Diagnostic Procedure of the system.
NOTE:
The Diagnostic Procedure in EC section described based on open circuit inspection. A short circuit inspection
is also required for the circuit check in the Diagnostic Procedure. For details, refer to Circuit Inspection in GI25, «How to Perform Efficient Diagnosis for an Electrical Incident» .
Is malfunctioning part detected?
Yes
>> GO TO 11.
No
>> Monitor input data from related sensors or check voltage of related ECM terminals using CONSULT-II. Refer to EC-95, «ECM Terminals and Reference Value» , EC-112, «CONSULT-II Reference Value in Data Monitor Mode» .

11. REPAIR OR REPLACE THE MALFUNCTIONING PART
1.
2.
3.

Repair or replace the malfunctioning part.
Reconnect parts or connectors disconnected during Diagnostic Procedure again after repair and replacement.
Check DTC. If DTC is displayed, erase it, refer to EC-57, «HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .
>> GO TO 12.

12. FINAL CHECK
When DTC was detected in step 2, perform DTC Confirmation Procedure or Overall Function Check again,
and then make sure that the malfunction have been repaired securely.
When symptom was described from the customer, refer to confirmed symptom in step 3 or 4, and make sure
that the symptom is not detected.
OK or NG
NG (DTC*1 is detected)>>GO TO 10.
NG (Symptom remains)>>GO TO 6.
OK
>> 1. Before returning the vehicle to the customer, make sure to erase unnecessary DTC*1 in ECM.
(Refer to EC-57, «HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .)
2. If the completion of SRT is needed, drive vehicle under the specific driving pattern. Refer to EC55, «Driving Pattern» .
3. INSPECTION END
*1: Include 1st trip DTC.
*2: Include 1st trip freeze frame data.

DIAGNOSTIC WORKSHEET
Description
There are many operating conditions that lead to the malfunction of
engine components. A good grasp of such conditions can make troubleshooting faster and more accurate.
In general, each customer feels differently about a incident. It is
important to fully understand the symptoms or conditions for a customer complaint.
Utilize a diagnostic worksheet like the one on the next page in order
to organize all the information for troubleshooting.
Some conditions may cause the MI to come on steady or blink and
DTC to be detected. Examples:
●
Vehicle ran out of fuel, which caused the engine to misfire.

EC-78

SEF907L

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
Worksheet Sample
A

EC

C

D

E

F

G

H

I

J

K

L

M

MTBL0017

EC-79

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

DTC Inspection Priority Chart

BBS002U2

If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
chart.
NOTE:
●
If DTC U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1001. Refer
to EC-134, «DTC U1001 CAN COMMUNICATION LINE» .
●
If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer
to EC-137, «DTC U1010 CAN COMMUNICATION» .
Priority
1

2

3

Detected items (DTC)
●

U1001 CAN communication line

●

U1010 CAN communication

●

P0107 P0108 Manifold absolute pressure sensor

●

P0112 P0113 Intake air temperature sensor

●

P0117 P0118 Engine coolant temperature sensor

●

P0122 P0123 P0222 P0223 P1225 P1226 P2135 Throttle position sensor

●

P0327 P0328 Knock sensor

●

P0335 Crankshaft position sensor (POS)

●

P0340 Camshaft position sensor (PHASE)

●

P0500 Vehicle speed sensor

●

P0605 ECM

●

P1171 Intake error

●

P1229 Sensor power supply

●

P1610-P1615 NATS

●

P1706 Park/Neutral position (PNP) switch

●

P2122 P2123 P2127 P2128 P2138 Accelerator pedal position sensor

●

P0031 P0032 Heated oxygen sensor 1 heater

●

P0037 P0038 Heated oxygen sensor 2 heater

●

P0132 P0133 P0134 P1143 P1144 Heated oxygen sensor 1

●

P0138 P0139 P1146 P1147 Heated oxygen sensor 2

●

P0444 EVAP canister purge volume control solenoid valve

●

P1065 ECM power supply

●

P1111 Intake valve timing control solenoid valve

●

P1122 Electric throttle control function

●

P1124 P1126 Throttle control motor relay

●

P1128 Throttle control mother

●

P1805 Brake switch

●

P0011 Intake valve timing control

●

P0171 P0172 Fuel injection system function

●

P0300 — P0304 Misfire

●

P0420 Three way catalyst function

●

P1121 Electric throttle control actuator

●

P1211 ESP control unit

●

P1212 ESP communication line

●

P1217 Engine over temperature (OVERHEAT)

EC-80

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

Fail-Safe Chart

BBS002U3

When the DTC listed bellow is detected, the ECM enters fail-safe mode and the MI lights up.
DTC No.
P0117
P0118

Detected items

Engine operating condition in fail-safe mode

Engine coolant temperature
sensor circuit

Engine coolant temperature will be determined by ECM based on the time after turning
ignition switch ON or START.
CONSULT-II displays the engine coolant temperature decided by ECM.
Condition

Engine coolant temperature decided
(CONSULT-II display)

Just as ignition switch is turned
ON or START

40°C (104°F)

More than approx. 4 minutes after
ignition ON or START

80°C (176°F)

Except as shown above

A

EC

C

D

40 — 80°C (104 — 176°F)
(Depends on the time)

E

When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates while engine is running.
P0122
P0123
P0222
P0223
P2135

Throttle position sensor

P1121

Electric throttle control
actuator

The ECM controls the electric throttle control actuator in regulating the throttle opening
in order for the idle position to be within +10 degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

H

(When throttle valve opening angle in fail-safe mode is not in specified range:)
ECM controls the electric throttle control actuator by regulating the throttle opening to
20 degrees or less.

I

P1122

Electric throttle control
function

ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.

P1124
P1126

Throttle control motor relay

ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.

P1128

Throttle control motor

ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.

P1171

Intake air system

P1229

Sensor power supply

ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.

P2122
P2123
P2127
P2128
P2138

Accelerator pedal position
sensor

The ECM controls the electric throttle control actuator in regulating the throttle opening
in order for the idle position to be within +10 degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

When accelerator pedal is depressed, engine speed will not rise more than 2,500 rpm
due to fuel cut.

When there is an open circuit on MI circuit, the ECM can not warn the driver by lighting up MI when there
is a malfunction on engine control system.
Therefore, when electrical controlled throttle and part of ECM related diagnoses is continuously detected
as NG for 5 trips, ECM warns the driver that engine control system has a malfunction and MI circuit is
open by means of operating fail-safe function.
The fail-safe function also operate when above diagnoses except MI circuit are detected and demands
the driver to repair the malfunction.
Engine operating condition in fail-safe mode

G

(When electric throttle control actuator does not function properly due to the return
spring malfunction:)
ECM controls the electric throttle control actuator by regulating the throttle opening
around the idle position. The engine speed will not rise more than 2,000 rpm.

(When ECM detects the throttle valve is stuck open:)
While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops,
the engine stalls.
The engine can restart in Neutral position, and engine speed will not exceed 1,000 rpm
or more.

●

F

Engine speed will not rise more than 2,500 rpm due to the fuel cut

EC-81

J

K

L

M

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

Symptom Matrix Chart

BBS002U5

SYSTEM — BASIC ENGINE CONTROL SYSTEM

1

1

2

3

2

Fuel pressure regulator system

3

3

4

4

4

Fuel injector circuit

1

1

2

3

2

Evaporative emission system

3

3

4

4

4

Air

Positive crankcase ventilation system

3

3

4

4

4

Incorrect idle speed adjustment

3

3

Electric throttle control actuator

1

1

2

3

3

Incorrect ignition timing adjustment

3

3

1

1

Ignition circuit

1

1

2

Power supply and ground circuit

2

2

Manifold absolute pressure sensor circuit

1

Engine coolant temperature sensor circuit

1

Ignition

Throttle position sensor circuit

AG

AH

AJ

AK

AL

AM

HA

2

2

4

4

2

2

4

4

4

4

4

1

1

4

2

EC-427

4

EC-72

2

EC-421

4

4

EC-40

4

4

4

1

1

1

EC-66

2

EC-291,
EC-293 ,
EC-299 ,
EC-305

EC-45

1

1

1

EC-66

2

2

2

2

2

EC-433

3

3

3

3

3

3

EC-128

1

2

2

2

2

2

2

EC-155

1

2

2

2

2

2

2

EC-166

2

EC-171,
EC-233 ,
EC-359 ,
EC-361 ,
EC-402

3

1

Knock sensor circuit
Crankshaft position sensor (POS) circuit

2

2

Camshaft position sensor (PHASE) circuit

2

2
2

2

2

2

3

2

2

1

2

3

2

2

2

2

2

1

1

2

2

3
4

2

Accelerator pedal position sensor circuit

Vehicle speed signal circuit

AF

Reference
page

2

1

Heated oxygen sensor 1 circuit

BATTERY DEAD (UNDER CHARGE)

Fuel pump circuit

EXCESSIVE OIL CONSUMPTION

Fuel

EXCESSIVE FUEL CONSUMPTION

AE

OVERHEATS/WATER TEMPERATURE HIGH

LACK OF POWER/POOR ACCELERATION

AD

SLOW/NO RETURN TO IDLE

SPARK KNOCK/DETONATION

AC

IDLING VIBRATION

HESITATION/SURGING/FLAT SPOT

AB

ROUGH IDLE/HUNTING

ENGINE STALL

AA

Warranty symptom code

HIGH IDLE/LOW IDLE

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

2

3

2

1

EC-363,
EC-383 ,
EC-392 ,
EC-409

2

2

2

2

2

EC-178,
EC-185 ,
EC-195 ,
EC-310 ,
EC-316

3

EC-246
EC-250
EC-257

3

EC-82

3

3

EC-277

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
SYMPTOM

HARD/NO START/RESTART (EXCP. HA)

ENGINE STALL

HESITATION/SURGING/FLAT SPOT

SPARK KNOCK/DETONATION

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

A

AA

AB

AC

AD

AE

AF

AG

AH

AJ

AK

AL

AM

HA

ECM

2

2

3

3

3

3

3

3

3

3

3

EC-279,
EC-282

Intake valve timing control solenoid valve circuit

3

3

2

1

3

2

2

3

3

EC-286

3

3

Warranty symptom code

PNP switch circuit
Refrigerant pressure sensor circuit

2

Electrical load signal circuit
Air conditioner circuit

2

ABS actuator and electric unit (control unit)

2

3

3

4

1 — 6: The numbers refer to the order of inspection.
(continued on next page)

3

EC

Reference
page

C

D

E

3

3

3

3

3

EC-371

3

3

3

3

4

EC-443

3

3

3

3

3

3

3

3

F

G

H

EC-419
3

2

ATC-26,
MTC-23

I

BRC-8 or
BRC-49

J

K

L

M

EC-83

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
SYSTEM — ENGINE MECHANICAL & OTHER

Fuel

ENGINE STALL

HESITATION/SURGING/FLAT SPOT

SPARK KNOCK/DETONATION

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

Warranty symptom code

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

AA

AB

AC

AD

AE

AF

AG

AH

AJ

AK

AL

AM

HA

Fuel tank

FL-8
5

Fuel piping

5

Vapor lock

5

5

5

5

FL-3, EM32

5

—

5

Valve deposit
Poor fuel (Heavy weight gasoline, Low octane)
Air

Reference
page

—
5

5

5

5

5

5

5
—

Air duct
Air cleaner
Air leakage from air duct
(Manifold absolute pressure sensor —electric throttle control
actuator)

EM-18
5

5

5

5
5

5

5

5

5
5

Electric throttle control actuator
Air leakage from intake manifold/
Collector/Gasket
Cranking

Battery

EM-22
1

1

1

1

1

1

1

1

Alternator circuit

Engine

SC-5
SC-15

Starter circuit

3

SC-45

Signal plate/Flywheel/Drive plate

6

EM-74

PNP switch

4

AT-109,
MT-16

Cylinder head
Cylinder head gasket

5

5

5

5

5

5

5

4

5

3

EM-60

Cylinder block
Piston

4

Piston ring
Connecting rod

6

6

6

6

Bearing
Crankshaft

EC-84

6

6

6

6

EM-74

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
SYMPTOM

Valve
mechanism

HARD/NO START/RESTART (EXCP. HA)

ENGINE STALL

HESITATION/SURGING/FLAT SPOT

SPARK KNOCK/DETONATION

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

Warranty symptom code

A

AA

AB

AC

AD

AE

AF

AG

AH

AJ

AK

AL

AM

HA

EC

Reference
page

D

E

Timing chain

EM-50

Camshaft

EM-38

Intake valve timing control

5

5

5

5

5

5

5

5

C

EM-50

F

G

Intake valve
3

Exhaust valve
Exhaust

Exhaust manifold/Tube/Muffler/
Gasket

H
5

5

5

5

5

5

5

EM-24, EX3

5

Three way catalyst
Lubrication

Cooling

Oil pan/Oil strainer/Oil pump/Oil
filter/Oil gallery

EM-60

5

5

5

5

5

5

5

5

2

EM-26, LU9 , LU-10 ,
LU-5

Oil level (Low)/Filthy oil

LU-6

Radiator/Hose/Radiator filler cap

CO-12

Thermostat

5

CO-19

Water pump
Water gallery

CO-17
5

5

5

5

Cooling fan

5

5

2
5

Coolant level (low)/Contaminated
coolant
NATS (Nissan Anti-theft System)

5

5

I

J

K

CO-7
CO-12

L

CO-8
1

BL-215 or
EC-44

1

1 — 6: The numbers refer to the order of inspection.

EC-85

M

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

Engine Control Component Parts Location

BBS002U6

MBIB1491E

1.

Intake valve timing control solenoid
valve

2.

Fuel injector

3.

Refrigerant pressure sensor

4.

Ignition coil (with power transistor)
and spark plug

5.

Heated oxygen sensor 1

6.

Crankshaft position sensor (POS)

7.

Cooling fan motor

8.

IPDM E/R

9.

ECM

10. Camshaft position sensor (PHASE)

11. EVAP canister purge volume control solenoid valve

12. Engine coolant temperature sensor

13. Manifold absolute pressure sensor
(with intake air temperature sensor)

14. Knock sensor

15. Electric throttle control actuator

EC-86

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
A

EC

C

D

E

F

G

H

I

J

K

L

M
MBIB1498E

: Vehicle front
1.

Manifold absolute pressure sensor
(with intake air temperature sensor)

2.

Crankshaft position sensor (POS)

3.

Engine coolant temperature sensor

6.

IPDM E/R

4.

Camshaft position sensor (PHASE)

5.

Battery

7.

Fuel injector

8.

Ignition coil
(with power transistor)

EC-87

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

MBIB1499E

1.

Condenser

2.

Oil filter

3.

Refrigerant pressure sensor

4.

Intake manifold

5.

Knock sensor

6.

Electric throttle control actuator

7.

ECM

8.

Battery

9.

Data link connector

EC-88

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
A

EC

C

D

E

F
MBIB0320E

G

H

I

J

K

L

M

MBIB1460E

: Vehicle front
1.

Exhaust manifold cover

2.

Heated oxygen sensor 1

3.

Heated oxygen sensor 1 harness
connector

4.

Heated oxygen sensor 2 harness
connector

5.

Heated oxygen sensor 2

6.

Oil pan

EC-89

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

MBIB1500E

: Vehicle front
1.

Park/neutral position switch

2.

Cooling fan motor

4.

Fuel pump fuse (15A)

5.

Fuel level sensor unit and fuel pump 6.
harness connector

Fuel level sensor unit

7.

Fuel pump and fuel filter

8.

Fuel pressure regulator

Intake valve timing control solenoid
valve

10.

EVAP canister purge volume control solenoid valve

EC-90

3.

9.

IPDM E/R

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
A

EC

C

D

E
MBIB1501E

1.

Accelerator pedal position sensor

4.

Brake pedal

2.

Accelerator pedal

3.

Stop lamp switch

F

G

H

I

J

K

L

M

EC-91

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

Vacuum Hose Drawing

BBS002TJ

MBIB1440E

: Vehicle front
1.

EVAP canister purge volume control
solenoid valve

2.

Intake manifold

NOTE:
Do not use soapy water or any type of solvent while installing vacuum hose or purge hoses.

Refer to EC-33, «System Diagram» for Vacuum Control System.

EC-92

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

Circuit Diagram

BBS002U7

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1500E

EC-93

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

MBWA1501E

EC-94

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

ECM Harness Connector Terminal Layout

BBS002U8

A

EC

C

MBIB0045E

ECM Terminals and Reference Value

BBS002U9

PREPARATION
1.
2.

D

E

ECM is located left hand side of the engine room.
Remove ECM harness protector.

F

G

H
MBIB0274E

3.
4.

When disconnecting ECM harness connector, loosen it with
levers as far as they will go as shown at right.
Connect a break-out box (SST) and Y-cable adapter (SST)
between the ECM and ECM harness connector.
● Use extreme care not to touch 2 pins at one time.
● Data is for comparison and may not be exact.

I

J

K

PBIB1512E

L

ECM INSPECTION TABLE
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
1

WIRE
COLOR
B

ITEM

ECM ground

CONDITION
[Engine is running]
●

Idle speed

EC-95

DATA (DC Voltage)

Body ground

M

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]

2

GR

●

Engine speed: Below 3,800 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load.

Heated oxygen sensor 2
heater

0 — 1.0V

[Ignition switch: ON]
●

Engine stopped

[Engine is running]
●

3

LG

Throttle control motor
relay power supply

BATTERY VOLTAGE
(11 — 14V)

Engine speed: Above 3,800 rpm

[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)
0 — 14V

[Ignition switch: ON]
4

L

Throttle control motor
(Close)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released
PBIB0534E

0 — 14V
[Ignition switch: ON]
5

P

Throttle control motor
(Open)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed
PBIB0533E

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 3.0V

NOTE:
The pulse cycle changes depending on rpm
at idle.
13

Y

PBIB0527E

Crankshaft position
sensor (POS)

Approximately 3.0V

[Engine is running]
●

Engine speed: 2,000 rpm

PBIB0528E

EC-96

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

[Engine is running]
●

Warm-up condition

●

Idle speed

DATA (DC Voltage)

1.0 — 4.0V

EC

NOTE:
The pulse cycle changes depending on rpm
at idle.
14

R

A

C
PBIB0525E

Camshaft position sensor (PHASE)

D

1.0 — 4.0V

E

[Engine is running]
●

Engine speed: 2,000 rpm

F
PBIB0526E

15

W

Knock sensor

[Engine is running]
●

Idle speed

Approximately 2.5V

G

[Engine is running]
●

16

LG

Heated oxygen sensor 2

Revving engine from idle to 3,000rpm
quickly after the following conditions are
met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load.

H
0 — Approximately 1.0V

I

BATTERY VOLTAGE

J

(11 — 14V)
[Engine is running]
●

19

LG

K

Idle speed

L

EVAP canister purge
volume control solenoid
valve

PBIB0050E

Approximately 10V

M
[Engine is running]
●

Engine speed: About 2,000 rpm (More than
100 seconds after starting engine)

PBIB0520E

EC-97

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)
BATTERY VOLTAGE

[Engine is running]

22
23
41
42

O
L
R
GR

●

Warm-up condition

●

Idle speed

(11 — 14V)

NOTE:
The pulse cycle changes depending on rpm
at idle.

Fuel injector No. 3
Fuel injector No. 1
Fuel injector No. 4
Fuel injector No. 2

PBIB0529E

BATTERY VOLTAGE
(11 — 14V)
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

PBIB0530E

Approximately 7.0V
[Engine is running]
24

Y

Heated oxygen sensor 1
heater

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

PBIB0519E

[Engine is running]
●

29

30

B

L

Engine speed: Above 3,600 rpm

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]

Sensor ground
(Camshaft position sensor)

●

Warm-up condition

●

Idle speed

Sensor ground
(Crankshaft position
sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]

34

O

Intake air temperature
sensor

[Engine is running]

35

BR

Heated oxygen sensor 1

●

Warm-up condition

●

Engine speed: 2,000 rpm

Approximately 0V

Approximately 0 — 4.8V
Output voltage varies with intake
air temperature.

[Engine is running]

45

0 — Approximately 1.0V
(Periodically change)

L

Sensor power supply

[Ignition switch: ON]

Approximately 5V

46

W

Sensor power supply
(Refrigerant pressure
sensor)

[Ignition switch: ON]

Approximately 5V

47

L

Sensor power supply
(Throttle position sensor)

[Ignition switch: ON]

Approximately 5V

EC-98

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

A

[Ignition switch: ON]

49

Y

Throttle position
sensor 1

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

EC

More than 0.36V

C

[Ignition switch: ON]
●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

Less than 4.75V

D

[Engine is running]

51

W

Manifold absolute pressure sensor

●

Warm-up condition

●

Idle speed

Approximately 1.5V

E

Approximately 1.2V

F

Approximately 0V

G

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

[Engine is running]
54

56

57

—

B

Y

Sensor ground
(Knock sensor)

●

Warm-up condition

●

Idle speed

[Engine is running]

Sensor ground
(Manifold absolute pressure sensor)

●

Warm-up condition

●

Idle speed

Sensor ground
(Refrigerant pressure
sensor)

●

Warm-up condition

●

Idle speed

[Engine is running]

[Engine is running]

60
61
79
80

Y
V
G
BR

H

Approximately 0V

●

Warm-up condition

●

Idle speed

I
Approximately 0V

J

0 — 0.1V

K

NOTE:
The pulse cycle changes depending on rpm
at idle.

Ignition signal No. 3
Ignition signal No. 1
Ignition signal No. 4
Ignition signal No. 2

PBIB0521E

L

0 — 0.2V

M

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

PBIB0522E

EC-99

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION
[Engine is running]
●

Warm-up condition

●

Idle speed

DATA (DC Voltage)

BATTERY VOLTAGE
(11 — 14V)
Approximately 4V — BATTERY

62

LG

Intake valve timing
control solenoid valve

VOLTAGE (11 — 14V)
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

PBIB1790E

66

B

Sensor ground
(Throttle position sensor)

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0V

[Ignition switch: ON]

68

R

Throttle position
sensor 2

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

Less than 4.75V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

More than 0.36V

[Engine is running]
69

BR

Refrigerant pressure
sensor

●

Warm-up condition

●

Both A/C switch and blower fan switch: ON

1.0 — 4.0V

(Compressor operates.)
72

P

Engine coolant temperature sensor

73

B

Sensor ground
(Engine coolant temperature sensor)

[Engine is running]

Approximately 0 — 4.8V
Output voltage varies with engine
coolant temperature.

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
82

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
83

85

B

LG

Sensor ground
(APP sensor 2)

DATA link connector

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]
●

CONSULT-II or GST: Disconnected

Approximately 0V

BATTERY VOLTAGE
(11 — 14V)

86

Y

CAN communication line

[Ignition switch: ON]

1.0 — 2.5V

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

EC-100

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
TERMINAL
NO.
94

WIRE
COLOR
L

ITEM
CAN communication line

CONDITION
[Ignition switch: ON]

DATA (DC Voltage)
2.5 — 4.0V

EC

[Ignition switch: ON]

98

G

Accelerator pedal
position sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

Engine stopped

●

Accelerator pedal: Fully depressed

[Ignition switch: OFF]
●

101

R

Stop lamp switch

Brake pedal: Fully released

[Ignition switch: OFF]
●

Brake pedal: Slightly depressed

[Ignition switch: ON]
●

102

GR

PNP switch

G

Throttle control motor
relay

Gear position: Neutral

[Ignition switch: ON]
●

104

0.3 — 0.6V

C

[Ignition switch: ON]
●

Except the above gear position

1.95 — 2.4V

D
Approximately 0V
BATTERY VOLTAGE
(11 — 14V)
Approximately 0V

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 1.0V

[Ignition switch: ON]

106

109

W

O

Accelerator pedal position sensor 1

Ignition switch

Engine stopped

●

Accelerator pedal: Fully released

●

Engine stopped

●

Accelerator pedal: Fully depressed

ECM relay
(Self shut-off)

3.9 — 4.7V

J

[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)

For a few seconds after turning ignition
switch OFF

[Ignition switch: OFF]
More than a few seconds passed after turning ignition switch OFF

0 — 1.0V

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]
●

R

Fuel pump relay

H

I

0V

●

113

G

0.6 — 0.9V

[Ignition switch: OFF]

●

P

F

[Ignition switch: ON]

[Engine is running]
[Ignition switch: OFF]
111

E

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: OFF]

●

A

For 1 second after turning ignition switch ON

0 — 1.0V

[Engine is running]
[Ignition switch: ON]
●

More than 1 second after turning ignition
switch ON

[Engine is running]

BATTERY VOLTAGE
(11 — 14V)

115
116

B
B

ECM ground

119
120

G
G

Power supply for ECM

[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)

121

BR

Power supply for ECM
(Back-up)

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

●

Idle speed

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-101

Body ground

K

L

M

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

CONSULT-II Function (ENGINE)

BBS002UA

FUNCTION
Diagnostic test mode

Function

Work support

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

Self-diagnostic results

Self-diagnostic results such as 1st trip DTC, DTCs and 1st trip freeze frame data or freeze frame data
can be read and erased quickly.*

Data monitor

Input/Output data in the ECM can be read.

Data monitor (SPEC)

Input/Output of the specification for Basic fuel schedule, A/F feedback control value and the other data
monitor items can be read.

CAN diagnostic support
monitor

The results of transmit/receive diagnosis of CAN communication can be read.

Active test

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

Function test

This mode is used to inform customers when their vehicle condition requires periodic maintenance.

DTC & SRT confirmation

The status of system monitoring tests and the self-diagnosis status/result can be confirmed.

ECM part number

ECM part number can be read.

*: The following emission-related diagnostic information is cleared when the ECM memory is erased.
●

Diagnostic trouble codes

●

1st trip diagnostic trouble codes

●

Freeze frame data

●

1st trip freeze frame data

●

System readiness test (SRT) codes

●

Test values

EC-102

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
A

DIAGNOSTIC TEST MODE
SELF-DIAGNOSTIC
RESULTS

INPUT

WORK
SUPPORT

DATA
MONITOR

×

×

DTC & SRT
CONFIRMATION
ACTIVE
TEST

DTC
WORK
SUPPORT

DTC*1

FREEZE
FRAME
DATA*2

Crankshaft position sensor (POS)

×

×

Camshaft position sensor (PHASE)

×

×

×

Manifold absolute pressure sensor

×

×

×

Engine coolant temperature sensor

×

×

×

Heated oxygen sensor 1

×

×

×

×

×

Heated oxygen sensor 2

×

×

×

×

×

Wheel sensor

×

×

×

Accelerator pedal position sensor

×

×

×

Throttle position sensor

×

×

×

Intake air temperature sensor

×

×

×

Knock sensor

×

Refrigerant pressure sensor

×

×

Closed throttle position switch
(accelerator pedal position sensor
signal)

×

×

×

×

×

C

D
×

E

F

G

×

×

Park/neutral position (PNP) switch

×

×

×

Stop lamp switch

×

×

×

EPS control unit

×

×

Battery voltage

×

×

Electrical load signal

×

×

Fuel injector

×

×

×

Power transistor (Ignition timing)

×

×

×

×

×

×

×

×

×

×

×

×
×

Throttle control motor relay

×

Throttle control motor

×

EVAP canister purge volume control solenoid valve

×

Air conditioner relay
Fuel pump relay

SRT
STATUS

EC

H

Air conditioner switch

OUTPUT

ENGINE CONTROL COMPONENT PARTS

ENGINE CONTROL COMPONENT PARTS

Item

DATA
MONITOR
(SPEC)

×

I

J

K

L

×

M

Cooling fan relay

×

×

×

Heated oxygen sensor 1 heater

×

×

×

×

Heated oxygen sensor 2 heater

×

×

×

×

Intake valve timing control solenoid
valve

×

×

×

×

×

×

Calculated load value

×

X: Applicable
*1: This item includes 1st trip DTCs.
*2: This mode includes 1st trip freeze frame data or freeze frame data. The items appear on CONSULT-II screen in freeze frame data
mode only if a 1st trip DTC or DTC is detected. For details, refer to EC-50 .

EC-103

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
INSPECTION PROCEDURE
Refer to GI-38, «CONSULT-II Data Link Connector (DLC) Circuit» .

WORK SUPPORT MODE
Work Item
WORK ITEM

CONDITION

USAGE

FUEL PRESSURE RELEASE

●

FUEL PUMP WILL STOP BY TOUCHING “START” DURING IDLING.
CRANK A FEW TIMES AFTER ENGINE STALLS.

When releasing fuel pressure
from fuel line

IDLE AIR VOL LEARN

●

THE IDLE AIR VOLUME THAT KEEPS THE ENGINE
WITHIN THE SPECIFIED RANGE IS MEMORIZED IN
ECM.

When learning the idle air volume

SELF-LEARNING CONT

●

THE COEFFICIENT OF SELF-LEARNING CONTROL
MIXTURE RATIO RETURNS TO THE ORIGINAL COEFFICIENT.

When clearing the coefficient of
self-learning control value

TARGET IGN TIM ADJ*

●

IDLE CONDITION

When adjusting target ignition timing

TARGET IDLE RPM ADJ*

●

IDLE CONDITION

When setting target idle speed

*: This function is not necessary in the usual service procedure.

SELF-DIAG RESULTS MODE
Self Diagnostic Item
Regarding items of DTC and 1st trip DTC, refer to EC-48, «EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS» .

Freeze Frame Data and 1st Trip Freeze Frame Data
Freeze frame data
item*
DIAG TROUBLE
CODE
[PXXXX]

Description
●

The engine control component part/control system has a trouble code, it is displayed as PXXXX. (Refer to
EC-22, «INDEX FOR DTC» .)

●

Fuel injection system status at the moment a malfunction is detected is displayed.

●

One mode in the following is displayed.
Mode2: Open loop due to detected system malfunction
Mode3: Open loop due to driving conditions (power enrichment, deceleration enleanment)
Mode4: Closed loop — using oxygen sensor(s) as feedback for fuel control
Mode5: Open loop — has not yet satisfied condition to go to closed loop

CAL/LD VALUE [%]

●

The calculated load value at the moment a malfunction is detected is displayed.

COOLANT TEMP
[°C] or [°F]

●

The engine coolant temperature at the moment a malfunction is detected is displayed.

●

“Long-term fuel trim” at the moment a malfunction is detected is displayed.

●

The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule
than short-term fuel trim.

FUEL SYS-B1

L-FUEL TRM-B1 [%]

●

“Short-term fuel trim” at the moment a malfunction is detected is displayed.

S-FUEL TRM-B1 [%]

●

The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel
schedule.

ENGINE SPEED
[rpm]

●

The engine speed at the moment a malfunction is detected is displayed.

VEHICL SPEED
[km/h] or [mph]

●

The vehicle speed at the moment a malfunction is detected is displayed.

B/FUEL SCHDL
[msec]

●

The base fuel schedule at the moment a malfunction is detected is displayed.

INT/A TEMP SE
[°C] or [°F]

●

The intake air temperature at the moment a malfunction is detected is displayed.

*: The items are the same as those of 1st trip freeze frame data.

EC-104

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
DATA MONITOR MODE
Monitored Item

Monitored item [Unit]

ECM
INPUT
SIGNALS

A
×: Applicable
MAIN
SIGNALS

Description

●

ENG SPEED [rpm]

×

×

Indicates the engine speed computed from
the signals of the crankshaft position sensor (POS) and camshaft position sensor
(PHASE).

Remarks

●

Accuracy becomes poor if engine
speed drops below the idle rpm.

●

If the signal is interrupted while the
engine is running, an abnormal value
may be indicated.

●
●

COOLAN TEMP/S
[°C] or [°F]

×

×

HO2S1 (B1) [V]

×

×

HO2S2 (B1) [V]

×

HO2S1 MNTR (B1)
[RICH/LEAN]

×

●

The signal voltage of the heated oxygen
sensor 1 is displayed.

●

The signal voltage of the heated oxygen
sensor 2 is displayed.

●

Display of heated oxygen sensor 1 signal
during air-fuel ratio feedback control:
RICH: means the mixture became “rich”,
and control is being affected toward a
leaner mixture.
LEAN: means the mixture became “lean”,
and control is being affected toward a rich
mixture.

×

●

HO2S2 MNTR (B1)
[RICH/LEAN]

×

×

A/F ALPHA-B1 [%]

The engine coolant temperature (determined by the signal voltage of the engine
coolant temperature sensor) is displayed.

●

Display of heated oxygen sensor 2 signal:
RICH: means the amount of oxygen after
three way catalyst is relatively small.
LEAN: means the amount of oxygen after
three way catalyst is relatively large.
The mean value of the air-fuel ratio feedback correction factor per cycle is indicated.

VHCL SPEED SE
[km/h] or [mph]

×

×

●

The vehicle speed computed from the vehicle speed signal is displayed.

BATTERY VOLT [V]

×

×

●

The power supply voltage of ECM is displayed.

●

“Base fuel schedule” indicates the fuel
injection pulse width programmed into
ECM, prior to any learned on board correction.

●

The accelerator pedal position sensor signal voltage is displayed.

●

The throttle position sensor signal voltage
is displayed.

●

The intake air temperature (determined by
the signal voltage of the intake air temperature sensor) is indicated.

●

The signal voltage of the manifold absolute
pressure sensor is displayed.

B/FUEL SCHDL
[msec]

×

ACCEL SEN 1 [V]

×

ACCEL SEN 2 [V]

×

THRTL SEN 1 [V]

×

THRTL SEN 2 [V]

×

INT/A TEMP SE [°C]
or [°F]

×

TURBO BST SEN
[V]

×

×

×

×

EC-105

When the engine coolant temperature sensor is open or short-circuited,
ECM enters fail-safe mode. The
engine coolant temperature determined by the ECM is displayed.

EC

C

D

E

F

G
●

●

After turning ON the ignition switch,
“RICH” is displayed until air-fuel mixture ratio feedback control begins.

H

When the air-fuel ratio feedback is
clamped, the value just before the
clamping is displayed continuously.

I

●

When the engine is stopped, a certain value is indicated.

●

When the engine is stopped, a certain value is indicated.

●

This data also includes the data for
the air-fuel ratio learning control.

J

K

L

M

●

ACCEL SEN 2 signal is converted by
ECM internally. Thus, it differs from
ECM terminal voltage signal.

●

THRTL SEN 2 signal is converted by
ECM internally. Thus, it differs from
ECM terminal voltage signal.

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
ECM
INPUT
SIGNALS

MAIN
SIGNALS

START SIGNAL
[ON/OFF]

×

×

CLSD THL POS
[ON/OFF]

×

×

AIR COND SIG [ON/
OFF]

×

×

P/N POSI SW
[ON/OFF]

×

×

PW/ST SIGNAL
[ON/OFF]

×

×

Monitored item [Unit]

Description

●

Indicates start signal status [ON/OFF] computed by the ECM according to the signals
of engine speed and battery voltage.

●

Indicates idle position [ON/OFF] computed
by the ECM according to the accelerator
pedal position sensor signal.

●

Indicates [ON/OFF] condition of the air conditioner switch as determined by the air
conditioner signal.

●

Indicates [ON/OFF] condition from the park/
neutral position (PNP) switch signal.

●

[ON/OFF] condition of the power steering
system (determined by the signal sent from
EPS control unit) is indicated.

●

Indicates [ON/OFF] condition from the electrical load signal.
ON: Rear window defogger switch is ON
and/or lighting switch is in 2nd position.
OFF: Both rear window defogger switch
and lighting switch are OFF.

LOAD SIGNAL [ON/
OFF]

×

IGNITION SW
[ON/OFF]

×

●

Indicates [ON/OFF] condition from ignition
switch.

HEATER FAN SW
[ON/OFF]

×

●

Indicates [ON/OFF] condition from the
heater fan switch signal.

BRAKE SW
[ON/OFF]

×

●

Indicates [ON/OFF] condition from the stop
lamp switch signal.

●

Indicates the actual fuel injection pulse
width compensated by ECM according to
the input signals.

●

Indicates the ignition timing computed by
ECM according to the input signals.

●

“Calculated load value” indicates the value
of the current airflow divided by peak airflow.

●

Indicates the EVAP canister purge volume
control solenoid valve control value computed by the ECM according to the input
signals.

●

The opening becomes larger as the value
increases.

●

Indicates [°CA] of intake camshaft
advanced angle.

●

The control value of the intake valve timing
control solenoid valve (determined by ECM
according to the input signals) is indicated.

●

The advance angle becomes larger as the
value increases.

●

The air conditioner relay control condition
(determined by ECM according to the input
signals) is indicated.

×

INJ PULSE-B1
[msec]

×

IGN TIMING [BTDC]

×

CAL/LD VALUE [%]

PURG VOL C/V [%]

INT/V TIM (B1) [°CA]

INT/V SOL (B1) [%]

AIR COND RLY [ON/
OFF]

×

EC-106

Remarks

●

After starting the engine, [OFF] is displayed regardless of the starter signal.

●

When the engine is stopped, a certain computed value is indicated.

●

When the engine is stopped, a certain value is indicated.

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
Monitored item [Unit]

ECM
INPUT
SIGNALS

MAIN
SIGNALS

FUEL PUMP RLY
[ON/OFF]

×

THRTL RELAY [ON/
OFF]

×

COOLING FAN
[HI/LOW/OFF]

Description

●

Indicates the fuel pump relay control condition determined by ECM according to the
input signals.

●

Indicates the throttle control motor relay
control condition determined by the ECM
according to the input signals.

●

Indicates the condition of the cooling fan
(determined by ECM according to the input
signals).
HI: High speed operation
LOW: Low speed operation
OFF: Stop

×

●

HO2S1 HTR (B1)
[ON/OFF]

●

HO2S2 HTR (B1)
[ON/OFF]

●

IDL A/V LEARN
[YET/CMPLT]

TRVL AFTER MIL
[km] or [mile]
O2 SEN HTR DTY
[%]
AC PRESS SEN [V]

×

Remarks

EC

C

D

E

Indicates [ON/OFF] condition of heated
oxygen sensor 1 heater determined by
ECM according to the input signals.

F

Indicates [ON/OFF] condition of heated
oxygen sensor 2 heater determined by
ECM according to the input signals.

G

Display the condition of idle air volume
learning
YET: Idle air volume learning has not been
performed yet.
CMPLT: Idle air volume learning has
already been performed successfully.

●

Distance traveled while MI is activated.

●

Indicates the heated oxygen sensor 1
heater control valve computed by the ECM
according to the input signals.

●

The signal voltage from the refrigerant
pressure sensor is displayed.

A

H

I

J

K

Voltage [V]
Frequency
[msec], [Hz] or [%]
DUTY-HI
DUTY-LOW

●

Voltage, frequency, duty cycle or pulse
width measured by the probe.

PLS WIDTH-HI

●

Only “#” is displayed if item is unable
to be measured.

L

●

Figures with “#”s are temporary
ones. They are the same figures as
an actual piece of data which was
just previously measured.

M

PLS WIDTH-LOW
NOTE:
● Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

EC-107

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
DATA MONITOR (SPEC) MODE
Monitored Item
Monitored item [Unit]

ECM
INPUT
SIGNALS

MAIN
SIGNALS

Description

●

Indicates the engine speed computed
from the signal of the crankshaft position
sensor (POS) and camshaft position
sensor (PHASE).

●

“Base fuel schedule” indicates the fuel
injection pulse width programmed into
ECM, prior to any learned on board correction.

×

ENG SPEED [rpm]

B/FUEL SCHDL
[msec]

●

×

A/F ALPHA-B1 [%]

The mean value of the air-fuel ratio feedback correction factor per cycle is indicated.

Remarks

●

When engine is running specification
range is indicated.

●

When engine is running specification
range is indicated.

●

This data also includes the data for the
air-fuel ratio learning control.

NOTE:
● Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

ACTIVE TEST MODE
Test Item
TEST ITEM

CONDITION
●

FUEL INJECTION

IGNITION TIMING

POWER BALANCE

COOLING FAN*

ENG COOLANT
TEMP

FUEL PUMP
RELAY

●

Engine: Return to the original
trouble condition
Change the amount of fuel injection using CONSULT-II.

●

Engine: Return to the original
trouble condition

●

Timing light: Set

●

Retard the ignition timing using
CONSULT-II.

●

Engine: After warming up, idle
the engine.

JUDGEMENT
If trouble symptom disappears, see
CHECK ITEM.

If trouble symptom disappears, see
CHECK ITEM.

CHECK ITEM (REMEDY)
●

Harness and connectors

●

Fuel injector

●

Heated oxygen sensor 1

●

Perform Idle Air Volume Learning.

●

Harness and connectors

●

Compression

●

Fuel injector

●

Power transistor

●

A/C switch: OFF

●

Shift lever: Neutral

●

Cut off each fuel injector signal
one at a time using CONSULT-II.

●

Spark plug

●

Ignition coil

●

Ignition switch: ON

●

Harness and connectors

●

Turn the cooling fan “HI”, “LOW”
and “OFF” with CONSULT-II.

●

Cooling fan relay

●

Cooling fan motor

●

Harness and connectors

●

Engine coolant temperature sensor

●

Fuel injector

●

Harness and connectors

●

Fuel pump relay

●

Engine: Return to the original
trouble condition

●

Change the engine coolant temperature using CONSULT-II.

●

Ignition switch: ON (Engine
stopped)

●

Turn the fuel pump relay ON and
OFF using CONSULT-II and listen to operating sound.

Engine runs rough or dies.

Cooling fan moves and stops.

If trouble symptom disappears, see
CHECK ITEM.

Fuel pump relay makes the operating sound.

EC-108

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
TEST ITEM

PURG VOL
CONT/V

CONDITION
●

Engine: After warming up, run
engine at 1,500 rpm.

●

Change the EVAP canister purge
volume control solenoid valve
opening percent using CONSULT-II.

●

V/T ASSIGN
ANGLE

JUDGEMENT

●

Engine: Return to the original
trouble condition
Change intake valve timing using
CONSULT-II.

CHECK ITEM (REMEDY)

A
Engine speed changes according to
the opening percent.

If trouble symptom disappears, see
CHECK ITEM.

●

Harness and connectors

●

Solenoid valve

●

Harness and connectors

●

Intake valve timing control solenoid valve

EC

C

D

*: Leaving cooling fan OFF with CONSULT-II while engine is running may cause the engine to overheat.

DTC & SRT CONFIRMATION MODE
SRT STATUS Mode

E

For details, refer to EC-51, «SYSTEM READINESS TEST (SRT) CODE» .

SRT Work Support Mode

F

This mode enables a technician to drive a vehicle to set the SRT while monitoring the SRT status.

DTC Work Support Mode
Test mode

HO2S1

Test item

Condition

HO2S1 (B1) P0133

EC-185

HO2S1 (B1) P0134

EC-195

HO2S1 (B1) P1143

Refer to corresponding
trouble diagnosis for
DTC.

HO2S1 (B1) P1144
HO2S2 (B1) P0139
HO2S2

Reference page

H

EC-310
EC-316
EC-210

HO2S2 (B1) P1146

EC-322

HO2S2 (B1) P1147

EC-330

REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA)
Description
CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR”
mode.
1. “AUTO TRIG” (Automatic trigger):
● The malfunction will be identified on the CONSULT-II screen
in real time.
In other words, DTC/1st trip DTC and malfunction item will be
displayed if the malfunction is detected by ECM.
At the moment a malfunction is detected by ECM, “MONITOR” in “DATA MONITOR” screen is changed to “Recording
Data … xx%” as shown in the figure, and the data after the
malfunction detection is recorded. Then when the percentage
reached 100%, “REAL-TIME DIAG” screen is displayed. If
“STOP” is touched on the screen during “Recording Data …
xx%”, “REAL-TIME DIAG” screen is also displayed.
MBIB0295E
The recording time after the malfunction detection and the

EC-109

G

I

J

K

L

M

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

2.

recording speed can be changed by “TRIGGER POINT” and
“Recording Speed”. Refer to CONSULT-II OPERATION MANUAL.
“MANU TRIG” (Manual trigger):
● DTC/1st trip DTC and malfunction item will not be displayed
automatically on CONSULT-II screen even though a malfunction is detected by ECM.
DATA MONITOR can be performed continuously even though
a malfunction is detected.
SEF707X

Operation
1.

2.

“AUTO TRIG”
● While trying to detect the DTC/1st trip DTC by performing the DTC Confirmation Procedure, be sure to
select to “DATA MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is
detected.
● While narrowing down the possible causes, CONSULT-II should be set in “DATA MONITOR (AUTO
TRIG)” mode, especially in case the incident is intermittent.
When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components and harness in the DTC Confirmation Procedure, the moment a malfunction is found the DTC/1st
trip DTC will be displayed. (Refer to Incident Simulation Tests in GI-25, «How to Perform Efficient Diagnosis for an Electrical Incident» .)
“MANU TRIG”
● If the malfunction is displayed as soon as “DATA MONITOR” is selected, reset CONSULT-II to “MANU
TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The data can be utilized for further diagnosis, such as a comparison with the value for the normal operating condition.

PBIB0197E

EC-110

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

Generic Scan Tool (GST) Function

BBS002UB

A

DESCRIPTION
Generic Scan Tool (OBDII scan tool) complying with ISO 15031 has
8 different functions explained below.
ISO9141 is used as the protocol.
The name GST or Generic Scan Tool is used in this service manual.

EC

C

D
SEF139P

FUNCTION

E

Diagnostic test mode
Service $01

Service $02

Service $03

Function

READINESS TESTS

This diagnostic service gains access to current emission-related data values, including
analog inputs and outputs, digital inputs and outputs, and system status information.

(FREEZE DATA)

This diagnostic service gains access to emission-related data value which were stored by
ECM during the freeze frame. For details, refer to EC-50, «FREEZE FRAME DATA AND
1ST TRIP FREEZE FRAME DATA» .

DTCs

This diagnostic service gains access to emission-related power train trouble codes which
were stored by ECM.
This diagnostic service can clear all emission-related diagnostic information. This
includes:

Service $04

Service $06

Service $07
Service $08
Service $09

CLEAR DIAG INFO

●

Clear number of diagnostic trouble codes (Service $01)

●

Clear diagnostic trouble codes (Service $03)

●

Clear trouble code for freeze frame data (Service $01)

●

Clear freeze frame data (Service $02)

●

Reset status of system monitoring test (Service $01)

●

Clear on board monitoring test results (Service $06 and Service $07)

(ON BOARD TESTS)

This diagnostic service enables the off board test drive to obtain test results for emissionrelated powertrain components/systems that are continuously monitored during normal
driving conditions.

3.

K

L

This diagnostic service is not applicable on this vehicle.
This diagnostic service enables the off-board test device to request specific vehicle information such as Vehicle Identification Number (VIN) and Calibration IDs.

INSPECTION PROCEDURE
1.
2.

H

J

This diagnostic service accesses the results of on board diagnostic monitoring tests of
specific components/systems that are not continuously monitored.

(CALIBRATION ID)

G

I

(ON BOARD TESTS)

—

F

Turn ignition switch OFF.
Connect GST to data link connector, which is located under drivers side dash panel near the fuse box cover.
Turn ignition switch ON.

MBIB0275E

EC-111

M

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
4.

Enter the program according to instruction on the screen or in
the operation manual.
(*: Regarding GST screens in this section, sample screens are
shown.)

SEF398S

5.

Perform each diagnostic mode according to each service procedure.
For further information, see the GST Operation Manual of the
tool maker.

SEF416S

CONSULT-II Reference Value in Data Monitor Mode

BBS002UC

Remarks:
● Specification data are reference values.
● Specification data are output/input values which are detected or supplied by the ECM at the connector.
* Specification data may not be directly related to their components signals/values/operations.
MONITOR ITEM
CONDITION

SPECIFICATION

●

Run engine and compare CONSULT-II value with the tachometer indication.

B/FUEL SCHDL

●

See EC-117, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .

A/F ALPHA-B1

●

See EC-117, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .

COOLAN TEMP/S

●

Engine: After warming up

HO2S1 (B1)

●

Engine: After warming up

●

Revving engine from idle to 3,000 rpm quickly after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute
and at idle for 1 minute under no load.

●

Engine: After warming up

●

Revving engine from idle to 3,000 rpm quickly after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute
and at idle for 1 minute under no load.

●

Turn drive wheels and compare CONSULT-II value with the speedometer
indication.

Almost the same speed as the
speedometer indication.

●

Ignition switch: ON (Engine stopped)

11 — 14V

●

Ignition switch: ON
(Engine stopped)

ENG SPEED

HO2S2 (B1)

HO2S1 MNTR (B1)

HO2S2 MNTR (B1)

VHCL SPEED SE
BATTERY VOLT
ACCEL SEN 1

Almost the same speed as the
tachometer indication.

More than 70°C (158°F)
Maintaining engine speed at 2,000
rpm

0 — 0.3V ←→ Approx. 0.6 — 1.0V

0 — 0.3V ←→ Approx. 0.6 — 1.0V

Maintaining engine speed at 2,000
rpm

LEAN ←→ RICH
Changes more than 5 times during 10 seconds.

LEAN ←→ RICH

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

4.0 — 4.8V

EC-112

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
MONITOR ITEM
ACCEL SEN 2*1

CONDITION
●

AIR COND SIG

P/N POSI SW

PW/ST SIGNAL

LOAD SIGNAL

IGNITION SW
HEATER FAN SW

BRAKE SW

Accelerator pedal: Fully depressed

3.9 — 4.8V
More than 0.36V

Accelerator pedal: Fully released

●

Shift lever: 1st

Accelerator pedal: Fully depressed

Less than 4.75V

●

Engine: After warming up

Idle

Approximately 1.5V

●

Air conditioner switch: OFF

●

Shift lever: Neutral

2,500 rpm

Approximately 1.2V

●

No load

●

Ignition switch: ON → START → ON

TURBO BST SEN

CLSD THL POS

0.6 — 0.9V

Ignition switch: ON
(Engine stopped)

1

START SIGNAL

Accelerator pedal: Fully released

●

THRTL SEN 1
THRTL SEN 2*

Ignition switch: ON
(Engine stopped)

SPECIFICATION

●

●

●

●

●

●
●

●

Ignition switch: ON
(Engine stopped)
Engine: After warming up, idle
the engine

Ignition switch: ON
Engine: After warming up, idle
the engine

Ignition switch: ON

Ignition switch: ON

●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

INJ PULSE-B1

IGN TIMING

CAL/LD VALUE

PURG VOL C/V

EC

C

D
OFF → ON → OFF

Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates.)

ON

Shift lever: Neutral

ON

Shift lever: Except above

OFF

Steering wheel: Not being turned.

OFF

Steering wheel: Being turned.

ON

Rear window defogger switch is ON
and/or lighting switch is in 2nd.

ON

Rear window defogger switch is OFF
and lighting switch is OFF.

OFF

Ignition switch: ON → OFF → ON
Engine: After warming up, idle
the engine

A

E

F

G

H

I

ON → OFF → ON
Heater fan: Operating.

ON

Heater fan: Not operating

OFF

Brake pedal: Fully released

OFF

Brake pedal: Slightly depressed

ON

Idle

2.0 — 3.0 msec

2,000 rpm

1.9 — 2.9 msec

Idle

0° — 10° BTDC

2,000 rpm

25° — 45° BTDC

Idle

10% — 35%

2,500 rpm

10% — 35%

Idle

0%

2,000 rpm

20 — 30%

EC-113

J

K

L

M

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

●

Engine: After warming up, idle
the engine

INT/V TIM (B1)

INT/V SOL (B1)

AIR COND RLY

FUEL PUMP RLY

THRTL RELAY

TRVL AFTER MIL

2,000 rpm

Approx. 0° — 20°CA

Idle

0% — 2%

2,000 rpm

Approx. 0% — 50%

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates)

ON

●

Engine running or cranking

●

Except above conditions

●

Ignition switch: ON

●

HO2S2 HTR (B1)

−5° — 5°CA

For 1 second after turning ignition switch ON

COOLING FAN

HO2S1 HTR (B1)

Idle

●

●

Engine: After warming up, idle
the engine
Air conditioner switch: OFF

ON
Engine coolant temperature: 94°C
(201°F) or less

OFF

Engine coolant temperature: Between
95°C (203°F) and 104°C (210°F)

LOW*2

Engine coolant temperature: 105°C
(212°F) or more

HIGH*2

Engine: After warming up

●

Engine speed: Below 3,600 rpm

●

Engine speed: Above 3,600 rpm

●

Engine speed: Below 3,800 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute
and at idle for 1 minute under no load.

●

Engine speed: Above 3,800 rpm

●

Ignition switch: ON

●

Engine coolant temperature when engine started: More than 80°C
(176°F)

●

Engine speed: Below 3,600 rpm

●

Engine: Idle

●

Both A/C switch and blower fan switch: ON (Compressor operates)

AC PRESS SEN

ON
OFF

●

O2SEN HTR DTY

SPECIFICATION

ON
OFF

ON

OFF
Vehicle has traveled after MI has
turned ON.

0 — 65,535 km
(0 — 40,723 mile)
Approx. 50%

1.0 — 4.0V

*1 : Accelerator pedal position sensor 2 signal and throttle position sensor 2 signal are converted by ECM internally. Thus, they differ
from ECM terminals voltage signal.
*2: Models without air conditioner, cooling fan operates only ON and OFF operation, but CONSULT-II display will change OFF, LOW and
HI depends on engine coolant temperature.

EC-114

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

Major Sensor Reference Graph in Data Monitor Mode

BBS002UD

A

The following are the major sensor reference graphs in “DATA MONITOR” mode.

CLSD THL POS, ACCEL SEN 1, THRTL SEN 1
Below is the data for “CLSD THL POS”, “ACCEL SEN 1” and “THRTL SEN 1” when depressing the accelera- EC
tor pedal with the ignition switch ON and with shift lever in 1st position.
The signal of “ACCEL SEN 1” and “THRTL SEN 1” should rise gradually without any intermittent drop or rise
after “CLSD THL POS” is changed from “ON” to “OFF”.
C

D

E

F
PBIB0198E

ENG SPEED, THRTL SEN 1, HO2S2 (B1), HO2S1 (B1), INJ PULSE-B1
Below is the data for “ENG SPEED”, “THRTL SEN 1”, “HO2S2 (B1)”, “HO2S1 (B1)” and “INJ PULSE-B1”
when revving engine quickly up to 4,800 rpm under no load after warming up engine sufficiently.
Each value is for reference, the exact value may vary.

G

H

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MBIB0545E

K

L

M

EC-115

TROUBLE DIAGNOSIS
[CR (WITH EURO-OBD)]

PBIB0668E

EC-116

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITH EURO-OBD)]

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
Description

PFP:00031

A
BBS002UE

The specification (SP) value indicates the tolerance of the value that is displayed in “DATA MONITOR (SPEC)”
mode of CONSULT-II during normal operation of the Engine Control System. When the value in “DATA MONI- EC
TOR (SPEC)” mode is within the SP value, the Engine Control System is confirmed OK. When the value in
“DATA MONITOR (SPEC)” mode is NOT within the SP value, the Engine Control System may have one or
more malfunctions.
The SP value is used to detect malfunctions that may affect the Engine Control System, but will not light the C
MI.
The SP value will be displayed for the following three items:
●
B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board cor- D
rection)
●
A/F ALPHA-B1 (The mean value of air-fuel ratio feedback correction factor per cycle)
E

Testing Condition
●
●
●
●
●
●
–
●
–

BBS002UF

Vehicle driven distance: More than 5,000 km (3,107 miles)
Barometric pressure: 98.3 — 104.3 kPa (0.983 — 1.043 bar, 1.003 — 1.064 kg/cm2 , 14.25 — 15.12 psi)
Atmospheric temperature: 20 — 30°C (68 — 86°F)
Engine coolant temperature: 75 — 95°C (167 — 203°F)
Engine speed: Idle
Transmission: Warmed-up
After the engine is warmed up to normal operating temperature, drive vehicle for 5 minutes.
Electrical load: Not applied
Rear window defogger switch, air conditioner switch, lighting switch are OFF. Steering wheel is straight
ahead.

Inspection Procedure

F

G

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BBS002UG

NOTE:
Perform “DATA MONITOR (SPEC)” mode in maximum scale display.
1. Perform EC-66, «Basic Inspection» .
2. Confirm that the testing conditions indicated above are met.
3. Select “B/FUEL SCHDL” and “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode with CONSULT-II.
4. Make sure that monitor items are within the SP value.
5. If NG, go to EC-118, «Diagnostic Procedure» .

J

K

L

M
SEF601Z

EC-117

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITH EURO-OBD)]

Diagnostic Procedure

BBS002UH

OVERALL SEQUENCE

PBIB2384E

EC-118

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITH EURO-OBD)]
A

EC

C

D

E

F

G

H

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J

K

L

M

MBIB1447E

EC-119

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITH EURO-OBD)]
DETAILED PROCEDURE

1. CHECK “A/F ALPHA-B1”
1.
2.
3.

Start engine.
Confirm that the testing conditions are met. Refer to EC-117, «Testing Condition» .
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode,
and make sure that the indication is within the SP value.
NOTE:
Check “A/F ALPHA-B1” for approximately 1 minute because
they may fluctuate. It is NG if the indication is out of the SP value
even a little.
OK or NG
OK
>> GO TO 17.
NG (Less than the SP value)>>GO TO 2.
NG (More than the SP value)>>GO TO 3.
PBIB2369E

2. CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and
make sure that the indication is within the SP value.
OK or NG
OK
>> GO TO 4.
NG (More than the SP value)>>GO TO 19.

PBIB2332E

3. CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and
make sure that the indication is within the SP value.
OK or NG
OK
>> GO TO 6.
NG (More than the SP value)>>GO TO 6.
NG (Less than the SP value)>>GO TO 25.

PBIB2332E

4. CHECK “A/F ALPHA-B1”
1.
2.
3.
4.

Stop the engine.
Disconnect PCV hose, and then plug it.
Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within
the SP value.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 6.

EC-120

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITH EURO-OBD)]

5. CHANGE ENGINE OIL
1.
2.

A
Stop the engine.
Change engine oil.
EC
NOTE:
This symptom may occur when a large amount of gasoline is mixed with engine oil because of driving
conditions (such as when engine oil temperature does not rise enough since a journey distance is too
short during winter). The symptom will not be detected after changing engine oil or changing driving con- C
dition.

>> INSPECTION END

D

6. CHECK FUEL PRESSURE
Check fuel pressure. (Refer to EC-71, «Fuel Pressure Check» .)
OK or NG
OK
>> GO TO 9.
NG (Fuel pressure is too high)>>Replace fuel pressure regulator, refer to EC-71, «Fuel Pressure Check» .
GO TO 8.
NG (Fuel pressure is too low)>>GO TO 7.

E

7. DETECT MALFUNCTIONING PART

G

1.
–
–
–

2.

Check the following.
Clogged and bent fuel hose and fuel tube
Clogged fuel filter
Fuel pump and its circuit (Refer to EC-427, «FUEL PUMP» .)
If NG, repair or replace the malfunctioning part. (Refer to EC-71, «Fuel Pressure Check» .)
If OK, replace fuel pressure regulator.

F

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>> GO TO 8.

8. CHECK “A/F ALPHA-B1”

K

1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within
the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 9.

9. PERFORM POWER BALANCE TEST
1.
2.

Perform “POWER BALANCE” in “ACTIVE TEST” mode.
Make sure that the each cylinder produces a momentary engine
speed drop.
OK or NG
OK
>> GO TO 12.
NG
>> GO TO 10.

PBIB0133E

EC-121

L

M

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITH EURO-OBD)]

10. DETECT MALFUNCTIONING PART
1.
–
–
–
–

2.

Check the following.
Ignition coil and its circuit (Refer to EC-433, «IGNITION SIGNAL» .)
Fuel injector and its circuit (Refer to EC-421, «FUEL INJECTOR» .)
Intake air leakage
Low compression pressure (Refer to EM-60, «COMPRESSION PRESSURE INSPECTION» .)
If NG, repair or replace the malfunctioning part.
If OK, replace fuel injector. (It may be caused by leakage from fuel injector or clogging.)
>> GO TO 11.

11. CHECK “A/F ALPHA-B1”
1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within
the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 12.

12. CHECK HEATED OXYGEN SENSOR 1 FUNCTION
1.
2.
3.

Run engine at about 2,000 rpm for about 2 minutes under no load.
Select “HO2S1 MNTR (B1)”, in “DATA MONITOR” mode.
Running engine at 2,000 rpm under no load (The engine is
warmed up to normal operating temperature.), check that the
monitor fluctuates between LEAN and RICH more than 5 times
during 10 seconds.
1 time
2 times

: RICH → LEAN → RICH
: RICH → LEAN → RICH → LEAN → RICH

OK or NG
OK
>> GO TO 15.
NG
>> GO TO 13.
SEF820Y

13. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT
Check heated oxygen sensor 1 and its circuit. Refer to EC-178, «DTC P0132 HO2S1» .
>> GO TO 14.

14. CHECK “A/F ALPHA-B1”
1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within
the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 15.

EC-122

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITH EURO-OBD)]

15. DISCONNECT AND RECONNECT ECM HARNESS CONNECTOR
1.
2.

A

Stop the engine.
Disconnect ECM harness connector. Check pin terminal and connector for damage, and then reconnect it.
EC

>> GO TO 16.

16. CHECK “A/F ALPHA-B1”

C

1.
2.

D

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within
the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> Detect malfunctioning part according to EC-82, «Symptom Matrix Chart» .

17. CHECK “B/FUEL SCHDL”

E

F

Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and
make sure that the indication is within the SP value.
OK or NG
OK
>> INSPECTION END
NG (More than the SP value)>>GO TO 18.
NG (Less than the SP value)>>GO TO 27.

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PBIB2332E

18. DETECT MALFUNCTIONING PART
1.
–
–
–
–
–

2.
–
–
–

J

Check for the cause of large engine friction. Refer to the following.
Engine oil level too high
Engine oil viscosity
Belt tension of power steering, alternator, A/C compressor, etc. is excessive
Noise from engine
Noise from transmission, etc.
Check for the cause of insufficient combustion. Refer to the following.
Valve clearance malfunction
Intake valve timing control function malfunction
Camshaft sprocket installation malfunction, etc.
>> Repair or replace malfunctioning part, and then GO TO 32.

19. CHECK INTAKE SYSTEM
Check for the cause of unsteady air flow passing through throttle body. Refer to the following.
●
Crushed air ducts
●
Malfunctioning seal of air cleaner element
●
Uneven dirt of air cleaner element
●
Improper specification of intake air system part
OK or NG
OK
>> GO TO 21.
NG
>> Repair or replace malfunctioning part, and then GO TO 20.

EC-123

K

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TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITH EURO-OBD)]

20. CHECK “A/F ALPHA-B1”, AND “B/FUEL SCHDL”
Select “A/F ALPHA-B1” and “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the
indication is within the SP value.
OK or NG
OK
>> INSPECTION END
NG (“B/FUEL SCHDL” is more, “A/F ALPHA-B1” is less than the SP value)>>GO TO 21.

21. DISCONNECT AND RECONNECT MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR HARNESS
CONNECTOR
1.
2.

Stop the engine.
Disconnect manifold absolute pressure (MAP) sensor harness connector. Check pin terminal and connector for damage and then reconnect it again.
>> GO TO 22.

22. CHECK “A/F ALPHA-B1”
1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within
the SP value.
OK or NG
OK
>> 1. Detect malfunctioning part of manifold absolute pressure (MAP) sensor circuit and repair it.
Refer to EC-155, «DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR» .
2. GO TO 26.
NG
>> GO TO 23.

23. CHECK “TURBO BST SEN”
Select “TURBO BST SEN” in “DATA MONITOR” mode, and make
sure that the indication is within the specified value as described
below.
Idle:
2,500 rpm:

Approximately 1.5V
Approximately 1.2V

OK or NG
OK
>> GO TO 25.
NG (More than the specified value)>>Replace manifold absolute
pressure (MAP) sensor, and then GO TO 24.
MBIB1448E

EC-124

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITH EURO-OBD)]

24. CHECK INTAKE SYSTEM

A
Check for the cause of air suction at downstream of throttle body. Refer to the following.
●
Disconnection looseness, or cracks of air duct
EC
●
Looseness of oil filler cap
●
Disconnection of oil level gauge
●
Open sticking, breakage, hose disconnection, or cracks of blow-by gas control valve
C
●
Disconnection or cracks of EVAP canister purge hose, open sticking of EVAP canister purge volume control valve
●
Malfunctioning seal of rocker cover gasket
D
●
Disconnection, looseness, or cracks of hoses, such as vacuum hose, connecting to intake air system
parts.
●
Malfunctioning seal of intake air system, etc.
E

>> GO TO 31.

25. REPLACE ECM

F

1.
2.

G

3.
4.
5.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs.
Refer to BL-218, «ECM Re-communicating Function» .
Perform EC-69, «Accelerator Pedal Released Position Learning» .
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .

H

I

>> GO TO 31.

26. CHECK “TURBO BST SEN”

J

Select “TURBO BST SEN” in “DATA MONITOR” mode, and make
sure that the indication is within the specified value as described
below.
Idle:
2,500 rpm:

K

Approximately 1.5V
Approximately 1.2V
L

OK or NG
OK
>> GO TO 31.
NG (More than the specified value)>>Replace manifold absolute
pressure (MAP) sensor, and then GO TO 32.

M
MBIB1448E

27. CHECK INTAKE SYSTEM
Check for the cause of uneven air flow passing through throttle body. Refer to the following.
●
Crushed air ducts
●
Malfunctioning seal of air cleaner element
●
Uneven dirt of air cleaner element
●
Improper specification of intake air system
OK or NG
OK
>> GO TO 29.
NG
>> Repair or replace malfunctioning part, and then GO TO 28.

EC-125

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITH EURO-OBD)]

28. CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the
SP value.
OK or NG
OK
>> INSPECTION END
NG (Less than the SP value)>>GO TO 29.

29. CHECK “TURBO BST SEN”
Select “TURBO BST SEN” in “DATA MONITOR” mode, and make
sure that the indication is within the specified value as described
below.
Idle:
2,500 rpm:

Approximately 1.5V
Approximately 1.2V

OK or NG
OK
>> GO TO 30.
NG (Less than the specified value)>>Replace manifold absolute
pressure (MAP) sensor, and then GO TO 32.
MBIB1448E

30. REPLACE ECM
1.
2.
3.
4.
5.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs.
Refer to BL-218, «ECM Re-communicating Function» .
Perform EC-69, «Accelerator Pedal Released Position Learning» .
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> GO TO 32.

31. CHECK “A/F ALPHA-B1” AND “B/FUEL SCHDL”
Select “A/F ALPHA-B1” and “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the
indication is within the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> Detect malfunctioning part according to EC-82, «Symptom Matrix Chart» .

32. CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and then make sure that the indication is within
the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> Detect malfunctioning part according to EC-82, «Symptom Matrix Chart» .

EC-126

TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT
[CR (WITH EURO-OBD)]

TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT
Description

PFP:00006

A
BBS002UI

Intermittent incidents may occur. In many cases, the malfunction resolves itself (the part or circuit function
returns to normal without intervention). It is important to realize that the symptoms described in the customer’s EC
complaint often do not recur on (1st trip) DTC visits. Realize also that the most frequent cause of intermittent
incident occurrences is poor electrical connections. Because of this, the conditions under which the incident
occurred may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may
C
not indicate the specific malfunctioning area.
Common Intermittent Incident Report Situations
STEP in Work Flow
2
3 or 4

Situation

D

The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than [0] or [1t].
The symptom described by the customer does not recur.

5

(1st trip) DTC does not appear during the DTC Confirmation Procedure.

10

The Diagnostic Procedure for PXXXX does not indicate the malfunctioning area.

Diagnostic Procedure

E

BBS002UJ

1. INSPECTION START
Erase (1st trip) DTCs. Refer to EC-57, «HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .
>> GO TO 2.

F

G

H

2. CHECK GROUND TERMINALS
Check ground terminals for corroding or loose connection.
Refer to EC-133, «Ground Inspection» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

3. SEARCH FOR ELECTRICAL INCIDENT

I

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K

Perform GI-25, «How to Perform Efficient Diagnosis for an Electrical Incident» , “Incident Simulation Tests”.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace.

L

M

EC-127

POWER SUPPLY AND GROUND CIRCUIT
[CR (WITH EURO-OBD)]

POWER SUPPLY AND GROUND CIRCUIT
Wiring Diagram

PFP:24110
BBS002UK

MBWA1502E

EC-128

POWER SUPPLY AND GROUND CIRCUIT
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
1
115
116
109

EC

WIRE
COLOR
B
B
B
O

ITEM

ECM ground

CONDITION

[Engine is running]
●

Ignition switch

Idle speed

ECM relay
(Self shut-off)

[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)

G
G

Power supply for
ECM

For a few seconds after turning ignition switch
OFF

[Ignition switch: OFF]
●

119
120

C
Body ground
0V

●

P

DATA (DC Voltage)

[Ignition switch: OFF]

[Engine is running]
[Ignition switch: OFF]
111

A

More than a few seconds passed after turning
ignition switch OFF

[Ignition switch: ON]

Diagnostic Procedure

D

E
0 — 1.0V

F
BATTERY VOLTAGE
(11 — 14V)

G

BATTERY VOLTAGE
(11 — 14V)
BBS002UL

H

1. INSPECTION START
Start engine.
Is engine running?
Yes or No
Yes
>> GO TO 8.
No
>> GO TO 2.

I

J

2. CHECK ECM POWER SUPPLY CIRCUIT-I
1.
2.

K

Turn ignition switch OFF and then ON.
Check voltage between ECM terminal 109 and ground with
CONSULT-II or tester.

L

Voltage: Battery voltage
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

M

MBIB0015E

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M1, E101
●
Fuse block (J/B) connector M7
●
10A fuse
●
Harness for open or short between ECM and fuse
>> Repair harness or connectors.

EC-129

POWER SUPPLY AND GROUND CIRCUIT
[CR (WITH EURO-OBD)]

4. CHECK GROUND CONNECTIONS-I
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body. Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace ground connections.

5. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-I
1.
2.

Disconnect ECM harness connector.
Check harness continuity between ECM terminals 1, 115, 116 and ground.
Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

6. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors F1, E48
●
Harness for open or short between ECM and ground
>> Repair open circuit or short to power in harness or connectors.

7. CHECK ECM POWER SUPPLY CIRCUIT-II
1.
2.
3.

Reconnect ECM harness connector.
Turn ignition switch ON.
Check voltage between IPDM E/R harness connector E7 terminal 33 and ground with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> Go to EC-433, «IGNITION SIGNAL» .
NG
>> GO TO 8.

MBIB1441E

EC-130

POWER SUPPLY AND GROUND CIRCUIT
[CR (WITH EURO-OBD)]

8. CHECK ECM POWER SUPPLY CIRCUIT-III
1.
2.

A

Turn ignition switch ON and then OFF.
Check voltage between ECM terminals 119, 120 and ground
with CONSULT-II or tester.
Voltage:

EC

After turning ignition switch OFF, battery
voltage will exist for a few seconds, then
drop approximately 0V.

OK or NG
OK
>> GO TO 13.
NG (Battery voltage does not exist.)>>GO TO 9.
NG (Battery voltage exists for more than a few seconds.)>>GO TO
11.

C

D
PBIB1630E

E

9. CHECK ECM POWER SUPPLY CIRCUIT-IV
1.
2.

Turn ignition switch OFF.
Check voltage between ECM terminal 111 and ground with
CONSULT-II or tester.

F

G

Voltage: Battery voltage
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 11.

H

I
PBIB1191E

10. CHECK ECM POWER SUPPLY CIRCUIT-VI
1.
2.
3.

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector.
Check harness continuity between ECM terminals 119, 120 and IPDM E/R terminal 32.
Refer to Wiring Diagram.
Continuity should exist.

K

L

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 13.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

11. CHECK ECM POWER SUPPLY CIRCUIT-VII
1.
2.
3.

J

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector.
Check harness continuity between ECM terminal 111 and IPDM E/R terminal 29.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 12.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-131

M

POWER SUPPLY AND GROUND CIRCUIT
[CR (WITH EURO-OBD)]

12. CHECK 20A FUSE
1. Disconnect 20A fuse from IPDM E/R.
2. Check 20A fuse.
OK or NG
OK
>> GO TO 16.
NG
>> Replace 20A fuse.

13. CHECK GROUND CONNECTIONS-II
1.

Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

OK or NG
OK
>> GO TO 14.
NG
>> Repair or replace ground connections.

14. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-II
1.
2.

Disconnect ECM harness connector.
Check harness continuity between ECM terminals 1, 115, 116 and ground.
Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 16.
NG
>> GO TO 15.

15. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors F1, E48
●
Harness for open or short between ECM and ground
>> Repair open circuit or short to power in harness or connectors.

16. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE
ENGINE ROOM)» .
NG
>> Repair open circuit or short to power in harness or connectors.

EC-132

POWER SUPPLY AND GROUND CIRCUIT
[CR (WITH EURO-OBD)]

Ground Inspection

BBS002UM

A
Ground connections are very important to the proper operation of electrical and electronic circuits. Ground
connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can
become an unwanted resistance. This unwanted resistance can change the way a circuit works.
Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drasti- EC
cally affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even
when the ground connection looks clean, there can be a thin film of rust on the surface.
When inspecting a ground connection follow these rules:
C
●
Remove the ground bolt or screw.
●
Inspect all mating surfaces for tarnish, dirt, rust, etc.
D
●
Clean as required to assure good contact.
●
Reinstall bolt or screw securely.
●
Inspect for “add-on” accessories which may be interfering with the ground circuit.
●
If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the E
wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one
eyelet make sure no ground wires have excess wire insulation.
F
For detailed ground distribution information, refer to PG-38, «Ground Distribution» .

G

H

I

J

K

PBIB1870E

L

M

EC-133

DTC U1001 CAN COMMUNICATION LINE
[CR (WITH EURO-OBD)]

DTC U1001 CAN COMMUNICATION LINE
Description

PFP:23710
BBS002UN

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

On Board Diagnosis Logic

BBS002UO

The MI will not light up for this self-diagnosis.
DTC No.

Trouble diagnosis name

DTC detecting condition
●

U1001
1001

CAN communication line
●

ECM cannot communicate to other control
units.

Possible cause
●

ECM cannot communicate for more than the
specified time.

DTC Confirmation Procedure
1.
2.
3.

Harness or connectors
(CAN communication line is open or
shorted.)

BBS002UP

Turn ignition switch ON and wait at least 3 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
If 1st trip DTC or DTC is detected, go to EC-136, «Diagnostic Procedure» .

EC-134

DTC U1001 CAN COMMUNICATION LINE
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002UQ

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1503E

EC-135

DTC U1001 CAN COMMUNICATION LINE
[CR (WITH EURO-OBD)]

Diagnostic Procedure

BBS002UR

Go to LAN-3, «Precautions When Using CONSULT-II» .

EC-136

DTC U1010 CAN COMMUNICATION
[CR (WITH EURO-OBD)]

DTC U1010 CAN COMMUNICATION
Description

PFP:23710

A
BBS003ZI

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- EC
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
C
Each control unit transmits/receives data but selectively reads required data only.

On Board Diagnosis Logic

BBS003ZJ

D

The MI will not light up for this diagnosis.
DTC No.
U1010
1010

Trouble diagnosis name
CAN communication bus

DTC detecting condition
Initializing CAN communication bus is malfunctioning.

DTC Confirmation Procedure

Possible cause
●

E

ECM

BBS003ZK

WITH CONSULT-II
1.
2.
3.

F

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
If 1st trip DTC is detected, go to EC-138, «Diagnostic Procedure»
.

G

H

I
SEF058Y

J

WITH GST
Follow the procedure “WITH CONSULT-II” above.

K

L

M

EC-137

DTC U1010 CAN COMMUNICATION
[CR (WITH EURO-OBD)]

Diagnostic Procedure

BBS003ZL

1. INSPECTION START
1.
2.
3.
4.
5.

With CONSULT-II
Turn ignition switch ON.
Select “SELF-DIAG RESULTS” mode with CONSULT-II.
Touch “ERASE”.
Perform DTC Confirmation Procedure.
See EC-137, «DTC Confirmation Procedure» .
Is the DTC U1010 displayed again?

With GST
1. Turn ignition switch ON.
2. Select “Service $04” with GST.
3. Perform DTC Confirmation Procedure.
See EC-137, «DTC Confirmation Procedure» .
4. Is the DTC U1010 displayed again?
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END

2. REPLACE ECM
1.
2.
3.
4.
5.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
Perform EC-69, «Accelerator Pedal Released Position Learning» .
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> INSPECTION END

EC-138

DTC P0011 IVT CONTROL
[CR (WITH EURO-OBD)]

DTC P0011 IVT CONTROL
Description

PFP:23796

A
BBS002US

SYSTEM DESCRIPTION
Sensor
Crankshaft position sensor (POS)

Input Signal to ECM

ECM Function

Actuator

EC

Engine speed and piston position

Camshaft position sensor (PHASE)
Engine coolant temperature sensor

Engine coolant temperature

Wheel sensor

Vehicle speed*

Intake valve
timing control

Intake valve timing control
solenoid valve

*: This signal is sent to the ECM through CAN communication line.

C

D

E

F

G

H

I

PBIB0540E

This mechanism hydraulically controls cam phases continuously with the fixed operating angle of the intake
valve.
The ECM receives signals such as crankshaft position, camshaft position, engine speed, and engine coolant
temperature. Then, the ECM sends ON/OFF pulse duty signals to the intake valve timing control solenoid
valve depending on driving status. This makes it possible to control the shut/open timing of the intake valve to
increase engine torque in low/mid speed range and output in high-speed range.

J

K

L

CONSULT-II Reference Value in Data Monitor Mode

BBS002UT

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

INT/V TIM (B1)

INT/V SOL (B1)

SPECIFICATION

Idle

−5° — 5°CA

2,000 rpm

Approx. 0° — 20°CA

Idle

0% — 2%

2,000 rpm

Approx. 0% — 50%

EC-139

M

DTC P0011 IVT CONTROL
[CR (WITH EURO-OBD)]

On Board Diagnosis Logic

BBS002UU

The MI will not light up for this self-diagnosis.
DTC No.

P0011
0011

Trouble diagnosis name

Detecting condition

Intake valve timing control
performance

There is a gap between angle of target and
phase-control angle degree.

Possible cause
●

Crankshaft position sensor (POS)

●

Camshaft position sensor (PHASE)

●

Intake valve control solenoid valve

●

Accumulation of debris to the signal pickup portion of the camshaft

●

Timing chain installation

●

Foreign matter caught in the oil groove for
intake valve timing control

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode.
Detected items

Engine operating condition in fail-safe mode

Intake valve timing control

The signal is not energized to the solenoid valve and the valve control does not function

DTC Confirmation Procedure

BBS002UV

CAUTION:
Always drive at a safe speed.
NOTE:
●
If DTC P0011 is displayed with DTC P1111, first perform trouble diagnosis for DTC P1111. See EC286 .
●
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
at least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is between 10V and 16V at
idle.

WITH CONSULT-II
1.
2.
3.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and warm it up to the normal operating temperature.
Maintain the following conditions from at least 6 consecutive
seconds
Hold the accelerator pedal as steady as possible

ENG SPEED

1,200 — 2,000 rpm (A constant rotation is maintained.)

COOLAN TEMP/S

60 — 120°C (140 — 248°F)

B/FUEL SCHDL

More than 3 msec

Shift lever

Neutral position

4.
5.
6.

PBIB0164E

Let engine idle for 10 seconds.
If the 1st trip DTC is detected, go to EC-141, «Diagnostic Procedure» .
If the 1st trip DTC is not detected, go to next step.
Maintain the following conditions for at least 20 consecutive seconds.

ENG SPEED

1,700 — 3,175 rpm (A constant rotation is maintained.)

COOLAN TEMP/S

70 — 105°C (176 — 194°F)

Shift lever

1st or 2nd position

Driving location uphill

Driving vehicle uphill
(Increased engine load will help maintain the driving
conditions required for this test.)

EC-140

DTC P0011 IVT CONTROL
[CR (WITH EURO-OBD)]
7.

If 1st trip DTC is detected, go to EC-141, «Diagnostic Procedure» .
A

WITH GST
Follow the procedure “WITH CONSULT-II” above.

Diagnostic Procedure

BBS002UW

EC

1. CHECK OIL PRESSURE WARNING LAMP
1.
2.

Start engine.
Check oil pressure warning lamp and confirm it is not illuminated.
OK or NG
OK
>> GO TO 2.
KG
>> Go to LU-6, «OIL PRESSURE CHECK» .

C

D

E

F
PBIA8559J

2. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE

G

Refer to EC-142, «Component Inspection» .
OK or NG
OK
>> GO TO 3.
NG
>> Replace intake valve timing control solenoid valve.

H

3. CHECK CRANKSHAFT POSITION SENSOR (POS)

I

Refer to EC-256, «Component Inspection» .
OK or NG
OK
>> GO TO 4.
NG
>> Replace crankshaft position sensor (POS).

J

K

4. CHECK CAMSHAFT POSITION SENSOR (PHASE)
Refer to EC-263, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace camshaft position sensor (PHASE).

L

M

5. CHECK CAMSHAFT (INTAKE)
Check the following.
●
Accumulation of debris to the signal plate of camshaft rear end
●
Chipping signal plate of camshaft rear end
OK or NG
OK
>> GO TO 6.
NG
>> Remove debris and clean the signal plate of camshaft
rear end or replace camshaft.

PBIB0565E

EC-141

DTC P0011 IVT CONTROL
[CR (WITH EURO-OBD)]

6. CHECK TIMING CHAIN INSTALLATION
Check service records for any recent repairs that may cause timing chain misaligned.
Are there any service records that may cause timing chain misaligned?
Yes or No
Yes
>> Check timing chain installation. Refer to EM-50, «TIMING CHAIN» .
No
>> GO TO 7.

7. CHECK LUBRICATION CIRCUIT
Refer to EM-47, «Inspection of Camshaft Sprocket (INT) Oil Groove» .
OK or NG
OK
>> GO TO 8.
NG
>> Clean lubrication line.

8. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
For Wiring Diagram, refer to EC-252 for CKP sensor (POS), EC-259 for CMP sensor (PHASE).
>> INSPECTION END

Component Inspection

BBS002UX

INTAKE VALVE TIMING CONTROL SOLENOID VALVE
1.
2.

3.
4.

Disconnect intake valve timing control solenoid valve harness connector.
Check resistance between intake valve timing control solenoid
valve as follows.
Terminal

Resistance

1 and 2

6.7 — 7.7Ω at 20°C (68°F)

1 or 2 and ground

∞Ω
(Continuity should not exist.)

If NG, replace intake valve timing control solenoid valve.
If OK, go to next step.
Remove intake valve timing control solenoid valve.

MBIB0027E

Provide 12V DC between intake valve timing control solenoid
valve terminals and then interrupt it. Make sure that the plunger
moves as shown in the figure.
CAUTION:
Do not apply 12V DC continuously for 5 seconds or more.
Doing so may result in damage to the coil in intake valve
timing control solenoid valve.
If NG, replace intake valve timing control solenoid valve.
NOTE:
Always replace O-ring when intake valve timing control
solenoid valve is removed.

PBIB2388E

Removal and Installation

BBS002UY

INTAKE VALVE TIMING CONTROL SOLENOID VALVE
Refer to EM-35, «ROCKER COVER» .

EC-142

DTC P0031, P0032 HO2S1 HEATER
[CR (WITH EURO-OBD)]

DTC P0031, P0032 HO2S1 HEATER
Description

PFP:22690

A
BBS002UZ

SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Camshaft position sensor (PHASE)
Crankshaft position sensor (POS)

Engine speed

Engine coolant temperature sensor

Engine coolant temperature

ECM Function

Actuator

Heated oxygen sensor 1
heater control

EC

Heated oxygen sensor 1
heater

The ECM performs ON/OFF duty control of the heated oxygen sensor 1 heater corresponding to the engine
speed and engine coolant temperature. The duty percent varies with engine coolant temperature when engine
is started.

C

D

OPERATION
Engine speed

rpm

Heated oxygen sensor 1 heater

Above 3,600

OFF

Below 3,600 after warming up

ON

E

F

CONSULT-II Reference Value in Data Monitor Mode

BBS002V0

Specification data are reference values.
MONITOR ITEM

HO2S1 HTR (B1)

CONDITION
●

Engine: After warming up

●

Engine speed: Below 3,600 rpm

●

Engine speed: Above 3,600 rpm

G

SPECIFICATION
ON

H
OFF

On Board Diagnosis Logic

BBS002V1

I
DTC No.
P0031
0031

P0032
0032

Trouble diagnosis name

DTC detecting condition
●

Heated oxygen sensor 1
heater control circuit low

The current amperage in the heated oxygen sensor 1 heater circuit is out of the normal range.
(An excessively low voltage signal is sent to ECM
through the heated oxygen sensor 1 heater.)

●

Heated oxygen sensor 1 heater

The current amperage in the heated oxygen sensor 1 heater circuit is out of the normal range.
(An excessively high voltage signal is sent to ECM
through the heated oxygen sensor 1 heater.)

●

Harness or connectors
(The heated oxygen sensor 1 heater
circuit is shorted.)

●

Heated oxygen sensor 1 heater

Heated oxygen sensor 1
heater control circuit high

Possible cause
Harness or connectors
(The heated oxygen sensor 1 heater
circuit is open or shorted.)

J

K

L

M

EC-143

DTC P0031, P0032 HO2S1 HEATER
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS002V2

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is between 10.5V and 16V at
idle.

WITH CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and run it for at least 6 seconds at idle speed.
If 1st trip DTC is detected, go to EC-146, «Diagnostic Procedure»
.

SEF174Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-144

DTC P0031, P0032 HO2S1 HEATER
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002V3

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1504E

EC-145

DTC P0031, P0032 HO2S1 HEATER
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Approximately 7.0V
[Engine is running]
24

Y

Heated oxygen sensor 1
heater

●

Warm-up condition.

●

Engine speed: Below 3,600 rpm

PBIB0519E

[Engine is running]
●

BATTERY VOLTAGE
(11 — 14V)

Engine speed: Above 3,600 rpm

[Engine is running]
35

BR

Heated oxygen sensor 1

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS002V4

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-146

3.

Body ground E28

DTC P0031, P0032 HO2S1 HEATER
[CR (WITH EURO-OBD)]

2. CHECK HO2S1 POWER SUPPLY CIRCUIT
1.
2.

A

Disconnect heated oxygen sensor 1 harness connector.
Turn ignition switch ON.
EC

C

D
MBIB1073E

3.

E

Check voltage between HO2S1 terminal 2 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

F

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

G

PBIA9576J

H

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F1
●
IPDM E/R connector E10
●
10A fuse
●
Harness for open or short between heated oxygen sensor 1 and fuse

I

J

K

>> Repair harness or connectors.

4. CHECK HO2S1 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

L

1.
2.
3.

M

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 24 and HO2S1 terminal 3.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK HEATED OXYGEN SENSOR 1 HEATER
Refer to EC-148, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 1.

EC-147

DTC P0031, P0032 HO2S1 HEATER
[CR (WITH EURO-OBD)]

6. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS002V5

HEATED OXYGEN SENSOR 1 HEATER
1.

Check resistance between HO2S1 terminals as follows.
Terminal No.

Resistance

2 and 3

3.4 — 4.4 Ω at 25°C (77°F)

1 and 2, 3, 4

∞Ω
(Continuity should not exist)

4 and 1, 2, 3

2. If NG, replace heated oxygen sensor 1.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped
from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system
threads using Oxygen Sensor Thread Cleaner and
approved anti-seize lubricant.

MBIB1306E

Removal and Installation

BBS002V6

HEATED OXYGEN SENSOR 1
Refer to EM-24, «EXHAUST MANIFOLD AND THREE WAY CATALYST» .

EC-148

DTC P0037, P0038 HO2S2 HEATER
[CR (WITH EURO-OBD)]

DTC P0037, P0038 HO2S2 HEATER
Description

PFP:226A0

A
BBS002V7

SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Camshaft position sensor (PHASE)

ECM Function

Actuator

EC

Engine speed

Crankshaft position sensor (POS)
Engine coolant temperature sensor

Engine coolant temperature

Manifold absolute pressure (MAP) sensor

Amount of intake air

Heated oxygen sensor 2
heater control

Heated oxygen sensor 2
heater

OPERATION

D
Engine speed rpm

Heated oxygen sensor 2 heater

Above 3,800

OFF

E

Below 3,800 rpm after the following conditions are met.
●

Engine: After warming up

●

Keeping the engine speed between 3,500 and 4,000 rpm for 1
minute and at idle for 1 minute under no load

ON

F

CONSULT-II Reference Value in Data Monitor Mode

BBS002V8

G

Specification data are reference values.
MONITOR ITEM

HO2S2 HTR (B1)

CONDITION

SPECIFICATION

●

Engine speed: Below 3,800 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed at between 3,500 to 4,000 rpm for 1 minute
and at idle for 1 minute under no load

●

Engine speed: Above 3,800 rpm

H
ON

I
OFF

On Board Diagnosis Logic
DTC No.
P0037
0037

P0038
0038

C

BBS002V9

J

Trouble diagnosis name

DTC detecting condition
The current amperage in the heated oxygen sensor
2 heater circuit is out of the normal range.
(An excessively low voltage signal is sent to ECM
through the heated oxygen sensor 2 heater.)

●

Heated oxygen sensor 2
heater control circuit low

●

Heated oxygen sensor 2 heater

The current amperage in the heated oxygen sensor
2 heater circuit is out of the normal range.
(An excessively high voltage signal is sent to ECM
through the heated oxygen sensor 2 heater.)

●

Harness or connectors
(The heated oxygen sensor 2 heater
circuit is shorted.)

L

●

Heated oxygen sensor 2 heater

M

Heated oxygen sensor 2
heater control circuit high

DTC Confirmation Procedure

Possible cause
Harness or connectors
(The heated oxygen sensor 2 heater
circuit is open or shorted.)

BBS002VA

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is between 10.5V and 16V at
idle.

EC-149

K

DTC P0037, P0038 HO2S2 HEATER
[CR (WITH EURO-OBD)]
WITH CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
If 1st trip DTC is detected, go to EC-152, «Diagnostic Procedure»
.

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-150

SEF058Y

DTC P0037, P0038 HO2S2 HEATER
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002VB

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1505E

EC-151

DTC P0037, P0038 HO2S2 HEATER
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]

2

GR

●

Engine speed: Below 3,800 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and
4,000 rpm for 1 minute and at idle for 1 minute
under no load.

Heated oxygen sensor 2
heater

0 — 1.0V

[Ignition switch: ON]
●

Engine stopped

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
●

Engine speed: Above 3,800 rpm

[Engine is running]

16

LG

Heated oxygen sensor 2

●

Revving engine from idle to 3,000rpm quickly
after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and
4,000 rpm for 1 minute and at idle for 1 minute
under no load.

0 — Approximately 1.0V

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

Diagnostic Procedure

BBS002VC

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-152

3.

Body ground E28

DTC P0037, P0038 HO2S2 HEATER
[CR (WITH EURO-OBD)]

2. CHECK HO2S2 POWER SUPPLY CIRCUIT

A

1.

Disconnect heated oxygen sensor 2 harness connector (1).

–

: Vehicle front
Heated oxygen sensor 2 (2)
Oil pan (3)
Turn ignition switch ON.

–
–

2.

EC

C

D
MBIB1459E

3.

E

Check voltage between HO2S2 terminal 2 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

F

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

G

MBIB1442E

H

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F1
●
IPDM E/R connector E10
●
10A fuse
●
Harness for open or short between heated oxygen sensor 2 and fuse

I

J

K

>> Repair harness or connectors.

4. CHECK HO2S2 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

L

1.
2.
3.

M

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 2 and HO2S2 terminal 3.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK HEATED OXYGEN SENSOR 2 HEATER
Refer to EC-154, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 2.

EC-153

DTC P0037, P0038 HO2S2 HEATER
[CR (WITH EURO-OBD)]

6. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS002VD

HEATED OXYGEN SENSOR 2 HEATER
1.

Check resistance between HO2S2 terminals as follows.
Terminal No.

Resistance

2 and 3

8.0 — 10.0 Ω at 25°C (77°F)

1 and 2, 3, 4

∞Ω
(Continuity should not exist)

4 and 1, 2, 3

2. If NG, replace heated oxygen sensor 2.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped
from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system
threads using Oxygen Sensor Thread Cleaner and
approved anti-seize lubricant.

SEF249Y

Removal and Installation

BBS002VE

HEATED OXYGEN SENSOR 2
Refer to EX-3, «EXHAUST SYSTEM» .

EC-154

DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR
[CR (WITH EURO-OBD)]

DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR
Component Description

PFP:22365

A
BBS002VF

The manifold absolute pressure (MAP) sensor is placed intake manifold corrector. It detects intake manifold pressure and sends the
voltage signal to the ECM, ECM uses the signal to compute intake
air volume value.
The sensor uses a silicon diaphragm which is sensitive to the
change in pressure. As the pressure increase, the voltage rises.

EC

C

D
MBIB0278E

E

On Board Diagnosis Logic

BBS002VG

If DTC P0107 or P0108 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229.
Refer to EC-363, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

Trouble diagnosis name

DTC detecting condition
●

P0107
0107

P0108
0108

Manifold absolute pressure
sensor circuit low input

Manifold absolute pressure
sensor circuit high input

An excessively low voltage from the sensor
is sent to ECM.

An excessively high voltage from the sensor
is sent to ECM.

F

Possible cause
Harness or connectors
(The sensor circuit is open or shorted.)

●

Manifold absolute pressure sensor

●

Harness or connectors
(The sensor circuit is open or shorted)

●

Manifold absolute pressure sensor

●

Intake air leaks

G

H

I

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode.
Detected items
Manifold absolute pressure sensor circuit

J

Engine operating condition in fail-safe mode
Engine speed will not rise more than 2,500 rpm due to the fuel cut.

DTC Confirmation Procedure

BBS002VH

K

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

L

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 5 seconds.
If 1st trip DTC is detected, go to EC-157, «Diagnostic Procedure»
.

M

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-155

DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002VI

MBWA1506E

EC-156

DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
45

WIRE
COLOR

L

EC
ITEM
Sensor power supply
(Manifold absolute
pressure sensor)

CONDITION

DATA (DC Voltage)

C
[Ignition switch: ON]

Approximately 5V

[Engine is running]

51

56

W

B

A

Manifold absolute pressure sensor

Sensor ground
(Manifold absolute
pressure sensor)

●

Warm-up condition

●

Idle speed

D
Approximately 1.5V

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

E
Approximately 1.2V

F

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0V

G

Diagnostic Procedure

BBS002VJ

1. INSPECTION START
Which malfunction (P0107 or P0108) is duplicated?
P0107 or P0108
P0107 >> GO TO 3.
P0108 >> GO TO 2.

2. CHECK INTAKE SYSTEM

H

I

J

Check the following for connection.
●
Air duct
●
Vacuum hoses
●
Intake air passage between air duct to intake manifold
OK or NG
OK
>> GO TO 3.
NG
>> Reconnect the parts.

K

L

M

EC-157

DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR
[CR (WITH EURO-OBD)]

3. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace ground connections.

4. CHECK MAP SENSOR POWER SUPPLY CIRCUIT
1.
2.

Disconnect manifold absolute pressure (MAP) sensor harness
connector.
Turn ignition switch ON.

MBIB0276E

3.

Check voltage between MAP sensor terminal 2 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 5.
NG
>> Repair harness or connectors.

MBIB0602E

EC-158

DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR
[CR (WITH EURO-OBD)]

5. CHECK MAP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between MAP sensor terminal 4 and ECM terminal 56
Refer to Wiring Diagram.

EC

Continuity should exist.

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D

6. CHECK MAP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

E

Check harness continuity between MAP sensor terminal 1 and ECM terminal 51.
Refer to Wiring Diagram
F

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

G

H

7. CHECK MAP SENSOR
Refer to EC-159, «Component Inspection» .
OK or NG
OK
>> GO TO 8.
NG
>> Replace manifold absolute pressure sensor.

I

J

8. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

K

>> INSPECTION END
L

Component Inspection

BBS002VK

MANIFOLD ABSOLUTE PRESSURE SENSOR
1.
2.
3.
4.

5.

Reconnect all harness connectors disconnected.
Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF, wait at least 5 seconds and then turn ON.
Check voltage between ECM terminal 51 (manifold absolute
pressure sensor signal) and ground.
NOTE:
● To avoid the affection of intake manifold vacuum, check the
voltage 1 or more minutes past after engine is stopped.
● Because the sensor is absolute pressure sensor, output value
may differ depends on atmospheric pressure and altitude.
Measure the atmospheric pressure.
NOTE:
As atmospheric pressure describe on synoptic chart is value at
sea level, please compensate the actual pressure with the following chart.

EC-159

M

SEF006P

DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR
[CR (WITH EURO-OBD)]

6.

Altitude

Compensated pressure

0m

0hPa

200m

-24hPa

400m

-47hPa

600m

-70hPa

800m

-92hPa

1,000m

-114hPa

1,500m

-168hPa

2,000m

-218hPa

Check the manifold absolute pressure sensor value corresponds to the atmospheric pressure.
Atmospheric pressure

Voltage

800hPa

3.2 — 3.6V

850hPa

3.4 — 3.8V

900hPa

3.7 — 4.1V

960hPa

3.9 — 4.3V

1,000hPa

4.1 — 4.5V

1,050hPa

4.3 — 4.7V

7.

Start engine and let it idle.

8.

Check the voltage between ECM terminal 51 and ground at
idling and confirm the voltage difference between engine is
stopped and at idling is within following chart.

MBIB0655E

Intake manifold vacuum

Voltage difference

-40kPa (-300mmHg)

1.6 — 2.0V

-53.3kPa (-400mmHg)

2.2 — 2.6V

-66.7kPa (-500mm)

2.8 — 3.2V

-80kPa (-600mmHg)

3.4 — 3.8V
SEF487R

Removal and Installation

BBS002VL

MANIFOLD ABSOLUTE PRESSURE SENSOR
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

EC-160

DTC P0112, P0113 IAT SENSOR
[CR (WITH EURO-OBD)]

DTC P0112, P0113 IAT SENSOR
Component Description

PFP:22630

A
BBS002VM

The intake air temperature sensor is built into manifold absolute
pressure sensor. The sensor detects intake air temperature and
transmits a signal to the ECM.
The temperature sensing unit uses a thermistor which is sensitive to
the change in temperature. Electrical resistance of the thermistor
decreases in response to the temperature rise.

EC

C

D
MBIB0276E

E

Intake air
temperature °C (°F)

Voltage*

V

Resistance

F

kΩ

25 (77)

3.32

1.9 — 2.1

80 (176)

1.23

0.31 — 0.37

G

*: This data is reference value and is measured between ECM terminal 34 (Intake air
temperature sensor) and ground.

H

CAUTION:
Do not use ECM ground terminals when measuring input/output
voltage. Doing so may result in damage to the ECM’s transistor.
Use a ground other than ECM terminals, such as the ground.

SEF012P

I

On Board Diagnosis Logic
DTC No.

Trouble diagnosis name

BBS002VN

DTC detecting condition

Possible cause

P0112
0112

Intake air temperature
sensor circuit low input

An excessively low voltage from the sensor is
sent to ECM.

●

Harness or connectors
(The sensor circuit is open or shorted.)

P0113
0113

Intake air temperature
sensor circuit high input

An excessively high voltage from the sensor is
sent to ECM.

●

Intake air temperature sensor

FAIL-SAFE MODE

J

K

L

When the malfunction is detected, the ECM enters fail-safe mode.
Detected items
Intake air temperature sensor circuit

Engine operating condition in fail-safe mode
Intake air temperature is determined as 30°C (86°F).

EC-161

M

DTC P0112, P0113 IAT SENSOR
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS002VO

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 5 seconds.
If 1st trip DTC is detected, go to EC-164, «Diagnostic Procedure»
.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-162

DTC P0112, P0113 IAT SENSOR
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002VP

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1507E

EC-163

DTC P0112, P0113 IAT SENSOR
[CR (WITH EURO-OBD)]

Diagnostic Procedure

BBS002VQ

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

2. CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT
1.
2.

Disconnect manifold absolute pressure (MAP) sensor (with
intake air temperature sensor) harness connector.
Turn ignition switch ON.

MBIB0276E

3.

Check voltage between MAP sensor terminal 3 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connectors.

MBIB0300E

EC-164

DTC P0112, P0113 IAT SENSOR
[CR (WITH EURO-OBD)]

3. CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between MAP sensor terminal 4 and ECM terminal 56.
Refer to Wiring Diagram.

EC

Continuity should exist.

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D

4. CHECK INTAKE AIR TEMPERATURE SENSOR

E

Refer to EC-165, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace manifold absolute pressure sensor (with intake air temperature sensor).

F

5. CHECK INTERMITTENT INCIDENT

G

Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
H

>> INSPECTION END

Component Inspection

BBS002VR

INTAKE AIR TEMPERATURE SENSOR
1.

2.

I

Check resistance between manifold absolute pressure sensor
terminals 3 and 4 under the following conditions.
J

Intake air temperature °C (°F)

Resistance kΩ

25 (77)

1.9 — 2.1

K

If NG, replace manifold absolute pressure sensor (with intake air
temperature sensor).

L
MBIB0276E

M

SEF012P

Removal and Installation

BBS002VS

MANIFOLD ABSOLUTE PRESSURE SENSOR
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

EC-165

DTC P0117, P0118 ECT SENSOR
[CR (WITH EURO-OBD)]

DTC P0117, P0118 ECT SENSOR
Component Description

PFP:22630
BBS002VT

The engine coolant temperature sensor is used to detect the engine
coolant temperature. The sensor modifies a voltage signal from the
ECM. The modified signal returns to the ECM as the engine coolant
temperature input. The sensor uses a thermistor which is sensitive to
the change in temperature. The electrical resistance of the thermistor decreases as temperature increases.

SEF594K

Engine coolant
temperature °C (°F)
−10 (14)

Voltage*

V

Resistance

4.4

kΩ

7.0 — 11.4

20 (68)

3.5

2.1 — 2.9

50 (122)

2.2

0.68 — 1.00

90 (194)

0.9

0.236 — 0.260

*: This data is reference value and is measured between ECM terminal 72 (Engine
coolant temperature sensor) and ground.

SEF012P

CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.

On Board Diagnosis Logic

BBS002VU

These self-diagnoses have the one trip detection logic.
DTC No.

Trouble Diagnosis Name

DTC Detecting Condition

Possible Cause

P0117
0117

Engine coolant temperature
sensor circuit low input

An excessively low voltage from the sensor
is sent to ECM.

●

Harness or connectors
(The sensor circuit is open or shorted.)

P0118
0118

Engine coolant temperature
sensor circuit high input

An excessively high voltage from the sensor
is sent to ECM.

●

Engine coolant temperature sensor

FAIL-SAFE MODE
When this malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Detected items

Engine operating condition in fail-safe mode
Engine coolant temperature will be determined by ECM based on the time after turning ignition switch ON
or START. CONSULT-II displays the engine coolant temperature decided by ECM.
Engine coolant temperature decided
(CONSULT-II display)

Condition
Engine coolant temperature sensor circuit

Just as ignition switch is turned ON or START

40°C (104°F)

More than approx. 4 minutes after ignition ON or
START

80°C (176°F)
40 — 80°C (104 — 176°F)
(Depends on the time)

Except as shown above

When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates
while engine is running.

EC-166

DTC P0117, P0118 ECT SENSOR
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS002VV

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

EC

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

A

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 5 seconds.
If DTC is detected, go to EC-169, «Diagnostic Procedure» .

C

D

E

SEF058Y

F

WITH GST
Follow the procedure “WITH CONSULT-II” above.
G

H

I

J

K

L

M

EC-167

DTC P0117, P0118 ECT SENSOR
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002VW

MBWA1508E

EC-168

DTC P0117, P0118 ECT SENSOR
[CR (WITH EURO-OBD)]

Diagnostic Procedure

BBS002VX

1. CHECK GROUND CONNECTIONS
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

EC

C

D

E
MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

F

Body ground E28

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

G

2. CHECK ECT SENSOR POWER SUPPLY CIRCUIT
1.
2.

H

Disconnect engine coolant temperature (ECT) sensor harness
connector.
Turn ignition switch ON.

I

J

K
MBIB0279E

3.

L

Check voltage between ECT sensor terminal 1 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

M

OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

PBIB0080E

EC-169

DTC P0117, P0118 ECT SENSOR
[CR (WITH EURO-OBD)]

3. CHECK ECT SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECT sensor terminal 2 and ECM terminal 73.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK ENGINE COOLANT TEMPERATURE SENSOR
Refer to EC-170, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace engine coolant temperature sensor.

5. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS002VY

ENGINE COOLANT TEMPERATURE SENSOR
1.

Check resistance between engine coolant temperature sensor
terminals 1 and 2 as shown in the figure.

PBIB2005E

Engine coolant temperature

2.

°C (°F)

Resistance

kΩ

20 (68)

2.1 — 2.9

50 (122)

0.68 — 1.00

90 (194)

0.236 — 0.260

If NG, replace engine coolant temperature sensor.

SEF012P

Removal and Installation

BBS002VZ

ENGINE COOLANT TEMPERATURE SENSOR
Refer to CO-19, «THERMOSTAT» .

EC-170

DTC P0122, P0123 TP SENSOR
[CR (WITH EURO-OBD)]

DTC P0122, P0123 TP SENSOR
Component Description

PFP:16119

A
BBS002W0

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

EC

C

D
PBIB0145E

E

CONSULT-II Reference Value in Data Monitor Mode

BBS002W1

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

More than 0.36V

●

Shift lever: 1st

Accelerator pedal: Fully depressed

Less than 4.75V

THRTL SEN 1
THRTL SEN 2*

F

SPECIFICATION

G

*: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic

BBS002W2

H

These self-diagnoses have the one trip detection logic.
DTC No.
P0122
0122

P0123
0123

Trouble diagnosis name

DTC detecting condition

Throttle position sensor 2
circuit low input

An excessively low voltage from the TP sensor 2
is sent to ECM.

Throttle position sensor 2
circuit high input

An excessively high voltage from the TP sensor 2
is sent to ECM.

Possible cause
●

Harness or connectors
(TP sensor 2 circuit is open or
shorted.)
(APP sensor 2 circuit is shorted.)

●

Electric throttle control actuator
(TP sensor 2)

●

Accelerator pedal position sensor
(APP sensor 2)

I

J

K

L

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-171

M

DTC P0122, P0123 TP SENSOR
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS002W3

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-174, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-172

DTC P0122, P0123 TP SENSOR
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002W4

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1509E

EC-173

DTC P0122, P0123 TP SENSOR
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL NO.
47

WIRE
COLOR
L

ITEM

CONDITION

Sensor power supply
(Throttle position sensor)

DATA (DC Voltage)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

49

Y

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

Throttle position sensor 1

More than 0.36V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

Less than 4.75V

[Engine is running]
66

B

Sensor ground
(Throttle position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Ignition switch: ON]

68

91

R

BR

Throttle position sensor 2

Sensor power supply
(APP sensor 2)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

Less than 4.75V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

More than 0.36V

[Ignition switch: ON]

Approximately 5V

Diagnostic Procedure

BBS002W5

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-174

3.

Body ground E28

DTC P0122, P0123 TP SENSOR
[CR (WITH EURO-OBD)]

2. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-I
1.
2.

A

Disconnect electric throttle control actuator harness connector.
Turn ignition switch ON.
EC

C

D
MBIB0308E

3.

Check voltage between electric throttle control actuator terminal
1 and ground with CONSULT-II or tester.

E

Voltage: Approximately 5V
F

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.

G

PBIB0082E

H

3. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between electric throttle control actuator terminal 1 and ECM terminal 47.
Refer to Wiring Diagram.

I

J

Continuity should exist.
K

OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit.

4. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-III
Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

47

Electric throttle control actuator terminal 1

EC-173

91

APP sensor terminal 5

EC-394

OK or NG
OK
>> GO TO 5.
NG
>> Repair short to ground or short to power in harness or connectors.

5. CHECK APP SENSOR
Refer to EC-400, «Component Inspection» .
OK or NG
OK
>> GO TO 11
NG
>> GO TO 6.

EC-175

L

M

DTC P0122, P0123 TP SENSOR
[CR (WITH EURO-OBD)]

6. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace accelerator pedal assembly.
Perform EC-69, «Accelerator Pedal Released Position Learning» .
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> INSPECTION END

7. CHECK THROTTLE POSITION SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 66 and electric throttle control actuator terminal 5.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK THROTTLE POSITION SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 68 and electric throttle control actuator terminal 2.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 9.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

9. CHECK THROTTLE POSITION SENSOR
Refer to EC-177, «Component Inspection» .
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

10. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> INSPECTION END

11. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-176

DTC P0122, P0123 TP SENSOR
[CR (WITH EURO-OBD)]

Component Inspection

BBS002W6

A

THROTTLE POSITION SENSOR
1.
2.
3.
4.
5.

Reconnect all harness connectors disconnected.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Turn ignition switch ON.
Set shift lever to 1st position.
Check voltage between ECM terminals 49 (TP sensor 1 signal),
68 (TP sensor 2 signal) and ground under the following conditions.
Terminal

Accelerator pedal

Voltage

49
(Throttle position sensor 1)

Fully released

More than 0.36V

68
(Throttle position sensor 2)

6.
7.
8.

Fully depressed

Less than 4.75V

Fully released

Less than 4.75V

Fully depressed

More than 0.36V

If NG, replace electric throttle control actuator and go to the next
step.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .

Removal and Installation

EC

C

D

E

MBIB1443E

F

G
BBS002W7

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

H

I

J

K

L

M

EC-177

DTC P0132 HO2S1
[CR (WITH EURO-OBD)]

DTC P0132 HO2S1
Component Description

PFP:22690
BBS002W8

The heated oxygen sensor 1 is placed into the exhaust manifold. It
detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.

SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

BBS002W9

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION
0 — 0.3V ←→ Approx. 0.6 — 1.0V

HO2S1 (B1)
●

HO2S1 MNTR (B1)

Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN ←→ RICH
Changes more than 5 times during
10 seconds.

On Board Diagnosis Logic

BBS002WA

To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 output is not inordinately high.

SEF301UA

DTC No.
P0132
0132

Trouble diagnosis name
Heated oxygen sensor 1
circuit high voltage

DTC detecting condition

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 1

An excessively high voltage from the sensor
is sent to ECM.

EC-178

DTC P0132 HO2S1
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS002WB

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

EC

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

A

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Restart engine and let it idle for 2 minutes.
If 1st trip DTC is detected, go to EC-181, «Diagnostic Procedure»
.

C

D

E

F
SEF174Y

G

WITH GST
Follow the procedure “WITH CONSULT-II” above.

H

I

J

K

L

M

EC-179

DTC P0132 HO2S1
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002WC

MBWA1510E

EC-180

DTC P0132 HO2S1
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
Approximately 7.0V
[Engine is running]

24

Y

Heated oxygen sensor 1
heater

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

D

E
PBIB0519E

[Engine is running]
●

BATTERY VOLTAGE
(11 — 14V)

Engine speed: Above 3,600 rpm

F

[Engine is running]
35

BR

Heated oxygen sensor 1

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

G

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

H

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

I

Diagnostic Procedure

BBS002WD

1. CHECK GROUND CONNECTIONS
1.
2.

J

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

K

L

M

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-181

3.

Body ground E28

DTC P0132 HO2S1
[CR (WITH EURO-OBD)]

2. RETIGHTEN HEATED OXYGEN SENSOR 1
Loosen and retighten heated oxygen sensor 1 (2).
●
●

: Vehicle front
Exhaust manifold cover (1)
Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb)
>> GO TO 3.

MBIB1493E

3. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Disconnect heated oxygen sensor 1 harness connector (1).
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 74 and HO2S1
terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

4. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 35 and HO2S1 terminal 4.
Refer to Wiring Diagram.
Continuity should exist.

2.

Check harness continuity between ECM terminal 35 or HO2S1 terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK HO2S1 CONNECTOR FOR WATER
Check connectors for water
Water should not exist.
OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace harness or connectors.

EC-182

MBIB1494E

DTC P0132 HO2S1
[CR (WITH EURO-OBD)]

6. CHECK HEATED OXYGEN SENSOR 1

A

Refer to EC-183, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace heated oxygen sensor 1.

EC

7. CHECK INTERMITTENT INCIDENT

C

Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
D

>> INSPECTION END

Component Inspection

BBS002WE

E

HEATED OXYGEN SENSOR 1
With CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULTII.
Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch “RECORD” on CONSULT-II screen.

F

G

H

I

MBIB0301E

6.

Check the following.
● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes
from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds.
5 times (cycles) are counted as shown in the figure.
● “HO2S1 (B1)” voltage goes above 0.6V at least once.
● “HO2S1 (B1)” voltage goes below 0.3V at least once.
● “HO2S1 (B1)” voltage never exceeds 1.0V.

K

L

M
SEF217YA

SEF648Y

CAUTION:
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.

●

EC-183

J

DTC P0132 HO2S1
[CR (WITH EURO-OBD)]
●

Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

Without CONSULT-II
1.
2.
3.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground.
Check the following with engine speed held at 2,000 rpm constant under no load.
● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
● The maximum voltage is over 0.6V at least one time.
● The minimum voltage is below 0.3V at least one time.
● The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V → 0 0.3V
MBIB0018E
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

Removal and Installation

BBS002WF

HEATED OXYGEN SENSOR 1
Refer to EM-24, «EXHAUST MANIFOLD AND THREE WAY CATALYST» .

EC-184

DTC P0133 HO2S1
[CR (WITH EURO-OBD)]

DTC P0133 HO2S1
Component Description

PFP:22690

A
BBS002WG

The heated oxygen sensor 1 is placed into the exhaust manifold. It
detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.

EC

C

D
SEF463R

E

F

G

H
SEF288D

CONSULT-II Reference Value in Data Monitor Mode

BBS002WH

I

Specification data are reference values.
MONITOR ITEM

CONDITION

J

0 — 0.3V ←→ Approx. 0.6 — 1.0V

HO2S1 (B1)
●

HO2S1 MNTR (B1)

SPECIFICATION

Engine: After warming up

Maintaining engine speed at 2,000 rpm

On Board Diagnosis Logic

LEAN ←→ RICH
Changes more than 5 times during 10 seconds.

K

BBS002WI

L

To judge the malfunction of heated oxygen sensor 1, this diagnosis
measures response time of heated oxygen sensor 1 signal. The time
is compensated by engine operating (speed and load), fuel feedback
control constant, and heated oxygen sensor 1 temperature index.
Judgment is based on whether the compensated time (heated oxygen sensor 1 cycling time index) is inordinately long or not.

M

PBIB2991E

EC-185

DTC P0133 HO2S1
[CR (WITH EURO-OBD)]
DTC No.

P0133
0133

Trouble diagnosis name

Heated oxygen sensor 1
circuit slow response

DTC detecting condition

The response of the voltage signal from the
sensor takes more than the specified time.

DTC Confirmation Procedure

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 1

●

Fuel pressure

●

Fuel injector

●

Intake air leak

●

Exhaust gas leak

●

Manifold absolute pressure sensor
BBS002WJ

CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
●
Always perform at a temperature above −10°C (14°F).
●
Before performing the following procedure, confirm that battery voltage is more than 11V at idle.

WITH CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Stop engine and wait at least 10 seconds.
Turn ignition switch ON and select “HO2S1 (B1) P0133” of “HO2S1” in “DTC WORK SUPPORT” mode
with CONSULT-II.
Touch “START”.
Start engine and let it idle for at least 3 minutes.
NOTE:
Never raise engine speed above 3,600 rpm after this step. If
the engine speed limit is exceeded, return to step 5.

SEF338Z

6.

When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will
take approximately 40 to 60 seconds.)

ENG SPEED

2,400 — 3,800 rpm

VHCL SPEED SE

More than 80 km/h (50 MPH)

B/FUEL SCHDL

2.8 — 7.0 msec

Shift lever

Suitable position

If “TESTING” is not displayed after 5 minutes, retry from
step 2.

EC-186

SEF339Z

DTC P0133 HO2S1
[CR (WITH EURO-OBD)]
7.

Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”. If “NG” is displayed, refer to EC-189, «Diagnostic
Procedure» .

A

EC

C
SEF658Y

D

Overall Function Check

BBS002WK

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st
trip DTC might not be confirmed.

E

WITH GST
1.
2.
3.
●

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground.
Check the following with engine speed held at 2,000 rpm constant under no load.
The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more
than 5 times within 10 seconds.
1 time:
2 times:

4.

F

G

0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V
→ 0 — 0.3V

H

I

If NG, go to EC-189, «Diagnostic Procedure» .
MBIB0018E

J

K

L

M

EC-187

DTC P0133 HO2S1
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002WL

MBWA1510E

EC-188

DTC P0133 HO2S1
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
Approximately 7.0V
[Engine is running]

24

Y

Heated oxygen sensor 1
heater

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

D

E
PBIB0519E

[Engine is running]
●

BATTERY VOLTAGE
(11 — 14V)

Engine speed: Above 3,600 rpm

F

[Engine is running]
35

BR

Heated oxygen sensor 1

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

G

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

H

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

I

Diagnostic Procedure

BBS002WM

1. CHECK GROUND CONNECTIONS
1.
2.

J

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

K

L

M

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-189

3.

Body ground E28

DTC P0133 HO2S1
[CR (WITH EURO-OBD)]

2. RETIGHTEN HEATED OXYGEN SENSOR 1
Loosen and retighten heated oxygen sensor 1 (2).
●
●

: Vehicle front
Exhaust manifold cover (1)
Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb)
>> GO TO 3.

MBIB1493E

3. CHECK FOR EXHAUST GAS LEAK
1.
2.

Start engine and run it at idle.
Listen for an exhaust gas leak before three way catalyst (Manifold).

MBIB0649E

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace.

4. CHECK FOR INTAKE AIR LEAK
Listen for an intake air leak after the manifold absolute pressure sensor.
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace.

EC-190

DTC P0133 HO2S1
[CR (WITH EURO-OBD)]

5. CLEAR THE SELF-LEARNING DATA
1.
2.
3.
4.

A

With CONSULT-II
Start engine and warm it up to normal operating temperature.
Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II.
Clear the self-learning control coefficient by touching “CLEAR”.
Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 or P0172 detected?
Is it difficult to start engine?

EC

C

D

E
SEF215Z

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF.
3. Disconnect manifold absolute pressure sensor harness connector, and restart and run engine for at least 5 seconds at idle
speed.
4. Stop engine and reconnect manifold absolute pressure sensor
harness connector.
5. Make sure that DTC P0107 is displayed.
6. Erase the DTC memory. Refer to EC-57, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .
7. Make sure that DTC P0000 is displayed.
8. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 or P0172 detected?
Is it difficult to start engine?
Yes or No
Yes
>> Perform trouble diagnosis for DTC P0171 or DTC P0172 (Refer to EC-218 or EC-226 ).
No
>> GO TO 6.

F

G

H

I

J
MBIB0276E

K

L

6. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect heated oxygen sensor 1 harness connector (1).
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 74 and HO2S1
terminal 1. Refer to Wiring Diagram.

M

Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

EC-191

MBIB1494E

DTC P0133 HO2S1
[CR (WITH EURO-OBD)]

7. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 35 and HO2S1 terminal 4.
Refer to Wiring Diagram.
Continuity should exist.

2.

Check harness continuity between ECM terminal 35 or HO2S1 terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 8.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK MANIFOLD ABSOLUTE PRESSURE SENSOR
Refer to EC-159, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace manifold absolute pressure sensor.

9. CHECK PCV VALVE
Refer to EC-45, «Component Inspection» .
OK or NG
OK
>> GO TO 10.
NG
>> Replace PCV valve.

10. CHECK HEATED OXYGEN SENSOR 1
Refer to EC-193, «Component Inspection» .
OK or NG
OK
>> GO TO 11.
NG
>> Replace heated oxygen sensor 1.

11. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-192

DTC P0133 HO2S1
[CR (WITH EURO-OBD)]

Component Inspection

BBS002WN

A

HEATED OXYGEN SENSOR 1
With CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC
II.
Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
C
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch “RECORD” on CONSULT-II screen.
D

E

MBIB0301E

F

6.

Check the following.
● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes
from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds.
5 times (cycles) are counted as shown in the figure.
● “HO2S1 (B1)” voltage goes above 0.6V at least once.
● “HO2S1 (B1)” voltage goes below 0.3V at least once.
● “HO2S1 (B1)” voltage never exceeds 1.0V.

G

H

I
SEF217YA

J

K

L

SEF648Y

CAUTION:
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.
●

EC-193

M

DTC P0133 HO2S1
[CR (WITH EURO-OBD)]
Without CONSULT-II
1.
2.
3.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground.
Check the following with engine speed held at 2,000 rpm constant under no load.
● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
● The maximum voltage is over 0.6V at least one time.
● The minimum voltage is below 0.3V at least one time.
● The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V → 0 0.3V
MBIB0018E
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

Removal and Installation

BBS002WO

HEATED OXYGEN SENSOR 1
Refer to EM-24, «EXHAUST MANIFOLD AND THREE WAY CATALYST» .

EC-194

DTC P0134 HO2S1
[CR (WITH EURO-OBD)]

DTC P0134 HO2S1
Component Description

PFP:22690

A
BBS002WP

The heated oxygen sensor 1 is placed into the exhaust manifold. It
detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.

EC

C

D
SEF463R

E

F

G

H
SEF288D

CONSULT-II Reference Value in Data Monitor Mode

BBS002WQ

I

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

J

0 — 0.3V ←→ Approx. 0.6 — 1.0V

HO2S1 (B1)
●

HO2S1 MNTR (B1)

Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN ←→ RICH
Changes more than 5 times during 10 seconds.

On Board Diagnosis Logic

BBS002WR

L

Under the condition in which the heated oxygen sensor 1 signal is
not input, the ECM circuits will read a continuous approximately
0.3V. Therefore, for this diagnosis, the time that output voltage is
within 200 to 400 mV range is monitored, and the diagnosis checks
that this time is not inordinately long.

M

SEF237U

DTC No.
P0134
0134

Trouble diagnosis name
Heated oxygen sensor 1
circuit no activity detected

K

DTC detecting condition

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 1

The voltage from the sensor is constantly
approx. 0.3V.

EC-195

DTC P0134 HO2S1
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS002WS

CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 11V at idle.

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

Start engine and warm it up to normal operating temperature.
Select “HO2S1 (B1) P0134” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II.
Touch “START”.
Let it idle for at least 3 minutes.
NOTE:
Never raise engine speed above 3,600 rpm after this step. If
the engine speed limit is exceeded, return to step 4.

PBIB0544E

5.

When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will
take approximately 10 to 60 seconds.)

ENG SPEED

2,100 — 4,100 rpm

VHCL SPEED SE

More than 64 km/h (40 MPH)

B/FUEL SCHDL

2.0 — 7.8 msec

Shift lever

Suitable position

6.

If “TESTING” is not displayed after 5 minutes, retry from
step 2.
Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”. If “NG” is displayed, refer to EC-199, «Diagnostic
Procedure» .

PBIB0545E

SEC750C

EC-196

DTC P0134 HO2S1
[CR (WITH EURO-OBD)]

Overall Function Check

BBS002WT

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a
1st trip DTC might not be confirmed.

WITH GST
1.
2.
3.
●

4.

A

EC

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground.
Check the following with engine speed held at 2,000 rpm constant under no load.
The voltage does not remain in the range of 0.2 to 0.4V.
If NG, go to EC-199, «Diagnostic Procedure» .

C

D

E

MBIB0018E

F

G

H

I

J

K

L

M

EC-197

DTC P0134 HO2S1
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002WU

MBWA1510E

EC-198

DTC P0134 HO2S1
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
Approximately 7.0V
[Engine is running]

24

Y

Heated oxygen sensor 1
heater

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

D

E
PBIB0519E

[Engine is running]
●

BATTERY VOLTAGE
(11 — 14V)

Engine speed Above 3,600 rpm

F

[Engine is running]
35

BR

Heated oxygen sensor 1

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

G

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

H

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

I

Diagnostic Procedure

BBS002WV

1. CHECK GROUND CONNECTIONS
1.
2.

J

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

K

L

M

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-199

3.

Body ground E28

DTC P0134 HO2S1
[CR (WITH EURO-OBD)]

2. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Disconnect heated oxygen sensor 1 harness connector (1).
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 74 and HO2S1
terminal 1. Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

3. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 35 and HO2S1 terminal 4.
Refer to Wiring Diagram.
Continuity should exist.

2.

Check harness continuity between ECM terminal 35 or HO2S1 terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK HEATED OXYGEN SENSOR 1
Refer to EC-201, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace heated oxygen sensor 1.

5. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-200

MBIB1494E

DTC P0134 HO2S1
[CR (WITH EURO-OBD)]

Component Inspection

BBS002WW

A

HEATED OXYGEN SENSOR 1
With CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC
II.
Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
C
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch “RECORD” on CONSULT-II screen.
D

E

MBIB0301E

F

6.

Check the following.
● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes
from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds.
5 times (cycles) are counted as shown in the figure.
● “HO2S1 (B1)” voltage goes above 0.6V at least once.
● “HO2S1 (B1)” voltage goes below 0.3V at least once.
● “HO2S1 (B1)” voltage never exceeds 1.0V.

G

H

I
SEF217YA

J

K

L

SEF648Y

CAUTION:
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.
●

Without CONSULT-II
1.
2.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground.

EC-201

M

DTC P0134 HO2S1
[CR (WITH EURO-OBD)]
3.

Check the following with engine speed held at 2,000 rpm constant under no load.
● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
● The maximum voltage is over 0.6V at least one time.
● The minimum voltage is below 0.3V at least one time.
● The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V → 0 0.3V
MBIB0018E
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

Removal and Installation

BBS002WX

HEATED OXYGEN SENSOR 1
Refer to EM-24, «EXHAUST MANIFOLD AND THREE WAY CATALYST» .

EC-202

DTC P0138 HO2S2
[CR (WITH EURO-OBD)]

DTC P0138 HO2S2
Component Description

PFP:226A0

A
BBS002WY

The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.

EC

C

D
SEF327R

E

CONSULT-II Reference Value in Data Monitor Mode

BBS002WZ

Specification data are reference values.
MONITOR ITEM
HO2S2 (B1)

HO2S2 MNTR (B1)

F

CONDITION

SPECIFICATION

●

Revving engine from idle to 3,000 rpm quickly after the following conditions are met.

0 — 0.3V ←→ Approx. 0.6 — 1.0V

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and
at idle for 1 minute under no load.

G

LEAN ←→ RICH

H

On Board Diagnosis Logic

BBS002X0

The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity before the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the voltage is unusually high during
the various driving condition such as fuel-cut.

I

J

K
SEF305UA

L
DTC No.
P0138
0138

Trouble diagnosis name
Heated oxygen sensor 2
circuit high voltage

DTC detecting condition

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 2

An excessively high voltage from the sensor
is sent to ECM.

EC-203

M

DTC P0138 HO2S2
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS002X1

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least 1 minute under no load.
Let engine idle for 2 minutes.
If 1st trip DTC is detected, go to EC-206, «Diagnostic Procedure»
.

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-204

SEF189Y

DTC P0138 HO2S2
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002X2

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1511E

EC-205

DTC P0138 HO2S2
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]

2

GR

●

Engine speed: Below 3,800 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and
4,000 rpm for 1 minute and at idle for 1 minute
under no load.

Heated oxygen sensor 2
heater

0 — 1.0V

[Ignition switch ON]
●

Engine stopped

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
●

Engine speed: Above 3,800 rpm

[Engine is running]

16

LG

Heated oxygen sensor 2

●

Revving engine from idle to 3,000rpm quickly
after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and
4,000 rpm for 1 minute and at idle for 1 minute
under no load.

0 — Approximately 1.0V

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

Diagnostic Procedure

BBS002X3

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-206

3.

Body ground E28

DTC P0138 HO2S2
[CR (WITH EURO-OBD)]

2. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT
1.

Disconnect heated oxygen sensor 2 harness connector (1).

–

: Vehicle front
Heated oxygen sensor 2 (2)
Oil pan (3)
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 74 and HO2S2
terminal 4.
Refer to Wiring Diagram.

–
–

2.
3.

Continuity should exist.

EC

C

D
MBIB1459E

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

A

Check harness continuity between ECM terminal 16 and HO2S2 terminal 1.
Refer to Wiring Diagram.

E

F

G

Continuity should exist.
2.

Check harness continuity between ECM terminal 16 or HO2S2 terminal 1 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

H

I

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK HO2S2 CONNECTOR FOR WATER

J

K

Check connectors for water.
Water should not exist.

L

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace harness or connectors.

5. CHECK HEATED OXYGEN SENSOR 2
Refer to EC-208, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 2.

6. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-207

M

DTC P0138 HO2S2
[CR (WITH EURO-OBD)]

Component Inspection

BBS002X4

HEATED OXYGEN SENSOR 2
With CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
SEF174Y

6.

Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select
“HO2S2(B1)” as the monitor item with CONSULT-II.

SEF662Y

7.

Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%.

MBIB1402E

“HO2S2 (B1)” should be above 0.61V at least once when the “FUEL INJECTION” is +25%.
“HO2S2 (B1)” should be below 0.52V at least once when the “FUEL INJECTION” is −25%.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

Without CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground.

EC-208

DTC P0138 HO2S2
[CR (WITH EURO-OBD)]
6.

Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
A
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.61V at least once during this
procedure.
EC
If the voltage is above 0.61V at step 6, step 7 is not necessary.
7. Keep vehicle idling for 10 minutes, then check voltage. Or check
C
the voltage when coasting from 80 km/h (50 MPH) in 3rd gear
position.
The voltage should be below 0.52V at least once during this
MBIB0020E
procedure.
D
8. If NG, replace heated oxygen sensor 2.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 E
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.
F

Removal and Installation

BBS002X5

HEATED OXYGEN SENSOR 2
G

Refer to EX-3, «EXHAUST SYSTEM» .

H

I

J

K

L

M

EC-209

DTC P0139 HO2S2
[CR (WITH EURO-OBD)]

DTC P0139 HO2S2
Component Description

PFP:226A0
BBS002X6

The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
SEF327R

CONSULT-II Reference Value in Data Monitor Mode

BBS002X7

Specification data are reference values.
MONITOR ITEM
HO2S2 (B1)

HO2S2 MNTR (B1)

CONDITION

SPECIFICATION

●

Revving engine from idle to 3,000 rpm quickly after the following conditions are met.

0 — 0.3V ←→ Approx. 0.6 — 1.0V

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and
at idle for 1 minute under no load.

LEAN ←→ RICH

On Board Diagnosis Logic

BBS002X8

The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity before the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the switching response of the sensor’s voltage is faster than specified during the various driving condition such as fuel-cut.

SEF302U

DTC No.

P0139
0139

Trouble diagnosis name

Heated oxygen sensor 2
circuit slow response

DTC detecting condition

It takes more time for the sensor to respond
between rich and lean than the specified time.

EC-210

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 2

●

Fuel pressure

●

Fuel injector

●

Intake air leak

DTC P0139 HO2S2
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS002X9

A
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
●
“COMPLETED” will appear on CONSULT-II screen when all tests “COND1”, “COND2” and EC
“COND3” are completed.
●
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
C
at least 10 seconds before conducting the next test.
TESTING CONDITION:
Never stop engine during this procedure. If the engine is stopped, retry this procedure from step 2 in
D
Procedure for COND1.

WITH CONSULT-II
Procedure for COND1
For the best results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30°(32 to 86°F).
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
4. Let engine idle 1 minute.
5. Select “HO2S2 (B1) P0139” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II.
6. Touch “START”.
7. Start engine and let it idle for at least 30 seconds.
8. Rev engine up to 2,000 rpm 2 or 3 times quickly under no load.
If “COMPLETED” appears on CONSULT-II screen, go to step 2 in “Procedure for COND3”.
If “COMPLETED” does not appear on CONSULT-II screen, go to the following step.
9. When the following conditions are met, “TESTING” will be displayed at “COND1” on the CONSULT-II
screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take
approximately 60 seconds.)
ENG SPEED

More than 1.0 msec

COOLAN TEMP/S

70 — 105 °C (158 — 221°F)

Shift level

Suitable position

F

G

H

I

J

More than 1,500 rpm

B/FUEL SCHDL

E

K

L

M

PBIB0552E

NOTE:
● If “TESTING” is not displayed after 5 minutes, retry from step 2 in Procedure for COND1.
● If “COMPLETED” already appears at “COND2” on CONSULT-II screen before Procedure for
COND2 is conducted, it is unnecessary to conduct step 1 in Procedure for COND2.

EC-211

DTC P0139 HO2S2
[CR (WITH EURO-OBD)]
Procedure for COND2
1.

While driving, release accelerator pedal completely from the
above condition [step 9] until “INCOMPLETE” at “COND2” on
CONSULT-II screen has turned to “COMPLETED”. (It will take
approximately 4 seconds.)
NOTE:
If “COMPLETED” already appears at “COND3” on CONSULT-II
screen before Procedure for COND3 is conducted, it is unnecessary to conduct step 1 in Procedure for COND3.

PBIB0553E

Procedure for COND3
1.

2.

a.
b.
c.
d.

Stop vehicle and let it idle until “INCOMPLETE” of “COND3” on
CONSULT-II screen has turned to “COMPLETED”. (It will take a
maximum of approximately 6 minutes.)
Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”.
If “NG” is displayed, refer to EC-214, «Diagnostic Procedure» .
If “CAN NOT BE DIAGNOSED” is displayed, perform the following.
Turn ignition switch OFF and leave the vehicle in a cool place
(soak the vehicle).
Turn ignition switch ON and select “COOLAN TEMP/S” in “DATA
MONITOR” mode with CONSULT-II.
Start engine and warm it up while monitoring “COOLAN TEMP/S” indication on CONSULT-II.
When “COOLAN TEMP/S” indication reaches to 70°(158°F), go to procedure for COND1 step 3.

Overall Function Check

SEF668Y

BBS002XA

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a
1st trip DTC might not be confirmed.

WITH GST
1.
2.
3.
4.
5.
6.

7.

8.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground.
Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
A change of voltage should be more than 0.06V for 1 second during this procedure.
If the voltage can be confirmed in step 6, step 7 is not necessary.
Keep vehicle at idling for 10 minutes, then check the voltage. Or
check the voltage when coasting from 80 km/h (50 MPH) in 3rd
gear position.
A change of voltage should be more than 0.06V for 1 secMBIB0020E
ond during this procedure.
If NG, go to EC-214, «Diagnostic Procedure» .

EC-212

DTC P0139 HO2S2
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002XB

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1511E

EC-213

DTC P0139 HO2S2
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]

2

GR

●

Engine speed: Below 3,800 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and
4,000 rpm for 1 minute and at idle for 1 minute
under no load.

Heated oxygen sensor 2
heater

0 — 1.0V

[Ignition switch ON]
●

Engine stopped

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
●

Engine speed: Above 3,800 rpm

[Engine is running]

16

LG

Heated oxygen sensor 2

●

Revving engine from idle to 3,000rpm quickly
after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and
4,000 rpm for 1 minute and at idle for 1 minute
under no load.

0 — Approximately 1.0V

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

Diagnostic Procedure

BBS002XC

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-214

3.

Body ground E28

DTC P0139 HO2S2
[CR (WITH EURO-OBD)]

2. CLEAR THE SELF-LEARNING DATA

A

With CONSULT-II
Start engine and warm it up to normal operating temperature.
Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode
with CONSULT-II.
3. Clear the self-learning control coefficient by touching “CLEAR”.
4. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 or P0172 detected?
Is it difficult to start engine?
1.
2.

EC

C

D

E
SEF215Z

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF.
3. Disconnect manifold absolute pressure sensor harness connector, and restart and run engine for at least 5 seconds at idle
speed.
4. Stop engine and reconnect manifold absolute pressure sensor
harness connector.
5. Make sure that DTC P0107 is displayed.
6. Erase the DTC memory. Refer to EC-57, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .
7. Make sure that DTC P0000 is displayed.
8. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 or P0172 detected?
Is it difficult to start engine?
Yes or No
Yes
>> Perform trouble diagnosis for DTC P0171 or P0172. Refer to EC-218 or EC-226 .
No
>> GO TO 3.

F

G

H

I

MBIB0276E

J

K

3. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT

L

1.
2.

Turn ignition switch OFF.
Disconnect heated oxygen sensor 2 harness connector (1).

M

–

: Vehicle front
Heated oxygen sensor 2 (2)
Oil pan (3)
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 74 and HO2S2
terminal 4.
Refer to Wiring Diagram.

–
–

3.
4.

Continuity should exist.

MBIB1459E

5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-215

DTC P0139 HO2S2
[CR (WITH EURO-OBD)]

4. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 16 and HO2S2 terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

2.

Check harness continuity between ECM terminal 16 or HO2S2 terminal 1 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK HEATED OXYGEN SENSOR 2
Refer to EC-216, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 2.

6. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS002XD

HEATED OXYGEN SENSOR 2
With CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
SEF174Y

6.

Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select
“HO2S2 (B1)” as the monitor item with CONSULT-II.

SEF662Y

EC-216

DTC P0139 HO2S2
[CR (WITH EURO-OBD)]
7.

Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%.
A

EC

C

MBIB1402E

“HO2S2 (B1)” should be above 0.61V at least once when the “FUEL INJECTION” is +25%.
“HO2S2 (B1)” should be below 0.52V at least once when the “FUEL INJECTION” is −25%.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

D

E

F

Without CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground.
Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.61V at least once during this
procedure.
If the voltage is above 0.61V at step 6, step 7 is not necessary.
7. Keep vehicle idling for 10 minutes, then check voltage. Or check
the voltage when coasting from 80 km/h (50 MPH) in 3rd gear
position.
The voltage should be below 0.52V at least once during this
MBIB0020E
procedure.
8. If NG, replace heated oxygen sensor 2.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

Removal and Installation

BBS002XE

HEATED OXYGEN SENSOR 2
Refer to EX-3, «EXHAUST SYSTEM» .

EC-217

G

H

I

J

K

L

M

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
[CR (WITH EURO-OBD)]

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
On Board Diagnosis Logic

PFP:16600
BBS002XF

With the Air/Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the
theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensor 1. The
ECM calculates the necessary compensation to correct the offset between the actual and the theoretical
ratios.
In case the amount of the compensation value is extremely large (The actual mixture ratio is too lean.), the
ECM judges the condition as the fuel injection system malfunction and lights up the MI (2 trip detection logic).
Sensor
Heated oxygen sensors 1

DTC No.

Input Signal to ECM
Density of oxygen in exhaust gas
(Mixture ratio feedback signal)

Trouble diagnosis name

Fuel injection system too
lean

Actuator

Fuel injection control

DTC detecting condition

●

P0171
0171

ECM function

●

Fuel injector

Possible cause
●

Intake air leaks

●

Heated oxygen sensor 1

Fuel injection system does not operate properly.

●

Fuel injector

The amount of mixture ratio compensation is too
large.
(The mixture ratio is too lean.)

●

Exhaust gas leak

●

Incorrect fuel pressure

●

Lack of fuel

●

Manifold absolute pressure sensor

●

Incorrect PCV hose connection

DTC Confirmation Procedure

BBS002XG

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

a.
b.

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON and select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II.
Clear the self-learning control coefficient by touching “CLEAR”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine again and let it idle for at least 10 minutes.
The 1st trip DTC P0171 should be detected at this stage, if a
malfunction exists. If so, go to EC-222, «Diagnostic Procedure» .
NOTE:
If 1st trip DTC is not detected during above procedure, performing the following procedure is advised.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and drive the vehicle under the similar conditions to
SEF215Z
(1st trip) Freeze Frame Data for 10 minutes. Refer to the table
below.
Hold the accelerator pedal as steady as possible.
The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time.

Engine speed

Engine speed in the freeze frame data ± 400 rpm

Vehicle speed

Vehicle speed in the freeze frame data ± 10 km/h (6 MPH)

EC-218

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
[CR (WITH EURO-OBD)]
Engine coolant temperature
(T) condition

7.
8.

When the freeze frame data shows lower than 70 °C (158 °F),
T should be lower than 70 °C (158 °F).

A

When the freeze frame data shows higher than or equal to 70 °C (158 °F),
T should be higher than or equal to 70 °C (158 °F).

EC
If it is difficult to start engine at step 6, the fuel injection system has a malfunction, too.
Crank engine while depressing accelerator pedal. If engine starts, go to EC-222, «Diagnostic Procedure» .
If engine does not start, check exhaust and intake air leak visually.
C

WITH GST
1.
2.
3.
4.
5.
6.
7.
8.
9.

a.
b.

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Disconnect manifold absolute pressure sensor harness connector.
Restart engine and let it idle for at least 5 seconds.
Stop engine and reconnect manifold absolute pressure sensor
harness connector.
Select Service $03 with GST. Make sure DTC P0107 is
detected.
Select Service $04 with GST and erase the DTC P0107.
Start engine again and let it idle for at least 10 minutes.
MBIB0276E
Select Service $07 with GST. The 1st trip DTC P0171 should be
detected at this stage, if a malfunction exists. If so, go to EC222, «Diagnostic Procedure» .
NOTE:
If 1st trip DTC is not detected during above procedure, performing the following procedure is advised.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for 10 minutes. Refer to the table below.
Hold the accelerator pedal as steady as possible.
The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time.

Engine speed

Engine speed in the freeze frame data ± 400 rpm

Vehicle speed

Vehicle speed in the freeze frame data ± 10 km/h (6 MPH)

Engine coolant temperature
(T) condition

When the freeze frame data shows lower than 70 °C (158 °F),
T should be lower than 70 °C (158 °F).
When the freeze frame data shows higher than or equal to 70 °C (158 °F),
T should be higher than or equal to 70 °C (158 °F).

10. If it is difficult to start engine at step 8, the fuel injection system has a malfunction.
11. Crank engine while depressing accelerator pedal. If engine starts, go to EC-222, «Diagnostic Procedure» .
If engine does not start, check exhaust and intake air leak visually.

EC-219

D

E

F

G

H

I

J

K

L

M

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002XH

MBWA1512E

EC-220

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
BATTERY VOLTAGE
[Engine is running]

22
23
41
42

O
L
R
GR

●

Warm-up condition

●

Idle speed

(11 — 14V)

D

NOTE:
The pulse cycle changes depending on rpm at
idle.

Fuel injector No. 3
Fuel injector No. 1
Fuel injector No. 4
Fuel injector No. 2

E
PBIB0529E

BATTERY VOLTAGE

F

(11 — 14V)
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

G

H
PBIB0530E

Approximately 7.0V

I
[Engine is running]
24

Y

Heated oxygen sensor 1
heater

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

J

PBIB0519E

[Engine is running]
●

Engine speed: Above 3,600 rpm

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
35

BR

Heated oxygen sensor 1

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-221

K

L

M
Approximately 0V

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
[CR (WITH EURO-OBD)]

Diagnostic Procedure

BBS002XI

1. CHECK EXHAUST GAS LEAK
1.
2.

Start engine and run it at idle.
Listen for an exhaust gas leak before three way catalyst (manifold).

MBIB0649E

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace.

2. CHECK FOR INTAKE AIR LEAK AND PCV HOSE
1. Listen for an intake air leak after the manifold absolute pressure sensor.
2. Check PCV hose connection.
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

3. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect heated oxygen sensor 1 (HO2S1) harness connector (1).
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 35 and HO2S1
terminal 4.
Refer to Wiring Diagram.
Continuity should exist.

5.

Check harness continuity between ECM terminal 35 or HO2S1
terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

6. Also check harness for short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-222

MBIB1494E

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
[CR (WITH EURO-OBD)]

4. CHECK FUEL PRESSURE
1.
2.

A

Release fuel pressure to zero. Refer to EC-71, «FUEL PRESSURE RELEASE» .
Install fuel pressure gauge and check fuel pressure. Refer to EC-72, «FUEL PRESSURE CHECK» .
At idling: Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi)

EC

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

C

5. DETECT MALFUNCTIONING PART

D

Check the following.
●
Fuel pump and circuit (Refer to EC-427, «FUEL PUMP» .)
●
Fuel pressure regulator (Refer to EC-71, «Fuel Pressure Check» .)
●
Fuel lines (Refer to EM-32, «FUEL INJECTOR AND FUEL TUBE» .)
●
Fuel filter for clogging

E

F

>> Repair or replace.

6. CHECK MANIFOLD ABSOLUTE PRESSUR SENSOR
1.
2.

With CONSULT-II
Install all removed parts.
Check manifold absolute pressure sensor signal with CONSULT-II.
Approximately 1.5V:
Approximately 1.2V:

1.
2.

H

I

at idling
at 2,500 rpm

With GST
Install all removed parts.
Check manifold absolute pressure sensor signal in Service $01 with GST.
Approximately 1.5V:
Approximately 1.2V:

G

J

K

at idling
at 2,500 rpm

OK or NG
OK
>> GO TO 7.
NG
>> Check connectors for rusted terminals or loose connections in the manifold absolute pressure
sensor circuit or ground. Refer to EC-155, «DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR» .

EC-223

L

M

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
[CR (WITH EURO-OBD)]

7. CHECK FUNCTION OF FUEL INJECTORS
With CONSULT-II
Start engine.
Perform “POWER BALANCE” in “ACTIVE TEST” mode with
CONSULT-II.
3. Make sure that each fuel circuit produces a momentary engine
speed drop.
1.
2.

MBIB0302E

Without CONSULT-II
1. Start engine.
2. Listen to each fuel injector operating sound.
Clicking noise should be heard.

PBIB1986E

OK or NG
OK
>> GO TO 8.
NG
>> Perform trouble diagnosis for FUEL INJECTOR, EC-421, «FUEL INJECTOR» .

8. CHECK FUEL INJECTOR
1.
2.
3.

4.
5.
6.

Confirm that the engine is cooled down and there are no fire hazards near the vehicle.
Turn ignition switch OFF.
Remove fuel tube assembly. Refer to EM-32, «FUEL INJECTOR AND FUEL TUBE» .
Keep fuel hose and all fuel injectors connected to fuel tube.
The fuel injector harness connectors should remain connected.
Disconnect all ignition coil harness connectors.
Prepare pans or saucers under each fuel injector.
Crank engine for about 3 seconds. Make sure that fuel sprays
out from fuel injectors.
Fuel should be sprayed evenly for each fuel injector.

OK or NG
OK
>> GO TO 9.
NG
>> Replace fuel injectors from which fuel does not spray
out. Always replace O-ring with new ones.

PBIB1726E

EC-224

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
[CR (WITH EURO-OBD)]

9. CHECK INTERMITTENT INCIDENT

A

Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
EC

>> INSPECTION END

C

D

E

F

G

H

I

J

K

L

M

EC-225

DTC P0172 FUEL INJECTION SYSTEM FUNCTION
[CR (WITH EURO-OBD)]

DTC P0172 FUEL INJECTION SYSTEM FUNCTION
On Board Diagnosis Logic

PFP:16600
BBS002XJ

With the Air/Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the
theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensors 1. The
ECM calculates the necessary compensation to correct the offset between the actual and the theoretical
ratios.
In case the amount of the compensation value is extremely large (The actual mixture ratio is too rich.), the
ECM judges the condition as the fuel injection system malfunction and lights up the MI (2 trip detection logic).
Sensor
Heated oxygen sensors 1

DTC No.

P0172
0172

Input Signal to ECM
Density of oxygen in exhaust gas
(Mixture ratio feedback signal)

Trouble diagnosis name

Fuel injection system too
rich

ECM function

Actuator

Fuel injection control

DTC detecting condition
●

Fuel injection system does not operate properly.

●

The amount of mixture ratio compensation is too
large.
(The mixture ratio is too rich.)

Fuel injector

Possible cause
●

Heated oxygen sensor 1

●

Fuel injector

●

Exhaust gas leak

●

Incorrect fuel pressure

●

Manifold absolute pressure sensor

DTC Confirmation Procedure

BBS002XK

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

a.
b.

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON and select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II.
Clear the self-learning control coefficient by touching “CLEAR”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine again and let it idle for at least 10 minutes.
The 1st trip DTC P0172 should be detected at this stage, if a
malfunction exists. If so, go to EC-230, «Diagnostic Procedure» .
NOTE:
If 1st trip DTC is not detected during above procedure, performing the following procedure is advised.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and drive the vehicle under the similar conditions to
SEF215Z
(1st trip) Freeze Frame Data for a certain time. Refer to the table
below.
Hold the accelerator pedal as steady as possible.
The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time.

Engine speed

Engine speed in the freeze frame data ± 400 rpm

Vehicle speed

Vehicle speed in the freeze frame data ± 10 km/h (6 MPH)

Engine coolant temperature
(T) condition

7.
8.

When the freeze frame data shows lower than 70 °C (158 °F),
T should be lower than 70 °C (158 °F).
When the freeze frame data shows higher than or equal to 70 °C (158 °F),
T should be higher than or equal to 70 °C (158 °F).

If it is difficult to start engine at step 6, the fuel injection system has a malfunction, too.
Crank engine while depressing accelerator pedal.

EC-226

DTC P0172 FUEL INJECTION SYSTEM FUNCTION
[CR (WITH EURO-OBD)]
If engine starts, go to EC-230, «Diagnostic Procedure» . If engine does not start, remove spark plugs and
check for fouling, etc.

A

WITH GST
1.
2.
3.

4.
5.
6.
7.
8.

a.
b.

Start engine and warm it up to normal operating temperature.
EC
Turn ignition switch OFF and wait at least 10 seconds.
Disconnect manifold absolute pressure sensor harness connector. Then restart and run engine for at least 5 seconds at idle
C
speed.
Stop engine and reconnect manifold absolute pressure sensor
harness connector.
D
Select Service $03 with GST. Make sure DTC P0107 is
detected.
Select Service $04 with GST and erase the DTC P0107.
E
Start engine again and let it idle for at least 10 minutes.
Select Service $07 with GST. The 1st trip DTC P0172 should be
MBIB0276E
detected at this stage, if a malfunction exists. If so, go to ECF
230, «Diagnostic Procedure» .
NOTE:
If 1st trip DTC is not detected during above procedure, performing the following procedure is advised.
G
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for a certain
time. Refer to the table below.
H
Hold the accelerator pedal as steady as possible.
The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time.

Engine speed

Engine speed in the freeze frame data ± 400 rpm

Vehicle speed

Vehicle speed in the freeze frame data ± 10 km/h (6 MPH)

Engine coolant temperature
(T) condition

When the freeze frame data shows lower than 70 °C (158 °F),
T should be lower than 70 °C (158 °F).
When the freeze frame data shows higher than or equal to 70 °C (158 °F),
T should be higher than or equal to 70 °C (158 °F).

9. If it is difficult to start engine at step 7, the fuel injection system has a malfunction.
10. Crank engine while depressing accelerator pedal.
If engine starts, go to EC-230, «Diagnostic Procedure» . If engine does not start, remove ignition plugs and
check for fouling, etc.

EC-227

I

J

K

L

M

DTC P0172 FUEL INJECTION SYSTEM FUNCTION
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002XL

MBWA1512E

EC-228

DTC P0172 FUEL INJECTION SYSTEM FUNCTION
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
BATTERY VOLTAGE
[Engine is running]

22
23
41
42

O
L
R
GR

●

Warm-up condition

●

Idle speed

(11 — 14V)

D

NOTE:
The pulse cycle changes depending on rpm at
idle.

Fuel injector No. 3
Fuel injector No. 1
Fuel injector No. 4
Fuel injector No. 2

E
PBIB0529E

BATTERY VOLTAGE

F

(11 — 14V)
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

G

H
PBIB0530E

Approximately 7.0V

I
[Engine is running]
24

Y

Heated oxygen sensor 1
heater

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

J

PBIB0519E

[Engine is running]
●

Engine speed: Above 3,600 rpm

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
35

BR

Heated oxygen sensor 1

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-229

K

L

M
Approximately 0V

DTC P0172 FUEL INJECTION SYSTEM FUNCTION
[CR (WITH EURO-OBD)]

Diagnostic Procedure

BBS002XM

1. CHECK EXHAUST GAS LEAK
1.
2.

Start engine and run it at idle.
Listen for an exhaust gas leak before three way catalyst (manifold).

MBIB0649E

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace.

2. CHECK FOR INTAKE AIR LEAK
Listen for an intake air leak after the manifold absolute pressure sensor.
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

3. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect heated oxygen sensor 1 (HO2S1) harness connector (1).
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 35 and HO2S1
terminal 4.
Refer to Wiring Diagram.
Continuity should exist.

5.

Check harness continuity between ECM terminal 35 or HO2S1
terminal 4 and ground.
Refer to Wiring Diagram.

MBIB1494E

Continuity should not exist.
6. Also check harness for short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK FUEL PRESSURE
1.
2.

Release fuel pressure to zero. Refer to EC-71, «FUEL PRESSURE RELEASE» .
Install fuel pressure gauge and check fuel pressure. Refer to EC-72, «FUEL PRESSURE CHECK» .
At idling: 350 kPa (3.5 bar, 3.57 kg/cm2, 51 psi)

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

EC-230

DTC P0172 FUEL INJECTION SYSTEM FUNCTION
[CR (WITH EURO-OBD)]

5. DETECT MALFUNCTIONING PART

A

Check the following.
●
Fuel pump and circuit (Refer to EC-427, «FUEL PUMP» .)
●
Fuel pressure regulator (Refer to EC-71, «Fuel Pressure Check» .)
●
Fuel lines (Refer to EM-32, «FUEL INJECTOR AND FUEL TUBE» .)
●
Fuel filter for clogging

EC

C

>> Repair or replace.

6. CHECK MANIFOLD ABSOLUTE PRESSUR SENSOR
1.
2.

With CONSULT-II
Install all removed parts.
Check manifold absolute pressure sensor signal with CONSULT-II.
Approximately 1.5V:
Approximately 1.2V:

at idling
at 2,500 rpm

E

F

With GST
1. Install all removed parts.
2. Check manifold absolute pressure sensor signal in Service $01 with GST.
Approximately 1.5V:
Approximately 1.2V:

D

G

H

at idling
at 2,500 rpm

OK or NG
OK
>> GO TO 7.
NG
>> Check connectors for rusted terminals or loose connections in the manifold absolute pressure
sensor circuit or ground. Refer to EC-155, «DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR» .

I

J

K

L

M

EC-231

DTC P0172 FUEL INJECTION SYSTEM FUNCTION
[CR (WITH EURO-OBD)]

7. CHECK FUNCTION OF FUEL INJECTORS
With CONSULT-II
Start engine.
Perform “POWER BALANCE” in “ACTIVE TEST” mode with
CONSULT-II.
3. Make sure that each circuit produces a momentary engine
speed drop.
1.
2.

MBIB0302E

Without CONSULT-II
1. Start engine.
2. Listen to each fuel injector operating sound.
Clicking noise should be heard.

PBIB1986E

OK or NG
OK
>> GO TO 8.
NG
>> Perform trouble diagnosis for FUEL INJECTOR, refer to EC-421, «FUEL INJECTOR» .

8. CHECK FUEL INJECTOR
Remove fuel injector assembly. Refer to EM-32, «FUEL INJECTOR AND FUEL TUBE» .
Keep fuel hose and all fuel injectors connected to fuel tube.
2. Confirm that the engine is cooled down and there are no fire hazards near the vehicle.
3. Disconnect fuel injector harness connectors.
4. Disconnect all ignition coil harness connectors.
5. Prepare pans or saucers under each fuel injectors.
6. Crank engine for about 3 seconds.
Make sure fuel does not drip from fuel injector.
OK or NG
OK (Does not drip.)>>GO TO 9.
NG (Drips.)>>Replace the fuel injectors from which fuel is dripping. Always replace O-ring with new one.
1.

9. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-232

DTC P0222, P0223 TP SENSOR
[CR (WITH EURO-OBD)]

DTC P0222, P0223 TP SENSOR
Component Description

PFP:16119

A
BBS002XN

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

EC

C

D
PBIB0145E

E

CONSULT-II Reference Value in Data Monitor Mode

BBS002XO

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

More than 0.36V

●

Shift lever: 1st

Accelerator pedal: Fully depressed

Less than 4.75V

THRTL SEN 1
THRTL SEN 2*

F

SPECIFICATION

G

*: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic

BBS002XP

H

These self-diagnoses have the one trip detection logic.
DTC No.
P0222
0222

P0223
0223

Trouble diagnosis name

DTC detecting condition

Throttle position sensor 1
circuit low input

An excessively low voltage from the TP sensor 1
is sent to ECM.

Throttle position sensor 1
circuit high input

Possible cause
●

Harness or connectors
(TP sensor 1 circuit is open or shorted.)
(APP sensor 2 circuit is shorted.)

●

Electric throttle control actuator
(TP sensor 1)

●

Accelerator pedal position sensor
(APP sensor 2)

An excessively high voltage from the TP sensor
1 is sent to ECM.

FAIL-SAFE MODE

I

J

K

L

When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-233

M

DTC P0222, P0223 TP SENSOR
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS002XQ

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-236, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-234

DTC P0222, P0223 TP SENSOR
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002XR

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1513E

EC-235

DTC P0222, P0223 TP SENSOR
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
47

WIRE
COLOR
L

ITEM

CONDITION

Sensor power supply
(Throttle position sensor)

DATA (DC Voltage)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

49

Y

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

Throttle position sensor 1

More than 0.36V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

Less than 4.75V

[Engine is running]
66

B

Sensor ground
(Throttle position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Ignition switch: ON]

68

91

R

BR

Throttle position sensor 2

Sensor power supply
(APP sensor 2)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

Less than 4.75V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

More than 0.36V

[Ignition switch ON]

Approximately 5V

Diagnostic Procedure

BBS002XS

1. RETIGHTEN GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-236

3.

Body ground E28

DTC P0222, P0223 TP SENSOR
[CR (WITH EURO-OBD)]

2. CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT-I
1.
2.

A

Disconnect electric throttle control actuator harness connector.
Turn ignition switch ON.
EC

C

D
MBIB0308E

3.

Check voltage between electric throttle control actuator terminal
1 and ground with CONSULT-II or tester.

E

Voltage: Approximately 5V
F

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.

G

PBIB0082E

H

3. CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between electric throttle control actuator terminal 1 and ECM terminal 47.
Refer to Wiring Diagram.

I

J

Continuity should exist.
K

OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit.

4. CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT-III
Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

47

Electric throttle control actuator terminal 1

EC-235

91

APP sensor terminal 5

EC-394

OK or NG
OK
>> GO TO 5.
NG
>> Repair short to ground or short to power in harness or connectors.

5. CHECK APP SENSOR
Refer to EC-400, «Component Inspection» .
OK or NG
OK
>> GO TO 11
NG
>> GO TO 6.

EC-237

L

M

DTC P0222, P0223 TP SENSOR
[CR (WITH EURO-OBD)]

6. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace accelerator pedal assembly.
Perform EC-69, «Accelerator Pedal Released Position Learning» .
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> INSPECTION END

7. CHECK THROTTLE POSITION SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 66 and electric throttle control actuator terminal 5.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK THROTTLE POSITION SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 49 and electric throttle control actuator terminal 4.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 9.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

9. CHECK THROTTLE POSITION SENSOR
Refer to EC-239, «Component Inspection» .
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

10. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> INSPECTION END

11. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-238

DTC P0222, P0223 TP SENSOR
[CR (WITH EURO-OBD)]

Component Inspection

BBS002XT

A

THROTTLE POSITION SENSOR
1.
2.
3.
4.
5.

Reconnect all harness connectors disconnected.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Turn ignition switch ON.
Set shift lever to 1st position.
Check voltage between ECM terminals 49 (TP sensor 1 signal),
68 (TP sensor 2 signal) and ground under the following conditions.
Terminal

Accelerator pedal

Voltage

49
(Throttle position sensor 1)

Fully released

More than 0.36V

68
(Throttle position sensor 2)

6.
7.
8.

Fully depressed

Less than 4.75V

Fully released

Less than 4.75V

Fully depressed

More than 0.36V

If NG, replace electric throttle control actuator and go to the next
step.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .

Removal and Installation

EC

C

D

E

MBIB1443E

F

G
BBS002XU

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

H

I

J

K

L

M

EC-239

DTC P0300 — P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 — 4 CYLINDER MISFIRE
[CR (WITH EURO-OBD)]

DTC P0300 — P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 — 4 CYLINDER MISFIRE
PFP:00000
On Board Diagnosis Logic

BBS002XV

When a misfire occurs, engine speed will fluctuate. If the engine speed fluctuates enough to cause the crankshaft position (CKP) sensor (POS) signal to vary, ECM can determine that a misfire is occurring.
Sensor
Crankshaft position sensor (POS)

Input Signal to ECM
Engine speed

ECM Function
On board diagnosis of misfire

The misfire detection logic consists of the following two conditions.
1. One Trip Detection Logic (Three Way Catalyst Damage)
On the first trip that a misfire condition occurs that can damage the three way catalyst (TWC) due to overheating, the MI will blink.
When a misfire condition occurs, the ECM monitors the CKP sensor (POS) signal every 200 engine revolutions for a change.
When the misfire condition decreases to a level that will not damage the TWC, the MI will turn off.
If another misfire condition occurs that can damage the TWC on a second trip, the MI will blink.
When the misfire condition decreases to a level that will not damage the TWC, the MI will remain on.
If another misfire condition occurs that can damage the TWC, the MI will begin to blink again.
2. Two Trip Detection Logic (Exhaust quality deterioration)
For misfire conditions that will not damage the TWC (but will affect vehicle emissions), the MI will only light
when the misfire is detected on a second trip. During this condition, the ECM monitors the CKP sensor
signal every 1,000 engine revolutions.
A misfire malfunction can be detected on any one cylinder or on multiple cylinders.
DTC No.

Trouble diagnosis name

DTC detecting condition

P0300
0300

Multiple cylinder misfire
detected

Multiple cylinder misfire.

P0301
0301

No.1 cylinder misfire
detected

No. 1 cylinder misfires.

P0302
0302

No. 2 cylinder misfire
detected

No. 2 cylinder misfires.

P0303
0303

No. 3 cylinder misfire
detected

P0304
0304

No. 4 cylinder misfire
detected

No. 3 cylinder misfires.

No. 4 cylinder misfires.

DTC Confirmation Procedure

Possible cause
●

Improper spark plug

●

Insufficient compression

●

Incorrect fuel pressure

●

The fuel injector circuit is open or
shorted

●

Fuel injector

●

Intake air leak

●

The ignition signal circuit is open or
shorted

●

Lack of fuel

●

Drive plate or flywheel

●

Heated oxygen sensor 1

●

Incorrect PCV hose connection
BBS002XW

CAUTION:
Always drive vehicle in safe manner according to traffic conditions and obey all traffic laws when driving.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

EC-240

DTC P0300 — P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 — 4 CYLINDER MISFIRE
[CR (WITH EURO-OBD)]
WITH CONSULT-II
1.
2.
3.
4.
5.

a.
b.

A
Turn ignition switch ON, and select “DATA MONITOR” mode
with CONSULT-II.
Start engine and warm it up to normal operating temperature.
EC
Turn ignition switch OFF and wait at least 10 seconds.
Restart engine and let it idle for about 15 minutes.
If 1st trip DTC is detected, go to EC-241, «Diagnostic Procedure»
C
.
NOTE:
If 1st trip DTC is not detected during above procedure, performD
ing the following procedure is advised.
PBIB0164E
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for a certain
E
time. Refer to the table below.
Hold the accelerator pedal as steady as possible.

The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time.
Engine speed

Engine speed in the freeze frame data ± 400 rpm

Vehicle speed

Vehicle speed in the feaze frame data ± 10 km/h (6 MPH)

Engine coolant temperature
(T) condition

F

G

When the freeze frame data shows lower than 70 °C (158 °F),
T should be lower than 70 °C (158 °F).

H

When the freeze frame data shows higher than or equal to 70 °C (158 °F),
T should be higher than or equal to 70 °C (158 °F).

I

The time to driving varies according to the engine speed in the freeze frame data.
Engine speed

Time

J

Around 1,000 rpm

Approximately 10 minutes

Around 2,000 rpm

Approximately 5 minutes

More than 3,000 rpm

Approximately 3.5 minutes

K

WITH GST
Follow the procedure “WITH CONSULT-II” above.
L

Diagnostic Procedure

BBS002XX

1. CHECK FOR INTAKE AIR LEAK AND PCV HOSE
M

1. Start engine and run it at idle speed.
2. Listen for the sound of the intake air leak.
3. Check PCV hose connection.
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace.

2. CHECK FOR EXHAUST SYSTEM CLOGGING
Stop engine and visually check exhaust tube, three way catalyst and muffler for dents.
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

EC-241

DTC P0300 — P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 — 4 CYLINDER MISFIRE
[CR (WITH EURO-OBD)]

3. PERFORM POWER BALANCE TEST
1.
2.

With CONSULT-II
Perform “POWER BALANCE” in “ACTIVE TEST” mode.
Is there any cylinder which does not produce a momentary
engine speed drop?

MBIB0302E

Without CONSULT-II
When disconnecting each fuel injector harness connector (1) one at
a time, is there any cylinder which does not produce a momentary
engine speed drop?
●

: Vehicle front

MBIB1458E

Yes or No
Yes
>> GO TO 4.
No
>> GO TO 9.

4. CHECK FUEL INJECTOR
Does each fuel injector make an operating sound at idle?
Yes or No
Yes
>> GO TO 5.
No
>> Check fuel injector(s) and circuit(s). Refer to EC-421,
«FUEL INJECTOR» .

PBIB1986E

EC-242

DTC P0300 — P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 — 4 CYLINDER MISFIRE
[CR (WITH EURO-OBD)]

5. CHECK FUNCTION OF IGNITION COIL-I

A

CAUTION:
Do the following procedure in the place where ventilation is good without the combustibles.
1. Turn ignition switch OFF.
2. Remove fuel pump fuse in IPDM E/R to release fuel pressure.
NOTE:
Do not use CONSULT-II to release fuel pressure, or fuel pressure applies again during the following procedure.
3. Start engine.
4. After engine stalls, crank it two or three times to release all fuel
pressure.
5. Turn ignition switch ON.
6. Remove all ignition coil harness connectors to avoid the electrical discharge from the ignition coils.
7. Remove ignition coil and spark plug of the cylinder to be
checked.
8. Crank engine for five seconds or more to remove combustion gas in the cylinder.
9. Connect spark plug and harness connector to ignition coil.
10. Fix ignition coil using a rope etc. with gap of 13 — 17 mm
between the edge of the spark plug and grounded metal portion
as shown in the figure.
11. Crank engine for about three seconds, and check whether spark
is generated between the spark plug and the grounded metal
portion.

EC

C

D

E
MBIB0277E

G

H

I

Spark should be generated.
CAUTION:
● Do not approach to the spark plug and the ignition coil
within 50cm. Be careful not to get an electrical shock
PBIB2325E
while checking, because the electrical discharge voltage
becomes 20kV or more.
● It might cause to damage the ignition coil if the gap of more than 17 mm is taken.
NOTE:
When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning.
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 6.

J

K

L

M

6. CHECK FUNCTION OF IGNITION COIL-II
1.
2.
3.

F

Turn ignition switch OFF.
Disconnect spark plug and connect a known-good spark plug.
Crank engine for about three seconds, and recheck whether spark is generated between the spark plug
and the grounded metal portion.
Spark should be generated.

OK or NG
OK
>> GO TO 7.
NG
>> Check ignition coil, power transistor and their circuits, Refer to EC-433, «IGNITION SIGNAL» .

EC-243

DTC P0300 — P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 — 4 CYLINDER MISFIRE
[CR (WITH EURO-OBD)]

7. CHECK SPARK PLUGS
Check the initial spark plug for fouling, etc.
OK or NG
OK
>> Replace spark plug(s) with standard type one(s). For
spark plug type, refer to MA-36, «Changing Spark Plugs»
.
NG
>> 1. Repair or clean spark plug.
2. GO TO 8.

SEF156I

8. CHECK FUNCTION OF IGNITION COIL-III
1.
2.

Reconnect the initial spark plugs.
Crank engine for about three seconds, and recheck whether spark is generated between the spark plug
and the grounded portion.
Spark should be generated.

OK or NG
OK
>> INSPECTION END
NG
>> Replace spark plug(s) with standard type one(s). For spark plug type, refer to MA-36, «Changing
Spark Plugs» .

9. CHECK COMPRESSION PRESSURE
Check compression pressure. Refer to EM-60, «COMPRESSION PRESSURE INSPECTION» .
OK or NG
OK
>> GO TO 10.
NG
>> Check pistons, piston rings, valves, valve seats and cylinder head gaskets.

10. CHECK FUEL PRESSURE
1.
2.
3.

Install all removed parts.
Release fuel pressure to zero. Refer to EC-71, «FUEL PRESSURE RELEASE» .
Install fuel pressure gauge and check fuel pressure. Refer to EC-72, «FUEL PRESSURE CHECK» .
At idle: Approx. 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi)

OK or NG
OK
>> GO TO 12.
NG
>> GO TO 11.

11. DETECT MALFUNCTIONING PART
Check the following.
Fuel pump and circuit (Refer to EC-427, «FUEL PUMP» .)
●
Fuel pressure regulator (Refer to EC-71, «Fuel Pressure Check» .)
●
Fuel lines (Refer to EM-32, «FUEL INJECTOR AND FUEL TUBE» .)
●
Fuel filter for clogging
●

>> Repair or replace.

EC-244

DTC P0300 — P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 — 4 CYLINDER MISFIRE
[CR (WITH EURO-OBD)]

12. CHECK HEATED OXYGEN SENSOR 1

A

Refer to EC-183, «Component Inspection» .
OK or NG
OK
>> GO TO 13.
NG
>> Replace heated oxygen sensor 1.

EC

13. CHECK MANIFOLD ABSOLUTE PRESSUR SENSOR
With CONSULT-II
Check manifold absolute pressure sensor signal in “DATA MONITOR” mode with CONSULT-II.
Approximately 1.5V:
Approximately 1.2V:

D

at idling
at 2,500 rpm

With GST
Check manifold absolute pressure sensor signal in Service $01 with GST.
Approximately 1.5V:
Approximately 1.2V:

C

at idling
at 2,500 rpm

E

F

OK or NG
OK
>> GO TO 14.
NG
>> Check connectors for rusted terminals or loose connections in the manifold absolute pressure
sensor circuit or ground. Refer to EC-155, «DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR» .

G

H

14. CHECK SYMPTOM MATRIX CHART
Check items on the rough idle symptom in EC-82, «Symptom Matrix Chart» .
OK or NG
OK
>> GO TO 15.
NG
>> Repair or replace.

I

J

15. ERASE THE 1ST TRIP DTC
Some tests may cause a 1st trip DTC to be set.
Erase the 1st trip DTC from the ECM memory after performing the tests. Refer to EC-57, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .

K

L

>> GO TO 16.

16. CHECK INTERMITTENT INCIDENT

M

Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-245

DTC P0327, P0328 KS
[CR (WITH EURO-OBD)]

DTC P0327, P0328 KS
Component Description

PFP:22060
BBS002XY

The knock sensor is attached to the cylinder block. It senses engine
knocking using a piezoelectric element. A knocking vibration from
the cylinder block is sensed as vibrational pressure. This pressure is
converted into a voltage signal and sent to the ECM.

MBIB0306E

On Board Diagnosis Logic

BBS002XZ

The MI will not light up for these self-diagnoses.
DTC No.

Trouble Diagnosis Name

DTC Detected Condition

Possible Cause

P0327
0327

Knock sensor circuit low
input

An excessively low voltage from the sensor is
sent to ECM.

●

Harness or connectors
(The sensor circuit is open or shorted.)

P0328
0328

Knock sensor circuit high
input

An excessively high voltage from the sensor is
sent to ECM.

●

Knock sensor

DTC Confirmation Procedure

BBS002Y0

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

WITH CONSULT-II
1.
2.
3.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and run it for at least 5 seconds at idle speed.
If 1st trip DTC is detected, go to EC-248, «Diagnostic Procedure»
.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-246

DTC P0327, P0328 KS
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002Y1

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA0571E

EC-247

DTC P0327, P0328 KS
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
15

WIRE
COLOR
W

ITEM

Knock sensor

CONDITION
[Engine is running]
●

Idle speed

DATA (DC Voltage)

Approximately 2.5V

[Engine is running]
54

—

Sensor ground
(Knock sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

Diagnostic Procedure

BBS002Y2

1. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-I
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check resistance between ECM terminal 15 and ground. Refer to Wiring Diagram.
NOTE:
It is necessary to use an ohmmeter which can measure more than 10 MΩ.
Resistance: Approximately 530 — 590kΩ [at 20°C (68°F)]

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 2.

2. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-II
1.
2.

Disconnect knock sensor harness connector.
Check harness continuity between ECM terminal 15 and knock
sensor terminal 2.
Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

3. CHECK KNOCK SENSOR
Refer to EC-249, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace knock sensor.

EC-248

MBIB0306E

DTC P0327, P0328 KS
[CR (WITH EURO-OBD)]

4. CHECK GROUND CONNECTIONS
1.

A

Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .
EC

C

D

MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

E

Body ground E28

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace ground connections.

F

5. CHECK KNOCK SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT

G

1.

Check harness continuity between ECM terminal 54 and knock sensor terminal 1.
Refer to Wiring Diagram.

H

Continuity should exist
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

I

J

6. CHECK INTERMITTENT INCIDENT
K

Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

L

Component Inspection

BBS002Y3

KNOCK SENSOR
Check resistance between knock sensor terminal 2 and ground.
NOTE:
It is necessary to use an ohmmeter which can measure more
than 10 MΩ.

M

Resistance: Approximately 530 — 590kΩ [at 20°C (68°F)]
CAUTION:
Do not use any knock sensors that have been dropped or physically damaged. Use only new ones.
PBIB0253E

Removal and Installation

BBS002Y4

KNOCK SENSOR
Refer to EM-74, «CYLINDER BLOCK» .

EC-249

DTC P0335 CKP SENSOR (POS)
[CR (WITH EURO-OBD)]

DTC P0335 CKP SENSOR (POS)
Component Description

PFP:23731
BBS002Y5

The crankshaft position sensor (POS) is located on the cylinder
block rear housing facing the gear teeth (cogs) of the signal plate at
the end of the crankshaft. It detects the fluctuation of the engine revolution.
The sensor consists of a permanent magnet and Hall IC.
When the engine is running, the high and low parts of the teeth
cause the gap with the sensor to change.
The changing gap causes the magnetic field near the sensor to
change.
Due to the changing magnetic field, the voltage from the sensor
changes.
The ECM receives the voltage signal and detects the fluctuation of
the engine revolution.
ECM receives the signals as shown in the figure.

PBIB0562E

PBIB2382E

CONSULT-II Reference Value in Data Monitor Mode

BBS002Y6

Specification data are reference values.
MONITOR ITEM
ENG SPEED

CONDITION
●

SPECIFICATION

Run engine and compare CONSULT-II value with the tachometer indication.

Almost the same speed as the
tachometer indication.

On Board Diagnosis Logic
DTC No.

Trouble diagnosis name

DTC detecting condition
●

P0335
0335

Crankshaft position
sensor (POS) circuit

BBS002Y7

●

●

The crankshaft position sensor (POS) signal is not
detected by the ECM during the first few seconds of
engine cranking.
The proper pulse signal from the crankshaft position
sensor (POS) is not sent to ECM while the engine is
running.
The crankshaft position sensor (POS) signal is not in
the normal pattern during engine running.

DTC Confirmation Procedure

Possible cause

●

Harness or connectors
(The sensor circuit is open or
shorted.)

●

Crankshaft position sensor (POS)

●

Signal plate

BBS002Y8

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON.

EC-250

DTC P0335 CKP SENSOR (POS)
[CR (WITH EURO-OBD)]
WITH CONSULT-II
1.
2.
3.

A

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed.
If 1st trip DTC is detected, go to EC-254, «Diagnostic Procedure»
.

EC

C

SEF058Y

D

WITH GST
Follow the procedure “WITH CONSULT-II” above.

E

F

G

H

I

J

K

L

M

EC-251

DTC P0335 CKP SENSOR (POS)
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002Y9

MBWA1515E

EC-252

DTC P0335 CKP SENSOR (POS)
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 3.0V

D

NOTE:
The pulse cycle changes depending on rpm at
idle.
13

Y

E
PBIB0527E

Crankshaft position
sensor (POS)

Approximately 3.0V

F
[Engine is running]
●

Engine speed: 2,000 rpm

G
PBIB0528E

30

L

Sensor ground
(Crankshaft position
sensor)

●

Warm-up condition

●

Idle speed

●

P

ECM relay
(Self shut-off)

For a few seconds after turning ignition switch
OFF

[Ignition switch: OFF]
●

119
120

G
G

Power supply for
ECM

Approximately 0V

I

[Engine is running]
[Ignition switch: OFF]
111

H

[Engine is running]

More than a few seconds passed after turning
ignition switch OFF

[Ignition switch: ON]

0 — 1.0V

J
BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

K

L

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

M

EC-253

DTC P0335 CKP SENSOR (POS)
[CR (WITH EURO-OBD)]

Diagnostic Procedure

BBS002YA

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

2. CHECK CRANKSHAFT POSITION (CKP) SENSOR (POS) POWER SUPPLY CIRCUIT
1.
2.

Disconnect crankshaft position (CKP) sensor (POS) harness
connector.
Turn ignition switch ON.

MBIB1078E

3.

Check voltage between CKP sensor (POS) terminal 3 and
ground with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

SEF479Y

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors F1, E48
●
Harness for open or short between crankshaft position sensor (POS) and ECM
●
Harness for open or short between crankshaft position sensor (POS) and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-254

DTC P0335 CKP SENSOR (POS)
[CR (WITH EURO-OBD)]

4. CHECK CKP SENSOR (POS) GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 30 and CKP sensor (POS) terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

EC

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK CKP SENSOR (POS) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

A

D

E

Check harness continuity between ECM terminal 13 and CKP sensor (POS) terminal 2.
Refer to Wiring Diagram.
F

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK CRANKSHAFT POSITION SENSOR (POS)
Refer to EC-256, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace crankshaft position sensor (POS).

G

H

I

J

7. CHECK GEAR TOOTH
Visually check for chipping signal plate gear tooth.
OK or NG
OK
>> GO TO 8.
NG
>> Replace the signal plate.

K

L

8. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-255

M

DTC P0335 CKP SENSOR (POS)
[CR (WITH EURO-OBD)]

Component Inspection

BBS002YB

CRANKSHAFT POSITION SENSOR (POS)
1.
2.
3.
4.

Loosen the fixing bolt of the sensor.
Disconnect crankshaft position sensor (POS) harness connector.
Remove the sensor.
Visually check the sensor for chipping.

PBIB0563E

5.

Check resistance as shown in the figure.
Terminal No. (Polarity)

Resistance Ω [at 25°C (77°F)]

3 (+) — 1 (-)
3 (+) — 2 (-)

Except 0 or ∞

2 (+) — 1 (-)

6.

If NG, replace crankshaft position sensor (POS).

MBIB0024E

Removal and Installation

BBS002YC

CRANKSHAFT POSITION SENSOR (POS)
Refer to EM-74, «CYLINDER BLOCK» .

EC-256

DTC P0340 CMP SENSOR (PHASE)
[CR (WITH EURO-OBD)]

DTC P0340 CMP SENSOR (PHASE)
Component Description

PFP:23731

A
BBS002YD

The camshaft position sensor (PHASE) senses the retraction of
camshaft (intake) to identify a particular cylinder. The camshaft position sensor (PHASE) senses the piston position.
When the crankshaft position sensor (POS) system becomes inoperative, the camshaft position sensor (PHASE) provides various controls of engine parts instead, utilizing timing of cylinder identification
signals.
The sensor consists of a permanent magnet and Hall IC.
When engine is running, the high and low parts of the teeth cause
the gap with the sensor to change.
The changing gap causes the magnetic field near the sensor to
change.
Due to the changing magnetic field, the voltage from the sensor changes.
ECM receives the signals as shown in the figure.

EC

C

D
PBIB0562E

E

F

G

H

PBIB2382E

I

On Board Diagnosis Logic
DTC No.

Trouble diagnosis name

DTC detecting condition
●

P0340
0340

Camshaft position sensor
(PHASE) circuit

BBS002YE

The cylinder No. signal is not sent to ECM
for the first few seconds during engine
cranking.

Possible cause

J

●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Camshaft position sensor (PHASE)
Camshaft (Intake)

●

The cylinder No. signal is not set to ECM
during engine running.

●
●

Starter motor (Refer to SC-45 .)

●

The cylinder No. signal is not in the normal
pattern during engine running.

●

Starting system circuit (Refer to SC-45 .)

●

Dead (Weak) battery

DTC Confirmation Procedure

BBS002YF

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON.

WITH CONSULT-II
1.

Turn ignition switch ON.

EC-257

K

L

M

DTC P0340 CMP SENSOR (PHASE)
[CR (WITH EURO-OBD)]
2.
3.
4.

5.
6.

Select “DATA MONITOR” mode with CONSULT-II.
Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed.
If 1st trip DTC is detected, go to EC-260, «Diagnostic Procedure»
.
If 1st trip DTC is not detected, go to next step.
Maintain engine speed at more than 800 rpm for at least 5 seconds.
If 1st trip DTC is detected, go to EC-260, «Diagnostic Procedure»
.

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-258

SEF058Y

DTC P0340 CMP SENSOR (PHASE)
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002YG

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1516E

EC-259

DTC P0340 CMP SENSOR (PHASE)
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

[Engine is running]
●

Warm-up condition

●

Idle speed

DATA (DC Voltage)

1.0 — 4.0V

NOTE:
The pulse cycle changes depending on rpm at
idle.
14

R

PBIB0525E

Camshaft position
sensor (PHASE)

1.0 — 4.0V

[Engine is running]
●

Engine speed: 2,000 rpm

PBIB0526E

29

B

Sensor ground
(Camshaft position
sensor)

[Engine is running]
●

Warm-up condition

●

Idle speed

[Engine is running]
[Ignition switch: OFF]
●

111

P

ECM relay
(Self shut-off)

For a few seconds after turning ignition switch
OFF

[Ignition switch: OFF]
●

119
120

G
G

Power supply for
ECM

More than a few seconds passed after turning
ignition switch OFF

[Ignition switch: ON]

Approximately 0V

0 — 1.0V

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS002YH

1. CHECK STARTING SYSTEM
Turn ignition switch to START position.
Does the engine turn over?
Does the starter motor operate?
Yes or No
Yes
>> GO TO 2.
No
>> Check starting system. (Refer to SC-45, «STARTING SYSTEM» .)

EC-260

DTC P0340 CMP SENSOR (PHASE)
[CR (WITH EURO-OBD)]

2. CHECK GROUND CONNECTIONS
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

EC

C

D

E
MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

F

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace ground connections.

G

3. CHECK CAMSHAFT POSITION (CMP) SENSOR (PHASE) POWER SUPPLY CIRCUIT
1.
2.

H

Disconnect camshaft position (CMP) sensor (PHASE) harness
connector.
Turn ignition switch ON.

I

J

MBIB0279E

3.

Check voltage between CMP sensor (PHASE) terminal 3 and
ground with CONSULT-II or tester.

K

L

Voltage: Battery voltage
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

M

SEF479Y

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors F1, E48
●
Harness for open or short between camshaft position sensor (PHASE) and ECM
●
Harness for open or short between camshaft position sensor (PHASE) and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-261

DTC P0340 CMP SENSOR (PHASE)
[CR (WITH EURO-OBD)]

5. CHECK CMP SENSOR (PHASE) GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 29 and CMP sensor (PHASE) terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK CMP SENSOR (PHASE) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 14 and CMP sensor (PHASE) terminal 2.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

7. CHECK CAMSHAFT POSITION SENSOR (PHASE)
Refer to EC-263, «Component Inspection» .
OK or NG
OK
>> GO TO 8.
NG
>> Replace camshaft position sensor (PHASE).

8. CHECK CAMSHAFT (INTAKE)
Check the following.
Accumulation of debris to the signal plate of camshaft rear end
●
Chipping signal plate of camshaft rear end
OK or NG
OK
>> GO TO 9.
NG
>> Remove debris and clean the signal plate of camshaft
rear end or replace camshaft.
●

PBIB0565E

9. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-262

DTC P0340 CMP SENSOR (PHASE)
[CR (WITH EURO-OBD)]

Component Inspection

BBS002YI

A

CAMSHAFT POSITION SENSOR (PHASE)
1.
2.
3.
4.

Loosen the fixing bolt of the sensor.
Disconnect camshaft position sensor (PHASE) harness connector.
Remove the sensor.
Visually check the sensor for chipping.

EC

C

D

E
PBIB0563E

5.

F

Check resistance as shown in the figure.
Terminal No. (Polarity)

Resistance Ω [at 25°C (77°F)]

G

3 (+) — 1 (-)
3 (+) — 2 (-)

Except 0 or ∞

2 (+) — 1 (-)

H

I
MBIB0024E

Removal and Installation

BBS002YJ

CAMSHAFT POSITION SENSOR (PHASE)

J

Refer to EM-38, «CAMSHAFT» .
K

L

M

EC-263

DTC P0420 THREE WAY CATALYST FUNCTION
[CR (WITH EURO-OBD)]

DTC P0420 THREE WAY CATALYST FUNCTION
On Board Diagnosis Logic

PFP:20905
BBS002YK

The ECM monitors the switching frequency ratio of heated oxygen
sensors 1 and 2.
A three way catalyst (Manifold) with high oxygen storage capacity
will indicate a low switching frequency of heated oxygen sensor 2.
As oxygen storage capacity decreases, the heated oxygen sensor 2
switching frequency will increase.
When the frequency ratio of heated oxygen sensors 1 and 2
approaches a specified limit value, the three way catalyst (Manifold)
malfunction is diagnosed.
SEF484YF

DTC No.

P0420
0420

Trouble diagnosis name

Catalyst system efficiency
below threshold

DTC detecting condition

●

Three way catalyst (Manifold) does not operate
properly.

●

Three way catalyst (Manifold) does not have
enough oxygen storage capacity.

DTC Confirmation Procedure

Possible cause
●

Three way catalyst (Manifold)

●

Exhaust tube

●

Intake air leak

●

Fuel injector

●

Fuel injector leak

●

Spark plug

●

Improper ignition timing
BBS002YL

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
TESTING CONDITION:
●
Open engine hood before conducting the following procedure.
●
Do not hold engine speed for more than the specified minutes below.
1. Start engine and warm it up to the normal operating temperature.
2. Turn ignition switch OFF and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
4. Let engine idle for 1 minute.
5. Select “DTC & SRT CONFIRMATION” then “SRT WORK SUPPORT” mode with CONSULT-II.
6. Rev engine up to 2,000 to 3,000 rpm and hold it for 3 consecutive minutes then release the accelerator pedal completely.
If “INCMP” of “CATALYST” changed to “COMPLT”, go to step 10
7. Wait 5 seconds at idle.

PBIB0566E

EC-264

DTC P0420 THREE WAY CATALYST FUNCTION
[CR (WITH EURO-OBD)]
8.

Rev engine up to 2,000 to 3,000 rpm and maintain it until
“INCMP” of “CATALYST” changes to “CMPLT” (It will take
approximately 5 minutes).
If not “CMPLT”, stop engine and cool it down to less than 70°C
(158 °F) and then retest from step 1.

A

EC

C
PBIB0567E

D

a.
b.
c.
d.

Turn ignition switch OFF and leave the vehicle in a cool place
(soak the vehicle)
Turn ignition switch ON and select “COOLAN TEMP/S” in “DATA
MONITOR” mode with CONSULT-II.
Start engine and warm it up while monitoring “COOLAN TEMP/
S” indication on CONSULT-II.
When “COOLAN TEMP/S” indication reaches to 70°(158°F), go
to step 3.

E

F

G
SEF013Y

9. Select “SELF-DIAG RESULTS” mode with CONSULT-II.
10. Confirm that the 1st trip DTC is not detected.
If the 1st trip DTC is detected, go to EC-266, «Diagnostic Procedure» .

H

I

J

SEF535Z

Overall Function Check

K

BBS002YM

Use this procedure to check the overall function of the three way catalyst (Manifold). During this check, a 1st
trip DTC might not be confirmed.

L

WITH GST
1.
2.
3.
4.
5.
6.

7.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Open engine hood.
Set voltmeters probes between ECM terminal 35 (HO2S1 signal) and ground, and ECM terminal 16 (HO2S2 signal) and
ground.
Keep engine speed at 2,000 rpm constant under no load.

MBIB0018E

EC-265

M

DTC P0420 THREE WAY CATALYST FUNCTION
[CR (WITH EURO-OBD)]
8.

Make sure that the voltage switching frequency (high & low)
between ECM terminal 16 and ground is very less than that of
ECM terminal 35 and ground.
Switching frequency ratio = A/B
A: Heated oxygen sensor 2 voltage switching frequency
B: Heated oxygen sensor 1 voltage switching frequency
This ratio should be less than 0.75.
If the ratio is greater than above, it means three way catalyst
(manifold) does not operate properly. Go to EC-266, «Diagnostic
Procedure» .
NOTE:
If the voltage at terminal 35 does not switch periodically more than 5
times within 10 seconds at step 8, perform trouble diagnosis for DTC P0133 first. (See EC-189 .)

Diagnostic Procedure

MBIB0124E

BBS002YN

1. CHECK EXHAUST SYSTEM
Visually check exhaust tubes and muffler for dent.
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace.

2. CHECK EXHAUST GAS LEAK
1.
2.

Start engine and run it at idle.
Listen for an exhaust gas leak before the three way catalyst (Manifold).

MBIB0649E

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

3. CHECK INTAKE AIR LEAK
Listen for an intake air leak after the manifold absolute pressure sensor.
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace.

EC-266

DTC P0420 THREE WAY CATALYST FUNCTION
[CR (WITH EURO-OBD)]

4. CHECK FUEL INJECTORS
1.
2.
3.

A

Stop engine and then turn ignition switch ON.
Refer to Wiring Diagram for FUEL INJECTOR, EC-422 .
Check voltage between ECM terminals 22, 23, 41, 42 and
ground with CONSULT-II or tester.
Voltage

EC

: Battery voltage

C

OK or NG
OK
>> GO TO 5.
NG
>> Perform EC-423, «Diagnostic Procedure» .

D

MBIB0030E

E

5. CHECK FUNCTION OF IGNITION COIL-I
CAUTION:
Do the following procedure in the place where ventilation is good without the combustibles.
1. Turn ignition switch OFF.
2. Remove fuel pump fuse in IPDM E/R to release fuel pressure.
NOTE:
Do not use CONSULT-II to release fuel pressure, or fuel pressure applies again during the following procedure.
3. Start engine.
4. After engine stalls, crank it two or three times to release all fuel
pressure.
5. Turn ignition switch ON.
6. Remove all ignition coil harness connectors to avoid the electrical discharge from the ignition coils.
7. Remove ignition coil and spark plug of the cylinder to be
checked.
8. Crank engine for five seconds or more to remove combustion gas in the cylinder.
9. Connect spark plug and harness connector to ignition coil.
10. Fix ignition coil using a rope etc. with gap of 13 — 17 mm
between the edge of the spark plug and grounded metal portion
as shown in the figure.
11. Crank engine for about three seconds, and check whether spark
is generated between the spark plug and the grounded metal
portion.

F

G

H

I

J
MBIB0277E

Spark should be generated.
CAUTION:
● Do not approach to the spark plug and the ignition coil
within 50cm. Be careful not to get an electrical shock
PBIB2325E
while checking, because the electrical discharge voltage
becomes 20kV or more.
● It might cause to damage the ignition coil if the gap of more than 17 mm is taken.
NOTE:
When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning.
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 6.

EC-267

K

L

M

DTC P0420 THREE WAY CATALYST FUNCTION
[CR (WITH EURO-OBD)]

6. CHECK FUNCTION OF IGNITION COIL-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect spark plug and connect a known-good spark plug.
Crank engine for about three seconds, and recheck whether spark is generated between the spark plug
and the grounded metal portion.
Spark should be generated.

OK or NG
OK
>> GO TO 7.
NG
>> Check ignition coil, power transistor and their circuits, Refer to EC-433, «IGNITION SIGNAL» .

7. CHECK SPARK PLUGS
Check the initial spark plug for fouling, etc.
OK or NG
OK
>> Replace spark plug(s) with standard type one(s). For
spark plug type, refer to MA-36, «Changing Spark Plugs»
.
NG
>> 1. Repair or clean spark plug.
2. GO TO 8.

SEF156I

8. CHECK FUNCTION OF IGNITION COIL-III
1.
2.

Reconnect the initial spark plugs.
Crank engine for about three seconds, and recheck whether spark is generated between the spark plug
and the grounded portion.
Spark should be generated.

OK or NG
OK
>> INSPECTION END
NG
>> Replace spark plug(s) with standard type one(s). For spark plug type, refer to MA-36, «Changing
Spark Plugs» .

9. CHECK FUEL INJECTOR
1.
2.

Turn ignition switch OFF.
Remove fuel injector assembly.
Refer to EM-32, «FUEL INJECTOR AND FUEL TUBE» .
Keep fuel hose and all fuel injectors connected to fuel tube.
3. Reconnect all fuel injector harness connectors.
4. Disconnect all ignition coil harness connectors.
5. Turn ignition switch ON.
Make sure fuel does not drip from fuel injector.
OK or NG
OK (Does not drip.)>>GO TO 10.
NG (Drips.)>>Replace the fuel injector(s) from which fuel is dripping.

EC-268

DTC P0420 THREE WAY CATALYST FUNCTION
[CR (WITH EURO-OBD)]

10. CHECK INTERMITTENT INCIDENT

A

Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
Trouble is fixed.>>INSPECTION END
Trouble is not fixed.>>Replace three way catalyst (Manifold).

EC

C

D

E

F

G

H

I

J

K

L

M

EC-269

DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[CR (WITH EURO-OBD)]

DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
PFP:14920

Description

BBS002YO

SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

ECM Function

Actuator

Engine speed*1

Manifold absolute pressure sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Battery

Battery voltage*1

Throttle position sensor

Throttle position

Accelerator pedal position sensor

Accelerator pedal position

Heated oxygen sensor 1

Density of oxygen in exhaust gas
(Mixture ratio feedback signal)

Wheel sensor

Vehicle speed*2

EVAP canister
purge flow control

EVAP canister purge volume
control solenoid valve

*1: ECM determines the start signal status by the signals of engine speed and battery voltage.
*2: This signal is sent to the ECM through CAN communication line.

This system controls flow rate of fuel vapor from the EVAP canister. The opening of the vapor by-pass passage in the EVAP canister purge volume control solenoid valve changes to control the flow rate. The EVAP
canister purge volume control solenoid valve repeats ON/OFF operation according to the signal sent from the
ECM. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is
determined by considering various engine conditions. When the engine is operating, the flow rate of fuel vapor
from the EVAP canister is regulated as the air flow changes.

COMPONENT DESCRIPTION
The EVAP canister purge volume control solenoid valve uses a ON/
OFF duty to control the flow rate of fuel vapor from the EVAP canister. The EVAP canister purge volume control solenoid valve is
moved by ON/OFF pulses from the ECM. The longer the ON pulse,
the greater the amount of fuel vapor that will flow through the valve.

SEF337U

CONSULT-II Reference Value in Data Monitor Mode

BBS002YP

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

PURG VOL C/V

SPECIFICATION

Idle

0%

2,000 rpm

20 — 30%

On Board Diagnosis Logic
DTC No.

P0444
0444

Trouble diagnosis name
EVAP canister purge volume
control solenoid valve circuit
open

BBS002YQ

DTC detecting condition

Possible cause
●

Harness or connectors
(The solenoid valve circuit is open or
shorted.)

●

EVAP canister purge volume control
solenoid valve

An excessively low voltage signal is sent
to ECM through the valve

EC-270

DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS002YR

A
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
EC
TESTING CONDITION:
Before performing the following procedure, confirm battery voltage is more than 11V at idle.

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

C

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for at least 13 seconds.
If 1st trip DTC is detected, go to EC-274, «Diagnostic Procedure»
.

D

E

F

SEF058Y

G

WITH GST
Follow the procedure “WITH CONSULT-II” above.
H

I

J

K

L

M

EC-271

DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002YS

MBWA1517E

EC-272

DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
BATTERY VOLTAGE
(11 — 14V)

D
[Engine is running]
●

Idle speed

E
19

LG

EVAP canister purge
volume control solenoid
valve

PBIB0050E

F

Approximately 10V
[Engine is running]
●

G

Engine speed: About 2,000 rpm
(More than 100 seconds after starting engine)

PBIB0520E

[Engine is running]
[Ignition switch: OFF]
●

111

P

ECM relay
(Self shut-off)

[Ignition switch: OFF]
●

119
120

G
G

Power supply for ECM

For a few seconds after turning ignition switch
OFF

More than a few seconds passed after turning
ignition switch OFF

[Ignition switch: ON]

0 — 1.0V

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

H

I

J

K

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

L

M

EC-273

DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[CR (WITH EURO-OBD)]

Diagnostic Procedure

BBS002YT

1. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect EVAP canister purge volume control solenoid valve
harness connector.
Turn ignition switch ON.

MBIB1076E

4.

Check voltage between EVAP canister purge volume control
solenoid valve terminal 1 and ground with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

PBIB0148E

2. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F1
●
Harness for open or short between EVAP canister purge volume control solenoid valve and IPDM E/R
●
Harness for open or short between EVAP canister purge volume control solenoid valve and ECM
>> Repair harness or connectors.

3. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 19 and EVAP canister purge volume control solenoid
valve terminal 2. Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK (With CONSULT-II)>>GO TO 4.
OK (Without CONSULT-II)>>GO TO 5.
NG
>> Repair open circuit or short to ground and short to power in harness or connectors.

EC-274

DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[CR (WITH EURO-OBD)]

4. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION

A

With CONSULT-II
Reconnect all harness connectors disconnected.
Start engine.
Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with
CONSULT-II. Check that engine speed varies according to the
valve opening.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.
1.
2.
3.

EC

C

D

E
PBIB0569E

5. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

F

Refer to EC-275, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace EVAP canister purge volume control solenoid valve.

G

H

6. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

I

>> INSPECTION END

Component Inspection

BBS002YU

J

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
With CONSULT-II
K

Check air passage continuity of EVAP canister purge volume control
solenoid valve under the following conditions.
Condition
(PURG VOL CONT/V value)

Air passage continuity
between A and B

100%

Yes

0%

No

L

M

PBIB0149E

Without CONSULT-II
Check air passage continuity of EVAP canister purge volume control
solenoid valve under the following conditions.
Condition

Air passage continuity
between A and B

12V direct current supply between terminals 1 and 2

Yes

No supply

No

PBIB0150E

EC-275

DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[CR (WITH EURO-OBD)]

Removal and Installation

BBS002YV

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

EC-276

DTC P0500 VSS
[CR (WITH EURO-OBD)]

DTC P0500 VSS
Description

PFP:32702

A
BBS002YW

NOTE:
●
If DTC P0500 is displayed with DTC U1001, first perform the trouble diagnosis for DTC U1001. EC
Refer to EC-134, «DTC U1001 CAN COMMUNICATION LINE» .
●
If DTC P0500 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010.
Refer to EC-137, «DTC U1010 CAN COMMUNICATION» .
C
The vehicle speed signal is sent to the combination meter from the “ABS actuator and electric unit (control
unit)” through CAN communication line. The combination meter then sends a signal to the ECM through CAN
communication line.
D

On Board Diagnosis Logic
DTC No.

P0500
0500

Trouble diagnosis name

Vehicle speed sensor

BBS002YX

DTC detecting condition

The almost 0 km/h (0 MPH) signal from
vehicle speed sensor is sent to ECM
even when vehicle is being driven.

Possible cause

E

●

Harness or connectors
(The CAN communication line is open or
shorted.)

●

ABS actuator and electric unit (control unit)

●

Wheel sensor

●

Combination meter

DTC Confirmation Procedure

F

G
BBS002YY

CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Steps 1 and 2 may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a
road test is expected to be easier, it is unnecessary to lift the vehicle.

H

I

J

WITH CONSULT-II
1.
2.

3.
4.
5.

Start engine.
Read “VHCL SPEED SE” in “DATA MONITOR” mode with CONSULT-II. The vehicle speed on CONSULTII should exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position.
If NG, go to EC-278, «Diagnostic Procedure» .
If OK, go to following step.
Select “DATA MONITOR” mode with CONSULT-II.
Warm engine up to normal operating temperature.
Maintain the following conditions for at least 60 consecutive seconds.

ENG SPEED

2,400 — 6,000 rpm

COOLAN TEMP/S

More than 70°C (158°F)

B/FUEL SCHDL

4.3 — 31.8 msec

Shift lever

Suitable position

PW/ST SIGNAL

OFF

6.

SEF196Y

If 1st trip DTC is detected, go to EC-278, «Diagnostic Procedure» .

EC-277

K

L

M

DTC P0500 VSS
[CR (WITH EURO-OBD)]

Overall Function Check

BBS002YZ

Use this procedure to check the overall function of the vehicle speed signal circuit. During this check, a 1st trip
DTC might not be confirmed.

WITH GST
1.
2.
3.

4.

Lift up drive wheels.
Start engine.
Read vehicle speed signal in Service $01 with GST.
The vehicle speed signal on GST should be able to exceed 10 km/h (6 MPH) when rotating wheels with
suitable gear position.
If NG, go to EC-278, «Diagnostic Procedure» .

Diagnostic Procedure

BBS002Z0

1. CHECK DTC WITH ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)
Refer to BRC-8, «TROUBLE DIAGNOSIS»
(models with ESP).
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace.

(models without ESP) or BRC-49, «TROUBLE DIAGNOSIS»

2. CHECK COMBINATION METER
Check combination meter function.
Refer to DI-4, «COMBINATION METERS» .
>> INSPECTION END

EC-278

DTC P0605 ECM
[CR (WITH EURO-OBD)]

DTC P0605 ECM
Component Description

PFP:23710

A
BBS002Z1

The ECM consists of a microcomputer and connectors for signal
input and output and for power supply. The ECM controls the engine.

EC

C

D
PBIB1164E

E

On Board Diagnosis Logic

BBS002Z2

This self-diagnosis has one or two trip detection logic.
DTC No.
P0605
0605

Trouble diagnosis name

Engine control module

DTC detecting condition
A)

ECM calculation function is malfunctioning.

B)

ECM EEP-ROM system is malfunctioning.

C)

ECM self shut-off function is malfunctioning.

F

Possible cause

●

ECM

G

FAIL-SAFE MODE

H

ECM enters fail-safe mode when malfunction A is detected.
Detected items
Malfunction A

Engine operation condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5
degrees) by the return spring.

DTC Confirmation Procedure

BBS002Z3

Perform PROCEDURE FOR MALFUNCTION A first. If the DTC cannot be confirmed, perform PROCEDURE FOR MALFUNCTION B. If there is no malfunction on PROCEDURE FOR MALFUNCTION B, perform PROCEDURE FOR MALFUNCTION C.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

PROCEDURE FOR MALFUNCTION A
With CONSULT-II
1.
2.
3.

SEF058Y

Follow the procedure “With CONSULT-II” above.

EC-279

J

K

L

M

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
If 1st trip DTC is detected, go to EC-280, «Diagnostic Procedure»
.

With GST

I

DTC P0605 ECM
[CR (WITH EURO-OBD)]
PROCEDURE FOR MALFUNCTION B
With CONSULT-II
1.
2.
3.
4.

Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch OFF, wait at least 10 seconds and then turn
ON.
If 1st trip DTC is detected, go to EC-280, «Diagnostic Procedure»
.

SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

PROCEDURE FOR MALFUNCTION C
With CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch OFF, wait at least 10 seconds and then turn
ON.
Repeat step 3 for 32 times.
If 1st trip DTC is detected, go to EC-280, «Diagnostic Procedure»
.

SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

Diagnostic Procedure

BBS002Z4

1. INSPECTION START
With CONSULT-II
Turn ignition switch ON.
Select “SELF DIAG RESULTS” mode with CONSULT-II.
Touch “ERASE”.
Perform DTC Confirmation Procedure.
See EC-279, «DTC Confirmation Procedure» .
5. Is the 1st trip DTC P0605 displayed again?
1.
2.
3.
4.

With GST
Turn ignition switch ON.
Select Service $04 with GST.
Perform DTC Confirmation Procedure.
See EC-279, «DTC Confirmation Procedure» .
4. Is the 1st trip DTC P0605 displayed again?
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END
1.
2.
3.

EC-280

DTC P0605 ECM
[CR (WITH EURO-OBD)]

2. REPLACE ECM
1.
2.
3.
4.
5.

A
Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
EC
Re-communicating Function» .
Perform EC-69, «Accelerator Pedal Released Position Learning» .
Perform EC-69, «Throttle Valve Closed Position Learning» .
C
Perform EC-69, «Idle Air Volume Learning» .

>> INSPECTION END

D

E

F

G

H

I

J

K

L

M

EC-281

DTC P1065 ECM POWER SUPPLY
[CR (WITH EURO-OBD)]

DTC P1065 ECM POWER SUPPLY
Component Description

PFP:23710
BBS002Z5

Battery voltage is supplied to the ECM even when the ignition switch
is turned OFF for the ECM memory function of the DTC memory, the
air-fuel ratio feedback compensation value memory, the idle air volume learning value memory, etc.

PBIB1164E

On Board Diagnosis Logic
DTC No.
P1065
1065

Trouble diagnosis name

ECM power supply circuit

BBS002Z6

DTC detecting condition

Possible cause
●

Harness or connectors
[ECM power supply (back-up) circuit is
open or shorted.]

●

ECM

ECM back-up RAM system does not function
properly.

DTC Confirmation Procedure

BBS002Z7

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn
ON.
Repeat steps 3 and 4 for 4 times.
If 1st trip DTC is detected, go to EC-284, «Diagnostic Procedure»
.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-282

DTC P1065 ECM POWER SUPPLY
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002Z8

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1518E

EC-283

DTC P1065 ECM POWER SUPPLY
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
121

WIRE
COLOR
BR

ITEM
Power supply for ECM
(Back-up)

CONDITION

[Ignition switch: OFF]

Diagnostic Procedure

DATA (DC Voltage)
BATTERY VOLTAGE
(11 — 14V)
BBS002Z9

1. CHECK ECM POWER SUPPLY
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check voltage between ECM terminal 121 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

MBIB0026E

2. DETECT MALFUNCTIONING PART
Check the following.
●
20A fuse
●
IPDM E/R harness connector E7
●
Harness for open or short between ECM and IPDM E/R
>> Repair or replace harness or connectors.

3. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace harness or connectors.

EC-284

DTC P1065 ECM POWER SUPPLY
[CR (WITH EURO-OBD)]

4. PERFORM DTC CONFIRMATION PROCEDURE
With CONSULT-II
Turn ignition switch ON.
Select “SELF DIAG RESULTS” mode with CONSULT-II.
Touch “ERASE”.
Perform DTC Confirmation Procedure.
See EC-282, «DTC Confirmation Procedure» .
5. Is the 1st trip DTC P1065 displayed again?
1.
2.
3.
4.

A

EC

C

With GST
Turn ignition switch ON.
Select Service $04 with GST.
Perform DTC Confirmation Procedure.
See EC-282, «DTC Confirmation Procedure» .
4. Is the 1st trip DTC P1065 displayed again?
Yes or No
Yes
>> GO TO 5.
No
>> INSPECTION END

D

5. REPLACE ECM

G

1.
2.
3.

1.
2.
3.
4.
5.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
Perform EC-69, «Accelerator Pedal Released Position Learning» .
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .

E

F

H

I

J

>> INSPECTION END
K

L

M

EC-285

DTC P1111 IVT CONTROL SOLENOID VALVE
[CR (WITH EURO-OBD)]

DTC P1111 IVT CONTROL SOLENOID VALVE
Component Description

PFP:23796
BBS002ZA

Intake valve timing control solenoid valve is activated by ON/OFF
pulse duty (ratio) signals from the ECM.
The intake valve timing control solenoid valve changes the oil
amount and direction of flow through intake valve timing control unit
or stops oil flow.
The longer pulse width advances valve angle.
The shorter pulse width retards valve angle.
When ON and OFF pulse widths become equal, the solenoid valve
stops oil pressure flow to fix the intake valve angle at the control
position.
PBIB1842E

CONSULT-II Reference Value in Data Monitor Mode

BBS002ZB

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

INT/V SOL (B1)

SPECIFICATION

Idle

0% — 2%

2,000 rpm

Approx. 0% — 50%

On Board Diagnosis Logic
DTC No.
P1111
1111

Trouble diagnosis name
Intake valve timing control
solenoid valve circuit

BBS002ZC

DTC detecting condition

Possible cause
●

Harness or connectors
(Intake valve timing control solenoid valve
circuit is open or shorted.)

●

Intake valve timing control solenoid valve

An improper voltage is sent to the ECM
through intake valve timing control solenoid
valve.

DTC Confirmation Procedure

BBS002ZD

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If 1st trip DTC is detected, go to EC-289, «Diagnostic Procedure»
.

SEF058Y

WITH GST
Following the procedure “WITH CONSULT-II” above.

EC-286

DTC P1111 IVT CONTROL SOLENOID VALVE
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002ZE

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1519E

EC-287

DTC P1111 IVT CONTROL SOLENOID VALVE
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]
●

Warm-up condition

●

Idle speed

BATTERY VOLTAGE
(11 — 14V)
Approximately 4V — BATTERY

62

LG

Intake valve timing
control solenoid valve

VOLTAGE (11 — 14V)
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

PBIB1790E

[Engine is running]
[Ignition switch: OFF]
●

111

P

ECM relay
(Self shut-off)

[Ignition switch: OFF]
●

119
120

G
G

Power supply for ECM

For a few seconds after turning ignition switch
OFF

More than a few seconds passed after turning
ignition switch OFF

[Ignition switch: ON]

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-288

0 — 1.0V

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

DTC P1111 IVT CONTROL SOLENOID VALVE
[CR (WITH EURO-OBD)]

Diagnostic Procedure

BBS002ZF

1. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect intake valve timing control solenoid valve harness
connector.
Turn ignition switch ON.

EC

C

D

MBIB0284E

4.

Check voltage between intake valve timing control solenoid
valve terminal 1 and ground with CONSULT-II or tester.

E

F

Voltage: Battery voltage
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

G

H

PBIB0285E

2. DETECT MALFUNCTION PART
Check the following.
●
Harness connectors E48, F1
●
Harness for open or short between intake valve timing control solenoid valve and IPDM E/R

I

J

K

>> Repair or replace harness or connectors.

3. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR

L

OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 62 and intake valve timing control solenoid valve terminal 2. Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE
Refer to EC-290, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace intake valve timing control solenoid valve.

EC-289

M

DTC P1111 IVT CONTROL SOLENOID VALVE
[CR (WITH EURO-OBD)]

5. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS002ZG

INTAKE VALVE TIMING CONTROL SOLENOID VALVE
1.
2.

3.
4.

Disconnect intake valve timing control solenoid valve harness connector.
Check resistance between intake valve timing control solenoid
valve as follows.
Terminal

Resistance

1 and 2

6.7 — 7.7Ω at 20°C (68°F)

1 or 2 and ground

∞Ω
(Continuity should not exist.)

If NG, replace intake valve timing control solenoid valve.
If OK, go to next step.
Remove intake valve timing control solenoid valve.

MBIB0027E

Provide 12V DC between intake valve timing control solenoid
valve terminals and then interrupt it. Make sure that the plunger
moves as shown in the figure.
CAUTION:
Do not apply 12V DC continuously for 5 seconds or more.
Doing so may result in damage to the coil in intake valve
timing control solenoid valve.
If NG, replace intake valve timing control solenoid valve.
NOTE:
Always replace O-ring when intake valve timing control
solenoid valve is removed.

PBIB2388E

Removal and Installation

BBS002ZH

INTAKE VALVE TIMING CONTROL SOLENOID VALVE
Refer to EM-35, «ROCKER COVER» .

EC-290

DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR
[CR (WITH EURO-OBD)]

DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR
Component Description

PFP:16119

A
BBS002ZI

Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc.
The throttle control motor is operated by the ECM and it opens and closes the throttle valve.
EC
The throttle position sensor detects the throttle valve position, and the opening and closing speed of the throttle valve and feeds the voltage signals to the ECM. The ECM judges the current opening angle of the throttle
valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening
C
angle properly in response to driving condition.

On Board Diagnosis Logic

BBS002ZJ

D

This self-diagnosis has the one trip detection logic.
DTC No.

P1121
1121

Trouble diagnosis name

Electric throttle control
actuator

DTC detecting condition
A)

Electric throttle control actuator does not function
properly due to the return spring malfunction.

B)

Throttle valve opening angle in fail-safe mode is
not in specified range.

C)

ECM detect the throttle valve is stuck open.

Possible cause

E
●

Electric throttle control actuator

F

FAIL-SAFE MODE

G

When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Detected items

Engine operating condition in fail-safe mode

Malfunction A

The ECM controls the electric throttle actuator by regulating the throttle opening around the idle position.
The engine speed will not rise more than 2,000 rpm.

Malfunction B

ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less.

Malfunction C

While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls.
The engine can restart in Neutral position, and engine speed will not exceed 1,000 rpm or more.

DTC Confirmation Procedure

H

I

BBS002ZK

J

NOTE:
●
Perform PROCEDURE FOR MALFUNCTION A AND B first. If the DTC cannot be confirmed, perform
PROCEDURE FOR MALFUNCTION C.
●
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
at least 10 seconds before conducting the next test.

K

L

PROCEDURE FOR MALFUNCTION A AND B
With CONSULT-II
1.
2.
3.
4.
5.
6.
7.
8.
9.

Turn ignition witch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Set shift lever to 1st position and wait at least 2 seconds.
Set shift lever to Neutral position.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON and wait at least 1 second.
Set shift lever to 1st position and wait at least 2 seconds.
Set shift lever to Neutral position.
Turn ignition switch OFF, wait at least 10 seconds and then turn
ON.
10. If DTC is detected, go to EC-292, «Diagnostic Procedure» .

EC-291

M

SEF058Y

DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR
[CR (WITH EURO-OBD)]
With GST
Follow the procedure “With CONSULT-II” above.

PROCEDURE FOR MALFUNCTION C
With CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Set shift lever to 1st position and wait at least 2 seconds.
Set shift lever to Neutral position.
Start engine and let it idle for 3 seconds.
If DTC is detected, go to EC-292, «Diagnostic Procedure» .

SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

Diagnostic Procedure

BBS002ZL

1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY
1.
2.

Remove the intake air duct.
Check if a foreign matter is caught between the throttle valve
and the housing.
OK or NG
OK
>> GO TO 2.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.

MBIB0307E

2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> INSPECTION END

EC-292

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[CR (WITH EURO-OBD)]

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
Description

PFP:16119

A
BBS002ZM

NOTE:
If DTC P1122 is displayed with DTC P1121 or P1126, first perform the trouble diagnosis for DTC P1121 EC
or P1126. Refer to EC-291 or EC-299 .
Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc.
The throttle control motor is operated by the ECM and it opens and closes the throttle valve.
The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feed- C
back to the ECM to control the throttle control motor to make the throttle valve opening angle properly in
response to driving condition.
D

On Board Diagnosis Logic

BBS002ZN

This self-diagnosis has the one trip detection logic.
DTC No.

Trouble diagnosis name

P1122
1122

Electric throttle control
performance

DTC detecting condition

E

Possible cause
●

Electric throttle control function does not
operate properly.
●

Harness or connectors
(Throttle control motor circuit is open or
shorted.)

F

Electric throttle control actuator

G

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode

H

ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.

DTC Confirmation Procedure

BBS002ZO

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 11V when engine
is running.

I

J

K

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

Turn ignition switch ON and wait at least 2 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If DTC is detected, go to EC-295, «Diagnostic Procedure» .

L

M

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-293

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002ZP

MBWA1520E

EC-294

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.
3

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
LG

Throttle control motor relay
power supply

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 14V

D

[Ignition switch: ON]
4

L

Throttle control motor
(Close)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

E

PBIB0534E

F

0 — 14V
[Ignition switch: ON]
5

P

Throttle control motor
(Open)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

G

H
PBIB0533E

104

G

Throttle control motor relay

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 1.0V

I

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

J

Diagnostic Procedure

BBS002ZQ

1. CHECK GROUND CONNECTIONS
1.
2.

K

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

L

M

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-295

3.

Body ground E28

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[CR (WITH EURO-OBD)]

2. CHECK THROTTLE CONTROL MOTOR RELAY SIGNAL CIRCUIT-I
Check voltage between ECM terminal 3 and ground under the following conditions with CONSULT-II or tester.
Ignition switch

Voltage

OFF

Approximately 0V

ON

Battery voltage
(11 — 14V)

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 3.

MBIB0028E

3. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-I
1.
2.

Turn ignition switch OFF.
Check voltage between ECM terminal 104 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 4.

PBIB1171E

4. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-II
1.
2.
3.

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E5.
Check continuity between ECM terminal 104 and IPDM E/R terminal 70.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK FUSE
1. Disconnect 20A fuse.
2. Check 20A fuse for blown.
OK or NG
OK
>> GO TO 8.
NG
>> Replace 20A fuse.

EC-296

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[CR (WITH EURO-OBD)]

6. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-II
1.
2.
3.

A

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between ECM terminal 3 and IPDM E/R terminal 28.
Refer to Wiring Diagram.

EC

Continuity should exist.

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

D

7. DETECT MALFUNCTIONING PART

E

Check the following.
●
Harness connectors E48, F1
●
Harness for open or short between ECM and IPDM E/R

F

>> Repair open circuit or short to ground or short to power in harness or connectors.

G

8. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connectors.

9. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT
1.
2.
3.
4.

3

6

ECM terminal

I

J

Turn ignition switch OFF.
Disconnect electric throttle control actuator harness connector.
Disconnect ECM harness connector.
Check harness continuity between the following terminals.
Refer to Wiring Diagram.
Electric throttle control
actuator terminal

H

K

L

Continuity

5

Should not exist

4

Should exist

5

Should exist

4

Should not exist

5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 10.
NG
>> Repair or replace.

EC-297

M

MBIB0308E

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[CR (WITH EURO-OBD)]

10. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY
1.
2.

Remove the intake air duct.
Check if foreign matter is caught between the throttle valve and
the housing.
OK or NG
OK
>> GO TO 11.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.

MBIB0307E

11. CHECK THROTTLE CONTROL MOTOR
Refer to EC-298, «Component Inspection» .
OK or NG
OK
>> GO TO 12.
NG
>> GO TO 13.

12. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> GO TO 13.
NG
>> Repair or replace harness or connectors.

13. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> INSPECTION END

Component Inspection

BBS002ZR

THROTTLE CONTROL MOTOR
1.
2.

Disconnect electric throttle control actuator harness connector.
Check resistance between terminals 3 and 6.
Resistance: Approximately 1 — 15 Ω [at 25 °C (77°F)]

3.
4.
5.

If NG, replace electric throttle control actuator and go to next
step.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .

PBIB0095E

Removal and Installation

BBS002ZS

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

EC-298

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[CR (WITH EURO-OBD)]

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
Component Description

PFP:16119

A
BBS002ZT

Power supply for the throttle control motor is provided to the ECM via throttle control motor relay. The throttle
control motor relay is ON/OFF controlled by the ECM. When the ignition switch is turned ON, the ECM sends EC
an ON signal to throttle control motor relay and battery voltage is provided to the ECM. When the ignition
switch is turned OFF, the ECM sends an OFF signal to throttle control motor relay and battery voltage is not
provided to the ECM.
C

CONSULT-II Reference Value in Data Monitor Mode

BBS002ZU

Specification data are reference values.
MONITOR ITEM
THRTL RELAY

CONDITION
●

D

SPECIFICATION

Ignition switch: ON

ON

On Board Diagnosis Logic

BBS002ZV

E

These self-diagnoses have the one trip detection logic.
DTC No.
P1124
1124

P1126
1126

Trouble diagnosis name
Throttle control motor
relay circuit short

Throttle control motor
relay circuit open

DTC detecting condition

F

Possible cause
●

Harness or connectors
(Throttle control motor relay circuit is shorted.)

●

Throttle control motor relay

●

Harness or connectors
(Throttle control motor relay circuit is open.)

●

Throttle control motor relay

ECM detects the throttle control motor relay
is stuck ON.

ECM detects a voltage of power source for
throttle control motor is excessively low.

G

H

FAIL-SAFE MODE
I

When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.

DTC Confirmation Procedure

BBS002ZW

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

PROCEDURE FOR DTC P1124
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 8V.
Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
If DTC is detected, go to EC-302, «Diagnostic Procedure» .

SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

EC-299

K

L

M

With CONSULT-II
1.
2.
3.

J

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[CR (WITH EURO-OBD)]
PROCEDURE FOR DTC P1126
With CONSULT-II
1.
2.
3.
4.

Turn ignition switch ON and wait at least 2 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If DTC is detected, go to EC-302, «Diagnostic Procedure» .

SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

EC-300

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS002ZX

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1521E

EC-301

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
3

WIRE
COLOR
LG

ITEM
Throttle control motor relay
power supply

CONDITION

[Ignition switch: ON]

DATA (DC Voltage)
BATTERY VOLTAGE
(11 — 14V)
0 — 14V

[Ignition switch: ON]
4

L

Throttle control motor
(Close)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released
PBIB0534E

0 — 14V
[Ignition switch: ON]
5

P

Throttle control motor
(Open)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed
PBIB0533E

104

G

Throttle control motor relay

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 1.0V

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS002ZY

1. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-I
1.
2.

Turn ignition switch OFF.
Check voltage between ECM terminal 104 and ground with
CONSULT-II or tester.
Voltage: Battery voltage.

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 2.

PBIB1171E

EC-302

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[CR (WITH EURO-OBD)]

2. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-II
1.
2.
3.

A

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E5.
Check continuity between ECM terminal 104 and IPDM E/R terminal 70.

EC

Continuity should exist.
C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D

3. CHECK FUSE
E

1. Disconnect 20A fuse.
2. Check 20A fuse for blown.
OK or NG
OK
>> GO TO 7.
NG
>> Replace 20A fuse.

F

4. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-I
1.
2.

G

Reconnect all disconnected connectors.
Check voltage between ECM terminal 3 and ground under the
following conditions with CONSULT-II or tester.
Ignition switch

Voltage

OFF

Approximately 0V

ON

Battery voltage
(11 — 14V)

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 5.

H

I

J

MBIB0028E

K

5. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-II
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E7.
Check continuity between ECM terminal 3 and IPDM E/R terminal 28.
Refer to Wiring Diagram.
Continuity should exist.

5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

6. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F1
●
Harness for open or short between ECM and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-303

L

M

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[CR (WITH EURO-OBD)]

7. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connectors.

EC-304

DTC P1128 THROTTLE CONTROL MOTOR
[CR (WITH EURO-OBD)]

DTC P1128 THROTTLE CONTROL MOTOR
Component Description

PFP:16119

A
BBS002ZZ

The throttle control motor is operated by the ECM and it opens and closes the throttle valve.
The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feed- EC
back to the ECM to control the throttle control motor to make the throttle valve opening angle properly in
response to driving condition.

On Board Diagnosis Logic

BBS00300

C

This self-diagnosis has the one trip detection logic.
DTC No.
P1128
1128

Trouble diagnosis name
Throttle control motor
circuit short

DTC detecting condition
ECM detects short in both circuits between
ECM and throttle control motor.

Possible cause

D

●

Harness or connectors
(Throttle control motor circuit is shorted.)

●

Electric throttle control actuator
(Throttle control motor)

E

FAIL-SAFE MODE

F

When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.

DTC Confirmation Procedure

BBS00301

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

G

H

I

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

Turn ignition switch ON and wait at least 2 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If DTC is detected, go to EC-307, «Diagnostic Procedure» .

J

K

L

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-305

M

DTC P1128 THROTTLE CONTROL MOTOR
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS00302

MBWA1522E

EC-306

DTC P1128 THROTTLE CONTROL MOTOR
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.
3

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
LG

Throttle control motor
relay power supply

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 14V

D

[Ignition switch: ON]
4

L

Throttle control motor
(Close)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

E

PBIB0534E

F

0 — 14V
[Ignition switch: ON]
5

P

Throttle control motor
(Open)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

G

H
PBIB0533E

104

G

Throttle control motor
relay

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 1.0V

I

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

J

Diagnostic Procedure

BBS00303

1. CHECK GROUND CONNECTIONS
1.
2.

K

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

L

M

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-307

3.

Body ground E28

DTC P1128 THROTTLE CONTROL MOTOR
[CR (WITH EURO-OBD)]

2. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT
1.
2.
3.

Disconnect electric throttle control actuator harness connector.
Disconnect ECM harness connector.
Check harness continuity between the following terminals.
Refer to Wiring Diagram.
Electric throttle control
actuator terminal

ECM terminal

3

6

Continuity

4

Should exist

5

Should not exist

4

Should not exist

5

Should exist

MBIB0308E

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

3. CHECK THROTTLE CONTROL MOTOR
Refer to EC-308, «Component Inspection» .
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 5.

4. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace harness or connectors.

5. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> INSPECTION END

Component Inspection

BBS00304

THROTTLE CONTROL MOTOR
1.
2.

Disconnect electric throttle control actuator harness connector.
Check resistance between terminals 3 and 6.
Resistance: Approximately 1 — 15 Ω [at 25 °C (77°F)]

3.
4.
5.

If NG, replace electric throttle control actuator and go to next
step.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .

PBIB0095E

EC-308

DTC P1128 THROTTLE CONTROL MOTOR
[CR (WITH EURO-OBD)]

Removal and Installation

BBS00305

ELECTRIC THROTTLE CONTROL ACTUATOR

A

Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
EC

C

D

E

F

G

H

I

J

K

L

M

EC-309

DTC P1143 HO2S1
[CR (WITH EURO-OBD)]

DTC P1143 HO2S1
Component Description

PFP:22690
BBS00306

The heated oxygen sensor 1 is placed into the exhaust manifold. It
detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.

SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

BBS00307

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION
0 — 0.3V ←→ Approx. 0.6 — 1.0V

HO2S1 (B1)
●

HO2S1 MNTR (B1)

Engine: After warming up

Maintaining engine speed at 2,000
rpm

LEAN ←→ RICH
Changes more than 5 times during 10 seconds.

On Board Diagnosis Logic

BBS00308

To judge the malfunction, the output from the heated oxygen sensor
1 is monitored to determine whether the “rich” output is sufficiently
high and whether the “lean” output is sufficiently low. When both the
outputs are shifting to the lean side, the malfunction will be detected.

SEF300U

DTC No.

P1143
1143

Trouble diagnosis name

Heated oxygen sensor 1
lean shift monitoring

DTC detecting condition

The maximum and minimum voltage from the
sensor are not reached to the specified voltages.

EC-310

Possible cause
●

Heated oxygen sensor 1

●

Heated oxygen sensor 1 heater

●

Fuel pressure

●

Fuel injector

●

Intake air leak

DTC P1143 HO2S1
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS00309

A
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at EC
least 10 seconds before conducting the next test.
TESTING CONDITION:
C
●
Always perform at a temperature above −10°C (14°F).
●
Before performing following procedure, confirm that battery voltage is more than 11V at idle.

WITH CONSULT-II
1.
2.
3.
4.
5.

D

Start engine and warm it up to normal operating temperature.
Stop engine and wait at least 10 seconds.
Turn ignition switch ON and select “HO2S1 (B1) P1143” of “HO2S1” in “DTC WORK SUPPORT” mode
with CONSULT-II.
Touch “START”.
Start engine and let it idle for at least 3 minutes.
NOTE:
Never raise engine speed above 3,600 rpm after this step. If
the engine speed limit is exceeded, return to step 5.

E

F

G

H
PBIB0546E

I

6.

When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will
take approximately 50 seconds or more.)

ENG SPEED

1,500 — 3,200 rpm

VHCL SPEED SE

50 — 100 km/h (31 — 62 MPH)

B/FUEL SCHDL

1.8 — 5.5 msec

Shift lever

Suitable position

7.

J

K

L

If “TESTING” is not displayed after 5 minutes, retry from
step 2.
Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”. If “NG” is displayed, refer to EC-312, «Diagnostic
Procedure» .

PBIB0547E

M

SEC769C

EC-311

DTC P1143 HO2S1
[CR (WITH EURO-OBD)]

Overall Function Check

BBS0030A

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st
trip DTC might not be confirmed.

WITH GST
1.
2.
3.
●
●

4.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground.
Check one of the following with engine speed held at 2,000 rpm
constant under no load.
The maximum voltage is over 0.6V at least one time.
The minimum voltage is over 0.1V at least one time.
If NG, go to EC-312, «Diagnostic Procedure» .

MBIB0018E

Diagnostic Procedure

BBS0030B

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

2. RETIGHTEN HEATED OXYGEN SENSOR 1
Loosen and retighten heated oxygen sensor 1 (2).
●
●

: Vehicle front
Exhaust manifold cover (1)
Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb)
>> GO TO 3.

MBIB1493E

EC-312

DTC P1143 HO2S1
[CR (WITH EURO-OBD)]

3. CHECK FOR INTAKE AIR LEAK

A

Listen for an intake air leak after the manifold absolute pressure sensor.
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace.

EC

4. CLEAR THE SELF-LEARNING DATA
1.
2.
3.
4.

C

With CONSULT-II
Start engine and warm it up to normal operating temperature.
Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II.
Clear the self-learning control coefficient by touching “CLEAR”.
Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 detected?
Is it difficult to start engine?

D

E

F

G
SEF215Z

H

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF.
3. Disconnect manifold absolute pressure sensor harness connector, and restart and run engine for at least 5 seconds at idle
speed.
4. Stop engine and reconnect manifold absolute pressure sensor
harness connector.
5. Make sure that DTC P0107 is displayed.
6. Erase the DTC memory. Refer to EC-57, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .
7. Make sure that DTC P0000 is displayed.
8. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 detected?
Is it difficult to start engine?
Yes or No
Yes
>> Perform trouble diagnosis for DTC P0171. Refer to EC-218 .
No
>> GO TO 5.

5. CHECK HEATED OXYGEN SENSOR 1 HEATER
Refer to EC-148, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 1.

6. CHECK HEATED OXYGEN SENSOR 1
Refer to EC-314, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace heated oxygen sensor 1.

EC-313

I

J

K

L
MBIB0276E

M

DTC P1143 HO2S1
[CR (WITH EURO-OBD)]

7. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
For circuit, refer to EC-180, «Wiring Diagram» .
>> INSPECTION END

Component Inspection

BBS0030C

HEATED OXYGEN SENSOR 1
With CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULTII.
Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch “RECORD” on CONSULT-II screen.

MBIB0301E

6.

Check the following.
● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes
from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds.
5 times (cycles) are counted as shown in the figure.
● “HO2S1 (B1)” voltage goes above 0.6V at least once.
● “HO2S1 (B1)” voltage goes below 0.3V at least once.
● “HO2S1 (B1)” voltage never exceeds 1.0V.
SEF217YA

SEF648Y

CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

EC-314

DTC P1143 HO2S1
[CR (WITH EURO-OBD)]
Without CONSULT-II
A
Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground.
Check the following with engine speed held at 2,000 rpm conEC
stant under no load.
● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
C
● The maximum voltage is over 0.6V at least one time.
● The minimum voltage is below 0.3V at least one time.
● The voltage never exceeds 1.0V.
D
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V → 0 0.3V
MBIB0018E
E
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread F
Cleaner and approved anti-seize lubricant.

1.
2.
3.

Removal and Installation

BBS0030D

HEATED OXYGEN SENSOR 1

G

Refer to EM-24, «EXHAUST MANIFOLD AND THREE WAY CATALYST» .
H

I

J

K

L

M

EC-315

DTC P1144 HO2S1
[CR (WITH EURO-OBD)]

DTC P1144 HO2S1
Component Description

PFP:22690
BBS0030E

The heated oxygen sensor 1 is placed into the exhaust manifold. It
detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.

SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

BBS0030F

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION
0 — 0.3V ←→ Approx. 0.6 — 1.0V

HO2S1 (B1)
●

HO2S1 MNTR (B1)

Engine: After warming up

Maintaining engine speed at 2,000
rpm

LEAN ←→ RICH
Changes more than 5 times during 10 seconds.

On Board Diagnosis Logic

BBS0030G

To judge the malfunction, the output from the heated oxygen sensor
1 is monitored to determine whether the “rich” output is sufficiently
high and whether the “lean” output is sufficiently low. When both the
outputs are shifting to the rich side, the malfunction will be detected.

SEF299U

DTC No.

P1144
1144

Trouble diagnosis name

DTC detecting condition

Heated oxygen sensor 1
rich shift monitoring

The maximum and minimum voltages from the
sensor are beyond the specified voltages.

EC-316

Possible cause
●

Heated oxygen sensor 1

●

Heated oxygen sensor 1 heater

●

Fuel pressure

●

Fuel injector

DTC P1144 HO2S1
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS0030H

A
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at EC
least 10 seconds before conducting the next test.
TESTING CONDITION:
C
●
Always perform at a temperature above −10°C (14°F).
●
Before performing the following procedure, confirm that battery voltage is more than 11V at idle.

WITH CONSULT-II
1.
2.
3.
4.
5.

D

Start engine and warm it up to normal operating temperature.
Stop engine and wait at least 5 seconds.
Turn ignition switch ON and select “HO2S1 (B1) P1144” of “HO2S1” in “DTC WORK SUPPORT” mode
with CONSULT-II.
Touch “START”.
Start engine and let it idle for at least 3 minutes.
NOTE:
Never raise engine speed above 3,600 rpm after this step. If
the engine speed limit is exceeded, return to step 5.

E

F

G

H
PBIB0548E

I

6.

When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will
take approximately 50 seconds or more.)

ENG SPEED

1,500 — 3,200 rpm

VHCL SPEED SE

50 — 100 km/h (31 — 62 MPH)

B/FUEL SCHDL

1.8 — 5.5 msec

Shift lever

Suitable position

7.

J

K

L

If “TESTING” is not displayed after 5 minutes, retry from
step 2.
Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”. If “NG” is displayed, refer to EC-318, «Diagnostic
Procedure» .

PBIB0549E

M

SEC772C

EC-317

DTC P1144 HO2S1
[CR (WITH EURO-OBD)]

Overall Function Check

BBS0030I

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a
1st trip DTC might not be confirmed.

WITH GST
1.
2.
3.
●
●

4.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground.
Check one of the following with engine speed held at 2,000 rpm
constant under no load.
The maximum voltage is below 0.8V at least one time.
The minimum voltage is below 0.35V at least one time.
If NG, go to EC-318, «Diagnostic Procedure» .

MBIB0018E

Diagnostic Procedure

BBS0030J

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

2. RETIGHTEN HEATED OXYGEN SENSOR 1
Loosen and retighten heated oxygen sensor 1 (2).
●
●

: Vehicle front
Exhaust manifold cover (1)
Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb)
>> GO TO 3.

MBIB1493E

EC-318

DTC P1144 HO2S1
[CR (WITH EURO-OBD)]

3. CLEAR THE SELF-LEARNING DATA
1.
2.
3.
4.

A

With CONSULT-II
Start engine and warm it up to normal operating temperature.
Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II.
Clear the self-learning control coefficient by touching “CLEAR”.
Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0172 detected?
Is it difficult to start engine?

EC

C

D

E
SEF215Z

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF.
3. Disconnect manifold absolute pressure sensor harness connector, and restart and run engine for at least 5 seconds at idle
speed.
4. Stop engine and reconnect manifold absolute pressure sensor
harness connector.
5. Make sure that DTC P0107 is displayed.
6. Erase the DTC memory. Refer to EC-57, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .
7. Make sure that DTC P0000 is displayed.
8. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0172 detected?
Is it difficult to start engine?
Yes or No
Yes
>> Perform trouble diagnosis for DTC P0172. Refer to EC-226 .
No
>> GO TO 4.

F

G

H

I

J
MBIB0276E

K

L

4. CHECK HO2S1 CONNECTOR FOR WATER
1.
2.
3.

Turn ignition switch OFF.
Disconnect heated oxygen sensor 1 harness connector (1).
Check connectors for water.

M

Water should not exist.
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace harness or connectors.

MBIB1494E

EC-319

DTC P1144 HO2S1
[CR (WITH EURO-OBD)]

5. CHECK HEATED OXYGEN SENSOR 1 HEATER
Refer to EC-148, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 1.

6. CHECK HEATED OXYGEN SENSOR 1
Refer to EC-320, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace heated oxygen sensor 1.

7. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
For circuit, refer to EC-180, «Wiring Diagram» .
>> INSPECTION END

Component Inspection

BBS0030K

HEATED OXYGEN SENSOR 1
With CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULTII.
Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch “RECORD” on CONSULT-II screen.

MBIB0301E

6.

Check the following.
● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes
from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds.
5 times (cycles) are counted as shown in the figure.
● “HO2S1 (B1)” voltage goes above 0.6V at least once.
● “HO2S1 (B1)” voltage goes below 0.3V at least once.
● “HO2S1 (B1)” voltage never exceeds 1.0V.
SEF217YA

EC-320

DTC P1144 HO2S1
[CR (WITH EURO-OBD)]
A

EC

C
SEF648Y

CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

Without CONSULT-II
1.
2.
3.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground.
Check the following with engine speed held at 2,000 rpm constant under no load.
● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
● The maximum voltage is over 0.6V at least one time.
● The minimum voltage is below 0.3V at least one time.
● The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V → 0 0.3V
MBIB0018E
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

Removal and Installation

BBS0030L

D

E

F

G

H

I

J

K

L

HEATED OXYGEN SENSOR 1
Refer to EM-24, «EXHAUST MANIFOLD AND THREE WAY CATALYST» .
M

EC-321

DTC P1146 HO2S2
[CR (WITH EURO-OBD)]

DTC P1146 HO2S2
Component Description

PFP:226A0
BBS0030M

The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas on each bank.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
SEF327R

CONSULT-II Reference Value in Data Monitor Mode

BBS0030N

Specification data are reference values.
MONITOR ITEM
HO2S2 (B1)

HO2S2 MNTR (B1)

CONDITION

SPECIFICATION

●

Revving engine from idle to 3,000 rpm quickly after the following conditions are met.

0 — 0.3V ←→ Approx. 0.6 — 1.0V

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute
and at idle for 1 minute under no load.

LEAN ←→ RICH

On Board Diagnosis Logic

BBS0030O

The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity of the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the minimum voltage of sensor is
sufficiently low during the various driving condition such as fuel-cut.

PBIB1201E

DTC No.

P1146
1146

Trouble diagnosis name

Heated oxygen sensor 2
minimum voltage monitoring

DTC detecting condition

The minimum voltage from the sensor is not
reached to the specified voltage.

DTC Confirmation Procedure

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 2

●

Fuel pressure

●

Fuel Injector
BBS0030P

CAUTION:
Always drive vehicle at a safe speed.
NOTE:
●
“COMPLETED” will appear on CONSULT-II screen when all tests “COND1”, “COND2” and
“COND3” are completed.
●
If DTC confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
at least 10 seconds before conducting the next test.
TESTING CONDITION:
Never stop engine during this procedure. If the engine is stopped, retry procedure from step 2 in Procedure for COND1.

EC-322

DTC P1146 HO2S2
[CR (WITH EURO-OBD)]
WITH CONSULT-II
Procedure for COND1

A

For the best results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30°C(32 to 86°F).
1. Start engine and warm it up to normal operating temperature.
EC
2. Turn ignition switch OFF and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
4. Let engine idle 1 minute.
C
5. Select “HO2S2 (B1) P1146” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II.
6. Touch “START”.
7. Start engine and let it idle for at least 30 seconds.
D
8. Rev engine up to 2,000 rpm 2 or 3 times quickly under no load.
If “COMPLETED” appears on CONSULT-II screen, go to step 2 in Procedure for COND3”.
If “COMPLETED” does not appear on CONSULT-II screen, go to the following step.
E
9. When the following conditions are met, “TESTING” will be displayed at “COND1” on the CONSULT-II
screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take
approximately 60 seconds.)
F
ENG SPEED

More than 1,500 rpm

B/FUEL SCHDL

More than 1.0 msec

COOLAN TEMP/S

70 — 105°C

Shift lever

Suitable position

G

H

I

J

PBIB0555E

NOTE:
● If “TESTING” is not displayed after 5 minutes, retry from step 2 in Procedure for COND1.
● If “COMPLETED” already appears at “COND2” on CONSULT-II screen before Procedure for
COND2 is conducted, it is unnecessary to conduct step 1 in Procedure for COND2.

Procedure for COND2
1.

L

M

While driving, release accelerator pedal completed from the
above condition [step 9] until “INCOMPLETE” at “COND2” on
CONSULT-II screen has turned to “COMPLETED” (It will take
approximately 4 seconds.)
NOTE:
If “COMPLETE” already appears at “COND3” on CONSULTII screen before Procedure for COND3 is conducted, it is
unnecessary to conduct step 1 in Procedure for COND3.

PBIB0556E

EC-323

K

DTC P1146 HO2S2
[CR (WITH EURO-OBD)]
Procedure for COND3
1.

2.

a.
b.
c.
d.

Stop vehicle and let it idle until “INCOMPLETE” of “COND3” on
CONSULT-II screen has turned to “COMPLETED”. (It will take a
maximum of approximately 6 minutes.)
Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”.
If “NG” is displayed, refer to EC-326, «Diagnostic Procedure» .
If “CAN NOT BE DIAGNOSED” is displayed, performed the following.
Turn ignition switch OFF and leave the vehicle in a cool place
(soak the vehicle).
SEC775C
Turn ignition switch ON and select “COOLAN TEMP/S” in “DATA
MONITOR” mode with CONSULT-II.
Start engine and warm it up while monitoring “COOLAN TEMP/S” indication on CONSULT-II.
When “COOLAN TEMP/S” indication reaches to 70°C(158°F), go to procedure for COND1 step 3.

Overall Function Check

BBS0030Q

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a
1st trip DTC might not be confirmed.

WITH GST
1.
2.
3.
4.
5.
6.

7.

8.

Start engine and warm it up to the operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground.
Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be below 0.52V at least once during this
procedure.
If the voltage can be confirmed in step 6, step 7 is not necessary.
Keep vehicle at idling for 10 minutes, then check the voltage. Or
check the voltage when coasting from 80 km/h (50 MPH) in 3rd
gear position.
The voltage should be below 0.52V at least once during this
MBIB0020E
procedure.
If NG, go to EC-326, «Diagnostic Procedure» .

EC-324

DTC P1146 HO2S2
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS0030R

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1511E

EC-325

DTC P1146 HO2S2
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]

2

GR

●

Engine speed: Below 3,800 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and
4,000 rpm for 1 minute and at idle for 1 minute
under no load.

Heated oxygen sensor 2
heater

0 — 1.0V

[Ignition switch: ON]
●

Engine stopped

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
●

Engine speed: Above 3,800 rpm

[Engine is running]

16

LG

Heated oxygen sensor 2

●

Revving engine from idle to 3,000rpm quickly
after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and
4,000 rpm for 1 minute and at idle for 1 minute
under no load.

0 — Approximately 1.0V

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

Diagnostic Procedure

BBS0030S

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-326

3.

Body ground E28

DTC P1146 HO2S2
[CR (WITH EURO-OBD)]

2. CLEAR THE SELF-LEARNING DATA

A

With CONSULT-II
Start engine and warm it up to normal operating temperature.
Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode
with CONSULT-II.
3. Clear the self-learning control coefficient by touching “CLEAR”.
4. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0172 detected?
Is it difficult to start engine?
1.
2.

EC

C

D

E
SEF215Z

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF.
3. Disconnect manifold absolute pressure sensor harness connector, and restart and run engine for at least 5 seconds at idle
speed.
4. Stop engine and reconnect manifold absolute pressure sensor
harness connector.
5. Make sure that DTC P0107 is displayed.
6. Erase the DTC memory. Refer to EC-57, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .
7. Make sure that DTC P0000 is displayed.
8. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0172 detected?
Is it difficult to start engine?
Yes or No
Yes
>> Perform trouble diagnosis for DTC P0172. Refer to EC-226 .
No
>> GO TO 3.

F

G

H

I

MBIB0276E

J

K

3. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT

L

1.
2.
3.
4.

M

Turn ignition switch OFF.
Disconnect heated oxygen sensor 2 harness connector.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 74 and HO2S2
terminal 4.
Refer to Wiring Diagram.
Continuity should exist.

5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

EC-327

MBIB0282E

DTC P1146 HO2S2
[CR (WITH EURO-OBD)]

4. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 16 and HO2S2 terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

2.

Check harness continuity between ECM terminal 16 or HO2S2 terminal 1 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK HEATED OXYGEN SENSOR 2
Refer to EC-328, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 2.

6. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS0030T

HEATED OXYGEN SENSOR 2
With CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
SEF174Y

6.

Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select
“HO2S2 (B1)” as the monitor item with CONSULT-II.

SEF662Y

EC-328

DTC P1146 HO2S2
[CR (WITH EURO-OBD)]
7.

Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%.
A

EC

C

MBIB1402E

“HO2S2 (B1)” should be above 0.61V at least once when the “FUEL INJECTION” is +25%.
“HO2S2 (B1)” should be below 0.52V at least once when the “FUEL INJECTION” is −25%.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

D

E

F

Without CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground.
Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.61V at least once during this
procedure.
If the voltage is above 0.61V at step 6, step 7 is not necessary.
7. Keep vehicle at idling for 10 minutes, then check voltage. Or
check the voltage when coasting from 80 km/h (50 MPH) in 3rd
gear position.
The voltage should be below 0.52V at least once during this
MBIB0020E
procedure.
8. If NG, replace heated oxygen sensor 2.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

Removal and Installation

BBS0030U

HEATED OXYGEN SENSOR 2
Refer to EX-3, «EXHAUST SYSTEM» .

EC-329

G

H

I

J

K

L

M

DTC P1147 HO2S2
[CR (WITH EURO-OBD)]

DTC P1147 HO2S2
Component Description

PFP:226A0
BBS0030V

The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas on each bank.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
SEF327R

CONSULT-II Reference Value in Data Monitor Mode

BBS0030W

Specification data are reference values.
MONITOR ITEM
HO2S2 (B1)

HO2S2 MNTR (B1)

CONDITION

SPECIFICATION

●

Revving engine from idle to 3,000 rpm quickly after the following conditions are met.

0 — 0.3V ←→ Approx. 0.6 — 1.0V

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute
and at idle for 1 minute under no load.

LEAN ←→ RICH

On Board Diagnosis Logic

BBS0030X

The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity of the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the maximum voltage of the sensor
is sufficiently high during the various driving condition such as fuelcut.

SEF560Z

DTC No.

P1147
1147

Trouble diagnosis name

Heated oxygen sensor 2
maximum voltage monitoring

DTC detecting condition

The maximum voltage from the sensor is
not reached to the specified voltage.

EC-330

Possible cause
●

Harness or connectors
(The sensor circuit open or shorted.)

●

Heated oxygen sensor 2

●

Fuel pressure

●

Fuel injector

●

Intake air leak

DTC P1147 HO2S2
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS0030Y

A
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
●
“COMPLETED” will appear on CONSULT-II screen when all tests “COND1”, “COND2” and EC
“COND3” are completed.
●
If DTC confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
C
at least 10 seconds before conducting the next test.
TESTING CONDITION:
Never stop engine during this procedure. If the engine is stopped, retry procedure from step 2 in ProD
cedure for COND1.

WITH CONSULT-II
Procedure for COND1
For the best results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30°C(32 to 86°F).
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
4. Let engine idle 1 minute.
5. Select “HO2S2 (B1) P1147” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II.
6. Touch “START”.
7. Start engine and let it idle for at least 30 seconds.
8. Rev engine up to 2,000 rpm 2 or 3 times quickly under no load.
If “COMPLETED” appears on CONSULT-II screen, go to step 2 in Procedure for COND3.
If “COMPLETED” does not appear on CONSULT-II screen, go to the following step.
9. When the following conditions are met, “TESTING” will be displayed at “COND1” on the CONSULT-II
screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take
approximately 60 seconds.)
ENG SPEED

More than 1.0 msec

COOLAN TEMP/S

70 — 105°C

Shift lever

Suitable position

F

G

H

I

J

More than 1,500 rpm

B/FUEL SCHDL

E

K

L

M

PBIB0557E

NOTE:
● If “TESTING” is not displayed after 5 minutes, retry from step 2 in Procedure for COND1.
● If “COMPLETED” already appears at “COND2” on CONSULT-II screen before Procedure for
COND2 is conducted, it is unnecessary to conduct step 1 in Procedure for COND2.

EC-331

DTC P1147 HO2S2
[CR (WITH EURO-OBD)]
Procedure for COND2
1.

While driving, release accelerator pedal completed from the
above condition [step 9] until “INCOMPLETE” at “COND2” on
CONSULT-II screen has turned to “COMPLETED” (It will take
approximately 4 seconds.)
NOTE:
If “COMPLETE” already appears at “COND3” on CONSULTII screen before Procedure for COND3 is conducted, it is
unnecessary to conduct step 1 in Procedure for COND3.

PBIB0558E

Procedure for COND3
1.

2.

a.
b.
c.
d.

Stop vehicle and let it idle until “INCOMPLETE” of “COND3” on
CONSULT-II screen has turned to “COMPLETED”. (It will take a
maximum of approximately 6 minutes.)
Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”.
If “NG” is displayed, refer to EC-334, «Diagnostic Procedure» .
If “CAN NOT BE DIAGNOSED” is displayed, perform the following.
Turn ignition switch OFF and leave the vehicle in a cool place
(soak the vehicle).
SEC778C
Turn ignition switch ON and select “COOLAN TEMP/S” in “DATA
MONITOR” mode with CONSULT-II.
Start engine and warm it up while monitoring “COOLAN TEMP/S” indication on CONSULT-II.
When “COOLAN TEMP/S” indication reaches to 70°C(158°F), go to procedure for COND1 step 3.

Overall Function Check

BBS0030Z

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st
trip DTC might not be confirmed.

WITH GST
1.
2.
3.
4.
5.
6.

7.

8.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground.
Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.61V at least once during this
procedure.
If the voltage can be confirmed in step 6, step 7 is not necessary.
Keep vehicle idling for 10 minutes, then check the voltage. Or
check the voltage when coasting from 80 km/h (50 MPH) in 3rd
gear position.
The voltage should be above 0.61V at least once during this
MBIB0020E
procedure.
If NG, go to EC-334, «Diagnostic Procedure» .

EC-332

DTC P1147 HO2S2
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS00310

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1511E

EC-333

DTC P1147 HO2S2
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]

2

GR

●

Engine speed: Below 3,800 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and
4,000 rpm for 1 minute and at idle for 1 minute
under no load.

Heated oxygen sensor 2
heater

0 — 1.0V

[Ignition switch: ON]
●

Engine stopped

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
●

Engine speed: Above 3,800 rpm

[Engine is running]

16

LG

Heated oxygen sensor 2

●

Revving engine from idle to 3,000rpm quickly
after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and
4,000 rpm for 1 minute and at idle for 1 minute
under no load.

0 — Approximately 1.0V

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

Diagnostic Procedure

BBS00311

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-334

3.

Body ground E28

DTC P1147 HO2S2
[CR (WITH EURO-OBD)]

2. CLEAR THE SELF-LEARNING DATA

A

With CONSULT-II
Start engine and warm it up to normal operating temperature.
Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode
with CONSULT-II.
3. Clear the self-learning control coefficient by touching “CLEAR”.
4. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 detected?
Is it difficult to start engine?
1.
2.

EC

C

D

E
SEF215Z

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF.
3. Disconnect manifold absolute pressure sensor harness connector, and restart and run engine for at least 5 seconds at idle
speed.
4. Stop engine and reconnect manifold absolute pressure sensor
harness connector.
5. Make sure that DTC P0107 is displayed.
6. Erase the DTC memory. Refer to EC-57, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .
7. Make sure that DTC P0000 is displayed.
8. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 detected?
Is it difficult to start engine?
Yes or No
Yes
>> Perform trouble diagnosis for DTC P0171. Refer to EC-218 .
No
>> GO TO 3.

F

G

H

I

MBIB0276E

J

K

3. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT

L

1.
2.
3.
4.

M

Turn ignition switch OFF.
Disconnect heated oxygen sensor 2 harness connector.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 74 and HO2S2
terminal 4.
Refer to Wiring Diagram.
Continuity should exist.

5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

EC-335

MBIB0282E

DTC P1147 HO2S2
[CR (WITH EURO-OBD)]

4. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 16 and HO2S2 terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

2.

Check harness continuity between ECM terminal 16 or HO2S2 terminal 1 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK HEATED OXYGEN SENSOR 2
Refer to EC-336, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 2.

6. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS00312

HEATED OXYGEN SENSOR 2
With CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
SEF174Y

6.

Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select
“HO2S2 (B1)” as the monitor item with CONSULT-II.

SEF662Y

EC-336

DTC P1147 HO2S2
[CR (WITH EURO-OBD)]
7.

Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%.
A

EC

C

MBIB1402E

“HO2S2 (B1)” should be above 0.61V at least once when the “FUEL INJECTION” is +25%.
“HO2S2 (B1)” should be below 0.52V at least once when the “FUEL INJECTION” is −25%.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

D

E

F

Without CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground.
Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.61V at least once during this
procedure.
If the voltage is above 0.61V at step 6, step 7 is not necessary.
7. Keep vehicle idling for 10 minutes, then check voltage. Or check
the voltage when coasting from 80 km/h (50 MPH) in 3rd gear
position.
The voltage should be below 0.52V at least once during this
MBIB0020E
procedure.
8. If NG, replace heated oxygen sensor 2.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

Removal and Installation

BBS00313

HEATED OXYGEN SENSOR 2
Refer to EX-3, «EXHAUST SYSTEM» .

EC-337

G

H

I

J

K

L

M

DTC P1171 INTAKE ERROR
[CR (WITH EURO-OBD)]

DTC P1171 INTAKE ERROR
On Board Diagnosis Logic

PFP:22365
BBS00314

NOTE:
●
If DTC P1171 is displayed with DTC P0108, first perform the trouble diagnosis for DTC P0108.
Refer to EC-155, «DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR»
●
If DTC P1171 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229.
Refer to EC-363, «DTC P1229 SENSOR POWER SUPPLY» .
ECM computes two intake air volume values.
1: Computed from manifold absolute pressure signal and intake air temperature signal.
2: Computed from engine revolution signal and throttle position signal.
In normal condition, value 1 is used for engine control.
If intake air leak occurred between throttle valve and intake air port, manifold absolute pressure sensor signal
might increase, and then ECM increases amount of fuel injected. In this case, ECM uses value 2 for engine
control instead of value1.
ECM monitors the difference between value 1 and value 2. If the difference is extremely large, ECM judges
intake air leak occurs and light up the MI
This diagnosis has one trip detection logic.
DTC No.

P1171
1171

Trouble diagnosis name

Intake error

DTC detecting condition

A high voltage from the sensor is sent to
ECM under light load driving condition.

Possible cause
●

Harness or connectors
(The manifold absolute pressure sensor
circuit is open or shorted.)

●

Manifold absolute pressure

●

Intake air leaks

●

Vacuum hoses

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and MI lights up.
Detected items
Intake air system

Engine operating condition in fail-safe mode
When accelerator pedal is depressed, engine speed will not rise more than 2,500 rpm
due to fuel cut.

DTC Confirmation Procedure

BBS00315

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and wait at least 5 seconds.
If DTC is detected, go to EC-340, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-338

DTC P1171 INTAKE ERROR
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS00316

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1506E

EC-339

DTC P1171 INTAKE ERROR
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
45

WIRE
COLOR

L

ITEM
Sensor power supply
(Manifold absolute
pressure sensor)

CONDITION

[Ignition switch: ON]

DATA (DC Voltage)

Approximately 5V

[Engine is running]

51

56

W

B

Manifold absolute pressure sensor

Sensor ground
(Manifold absolute
pressure sensor)

●

Warm-up condition

●

Idle speed

Approximately 1.5V

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

Approximately 1.2V

[Engine is running]
●

Warm-up condition

●

Idle speed

Diagnostic Procedure

Approximately 0V

BBS00317

1. CHECK INTAKE AIR LEAK
Listen for an intake air leak after the air cleaner element.
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace.

2. CHECK VACUUM HOSE
Check intake manifold vacuum hoses for clogging or disconnection. Refer to EC-92, «Vacuum Hose Drawing» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.
1.

EC-340

DTC P1171 INTAKE ERROR
[CR (WITH EURO-OBD)]

3. CHECK GROUND CONNECTIONS
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

EC

C

D

E
MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

F

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace ground connections.

G

4. CHECK MAP SENSOR POWER SUPPLY CIRCUIT
1.
2.

H

Disconnect manifold absolute pressure sensor harness connector.
Turn ignition switch ON.

I

J

MBIB0276E

3.

Check voltage between manifold absolute pressure sensor terminal 2 and ground with CONSULT-II or tester.

K

L

Voltage: Approximately 5V
OK or NG
OK
>> GO TO 5.
NG
>> Repair harness or connectors.

M

MBIB0602E

EC-341

DTC P1171 INTAKE ERROR
[CR (WITH EURO-OBD)]

5. CHECK MAP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between manifold absolute pressure sensor terminal 4 and ECM terminal 56.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK MAP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between manifold absolute pressure sensor terminal 1 and ECM terminal 51.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

7. CHECK MAP SENSOR
Refer to EC-159, «Component Inspection» .
OK or NG
OK
>> GO TO 8.
NG
>> Replace manifold absolute pressure sensor.

8. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-342

DTC P1211 TCS CONTROL UNIT
[CR (WITH EURO-OBD)]

DTC P1211 TCS CONTROL UNIT
Description

PFP:47850

A
BBS00318

The malfunction information related to TCS is transferred through the CAN communication line from “ABS
actuator and electric unit (control unit)” to ECM.
EC
Be sure to erase the malfunction information such as DTC not only for “ABS actuator and electric unit
(control unit)” but also for ECM after TCS related repair.

On Board Diagnosis Logic

BBS00319

C

Freeze frame data is not stored in the ECM for this self-diagnosis.
The MI will not light up for this self-diagnosis.
D
DTC No.
P1211
1211

Trouble diagnosis name
TCS control unit

DTC detecting condition

Possible cause
●

ABS actuator and electric unit (control
unit)

●

TCS related parts

ECM receives a malfunction information from
“ABS actuator and electric unit (control unit)”.

DTC Confirmation Procedure

BBS0031A

TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle.

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

E

F

G

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for at least 60 seconds.
If 1st trip DTC is detected, go to EC-343, «Diagnostic Procedure»
.

H

I

J

SEF058Y

K

WITH GST
Follow the procedure “WITH CONSULT-II” above.

L

Diagnostic Procedure

BBS0031B

Go to BRC-49, «TROUBLE DIAGNOSIS» .

M

EC-343

DTC P1212 TCS COMMUNICATION LINE
[CR (WITH EURO-OBD)]

DTC P1212 TCS COMMUNICATION LINE
Description

PFP:47850
BBS0031C

NOTE:
●
If DTC P1212 is displayed with DTC U1001, first perform the trouble diagnosis for DTC U1001.
Refer to EC-134, «DTC U1001 CAN COMMUNICATION LINE» .
●
If DTC P1212 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010.
Refer to EC-137, «DTC U1010 CAN COMMUNICATION» .
This CAN communication line is used to control the smooth engine operation during the TCS operation. Pulse
signals are exchanged between ECM and “ABS actuator and electric unit (control unit)”.
Be sure to erase the malfunction information such as DTC not only for “ABS actuator and electric unit
(control unit)” but also for ECM after TCS related repair.

On Board Diagnosis Logic

BBS0031D

The MI will not light up for this self-diagnosis.
Freeze frame data is not stored in the ECM for this self-diagnosis.
DTC No.

P1212
1212

Trouble diagnosis name

TCS communication
line

DTC detecting condition

ECM can not receive the information from
“ABS actuator and electric unit (control
unit)” continuously.

DTC Confirmation Procedure

Possible cause
●

Harness or connectors
(The CAN communication line is open or
shorted.)

●

ABS actuator and electric unit (control unit).

●

Dead (Weak) battery
BBS0031E

TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for at least 10 seconds.
If 1st trip DTC is detected, go to EC-344, «Diagnostic Procedure»
.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

Diagnostic Procedure

BBS0031F

Refer to BRC-49, «TROUBLE DIAGNOSIS» .

EC-344

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITH EURO-OBD)]

DTC P1217 ENGINE OVER TEMPERATURE
System Description

PFP:00000

A
BBS0031G

NOTE:
●
If DTC P1217 is displayed with DTC U1001, first perform the trouble diagnosis for DTC U1001. EC
Refer to EC-134, «DTC U1001 CAN COMMUNICATION LINE» .
●
If DTC P1217 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010.
Refer to EC-137, «DTC U1010 CAN COMMUNICATION» .
C

COOLING FAN CONTROL
Sensor

Input Signal to ECM

ECM Function

Actuator

D

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*1

Battery

Battery voltage*1
2

Wheel sensor

Vehicle speed*

Engine coolant temperature sensor

Engine coolant temperature

Air conditioner switch*3

Air conditioner ON signal*2

Refrigerant pressure sensor*3

Refrigerant pressure

E
Cooling fan
control

IPDM E/R
(Cooling fan relay)

F

*1: ECM determines the start signal status by the signals of engine speed and battery voltage.
*2: This signal is sent to ECM through CAN communication line.
*3: Models with air conditioner.

G

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, refrigerant
pressure, and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF] (models with
A/C) or 2 step control [ON/OFF] (models without A/C).
The ECM controls cooling fan relays through CAN communication line.

H

I

OPERATION
Models with A/C
J

K

L

M

MBIB0650E

EC-345

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITH EURO-OBD)]
Models without A/C

MBIB0656E

CONSULT-II Reference Value in Data Monitor Mode

BBS0031H

Specification data are reference values.
MONITOR ITEM
AIR COND SIG

CONDITION
●

●

COOLING FAN
●

Engine: After warming up, idle
the engine

Engine: After warming up, idle
the engine
Air conditioner switch: OFF

SPECIFICATION

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates.)

ON

Engine coolant temperature: 94°C
(201°F) or less

OFF

Engine coolant temperature: Between
95°C (203°F) and 104°C (210°F)

LOW*

Engine coolant temperature: 105°C
(212°F) or more

HI*

*: Models without air conditioner, cooling fan operates only ON and OFF operation, but CONSULT-II display will change OFF, LOW and
HI depends on engine coolant temperature.

On Board Diagnosis Logic

BBS0031I

If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise. When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction
is indicated.
This self-diagnosis has the one trip detection logic.
DTC No.

Trouble diagnosis name

DTC detecting condition

●

●

P1217
1217

Engine over temperature (Overheat)

Possible cause
●

Harness or connectors
(The cooling fan circuit is open or
shorted.)

●

Cooling fan

Cooling fan does not operate properly (Overheat).

●

IPDM E/R (Cooling fan relay)

●

Radiator hose

Cooling fan system does not operate properly (Overheat).

●

Radiator

●

Reservoir tank cap
(Models with A/C)

●

Radiator cap
(Models without A/C)

●

Water pump

●

Thermostat

●

Engine coolant was not added to the system
using the proper filling method.

●

Engine coolant is not within the specified
range.

For more information, refer to EC-357,
«Main 12 Causes of Overheating» .

CAUTION:
When a malfunction is indicated, be sure to replace the coolant. Refer to CO-9, «Changing Engine
coolant» . Also, replace the engine oil. Refer to LU-7, «Changing Engine Oil» .
1. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to
use coolant with the proper mixture ratio. Refer to MA-26, «Engine Coolant Mixture Ratio» .

EC-346

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITH EURO-OBD)]
2.

After refilling coolant, run engine to ensure that no water-flow noise is emitted.
A

Overall Function Check

BBS0031J

Use this procedure to check the overall function of the cooling fan. During this check, a DTC might not be confirmed.
EC
WARNING:
Never remove the radiator cap (Models without A/C) or reservoir tank cap (Models with A/C) when the
engine is hot. Serious burns could be caused by high pressure fluid escaping from the radiator (ModC
els without A/C) or reservoir tank (Models with A/C).
Wrap a thick cloth around cap. Carefully remove the cap by turning it a quarter turn to allow built-up
pressure to escape. Then turn the cap all the way off.
D

WITH CONSULT-II

1.

2.

3.

Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to EC-351,
«Diagnostic Procedure» .
Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to EC-351,
«Diagnostic Procedure» .
Turn ignition switch ON.

E

F

G
SEF621W

4.
5.

H

Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II.
If the results are NG, go to EC-351, «Diagnostic Procedure» .

I

J

K
SEF784Z

WITH GST
Models with Air Conditioner
1.

2.

3.

4.
5.
6.
7.

L

Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to EC-351,
«Diagnostic Procedure» .
Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to EC-351,
«Diagnostic Procedure» .
Start engine.
CAUTION:
Be careful not to overheat engine.
Set temperature control lever to full cold position.
Turn air conditioner switch ON.
Turn blower fan switch ON.
Run engine at idle for a few minutes with air conditioner operating.
CAUTION:
Be careful not to overheat engine.

EC-347

M

SEF621W

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITH EURO-OBD)]
8.

Make sure that cooling fans operates at low speed.
If NG, go to EC-351, «Diagnostic Procedure» .
If OK, go to the following step.
9. Turn ignition switch OFF.
10. Turn air conditioner switch and blower fan switch OFF.
11. Disconnect engine coolant temperature sensor harness connector.
12. Connect 150Ω resistor to engine coolant temperature sensor
harness connector.
MBIB0651E

13. Restart engine and make sure that cooling fan operates at
higher speed than low speed.
CAUTION:
Be careful not to overheat engine.
14. If NG, go to EC-351, «Diagnostic Procedure» .

SEF023R

Models without Air Conditioner
1.

2.

3.
4.
5.
6.

Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to EC-351,
«Diagnostic Procedure» .
Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to EC-351,
«Diagnostic Procedure» .
Disconnect engine coolant temperature sensor harness connector.
Connect 150Ω resistor to engine coolant temperature sensor
harness connector.
Start engine and make that cooling fan operates. Be careful not
to overheat engine.
If NG, go to EC-351, «Diagnostic Procedure» .

SEF621W

SEF023R

EC-348

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS0031K

A

MODELS WITH AIR CONDITIONER

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1523E

EC-349

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITH EURO-OBD)]
MODELS WITHOUT AIR CONDITIONER

MBWA1524E

EC-350

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITH EURO-OBD)]

Diagnostic Procedure

BBS0031L

A

PROCEDURE FOR MODELS WITH AIR CONDITIONER

1. INSPECTION START
EC

Do you have CONSULT-II?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 4.

C

2. CHECK COOLING FAN LOW SPEED OPERATION
D

With CONSULT-II
1. Turn ignition switch ON.
2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II and touch “LOW” on the CONSULT-II screen.
3. Make sure that cooling fan operates at low speed.
OK or NG
OK
>> GO TO 3.
NG
>> Check cooling fan low speed control circuit. (Go to EC353, «Procedure A» .)

E

F

G

SEF784Z

H

3. CHECK COOLING FAN HIGH SPEED OPERATION
I

With CONSULT-II
1. Touch “HIGH” on the CONSULT-II screen.
2. Make sure that cooling fan operate at higher speed than low
speed.
OK or NG
OK
>> GO TO 6.
NG
>> Check cooling fan high speed control circuit. (Go to EC354, «Procedure B» .)

J

K

L
SEF785Z

M

4. CHECK COOLING FAN LOW SPEED OPERATION
Without CONSULT-II
1. Start engine and let it idle.
2. Turn air conditioner switch ON.
3. Turn blower fan switch ON.
4. Make sure that cooling fan operates at low speed.
OK or NG
OK
>> GO TO 5.
NG
>> Check cooling fan low speed control circuit. (Go to EC353, «Procedure A» .)

MBIB0651E

EC-351

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITH EURO-OBD)]

5. CHECK COOLING FAN HIGH SPEED OPERATION
Without CONSULT-II
Turn ignition switch OFF.
Turn air conditioner switch and blower fan switch OFF.
Disconnect engine coolant temperature sensor harness connector.
Connect 150Ω resistor to engine coolant temperature sensor harness connector.
Restart engine and make sure that cooling fan operate at higher
speed than low speed.
OK or NG
OK
>> GO TO 6.
NG
>> Check cooling fan high speed control circuit. (Go to EC354, «Procedure B» .)

1.
2.
3.
4.
5.

SEF023R

6. CHECK COOLING SYSTEM FOR LEAK
Refer to CO-8, «ENGINE COOLANT» .
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

7. DETECT MALFUNCTIONING PART
Check the following for leak.
●
Hose
●
Radiator
●
Water pump (Refer to CO-17, «WATER PUMP» .)
>> Repair or replace.

8. CHECK RESERVOIR TANK CAP
Refer to CO-16, «Checking Reservoir Tank Cap (Models with A/C)» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace reservoir tank cap.

9. CHECK COMPONENT PARTS
Check the following.
Thermostat. Refer to CO-19, «THERMOSTAT» .
●
Engine coolant temperature sensor. Refer to EC-170, «Component Inspection» .
OK or NG
OK
>> GO TO 10.
NG
>> Replace malfunctioning component.
●

10. CHECK MAIN 12 CAUSES
If the cause cannot be isolated, go to EC-357, «Main 12 Causes of Overheating» .
>> INSPECTION END

EC-352

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITH EURO-OBD)]
Procedure A
A

1. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E6.
Check voltage between IPDM E/R terminal 14 and ground with
CONSULT-II or tester.

EC

C

Voltage: Battery voltage
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

D

E
MBIB1307E

2. DETECT MALFUNCTIONING PART

F

Check the following.
●
40A fusible link
●
Harness for open or short between IPDM E/R and battery

G

H

>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK COOLING FAN MOTORS CIRCUIT
1.
2.

I

Disconnect cooling fan motor harness connector.
Check harness continuity between cooling fan motor terminal 1
and IPDM E/R terminal 10, cooling fan motor terminal 2 and
ground. Refer to Wiring Diagram.

J

Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

4. DETECT MALFUNCTIONING PART

K

L
MBIB1074E

M

Check the following.
●
Harness for open or short between cooling fan motor and IPDM E/R
●
Harness for open or short between cooling fan motor and ground
●
Harness for open or short between resistor and IPDM E/R
●
Harness for open or short between resistor and cooling fan motor
●
Resistor E62
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK COOLING FAN MOTOR
Refer to EC-358, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace cooling fan motor.

EC-353

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITH EURO-OBD)]

6. CHECK INTERMITTENT INCIDENT
Perform EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connector.

Procedure B

1. CHECK COOLING FAN MOTORS CIRCUIT
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E6.
Disconnect cooling fan motor harness connector.
Check harness continuity between IPDM E/R terminal 12 and
cooling fan motor terminal 1, cooling fan motor terminal 2 and
ground. Refer to Wiring Diagram.
Continuity should exist.

5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

MBIB1074E

2. DETECT MALFUNCTIONING PART
Check the following.
●
Harness for open or short between cooling fan motor and IPDM E/R
●
Harness for open or short between cooling fan motor and ground
>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK COOLING FAN MOTOR
Refer to EC-358, «Component Inspection» .
OK or NG
OK
>> GO TO 4.
NG
>> Replace cooling fan motor.

4. CHECK INTERMITTENT INCIDENT
Perform EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connector.

EC-354

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITH EURO-OBD)]
PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER
A

1. INSPECTION START
Do you have CONSULT-II?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.

EC

C

2. CHECK COOLING FAN OPERATION
With CONSULT-II
1. Turn ignition switch ON.
2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II and touch “LOW” on the CONSULT-II screen.
3. Make sure that cooling fan operates.
OK or NG
OK
>> GO TO4.
NG
>> Check cooling fan control circuit. (Go to EC-356, «Procedure A» .)

D

E

F

G
SEF784Z

H

3. CHECK COOLING FAN OPERATION
Without CONSULT-II
1. Turn ignition switch OFF.
2. Disconnect engine coolant temperature sensor harness connector.
3. Connect 150Ω resistor to engine coolant temperature sensor harness connector.
4. Restart engine and make sure that cooling fan operates.
OK or NG
OK
>> GO TO 4.
NG
>> Check cooling fan control circuit. (Go to EC-356, «Procedure A» .)

I

J

K

L

M
SEF023R

4. CHECK COOLING SYSTEM FOR LEAK
Refer to CO-8, «ENGINE COOLANT» .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

EC-355

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITH EURO-OBD)]

5. DETECT MALFUNCTIONING PART
Check the following for leak.
●
Hose
●
Radiator
●
Water pump (Refer to CO-17, «WATER PUMP» .)
>> Repair or replace.

6. CHECK RADIATOR CAP
Refer to CO-15, «Checking Radiator Cap (Models without A/C)» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace radiator cap.

7. CHECK THERMOSTAT
Check the following.
Thermostat. Refer to CO-19, «THERMOSTAT» .
●
Engine coolant temperature sensor. Refer to EC-170, «Component Inspection» .
OK or NG
OK
>> GO TO 8.
NG
>> Replace malfunctioning component.
●

8. CHECK MAIN 12 CAUSES
If the cause cannot be isolated, go to EC-357, «Main 12 Causes of Overheating» .
>> INSPECTION END

Procedure A

1. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E6.
Check voltage between IPDM E/R terminal 14 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

MBIB1307E

2. DETECT MALFUNCTIONING PART
Check the following.
40A fusible link
●
Harness for open or short between IPDM E/R and battery
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-356

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITH EURO-OBD)]

3. CHECK COOLING FAN MOTORS CIRCUIT
1.
2.

A

Disconnect cooling fan motor harness connector.
Check harness continuity between cooling fan motor terminal 1
and IPDM E/R terminal 10, cooling fan motor terminal 2 and
ground.
Refer to wiring diagram.

EC

C

Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

D
MBIB1074E

4. DETECT MALFUNCTIONING PART

E

Check the following.
●
Harness for open or short between cooling fan motor and IPDM E/R
●
Harness for open or short between cooling fan motor and ground

F

G

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK COOLING FAN MOTOR
H

Refer to EC-358, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace cooling fan motor.

I

6. CHECK INTERMITTENT INCIDENT

J

Perform EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connector.

L

Main 12 Causes of Overheating
Engine

Step

OFF

1

Inspection item
●

Blocked radiator

●

Blocked condenser

●

Blocked radiator grille

●

Blocked bumper

2

●

3

4*5

BBS0031M

Equipment

Standard

Reference page

●

Visual

No blocking

Coolant mixture

●

Coolant tester

50 — 50% coolant mixture

See MA-26, «Engine
Coolant Mixture Ratio» .

●

Coolant level

●

Visual

Coolant up to MAX level
in reservoir tank and radiator filler neck

See CO-8, «LEVEL
CHECK» .

●

Radiator cap

●

Pressure tester

59 — 98 kPa
(0.59 — 0.98 bar, 0.6 — 1.0

See CO-15, «Checking
Radiator Cap (Models
without A/C)» .

kg/cm2 , 9 — 14 psi) (Limit)
4*6

●

Reservoir tank cap

●

K

Pressure tester

EC-357

88 kPa (0.88 bar, 0.90 kg/
2

cm , 12.8psi)

—

See CO-16, «Checking
Reservoir Tank Cap
(Models with A/C)» .

M

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITH EURO-OBD)]
Engine

Step

Inspection item

Equipment

Standard

Reference page

ON*2

5

●

Coolant leaks

●

Visual

No leaks

See CO-8, «LEAK
CHECK» .

ON*2

6

●

Thermostat

●

Touch the upper and
lower radiator hoses

Both hoses should be hot

See CO-19, «THERMOSTAT» , and CO-12,
«RADIATOR» .

ON*1

7

●

Cooling fan

●

CONSULT-II

Operating

See trouble diagnosis for
DTC P1217 (EC-351 ).

OFF

8

●

Combustion gas leak

●

Color checker chemical
tester 4 Gas analyzer

Negative

—

ON*3

9

●

Coolant temperature
gauge

●

Visual

Gauge less than 3/4
when driving

—

●

Coolant overflow to
reservoir tank

●

Visual

No overflow during driving
and idling

See CO-9, «Changing
Engine coolant» .

OFF*4

10

●

Coolant return from
reservoir tank to radiator

●

Visual

Should be initial level in
reservoir tank

See CO-8, «LEVEL
CHECK» .

OFF

11

●

Cylinder head

●

Straight gauge feeler
gauge

0.1 mm (0.004 in) Maximum distortion (warping)

See EM-60, «CYLINDER
HEAD» .

12

●

Cylinder block and pistons

●

Visual

No scuffing on cylinder
walls or piston

See EM-74, «CYLINDER
BLOCK» .

*1: Turn the ignition switch ON.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
*5: Models without A/C.
*6: Models with A/C.
For more information, refer to CO-5, «OVERHEATING CAUSE ANALYSIS» .

Component Inspection

BBS0031N

COOLING FAN MOTOR
1.
2.

Disconnect cooling fan motor harness connector.
Supply cooling fan motor terminals with battery voltage and
check operation.
Terminals

Cooling fan motor

(+)

(-)

1

2

MBIB0607E

EC-358

DTC P1225 TP SENSOR
[CR (WITH EURO-OBD)]

DTC P1225 TP SENSOR
Component Description

PFP:16119

A
BBS0031O

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

EC

C

D
PBIB0145E

E

On Board Diagnosis Logic

BBS0031P

The MI will not light up for this self-diagnosis.
F
DTC No.

Trouble diagnosis name

DTC detecting condition

P1225
1225

Closed throttle position
learning performance

Closed throttle position learning value is excessively
low.

DTC Confirmation Procedure

Possible cause
●

Electric throttle control actuator
(TP sensor 1 and 2)

G
BBS0031Q

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

H

I

WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON.
If 1st trip DTC is detected, go to EC-360, «Diagnostic Procedure»
.

J

K

L

M
SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-359

DTC P1225 TP SENSOR
[CR (WITH EURO-OBD)]

Diagnostic Procedure

BBS0031R

1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY
1.
2.
3.

Turn ignition switch OFF.
Remove the intake air duct.
Check if foreign matter is caught between the throttle valve and
the housing.
OK or NG
OK
>> GO TO 2.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.

MBIB0307E

2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> INSPECTION END

Removal and Installation

BBS0031S

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

EC-360

DTC P1226 TP SENSOR
[CR (WITH EURO-OBD)]

DTC P1226 TP SENSOR
Component Description

PFP:16119

A
BBS0031T

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

EC

C

D
PBIB0145E

E

On Board Diagnosis Logic

BBS0031U

The MI will not light up for this self-diagnosis.
F
DTC No.

Trouble diagnosis name

DTC detecting condition

P1226
1226

Closed throttle position
learning performance

Closed throttle position learning is not performed
successfully, repeatedly.

DTC Confirmation Procedure

Possible cause
●

Electric throttle control actuator
(TP sensor 1 and 2)

G
BBS0031V

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

H

I

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON.
Repeat steps 3 and 4 for 32 times.
If 1st trip DTC is detected, go to EC-362, «Diagnostic Procedure»
.

J

K

L

M
SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-361

DTC P1226 TP SENSOR
[CR (WITH EURO-OBD)]

Diagnostic Procedure

BBS0031W

1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY
1.
2.
3.

Turn ignition switch OFF.
Remove the intake air duct.
Check if foreign matter is caught between the throttle valve and
the housing.
OK or NG
OK
>> GO TO 2.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.

MBIB0307E

2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> INSPECTION END

Removal and Installation

BBS0031X

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

EC-362

DTC P1229 SENSOR POWER SUPPLY
[CR (WITH EURO-OBD)]

DTC P1229 SENSOR POWER SUPPLY
On Board Diagnosis Logic

PFP:16119

A
BBS0031Y

This self-diagnosis has the one trip detection logic.
DTC No.

Trouble diagnosis name

DTC detecting condition
●

P1229
1229

Sensor power supply circuit
short

EC

Possible cause

ECM detects a voltage of power source
for sensor is excessively low or high.

Harness or connectors
(APP sensor 1 circuit is shorted.)
(Manifold absolute pressure sensor is
shorted.)
(Refrigerant pressure sensor circuit is
shorted.)

●

Accelerator pedal position sensor
(APP sensor 1)

●

Manifold absolute pressure sensor

●

Refrigerant pressure sensor

C

D

E

FAIL-SAFE MODE

F

When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.

DTC Confirmation Procedure

BBS0031Z

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

H

I

J

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

G

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-368, «Diagnostic Procedure» .

K

L

M
SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-363

DTC P1229 SENSOR POWER SUPPLY
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS00320

LHD MODELS

MBWA1525E

EC-364

DTC P1229 SENSOR POWER SUPPLY
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

EC
ITEM

CONDITION

DATA (DC Voltage)

45

L

Sensor power supply
(Manifold absolute pressure sensor)

[Ignition switch: ON]

Approximately 5V

46

W

Sensor power supply
(Refrigerant pressure
sensor)

[Ignition switch: ON]

Approximately 5V

B

Sensor ground
(APP sensor 1)

C

[Engine is running]
82

●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
83

B

A

Sensor ground
(APP sensor 2)

●

Warm-up condition

●

Idle speed

D

E

F
Approximately 0V

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

G

H
[Ignition switch: ON]

98

G

Accelerator pedal
position sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

I

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

J

[Ignition switch: ON]

106

W

Accelerator pedal position sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

K

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

L

M

EC-365

DTC P1229 SENSOR POWER SUPPLY
[CR (WITH EURO-OBD)]
RHD MODELS

MBWA1526E

EC-366

DTC P1229 SENSOR POWER SUPPLY
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

EC
ITEM

CONDITION

DATA (DC Voltage)

45

L

Sensor power supply
(Manifold absolute pressure sensor)

[Ignition switch: ON]

Approximately 5V

46

W

Sensor power supply
(Refrigerant pressure
sensor)

[Ignition switch: ON]

Approximately 5V

B

Sensor ground
(APP sensor 1)

C

[Engine is running]
82

●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
83

B

A

Sensor ground
(APP sensor 2)

●

Warm-up condition

●

Idle speed

D

E

F
Approximately 0V

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

G

H
[Ignition switch: ON]

98

G

Accelerator pedal
position sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

I

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

J

[Ignition switch: ON]

106

W

Accelerator pedal position sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

K

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

L

M

EC-367

DTC P1229 SENSOR POWER SUPPLY
[CR (WITH EURO-OBD)]

Diagnostic Procedure

BBS00321

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

2. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT-I
1.
2.

Disconnect accelerator pedal position sensor (APP) sensor harness connector.
Turn ignition switch ON.

MBIB0285E

3.

Check voltage between APP sensor terminal 4 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.

MBIB0304E

EC-368

DTC P1229 SENSOR POWER SUPPLY
[CR (WITH EURO-OBD)]

3. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between APP sensor terminal 4 and ECM terminal 90.
Refer to Wiring Diagram.

A

EC

Continuity should exist.

C

OK or NG
OK
>> GO TO 5.
NG (LHD models)>>Repair open circuit.
NG (RHD models)>>GO TO 4.

D

4. DETECT MALFUNCTIONING PART

E

Check the following.
●
Harness connectors M201, M8
●
Harness connectors M1, E101
●
Harness for open or short between APP sensor and ECM

F

G

>> Repair open circuit.

5. CHECK SENSOR POWER SUPPLY CIRCUIT

H

Check harness for short to power and short to ground, between the following terminals
ECM terminal

Sensor terminal

Reference Wiring Diagram

90

APP sensor terminal 4

EC-364

45

Manifold absolute pressure sensor terminal 2

EC-156

46

Refrigerant pressure sensor terminal 3

EC-444

I

J

OK or NG
OK
>> GO TO 6.
NG
>> Repair short to ground or short to power in harness or connectors.

K

6. CHECK COMPONENTS
Check the following.
●
Manifold absolute pressure sensor (Refer to EC-159, «Component Inspection» .)
●
Refrigerant pressure sensor (Refer to ATC-85, «COMPONENT INSPECTION»
NENT INSPECTION» .)
OK or NG
OK
>> GO TO 9.
NG
>> Replace malfunctioning component.

7. CHECK APP SENSOR
Refer to EC-400, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.

EC-369

L

or MTC-51, «COMPO-

M

DTC P1229 SENSOR POWER SUPPLY
[CR (WITH EURO-OBD)]

8. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace accelerator pedal assembly.
Perform EC-69, «Accelerator Pedal Released Position Learning» .
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> INSPECTION END

9. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-370

DTC P1706 PNP SWITCH
[CR (WITH EURO-OBD)]

DTC P1706 PNP SWITCH
Component Description

PFP:32006

A
BBS00322

When the shift lever position is Neutral, park/neutral position (PNP) switch is ON.
ECM detects the position because the continuity of the line (the ON signal) exists.

EC

CONSULT-II Reference Value in Data Monitor Mode

BBS00323

Specification data are reference values.
MONITOR ITEM
P/N POSI SW

C
CONDITION

●

Ignition switch: ON

SPECIFICATION

Shift lever: Neutral

ON

Shift lever: Except above

OFF

D

On Board Diagnosis Logic
DTC No.

BBS00324

Trouble diagnosis name

DTC detecting condition

Park/neutral position switch

The signal of the park/neutral position (PNP)
switch is not changed in the process of
engine starting and driving.

●

P1706
1706

●

DTC Confirmation Procedure

E

Possible cause
Harness or connectors
[The park/neutral position (PNP) switch
circuit is open or shorted.]

F

Park/neutral position (PNP) switch
BBS00325

G

CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

H

I

WITH CONSULT-II
1.
2.

Turn ignition switch ON.
Select “P/N POSI SW” in “DATA MONITOR” mode with CONSULT-II. Then check the “P/N POSI SW” signal under the following conditions.
Position (Shift lever)

Known-good signal

Neutral position

ON

Except the above position

OFF

3.
4.
5.

If NG, go to EC-374, «Diagnostic Procedure» .
If OK, go to following step.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and warm it up to normal operating temperature.
Maintain the following conditions for at least 60 consecutive seconds.

ENG SPEED

1,500 — 4,400 rpm

COOLAN TEMP/S

More than 70°C (158°F)

B/FUEL SCHDL

1.8 — 6.7 msec

VHCL SPEED SE

More than 46 km/h (29 MPH)

Shift lever

Suitable position

6.

J

If 1st trip DTC is detected, go to EC-374, «Diagnostic Procedure»
.

EC-371

K

L

SEF212Y

SEF213Y

M

DTC P1706 PNP SWITCH
[CR (WITH EURO-OBD)]

Overall Function Check

BBS00326

Use this procedure to check the overall function of the park/neutral position (PNP) switch circuit. During this
check, a 1st trip DTC might not be confirmed.

WITH GST
1.
2.

Turn ignition switch ON.
Check voltage between ECM terminal 102 (PNP switch signal)
and ground under the following conditions.
Condition (Gear position)

Neutral position
Except the above position

3.

Voltage V (Known-good data)
Approx. 0
BATTERY VOLTAGE
(11 — 14V)

If NG, go to EC-374, «Diagnostic Procedure» .
MBIB0029E

EC-372

DTC P1706 PNP SWITCH
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS00327

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1527E

EC-373

DTC P1706 PNP SWITCH
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION
[Ignition switch: ON]
●

102

GR

PNP switch

Shift lever position: Neutral

[Ignition switch: ON]
●

Except the above gear position

Diagnostic Procedure

DATA (DC Voltage)

Approximately 0V
BATTERY VOLTAGE
(11 — 14V)
BBS00328

1. CHECK PNP SWITCH CIRCUIT
1.
2.

Turn ignition switch ON.
Check voltage between IPDM E/R terminal 31 and ground under
following condition.
Shift lever position

Voltage

Neutral

Battery voltage (11- 14V)

Except above position

Approximately 0V

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 2.
MBIB0652E

2. CHECK PNP SWITCH POWER SUPPLY CIRCUIT
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect PNP switch harness connector.
Turn ignition switch ON.
Check voltage between PNP switch terminal 2 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

MBIB1444E

3. DETECT MALFUNCTIONING PARTS
Check the following.
●
10A fuse
●
Harness connectors E48, F1
●
IPDM E/R connector E7
●
Harness for short or open between PNP switch and fuse
>> Repair or replace harness or connectors.

EC-374

DTC P1706 PNP SWITCH
[CR (WITH EURO-OBD)]

4. CHECK HARNESS CONTINUTY BETWEEN PNP SWITCH AND IPDM E/R
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between IPDM E/R terminal 31 and PNP switch terminal 3.
Refer to Wiring Diagram.
Continuity should exist.

A

EC

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. DETECT MALFUNCTIONING PARTS

D

E

Check the following.
●
Harness connectors E48, F1
●
Harness for short or open between PNP switch and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

F

G

6. CHECK PNP SWITCH
H

Refer to MT-16, «Park/Neutral Position Switch» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace PNP switch.

I

7. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

J

K

8. CHECK PNP SWITCH GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connectors E11 and E12.
Check harness continuity between IPDM E/R terminal 3, 54 and ground.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to power.
OK or NG
OK
>> GO TO 9.
NG
>> Repair open circuit or short to power in harness or connectors.

EC-375

L

M

DTC P1706 PNP SWITCH
[CR (WITH EURO-OBD)]

9. CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Disconnect IPDM E/R harness connector E5
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 102 and IPDM E/R terminal 64.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 10.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

10. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace.

EC-376

DTC P1805 BRAKE SWITCH
[CR (WITH EURO-OBD)]

DTC P1805 BRAKE SWITCH
Description

PFP:25320

A
BBS00329

Brake switch signal is applied to the ECM through the stop lamp
switch when the brake pedal is depressed. This signal is used
mainly to decrease the engine speed when the vehicle is driving.

EC

C

D
MBIB0286E

E

CONSULT-II Reference Value in Data Monitor Mode

BBS0032A

Specification data are reference values.
MONITOR ITEM
BRAKE SW

CONDITION
●

Ignition switch: ON

F

SPECIFICATION

Brake pedal: Fully released

OFF

Brake pedal: Slightly depressed

ON

On Board Diagnosis Logic

G
BBS0032B

The MI will not light up for this self-diagnosis.
DTC No.

Trouble diagnosis name

P1805
1805

Brake switch

H

DTC detecting condition
A brake switch signal is not sent to ECM for
extremely long time while the vehicle is driving.

Possible cause
●

Harness or connectors
(Stop lamp switch circuit is open or shorted.)

●

Stop lamp switch

FAIL-SAFE MODE

I

J

When the malfunction is detected, the ECM enters fail-safe mode.
Engine operation condition in fail-fail safe mode
ECM controls the electric throttle control actuator by regulating the throttle opening to a small range.Therefore,acceleration will be
poor.
Vehicle condition

Driving condition

When engine is idling

Normal

When accelerating

Poor acceleration

L

M

DTC Confirmation Procedure

BBS0032D

WITH CONSULT-II
1.
2.
3.
4.
5.

K

Turn ignition switch ON.
Fully depress the brake pedal for at least 5 seconds.
Erase the DTC with CONSULT-II.
Select “DATA MONITOR” mode with CONSULT-II.
If 1st trip DTC is detected, go to EC-380, «Diagnostic Procedure»
.

SEF058Y

EC-377

DTC P1805 BRAKE SWITCH
[CR (WITH EURO-OBD)]
WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-378

DTC P1805 BRAKE SWITCH
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS0032E

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1528E

EC-379

DTC P1805 BRAKE SWITCH
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION
[Ignition switch: OFF]
●

101

R

Stop lamp switch

Brake pedal: Fully released

[Ignition switch: OFF]
●

Brake pedal: Slightly depressed

Diagnostic Procedure

DATA (DC Voltage)

Approximately 0V
BATTERY VOLTAGE
(11 — 14V)
BBS0032F

1. CHECK STOP LAMP SWITCH CIRCUIT
1.
2.

Turn ignition switch OFF.
Check the stop lamp when depressing and releasing the brake pedal.
Brake pedal

Stop lamp

Fully released

Not illuminated

Slightly depressed

Illuminated

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 2.

2. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT
1.

Disconnect stop lamp switch harness connector.

MBIB0286E

2.

Check voltage between stop lamp switch terminal 1 and ground
with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

PBIB0117E

EC-380

DTC P1805 BRAKE SWITCH
[CR (WITH EURO-OBD)]

3. DETECT MALFUNCTIONING PART

A

Check the following.
●
10A fuse
●
Fuse block (J/B) connector M7
●
Harness connectors M1, E101 (LHD models)
●
Harness connectors M8, M201 (RHD models)
●
Harness for open and short between stop lamp switch and battery
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC

C

D

4. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Disconnect ECM harness connector.
Disconnect stop lamp switch harness connector.
Check harness continuity between ECM terminal 101 and stop lamp switch terminal 2.
Refer to Wiring Diagram.

E

F

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 5.

5. DETECT MALFUNCTIONING PART

G

H

I

Check the following.
●
Harness connectors M8, M201
●
Harness connectors M1, E101
●
Harness for open or short between ECM and stop lamp switch
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK STOP LAMP SWITCH

J

K

L

Refer to EC-382, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace stop lamp switch.

M

7. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-381

DTC P1805 BRAKE SWITCH
[CR (WITH EURO-OBD)]

Component Inspection

BBS0032G

STOP LAMP SWITCH
1.

Disconnect stop lamp switch harness connector.

MBIB0286E

2.

Check continuity between stop lamp switch terminals 1 and 2
under the following conditions.
Conditions

Brake pedal: Fully released
Brake pedal: Slightly depressed

Continuity
Should not exist.
Should exist.

If NG, adjust brake pedal installation, refer to BR-6, «BRAKE
PEDAL» , and perform step 2 again.
PBIB0118E

EC-382

DTC P2122, P2123 APP SENSOR
[CR (WITH EURO-OBD)]

DTC P2122, P2123 APP SENSOR
Component Description

PFP:18002

A
BBS0032H

The accelerator pedal position sensor is installed on the upper end
of the accelerator pedal assembly. The sensor detects the acceleraEC
tor position and sends a signal to the ECM.
Accelerator pedal position sensor has two sensors. These sensors
are a kind of potentiometers which transform the accelerator pedal
C
position into output voltage, and emit the voltage signal to the ECM.
In addition, these sensors detect the opening and closing speed of
the accelerator pedal and feed the voltage signals to the ECM. The
ECM judges the current opening angle of the accelerator pedal from
D
these signals and controls the throttle control motor based on these
signals.
PBIB1741E
Idle position of the accelerator pedal is determined by the ECM
E
receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut.

CONSULT-II Reference Value in Data Monitor Mode

BBS0032I

F

Specification data are reference values.
MONITOR ITEM
ACCEL SEN 1

ACCEL SEN 2*

CLSD THL POS

CONDITION
●

●

●

SPECIFICATION

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

4.0 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

3.9 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

G

H

I

*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage.

On Board Diagnosis Logic

BBS0032J

These self-diagnoses have the one trip detection logic.
NOTE:
If DTC P2122 or P2123 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229.
Refer to EC-363, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

Trouble diagnosis name

DTC detecting condition

P2122
2122

Accelerator pedal position
sensor 1 circuit low input

An excessively low voltage from the APP sensor 1
is sent to ECM.

P2123
2123

Accelerator pedal position
sensor 1 circuit high input

An excessively high voltage from the APP sensor 1
is sent to ECM.

Possible cause
●

Harness or connectors
(APP sensor 1 circuit is open or
shorted.)

●

Accelerator pedal position sensor
(APP sensor 1)

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-383

J

K

L

M

DTC P2122, P2123 APP SENSOR
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS0032K

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-388, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-384

DTC P2122, P2123 APP SENSOR
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS0032L

A

LHD MODELS

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1529E

EC-385

DTC P2122, P2123 APP SENSOR
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]
82

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Ignition switch: ON]
83

B

Sensor ground
(APP sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

98

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Ignition switch: ON]

106

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

EC-386

3.9 — 4.7V

DTC P2122, P2123 APP SENSOR
[CR (WITH EURO-OBD)]
RHD MODELS
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1530E

EC-387

DTC P2122, P2123 APP SENSOR
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]
82

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Ignition switch: ON]
83

B

Sensor ground
(APP sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

98

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Ignition switch: ON]

106

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

Diagnostic Procedure

BBS0032M

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-388

3.

Body ground E28

DTC P2122, P2123 APP SENSOR
[CR (WITH EURO-OBD)]

2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT
1.
2.

A

Disconnect accelerator pedal position (APP) sensor harness
connector.
Turn ignition switch ON.

EC

C

D
MBIB0285E

3.

Check voltage between APP sensor terminal 4 and ground with
CONSULT-II or tester.

E

Voltage: Approximately 5V
F

G

MBIB0304E

H

OK or NG
OK
>> GO TO 4.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 3.

I

3. DETECT MALFUNCTIONING PART

J

Check the following.
●
Harness connectors M1, E101
●
Harness connectors M8, M201
●
Harness for open or short between ECM and accelerator pedal position sensor

K

L

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK APP SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 82 and APP sensor terminal 2.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 5.

EC-389

M

DTC P2122, P2123 APP SENSOR
[CR (WITH EURO-OBD)]

5. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M1, E101
●
Harness connectors M8, M201
●
Harness for open or short between ECM and accelerator pedal position sensor
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK APP SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 106 and APP sensor terminal 3.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 7.

7. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors M1, E101
●
Harness connectors M8, M201
●
Harness for open or short between ECM and accelerator pedal position sensor
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK APP SENSOR
Refer to EC-390, «Component Inspection» .
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 9.

9. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace the accelerator pedal assembly.
Perform EC-69, «Accelerator Pedal Released Position Learning» .
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> INSPECTION END

10. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS0032N

ACCELERATOR PEDAL POSITION SENSOR
1.
2.

Reconnect all harness connectors disconnected.
Turn ignition switch ON.

EC-390

DTC P2122, P2123 APP SENSOR
[CR (WITH EURO-OBD)]
3.

Check voltage between ECM terminals 106 (APP sensor 1 signal), 98 (APP sensor 2 signal) and ground under the following
conditions.
Terminal

Accelerator pedal

Voltage

106
(Accelerator pedal position
sensor 1)

Fully released

0.6 — 0.9V

Fully depressed

3.9 — 4.7V

Fully released

0.3 — 0.6V

Fully depressed

1.95 — 2.4V

98
(Accelerator pedal position
sensor 2)

4.
5.
6.
7.

A

EC

C
MBIB0023E

D

If NG, replace accelerator pedal assembly and go to the next
step.
Perform EC-69, «Accelerator Pedal Released Position Learning» .
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .

Removal and Installation

E

BBS0032O

ACCELERATOR PEDAL

F

Refer to ACC-2, «ACCELERATOR CONTROL SYSTEM» .
G

H

I

J

K

L

M

EC-391

DTC P2127, P2128 APP SENSOR
[CR (WITH EURO-OBD)]

DTC P2127, P2128 APP SENSOR
Component Description

PFP:18002
BBS0032P

The accelerator pedal position sensor is installed on the upper end
of the accelerator pedal assembly. The sensor detects the accelerator position and sends a signal to the ECM.
Accelerator pedal position sensor has two sensors. These sensors
are a kind of potentiometers which transform the accelerator pedal
position into output voltage, and emit the voltage signal to the ECM.
In addition, these sensors detect the opening and closing speed of
the accelerator pedal and feed the voltage signals to the ECM. The
ECM judges the current opening angle of the accelerator pedal from
these signals and controls the throttle control motor based on these
signals.
PBIB1741E
Idle position of the accelerator pedal is determined by the ECM
receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut.

CONSULT-II Reference Value in Data Monitor Mode

BBS0032Q

Specification data are reference values.
MONITOR ITEM
ACCEL SEN 1

ACCEL SEN 2*

CLSD THL POS

CONDITION
●

●

●

SPECIFICATION

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

4.0 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

3.9 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differ from ECM terminal voltage signal.

On Board Diagnosis Logic

BBS0032R

These self-diagnoses have the one trip detection logic.
DTC No.

Trouble diagnosis name

DTC detecting condition

Possible cause

P2127
2127

Accelerator pedal position
sensor 2 circuit low input

An excessively low voltage from the APP sensor 2
is sent to ECM.

●

Harness or connectors
(APP sensor 2 circuit is open or
shorted.)
(TP sensor circuit is shorted.)

P2128
2128

Accelerator pedal position
sensor 2 circuit high input

An excessively high voltage from the APP sensor 2
is sent to ECM.

●

Accelerator pedal position sensor
(APP sensor 2)

●

Electric throttle control actuator
(TP sensor 1 and 2)

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-392

DTC P2127, P2128 APP SENSOR
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS0032S

A
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
EC
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

C

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-397, «Diagnostic Procedure» .

D

E

F
SEF058Y

WITH GST

G

Follow the procedure “WITH CONSULT-II” above.
H

I

J

K

L

M

EC-393

DTC P2127, P2128 APP SENSOR
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS0032T

LHD MODELS

MBWA1531E

EC-394

DTC P2127, P2128 APP SENSOR
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

A

EC
ITEM

47

G

Sensor power supply
(Throttle position sensor)

82

B

Sensor ground
(APP sensor 1)

CONDITION

[Ignition switch: ON]

DATA (DC Voltage)

Approximately 5V

C

Approximately 0V

D

Approximately 0V

E

F

[Engine is running]
●

Warm-up condition

●

Idle speed

[Ignition switch: ON]
83

B

Sensor ground
(APP sensor 2)

●

Warm-up condition

●

Idle speed

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

G

[Ignition switch: ON]

98

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

H

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

I

[Ignition switch: ON]

106

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

J

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

K

L

M

EC-395

DTC P2127, P2128 APP SENSOR
[CR (WITH EURO-OBD)]
RHD MODELS

MBWA1532E

EC-396

DTC P2127, P2128 APP SENSOR
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

A

EC

WIRE
COLOR

ITEM

CONDITION

47

G

Sensor power supply
(Throttle position sensor)

82

B

Sensor ground
(APP sensor 1)

DATA (DC Voltage)

[Ignition switch: ON]

Approximately 5V

C

Approximately 0V

D

Approximately 0V

E

F

[Engine is running]
●

Warm-up condition

●

Idle speed

[Ignition switch: ON]
83

B

Sensor ground
(APP sensor 2)

●

Warm-up condition

●

Idle speed

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

G

[Ignition switch: ON]

98

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

H

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

I

[Ignition switch: ON]

106

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

J

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

K

Diagnostic Procedure

BBS0032U

1. CHECK GROUND CONNECTIONS
1.
2.

L

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

M

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-397

3.

Body ground E28

DTC P2127, P2128 APP SENSOR
[CR (WITH EURO-OBD)]

2. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I
1.
2.

Disconnect accelerator pedal position (APP) sensor harness
connector.
Turn ignition switch ON.

MBIB0285E

3.

Check voltage between APP sensor terminal 5 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 3.

MBIB0309E

3. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between APP sensor terminal 5 and ECM terminal 91.
Refer to Wiring Diagram.
Continuity should exist.

OK or NG
OK
>> GO TO 5.
NG (LHD models)>>Repair open circuit.
NG (RHD models)>>GO TO 4.

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M201, M8
●
Harness connectors M1, E101
●
Harness for open or short between accelerator pedal position sensor and ECM
>> Repair open circuit.

EC-398

DTC P2127, P2128 APP SENSOR
[CR (WITH EURO-OBD)]

5. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III

A

Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

91

APP sensor terminal 5

EC-394

47

Electric throttle control actuator terminal 1

EC-404

OK or NG
OK
>> GO TO 6.
NG
>> Repair short to ground or short to power in harness or connectors.

EC

C

D

6. CHECK THROTTLE POSITION SENSOR
Refer to EC-408, «Component Inspection» .
OK or NG
OK
>> GO TO 14.
NG
>> GO TO 7.

E

F

7. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .

G

H

>> INSPECTION END

8. CHECK APP SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT

I

1.
2.
3.

J

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 83 and APP sensor terminal 1.
Refer to Wiring Diagram.

K

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 10.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 9.

9. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M8, M201
●
Harness connectors M1, E101
●
Harness for open or short between accelerator pedal position sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-399

L

M

DTC P2127, P2128 APP SENSOR
[CR (WITH EURO-OBD)]

10. CHECK APP SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 98 and APP sensor terminal 6.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 12.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 11.

11. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors M8, M201
●
Harness connectors M1, E101
●
Harness for open or short between ECM and accelerator pedal position sensor
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

12. CHECK APP SENSOR
Refer to EC-400, «Component Inspection» .
OK or NG
OK
>> GO TO 14.
NG
>> GO TO 13.

13. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace the accelerator pedal assembly.
Perform EC-69, «Accelerator Pedal Released Position Learning» .
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> INSPECTION END

14. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS0032V

ACCELERATOR PEDAL POSITION SENSOR
1.
2.

Reconnect all harness connectors disconnected.
Turn ignition switch ON.

EC-400

DTC P2127, P2128 APP SENSOR
[CR (WITH EURO-OBD)]
3.

Check voltage between ECM terminals 106 (APP sensor 1 signal), 98 (APP sensor 2 signal) and ground under the following
conditions.
Terminal

Accelerator pedal

Voltage

106
(Accelerator pedal position
sensor 1)

Fully released

0.6 — 0.9V

Fully depressed

3.9 — 4.7V

Fully released

0.3 — 0.6V

Fully depressed

1.95 — 2.4V

98
(Accelerator pedal position
sensor 2)

4.
5.
6.
7.

A

EC

C
MBIB0023E

D

If NG, replace accelerator pedal assembly and go to the next
step.
Perform EC-69, «Accelerator Pedal Released Position Learning» .
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .

Removal and Installation

E

BBS0032W

ACCELERATOR PEDAL

F

Refer to ACC-2, «ACCELERATOR CONTROL SYSTEM» .
G

H

I

J

K

L

M

EC-401

DTC P2135 TP SENSOR
[CR (WITH EURO-OBD)]

DTC P2135 TP SENSOR
Component Description

PFP:16119
BBS0032X

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

PBIB0145E

CONSULT-II Reference Value in Data Monitor Mode

BBS0032Y

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

More than 0.36V

●

Shift lever: 1st

Accelerator pedal: Fully depressed

Less than 4.75V

THRTL SEN 1
THRTL SEN 2*

*: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic

BBS0032Z

This self-diagnosis has the one trip detection logic.
DTC No.

P2135
2135

Trouble diagnosis name

Throttle position sensor
circuit range/performance

DTC detecting condition

Rationally incorrect voltage is sent to ECM
compared with the signals from TP sensor 1
and TP sensor 2.

Possible cause
●

Harness or connector
(TP sensor 1 and 2 circuit is open or
shorted.)
(APP sensor 2 circuit is shorted.)

●

Electric throttle control actuator
(TP sensor 1 and 2)

●

Accelerator pedal position sensor
(APP sensor 2)

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-402

DTC P2135 TP SENSOR
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS00330

A
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
EC
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

C

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-405, «Diagnostic Procedure» .

D

E

F
SEF058Y

WITH GST

G

Follow the procedure “WITH CONSULT-II” above.
H

I

J

K

L

M

EC-403

DTC P2135 TP SENSOR
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS00331

MBWA1533E

EC-404

DTC P2135 TP SENSOR
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL NO.
47

WIRE
COLOR
L

ITEM

CONDITION

Sensor power supply
(Throttle position sensor)

EC

DATA (DC Voltage)

[Ignition switch: ON]

A

Approximately 5V

C

[Ignition switch: ON]

49

Y

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

Throttle position sensor 1

More than 0.36V

D

[Ignition switch: ON]
●

E

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

Less than 4.75V

F

[Engine is running]
66

B

Sensor ground
(Throttle position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

G

[Ignition switch: ON]

68

R

Throttle position sensor 2

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

BR

Sensor power supply
(APP sensor 2)

H

[Ignition switch: ON]
●

91

Less than 4.75V

I

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

More than 0.36V

J

[Ignition switch: ON]

Approximately 5V

Diagnostic Procedure

BBS00332

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

K

L

M

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-405

3.

Body ground E28

DTC P2135 TP SENSOR
[CR (WITH EURO-OBD)]

2. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT
1.
2.

Disconnect electric throttle control actuator harness connector.
Turn ignition switch ON.

MBIB0308E

3.

Check voltage between electric throttle control actuator terminal
1 and ground with CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.

PBIB0082E

3. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between electric throttle control actuator terminal 1 and ECM terminal 47.
Refer to Wiring Diagram.
Continuity should exist.

OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit.

4. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT-III
Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

47

Electric throttle control actuator terminal 1

EC-404

91

APP sensor terminal 5

EC-394

OK or NG
OK
>> GO TO 5.
NG
>> Repair short to ground or short to power in harness or connectors.

5. CHECK APP SENSOR
Refer to EC-400, «Component Inspection» .
OK or NG
OK
>> GO TO 11
NG
>> GO TO 6.

EC-406

DTC P2135 TP SENSOR
[CR (WITH EURO-OBD)]

6. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace accelerator pedal assembly.
Perform EC-69, «Accelerator Pedal Released Position Learning» .
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .

7. CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 66 and electric throttle control actuator terminal 5.
Refer to Wiring Diagram.
Continuity should exist.

D

E

F

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

EC

C

>> INSPECTION END

1.
2.
3.

A

Check harness continuity between ECM terminal 49 and electric throttle control actuator terminal 4, ECM
terminal 68 and electric throttle control actuator terminal 2.
Refer to Wiring Diagram.

G

H

I

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 9.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

J

K

9. CHECK THROTTLE POSITION SENSOR
L

Refer to EC-408, «Component Inspection» .
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

M

10. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> INSPECTION END

11. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-407

DTC P2135 TP SENSOR
[CR (WITH EURO-OBD)]

Component Inspection

BBS00333

THROTTLE POSITION SENSOR
1.
2.
3.
4.
5.

Reconnect all harness connectors disconnected.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Turn ignition switch ON.
Set shift lever to 1st position.
Check voltage between ECM terminals 49 (TP sensor 1 signal),
68 (TP sensor 2 signal) and ground under the following conditions.
Terminal

Accelerator pedal

Voltage

49
(Throttle position sensor 1)

Fully released

More than 0.36V

Fully depressed

Less than 4.75V

Fully released

Less than 4.75V

Fully depressed

More than 0.36V

68
(Throttle position sensor 2)

6.
7.
8.

If NG, replace electric throttle control actuator and go to the next
step.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .

Removal and Installation

MBIB1443E

BBS00334

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

EC-408

DTC P2138 APP SENSOR
[CR (WITH EURO-OBD)]

DTC P2138 APP SENSOR
Component Description

PFP:18002

A
BBS00335

The accelerator pedal position sensor is installed on the upper end
of the accelerator pedal assembly. The sensor detects the acceleraEC
tor position and sends a signal to the ECM.
Accelerator pedal position sensor has two sensors. These sensors
are a kind of potentiometers which transform the accelerator pedal
C
position into output voltage, and emit the voltage signal to the ECM.
In addition, these sensors detect the opening and closing speed of
the accelerator pedal and feed the voltage signals to the ECM. The
ECM judges the current opening angle of the accelerator pedal from
D
these signals and controls the throttle control motor based on these
signals.
PBIB1741E
Idle position of the accelerator pedal is determined by the ECM
E
receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut.

CONSULT-II Reference Value in Data Monitor Mode

BBS00336

F

Specification data are reference values.
MONITOR ITEM
ACCEL SEN 1

ACCEL SEN 2*

CLSD THL POS

CONDITION
●

●

●

SPECIFICATION

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

4.0 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

3.9 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

G

H

I

*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage.

On Board Diagnosis Logic

BBS00337

This self-diagnosis has the one trip detection logic.
NOTE:
If DTC P2138 is displayed with DTC P1229, first perform trouble diagnosis for DTC P1229.
Refer to EC-363, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

Trouble diagnosis name

DTC detecting condition

Possible cause
●

P2138
2138

Accelerator pedal position sensor
circuit range/performance

Rationally incorrect voltage is sent to ECM
compared with the signals from APP sensor
1 and APP sensor 2.

Harness or connector
(APP sensor 1 and 2 circuit is open
or shorted.)
(TP sensor circuit is shorted.)

●

Accelerator pedal position sensor
(APP sensor 1 and 2)

●

Electric throttle control actuator
(TP sensor 1 and 2)

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-409

J

K

L

M

DTC P2138 APP SENSOR
[CR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS00338

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-414, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-410

DTC P2138 APP SENSOR
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS00339

A

LHD MODELS

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1534E

EC-411

DTC P2138 APP SENSOR
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

47

G

Sensor power supply
(Throttle position sensor)

[Ignition switch: ON]

82

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

DATA (DC Voltage)

Approximately 5V

[Engine is running]
Approximately 0V

[Ignition switch: ON]
83

B

Sensor ground
(APP sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

98

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Ignition switch: ON]

106

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

EC-412

3.9 — 4.7V

DTC P2138 APP SENSOR
[CR (WITH EURO-OBD)]
RHD MODELS
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1535E

EC-413

DTC P2138 APP SENSOR
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

47

G

Sensor power supply
(Throttle position sensor)

[Ignition switch: ON]

82

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

DATA (DC Voltage)

Approximately 5V

[Engine is running]
Approximately 0V

[Ignition switch: ON]
83

B

Sensor ground
(APP sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

98

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Ignition switch: ON]

106

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

Diagnostic Procedure

BBS0033A

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-414

3.

Body ground E28

DTC P2138 APP SENSOR
[CR (WITH EURO-OBD)]

2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT
1.
2.

A

Disconnect accelerator pedal position (APP) sensor harness
connector.
Turn ignition switch ON.

EC

C

D
MBIB0285E

3.

Check voltage between APP sensor terminal 4 and ground with
CONSULT-II or tester.

E

Voltage: Approximately 5V
F

G

MBIB0304E

H

OK or NG
OK
>> GO TO 4.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 3.

I

3. DETECT MALFUNCTIONING PART

J

Check the following.
●
Harness connectors M1, E101
●
Harness connectors M8, M201
●
Harness for open or short between ECM and accelerator pedal position sensor

K

L

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I

M

Check voltage between APP sensor terminal 5 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 5.

MBIB0309E

EC-415

DTC P2138 APP SENSOR
[CR (WITH EURO-OBD)]

5. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between APP sensor terminal 5 and ECM terminal 91.
Refer to Wiring Diagram.
Continuity should exist.

OK or NG
OK
>> GO TO 7.
NG (LHD models)>>Repair open circuit.
NG (RHD models)>>GO TO 6.

6. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M1, E101
●
Harness connectors M8, M201
●
Harness for open or short between accelerator pedal position sensor and ECM
>> Repair open circuit.

7. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III
Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

91

APP sensor terminal 5

EC-411

47

Electric throttle control actuator terminal 1

EC-404

OK or NG
OK
>> GO TO 8.
NG
>> Repair short to ground or short to power in harness or connectors.

8. CHECK THROTTLE POSITION SENSOR
Refer to EC-408, «Component Inspection» .
OK or NG
OK
>> GO TO 16.
NG
>> GO TO 9.

9. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> INSPECTION END

EC-416

DTC P2138 APP SENSOR
[CR (WITH EURO-OBD)]

10. CHECK APP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

A
Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 82 and APP sensor terminal 2, ECM terminal 83 and EC
APP sensor terminal 1.
Refer to Wiring Diagram.
C
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 12.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 11.

D

E

11. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M1, E101
●
Harness connectors M8, M201
●
Harness for open or short between ECM and accelerator pedal position sensor
>> Repair open circuit or short to ground or short to power in harness or connectors.

F

G

H

12. CHECK APP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 106 and APP sensor terminal 3, ECM terminal 98 and
APP sensor terminal 6.
Refer to Wiring Diagram.

I

J

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 14.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 13.

13. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M1, E101
●
Harness connectors M8, M201
●
Harness for open or short between ECM and accelerator pedal position sensor
>> Repair open circuit or short to ground or short to power in harness or connectors.

14. CHECK APP SENSOR
Refer to EC-418, «Component Inspection» .
OK or NG
OK
>> GO TO 16.
NG
>> GO TO 15.

EC-417

K

L

M

DTC P2138 APP SENSOR
[CR (WITH EURO-OBD)]

15. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace the accelerator pedal assembly.
Perform EC-69, «Accelerator Pedal Released Position Learning» .
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .
>> INSPECTION END

16. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS0033B

ACCELERATOR PEDAL POSITION SENSOR
1.
2.
3.

Reconnect all harness connectors disconnected.
Turn ignition switch ON.
Check voltage between ECM terminals 106 (APP sensor 1 signal), 98 (APP sensor 2 signal) and ground under the following
conditions.
Terminal

Accelerator pedal

Voltage

106
(Accelerator pedal position
sensor 1)

Fully released

0.6 — 0.9V

Fully depressed

3.9 — 4.7V

Fully released

0.3 — 0.6V

Fully depressed

1.95 — 2.4V

98
(Accelerator pedal position
sensor 2)

4.
5.
6.
7.

MBIB0023E

If NG, replace accelerator pedal assembly and go to the next
step.
Perform EC-69, «Accelerator Pedal Released Position Learning» .
Perform EC-69, «Throttle Valve Closed Position Learning» .
Perform EC-69, «Idle Air Volume Learning» .

Removal and Installation

BBS0033C

ACCELERATOR PEDAL
Refer to ACC-2, «ACCELERATOR CONTROL SYSTEM» .

EC-418

ELECTRICAL LOAD SIGNAL
[CR (WITH EURO-OBD)]

ELECTRICAL LOAD SIGNAL
Description

PFP:25350

A
BBS0033Y

The electrical load signal (Headlamp switch signal, rear window defogger switch signal, etc.) is transferred
through the CAN communication line from IPDM E/R to ECM.
EC

CONSULT-II Reference Value in Data Monitor Mode

BBS0033Z

Specification data are reference values.
MONITOR ITEM

LOAD SIGNAL

C
CONDITION

●

●

HEATER FAN SW

Ignition switch: ON

Engine: After warming up, idle the
engine

SPECIFICATION

Rear window defogger switch is ON and/or
lighting switch is 2nd.

ON

Rear window defogger switch is OFF and lighting switch is OFF.

OFF

Heater fan: Operating

ON

Heater fan: Not operating

OFF

Diagnostic Procedure

D

E

BBS00340

F

1. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-I
1.
2.
3.

Turn ignition switch ON.
Connect CONSULT-II and select “DATA MONITOR” mode.
Select “LOAD SIGNAL” and check indication under the following
conditions.
Condition

G

H

Indication

Rear window defogger switch: ON

ON

Rear window defogger switch: OFF

OFF

I

OK or NG
OK
>> GO TO 2.
NG
>> GO TO 4.

J

PBIB0103E

K

2. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-II
Check “LOAD SIGNAL” indication under the following conditions.
Condition

L

Indication

Lighting switch: 2nd position

ON

Lighting switch: OFF

OFF

M

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 5.
PBIB0103E

EC-419

ELECTRICAL LOAD SIGNAL
[CR (WITH EURO-OBD)]

3. CHECK HEATER FAN SIGNAL CIRCUIT OVERALL FUNCTION
With CONSULT-II
Check “HEATER FAN SW” in “DATA MONITOR” mode with CONSULT-II under the following conditions.
Condition

HEATER FAN SW

Heater fan control switch: ON

ON

Heater fan control switch: OFF

OFF

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.

PBIB1995E

4. CHECK REAR WINDOW DEFOGGER SYSTEM
Refer to GW-12, «REAR WINDOW DEFOGGER» .
>> INSPECTION END

5. CHECK HEADLAMP SYSTEM
Refer to LT-7, «HEADLAMP -CONVENTIONAL TYPE-» or LT-35, «HEADLAMP — DAYTIME LIGHT SYSTEM «.
>> INSPECTION END

6. CHECK HEATER FAN CONTROL SYSTEM
Refer to ATC-26, «TROUBLE DIAGNOSIS» or MTC-23, «TROUBLE DIAGNOSIS» .
>> INSPECTION END

EC-420

FUEL INJECTOR
[CR (WITH EURO-OBD)]

FUEL INJECTOR
Component Description

PFP:16600

A
BBS0033I

The fuel injector is a small, precise solenoid valve. When the ECM
supplies a ground to the fuel injector circuit, the coil in the fuel injector is energized. The energized coil pulls the ball valve back and
allows fuel to flow through the fuel injector into the intake manifold.
The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the fuel injector remains
open. The ECM controls the injection pulse duration based on
engine fuel needs.

EC

C

D
SEF375Z

E

CONSULT-II Reference Value in Data Monitor Mode

BBS0033J

Specification data are reference values.
MONITOR ITEM
B/FUEL SCHDL

CONDITION
●

See EC-117, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .

●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

INJ PULSE-B1

SPECIFICATION

Idle

2.0 — 3.0 msec

2,000 rpm

1.9 — 2.9 msec

F

G

H

I

J

K

L

M

EC-421

FUEL INJECTOR
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS0033K

MBWA1538E

EC-422

FUEL INJECTOR
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
BATTERY VOLTAGE
[Engine is running]

22
23
41
42

O
L
R
GR

●

Warm-up condition

●

Idle speed

(11 — 14V)

D

NOTE:
The pulse cycle changes depending on
rpm at idle.

Fuel injector No. 3
Fuel injector No. 1
Fuel injector No. 4
Fuel injector No. 2

E
PBIB0529E

BATTERY VOLTAGE

F

(11 — 14V)
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

G

H
PBIB0530E

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

I

Diagnostic Procedure

BBS0033L

1. INSPECTION START
J

Turn ignition switch to START.
Is any cylinder ignited?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.

K

L

M

EC-423

FUEL INJECTOR
[CR (WITH EURO-OBD)]

2. CHECK OVERALL FUNCTION
With CONSULT-II
Start engine.
Perform “POWER BALANCE” in “ACTIVE TEST” mode with
CONSULT-II.
3. Make sure that each circuit produces a momentary engine
speed drop.
1.
2.

MBIB0302E

Without CONSULT-II
1. Start engine.
2. Listen to each fuel injector operating sound.
Clicking noise should be heard.

PBIB1986E

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 3.

EC-424

FUEL INJECTOR
[CR (WITH EURO-OBD)]

3. CHECK FUEL INJECTOR POWER SUPPLY CIRCUIT
1.
2.

Turn ignition switch OFF.
Disconnect fuel injector harness connector (1).

–

: Vehicle front
Turn ignition switch ON.

3.

A

EC

C

D
MBIB1458E

E

4.

Check voltage between fuel injector terminal 1 and ground with
CONSULT-II or tester.
F

Voltage: Battery voltage
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

G

H
PBIB0582E

4. DETECT MALFUNCTIONING PART

I

Check the following.
●
Harness connectors E48, F1
●
10A fuse
●
Harness for open or short between fuel injector and fuse

J

K

>> Repair harness or connectors.

5. CHECK FUEL INJECTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between fuel injector terminal 2 and ECM terminals 22, 23, 41, 42.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK FUEL INJECTOR
Refer to EC-426, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace fuel injector.

EC-425

L

M

FUEL INJECTOR
[CR (WITH EURO-OBD)]

7. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS0033M

FUEL INJECTOR
1.
2.

Disconnect fuel injector harness connector.
Check resistance between terminals as shown in the figure.
Resistance: 10.4 — 15.3Ω [at 10 — 60°C (50 — 140°F)]

PBIB1727E

Removal and Installation

BBS0033N

FUEL INJECTOR
Refer to EM-32, «FUEL INJECTOR AND FUEL TUBE» .

EC-426

FUEL PUMP
[CR (WITH EURO-OBD)]

FUEL PUMP
Description

PFP:17042

A
BBS0033O

SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*

Battery

Battery voltage*

ECM Function

Actuator

Fuel pump control

EC

Fuel pump relay

C

*: ECM determines the start signal status by the signals of engine speed and battery voltage.

The ECM activates the fuel pump for several seconds after the ignition switch is turned ON to improve engine
startability. If the ECM receives a engine speed signal from the crankshaft position sensor (POS) and camshaft position sensor (PHASE), it knows that the engine is rotating, and causes the pump to operate. If the
engine speed signal is not received when the ignition switch is ON, the engine stalls. The ECM stops pump
operation and prevents battery discharging, thereby improving safety. The ECM does not directly drive the fuel
pump. It controls the ON/OFF fuel pump relay, which in turn controls the fuel pump.
Condition

D

E

Fuel pump operation

Ignition switch is turned to ON.

F

Operates for 1 second.

Engine running and cranking

Operates.

When engine is stopped

Stops in 1.5 seconds.

Except as shown above

Stops.

G

COMPONENT DESCRIPTION

H

A turbine type design fuel pump is used in the fuel tank.

I

J

K
MBIB0291E

CONSULT-II Reference Value in Data Monitor Mode

BBS0033P

L

Specification data are reference values.
MONITOR ITEM

FUEL PUMP RLY

CONDITION
●

For 1 second after turning ignition switch ON

●

Engine running or cranking

●

Except above conditions

SPECIFICATION
ON
OFF

EC-427

M

FUEL PUMP
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS0033Q

MBWA1539E

EC-428

FUEL PUMP
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

EC

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch: ON]
●

113

R

A

Fuel pump relay

For 1 second after turning ignition switch ON

C
0 — 1.0V

[Engine is running]
[Ignition switch: ON]
●

More than 1 second after turning ignition switch
ON

D
BATTERY VOLTAGE
(11 — 14V)

E

Diagnostic Procedure

BBS0033R

1. CHECK OVERALL FUNCTION
F

1.
2.

Turn ignition switch ON.
Pinch fuel feed hose (1) with two fingers.
Fuel pressure pulsation should be felt on the fuel hose for 1
second after ignition switch is turned ON.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

G

H

I
MBIB1496E

2. CHECK FUEL PUMP RELAY POWER SUPPLY CIRCUIT
1.
2.
3.
4.

J

Turn ignition switch OFF.
Disconnect ECM harness connector.
Turn ignition switch ON.
Check voltage between ECM terminals 113 and ground with
CONSULT-II or tester.

K

L

Voltage: Battery voltage
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.

M

PBIB1187E

EC-429

FUEL PUMP
[CR (WITH EURO-OBD)]

3. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-I
Check voltage between IPDM E/R terminal 69 and ground with
CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 11.

MBIB1445E

4. DETECT MALFUNCTIONING PART
Check harness for open or short between IPDM E/R and ECM
>> Repair harness or connectors.

5. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-I
1.
2.
3.
4.

Turn ignition switch OFF.
Reconnect all harness connectors disconnected.
Disconnect “fuel level sensor unit and fuel pump” harness connector.
Turn ignition switch ON.

MBIB0288E

5.

Check voltage between “Fuel level sensor unit and fuel pump”
terminal 1 and ground with CONSULT-II or tester.
Voltage:

Battery voltage should exist for 1 second
after ignition switch is turned ON.

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 6.

MBIB1446E

6. CHECK 15A FUSE
1. Turn ignition switch OFF.
2. Disconnect 15A fuse.
3. Check 15A fuse.
OK or NG
OK
>> GO TO 7.
NG
>> Replace fuse.

EC-430

FUEL PUMP
[CR (WITH EURO-OBD)]

7. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-II
1.
2.

A
Disconnect IPDM E/R harness connector E10.
Check harness continuity between IPDM E/R terminal 20 and “fuel level sensor unit and fuel pump” termiEC
nal 1. Refer to Wiring Diagram.

Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 8.

C

D

8. DETECT MALFUNCTIONING PART
E

Check the following.
●
Harness connectors E101, M1
●
Harness connectors M72, B21
●
Harness for open or short between “fuel level sensor unit and fuel pump” and IPDM E/R

F

>> Repair open circuit or short to ground or short to power in harness or connectors.

G

9. CHECK FUEL PUMP GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.

H

Turn ignition switch OFF.
Check harness continuity between “fuel level sensor unit and fuel pump” terminal 3 and ground.
Refer to Wiring Diagram.

I

Continuity should exist.
3. Also check harness for short to power.
OK or NG
OK
>> GO TO 10.
NG
>> Repair open circuit or short to power in harness or connectors.

J

K

10. CHECK FUEL PUMP
Refer to EC-431, «Component Inspection» .
OK or NG
OK
>> GO TO 11.
NG
>> Replace “fuel level sensor unit and fuel pump”.

L

M

11. CHECK INTERMITTENT INCIDENT
Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connector
>> INSPECTION END

Component Inspection

BBS0033S

FUEL PUMP
1.

Disconnect “fuel level sensor unit and fuel pump” harness connector.

EC-431

FUEL PUMP
[CR (WITH EURO-OBD)]
2.

Check resistance between “fuel level sensor unit and fuel pump”
terminals 1 and 3.
Resistance: Approximately 0.2 — 5.0Ω [at 25°C (77°F)]

MBIB0311E

Removal and Installation

BBS0033T

FUEL PUMP
Refer to FL-4, «FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY» .

EC-432

IGNITION SIGNAL
[CR (WITH EURO-OBD)]

IGNITION SIGNAL
Component Description

PFP:22448

A
BBS0033D

IGNITION COIL & POWER TRANSISTOR
The ignition signal from the ECM is sent to and amplified by the
power transistor. The power transistor turns ON and OFF the ignition
coil primary circuit. This ON-OFF operation induces the proper high
voltage in the coil secondary circuit.

EC

C

D

MBIB0272E

E

F

G

H

I

J

K

L

M

EC-433

IGNITION SIGNAL
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS0033E

MBWA1536E

EC-434

IGNITION SIGNAL
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

EC
ITEM

CONDITION
[Engine is running]
[Ignition switch: OFF]
●

111

P

ECM relay
(Self shut-off)

G
G

Power supply for ECM

For a few seconds after turning ignition
switch OFF

[Ignition switch: OFF]
●

119
120

A

More than a few seconds passed after turning ignition switch OFF

[Ignition switch: ON]

DATA (DC Voltage)

C
0 — 1.0V

D
BATTERY VOLTAGE
(11 — 14V)

E
BATTERY VOLTAGE
(11 — 14V)

F

G

H

I

J

K

L

M

EC-435

IGNITION SIGNAL
[CR (WITH EURO-OBD)]

MBWA1537E

EC-436

IGNITION SIGNAL
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

C
[Engine is running]

60
61
79
80

DATA (DC Voltage)

Y
V
G
BR

●

Warm-up condition

●

Idle speed

0 — 0.1V

D

NOTE:
The pulse cycle changes depending on rpm
at idle.

Ignition signal No. 3
Ignition signal No. 1
Ignition signal No. 4
Ignition signal No. 2

E
PBIB0521E

0 — 0.2V

F
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

G
PBIB0522E

H
: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS0033F

I

1. CHECK ENGINE START
Turn ignition switch OFF and restart engine.
Is engine running?
Yes or No
Yes (With CONSULT-II)>>GO TO 2.
Yes (Without CONSULT-II)>>GO TO 3.
No
>> GO TO 4.

J

K

2. CHECK OVERALL FUNCTION

L

With CONSULT-II
Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.
Make sure that each circuit produces a momentary engine
speed drop.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 10.
1.
2.

M

MBIB0302E

EC-437

IGNITION SIGNAL
[CR (WITH EURO-OBD)]

3. CHECK OVERALL FUNCTION
Without CONSULT-II
Let engine idle.
Read the voltage signal between ECM terminals 60, 61, 79, 80
and ground with an oscilloscope.
3. Verify that the oscilloscope screen shows the signal wave as
shown in the figure.
NOTE:
The pulse cycle changes depending on rpm at idle.
1.
2.

MBIB0033E

PBIB0521E

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 10.

4. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-I
1.
2.

Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Check voltage between ECM terminals 119, 120 and ground
with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 5.
NG
>> Go to EC-128, «POWER SUPPLY AND GROUND CIRCUIT» .

MBIB0034E

5. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-II
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect condenser harness connector.
Turn ignition switch ON.
Check voltage between condenser terminal 1 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 6.

PBIB0624E

EC-438

IGNITION SIGNAL
[CR (WITH EURO-OBD)]

6. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-III
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector.
Check harness continuity between condenser terminal 1 and IPDM terminal 33.
Refer to Wiring Diagram.
Continuity should exist.

A

EC

C

4. Also check harness for short to power and short to ground.
OK or NG
OK
>> GO TO 15.
NG
>> GO TO 7.

7. DETECT MALFUNCTION PART

D

E

Check the following.
●
Harness connectors E48, F1
●
Harness for open or short between IPDM E/R and condenser
>> Repair open circuit or short to ground or short to power in harness or connectors.

F

G

8. CHECK CONDENSER GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.

Turn ignition switch OFF.
Check harness continuity between condenser terminal 2 and ground.
Refer to Wiring Diagram.

H

I

Continuity should exist.
3. Also check harness for short to power.
OK or NG
OK
>> GO TO 9.
NG
>> Repair open circuit or short to power in harness or connector.

J

K

9. CHECK CONDENSER
Refer to EC-441, «Component Inspection» .
OK or NG
OK
>> GO TO 10.
NG
>> Replace condenser.

L

M

EC-439

IGNITION SIGNAL
[CR (WITH EURO-OBD)]

10. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-V
1.
2.
3.
4.

Turn ignition switch OFF.
Reconnect all harness connectors disconnected.
Disconnect ignition coil harness connector.
Turn ignition switch ON.

MBIB0272E

5.

Check voltage between ignition coil terminal 1 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 12.
NG
>> GO TO 11.

SEF107S

11. DETECT MALFUNCTIONING PART
Check harness for open or short between ignition coil and harness connector F1.
>> Repair open circuit or short to ground or short to power in harness or connectors.

12. CHECK IGNITION COIL GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.

Turn ignition switch OFF.
Check harness continuity between ignition coil terminal 2 and ground.
Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 13.
NG
>> Repair open circuit or short to power in harness or connectors.

13. CHECK IGNITION COIL OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

Disconnect ECM harness connector.
Check harness continuity between ECM terminals 60, 61, 79, 80 and ignition coil terminal 3.
Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 14.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-440

IGNITION SIGNAL
[CR (WITH EURO-OBD)]

14. CHECK IGNITION COIL WITH POWER TRANSISTOR

A

Refer to EC-441, «Component Inspection» .
OK or NG
OK
>> GO TO 15.
NG
>> Replace malfunctioning ignition coil with power transistor.

EC

15. CHECK INTERMITTENT INCIDENT

C

Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace

Component Inspection

D

E

BBS0033G

IGNITION COIL WITH POWER TRANSISTOR
CAUTION:
Do the following procedure in the place where ventilation is good without the combustible.
1. Turn ignition switch OFF.
2. Disconnect ignition coil harness connector.
3. Check resistance between ignition coil terminals as follows.
Terminal No.

Resistance Ω [at 25°C (77°F)]

2 and 3

Except 0 or ∞

F

G

H

1 and 2
1 and 3

4.
5.
6.
7.

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

Except 0

If NG, replace ignition coil with power transistor.
If OK, go to next step.
Turn ignition switch OFF.
Reconnect all harness connectors disconnected.
Remove fuel pump fuse in IPDM E/R to release fuel pressure.
NOTE:
Do not use CONSULT-II to release fuel pressure, or fuel pressure applies again during the following procedure.
Start engine.
After engine stalls, crank it two or three times to release all fuel
pressure.
Turn ignition switch OFF.
Remove ignition coil harness connectors to avoid the electrical
discharge from the ignition coils.
Remove ignition coil and spark plug of the cylinder to be
checked.
Crank engine for 5 seconds or more to remove combustion gas in the cylinder.
Connect spark plug and harness connector to ignition coil.

EC-441

I

J
MBIB0032E

K

L

M

MBIB0277E

IGNITION SIGNAL
[CR (WITH EURO-OBD)]
15. Fix ignition coil using a rope etc. with gap of 13 — 17 mm
between the edge of the spark plug and grounded metal portion
as shown in the figure.
16. Crank engine for about 3 seconds, and check whether spark is
generated between the spark plug and the grounded part.
Spark should be generated.
CAUTION:
Do not approach to the spark plug and the ignition coil
within 50cm. Be careful not to get an electrical shock
while checking, because the electrical discharge voltage
PBIB2325E
becomes 20kV or more.
● If might cause to damage the ignition coil if the gap of more than 17 mm is taken.
NOTE:
When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning.
17. If NG, replace ignition coil with power transistor.
●

CONDENSER
1.
2.
3.

Turn ignition switch OFF.
Disconnect condenser harness connector.
Check resistance between condenser terminals 1 and 2.
Resistance: Above 1 MΩ at 25°C (77°F)

MBIB0031E

Removal and Installation

BBS0033H

IGNITION COIL WITH POWER TRANSISTOR
Refer to EM-29, «IGNITION COIL» .

EC-442

REFRIGERANT PRESSURE SENSOR
[CR (WITH EURO-OBD)]

REFRIGERANT PRESSURE SENSOR
Component Description

PFP:92136

A
BBS0033U

The refrigerant pressure sensor (1) is installed at the condenser of
the air conditioner system. The sensor uses an electrostatic volume
pressure transducer to convert refrigerant pressure to voltage. The
voltage signal is sent to ECM, and ECM controls cooling fan system.

EC

C

D
MBIB1492E

E

F

G

H
PBIB2657E

I

J

K

L

M

EC-443

REFRIGERANT PRESSURE SENSOR
[CR (WITH EURO-OBD)]

Wiring Diagram

BBS0033V

MBWA1540E

EC-444

REFRIGERANT PRESSURE SENSOR
[CR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

A

EC

WIRE
COLOR

ITEM

CONDITION

46

W

Sensor power supply
(Refrigerant pressure sensor)

57

Y

Sensor ground
(Refrigerant pressure sensor)

DATA (DC Voltage)

[Ignition switch: ON]

Approximately 5V

C

Approximately 0V

D

[Engine is running]
●

Warm-up condition

●

Idle speed

[Engine is running]
●

69

BR

Refrigerant pressure sensor
●

E

Warm-up condition
Both A/C switch and blower fan switch: ON.

1.0 — 4.0V

(Compressor operates.)

F

Diagnostic Procedure

BBS0033W

1. CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION
1.
2.
3.

G

Start engine and warm it up to normal operating temperature.
Turn A/C switch and blower fan switch ON.
Check voltage between ECM terminal 69 and ground with CONSULT-II or tester.

H

Voltage: 1.0 — 4.0V
I

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

J

MBIB0035E

K

2. CHECK GROUND CONNECTIONS
1.
2.
3.

L

Turn A/C switch and blower fan switch OFF.
Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-133, «Ground Inspection» .

M

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace ground connections.

EC-445

3.

Body ground E28

REFRIGERANT PRESSURE SENSOR
[CR (WITH EURO-OBD)]

3. CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT
1.
2.

Disconnect refrigerant pressure sensor (1) harness connector.
Turn ignition switch ON.

MBIB1492E

3.

Check voltage between refrigerant pressure sensor terminal 3
and ground with CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

SEF479Y

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F1
●
Harness for open or short between ECM and refrigerant pressure sensor
>> Repair harness or connectors.

5. CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 57 and refrigerant pressure sensor terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

6. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F1
●
Harness for open or short between ECM and refrigerant pressure sensor
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-446

REFRIGERANT PRESSURE SENSOR
[CR (WITH EURO-OBD)]

7. CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

A

Check harness continuity between ECM terminal 69 and refrigerant pressure sensor terminal 2.
Refer to Wiring Diagram.
EC

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.

C

8. DETECT MALFUNCTIONING PART

D

Check the following.
●
Harness connectors E48, F1
●
Harness for open or short between ECM and refrigerant pressure sensor

E

F

>> Repair open circuit or short to ground or short to power in harness or connectors.

9. CHECK INTERMITTENT INCIDENT

G

Refer to EC-127, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace refrigerant pressure sensor.
NG
>> Repair or replace.

Removal and Installation

H

BBS0033X

REFRIGERANT PRESSURE SENSOR
Refer to ATC-142, «Removal and Installation for Refrigerant Pressure Sensor» (Models with A/C) or MTC-88,
«Removal and Installation for Refrigerant Pressure Sensor» (Models without A/C).

I

J

K

L

M

EC-447

MI & DATA LINK CONNECTORS
[CR (WITH EURO-OBD)]

MI & DATA LINK CONNECTORS
Wiring Diagram

PFP:24814
BBS00341

MBWA1541E

EC-448

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR (WITH EURO-OBD)]

SERVICE DATA AND SPECIFICATIONS (SDS)
Fuel Pressure

PFP:00030

A
BBS00347

Approximately 350 kPa (3.5bar, 3.57kg/cm2 , 51psi)

Fuel pressure at idle

EC

Idle Speed

BBS00348

Target idle speed

No load* (in Neutral position)

Air conditioner: ON

In Neutral position

650 ± 50 rpm

C

900 rpm or more

*: Under the following conditions:
●

Air conditioner switch: OFF

●

Electric load: OFF (Lights, heater fan & rear window defogger)

●

Steering wheel: Kept in straight-ahead position

D

Calculated Load Value

BBS00349

Condition

E

Calculated load value% (Using CONSULT-II or GST)

At idle

10 – 35

At 2,500 rpm

10 – 35

Manifold Absolute Pressure Sensor

F

BBS0034A

Supply voltage

G

Approximately 5.0V

Output voltage at idle

1.4 – 1.5 V*

H

*: Engine is warmed up to normal operating temperature and running under no load.

Intake Air Temperature Sensor

BBS00487

Temperature °C (°F)

I

Resistance kΩ

25 (77)

1.9 – 2.1

Engine Coolant Temperature Sensor
Temperature °C (°F)

BBS00488

J

Resistance kΩ

20 (68)

2.1 – 2.9

50 (122)

0.68 – 1.00

90 (194)

0.236 – 0.260

K

L

Knock Sensor

BBS00489

Resistance [at 20°C (68°F)]

Approximately 530 – 590kΩ

M

Crankshaft Position Sensor (POS)

BBS0034F

Refer to EC-256, «Component Inspection» .

Camshaft Position Sensor (PHASE)

BBS0034G

Refer to EC-263, «Component Inspection» .

Heated Oxygen Sensor 1 Heater

BBS0034D

Resistance [at 25°C (77°F)]

3.4 – 4.4Ω

Heated Oxygen Sensor 2 Heater

BBS0034E

Resistance [at 25°C (77°F)]

8.0 – 10.0Ω

Intake Valve Timing Control Solenoid Valve
Resistance [at 20°C (68°F)]

BBS0048A

6.7 – 7.7Ω

EC-449

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR (WITH EURO-OBD)]

Throttle Control Motor

BBS0034H

Resistance [at 25°C (77°F)]

Approximately 1 – 15Ω

Fuel Injector

BBS0034I

Resistance [at 10 — 60°C (50 — 140°F)]

10.4 – 15.3Ω

Fuel Pump

BBS0034J

Resistance [at 25°C (77°F)]

Approximately 0.2 – 5.0Ω

EC-450

INDEX FOR DTC
[CR (WITHOUT EURO-OBD)]

INDEX FOR DTC
DTC No. Index

[CR (WITHOUT EURO-OBD)]

PFP:00024

A
BBS0034L

NOTE:
●
If DTC U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1001. Refer EC
to EC-549, «DTC U1001 CAN COMMUNICATION LINE» .
●
If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer
to EC-552, «DTC U1010 CAN COMMUNICATION» .
C
DTC*1
CONSULT-II

Items
(CONSULT-II screen terms)

ECM*2

Reference page

D
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

EC-480

No DTC

Flashing*3

U1001

1001*4

CAN COMM CIRCUIT

EC-549

U1010

1010

CONTROL UNIT(CAN)

EC-552

P0000

0000

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

P0011

0011

INT/V TIM CONT-B1

EC-554

P0107

0107

ABSL PRES SEN/CIRC

EC-559

P0108

0108

ABSL PRES SEN/CIRC

EC-559

P0117

0117

ECT SEN/CIRC

EC-565

P0118

0118

ECT SEN/CIRC

EC-565

P0122

0122

TP SEN 2/CIRC

EC-570

P0123

0123

TP SEN 2/CIRC

EC-570

P0132

0132

HO2S1 (B1)

EC-577

P0134

0134

HO2S1 (B1)

EC-584

P0138

0138

HO2S2 (B1)

EC-591

P0222

0222

TP SEN 1/CIRC

EC-598

P0223

0223

TP SEN 1/CIRC

EC-598

P0327

0327

KNOCK SEN/CIRC-B1

EC-605

P0328

0328

KNOCK SEN/CIRC-B1

EC-605

P0335

0335

CKP SEN/CIRCUIT

EC-609

P0340

0340

CMP SEN/CIRC-B1

EC-616

P0605

0605

ECM

EC-623

P1065

1065

ECM BACK UP/CIRCUIT

EC-626

P1111

1111

INT/V TIM V/CIR-B1

EC-630

P1121

1121

ETC ACTR

EC-635

P1122

1122

ETC FUNCTION/CIRC

EC-637

P1124

1124

ETC MOT PWR

EC-643

P1126

1126

ETC MOT PWR

EC-643

P1128

1128

ETC MOT

EC-649

E

F
—

P1171

1171

INTAKE ERROR

EC-654

P1211

1211

TCS C/U FUNTN

EC-660

P1212

1212

TCS/CIRC

EC-661

P1217

1217

ENG OVER TEMP

EC-662

P1225

1225

CTP LEARNING

EC-676

EC-451

G

H

I

J

K

L

M

INDEX FOR DTC
[CR (WITHOUT EURO-OBD)]
DTC*1

Items
(CONSULT-II screen terms)

Reference page

CONSULT-II

ECM*2

P1226

1226

CTP LEARNING

EC-678

P1229

1229

SENSOR POWER/CIRC

EC-680

P1610 — P1615

1610 — 1615

NATS MALFUNCTION

EC-473

P1706

1706

P-N POS SW/CIRCUIT

EC-688

P1805

1805

BRAKE SW/CIRCUIT

EC-693

P2122

2122

APP SEN 1/CIRC

EC-699

P2123

2123

APP SEN 1/CIRC

EC-699

P2127

2127

APP SEN 2/CIRC

EC-708

P2128

2128

APP SEN 2/CIRC

EC-708

P2135

2135

TP SENSOR

EC-718

P2138

2138

APP SENSOR

EC-725

*1: 1st trip DTC No. is the same as DTC No.
*2: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN.
*3: When engine is running.
*4: The troubleshooting for this DTC needs CONSULT-II.

EC-452

INDEX FOR DTC
[CR (WITHOUT EURO-OBD)]

Alphabetical Index

BBS0034K

A
NOTE:
●
If DTC U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1001. Refer
to EC-549, «DTC U1001 CAN COMMUNICATION LINE» .
●
If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer EC
to EC-552, «DTC U1010 CAN COMMUNICATION» .
Items
(CONSULT-II screen terms)

DTC*1

Reference page
ECM*

ABSL PRES SEN/CIRC

P0107

0107

EC-559

ABSL PRES SEN/CIRC

P0108

0108

EC-559

APP SEN 1/CIRC

P2122

2122

EC-699

APP SEN 1/CIRC

P2123

2123

EC-699

APP SEN 2/CIRC

P2127

2127

EC-708

APP SEN 2/CIRC

P2128

2128

EC-708

APP SENSOR

P2138

2138

EC-725

BRAKE SW/CIRCUIT

P1805

1805

EC-693

4

CAN COMM CIRCUIT

U1001

1001*

EC-549

CKP SEN/CIRCUIT

P0335

0335

EC-609

CMP SEN/CIRC-B1

P0340

0340

EC-616

CONTROL UNIT(CAN)

U1010

1010

EC-552

CTP LEARNING

P1225

1225

EC-676

CTP LEARNING

P1226

1226

EC-678

ECM

P0605

0605

EC-623

ECM BACK UP/CIRCUIT

P1065

1065

EC-626

ECT SEN/CIRC

P0117

0117

EC-565

ECT SEN/CIRC

P0118

0118

EC-565

ENG OVER TEMP

P1217

1217

EC-662

ETC ACTR

P1121

1121

EC-635

ETC FUNCTION/CIRC

P1122

1122

EC-637

ETC MOT

P1128

1128

EC-649

ETC MOT PWR

P1124

1124

EC-643

ETC MOT PWR

P1126

1126

EC-643

HO2S1 (B1)

P0132

0132

EC-577

HO2S1 (B1)

P0134

0134

EC-584

HO2S2 (B1)

P0138

0138

EC-591

INT/V TIM CONT-B1

P0011

0011

EC-554

INT/V TIM V/CIR-B1

P1111

1111

EC-630

INTAKE ERROR

P1171

1171

EC-654

KNOCK SEN/CIRC-B1

P0327

0327

EC-605

KNOCK SEN/CIRC-B1

P0328

0328

EC-605

NATS MALFUNCTION

P1610 — P1615

1610 — 1615

EC-473

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

No DTC

Flashing*3

EC-480

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

P0000

0000

—

EC-453

C

2

CONSULT-II

D

E

F

G

H

I

J

K

L

M

INDEX FOR DTC
[CR (WITHOUT EURO-OBD)]
Items
(CONSULT-II screen terms)

DTC*1
Reference page
CONSULT-II

ECM*2

P-N POS SW/CIRCUIT

P1706

1706

EC-688

SENSOR POWER/CIRC

P1229

1229

EC-680

TCS C/U FUNCTN

P1211

1211

EC-660

TCS/CIRC

P1212

1212

EC-661

TP SEN 1/CIRC

P0222

0222

EC-598

TP SEN 1/CIRC

P0223

0223

EC-598

TP SEN 2/CIRC

P0122

0122

EC-570

TP SEN 2/CIRC

P0123

0123

EC-570

TP SENSOR

P2135

2135

EC-718

*1: 1st trip DTC No. is the same as DTC No.
*2: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN.
*3: When engine is running.
*4: The troubleshooting for this DTC needs CONSULT-II.

EC-454

PRECAUTIONS
[CR (WITHOUT EURO-OBD)]

PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

A

BBS0047X

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along EC
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
C
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be perD
formed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
E
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
F

Maintenance Information

BBS005AR

If any of following part is replaced, always replace with new* one.
If it’s not (or fail to do so), the electrical system may not be operated properly.
*: New one means a virgin control unit that has never been energized on-board.

G

RHD MODELS

H

●
●
●
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM
IPDM E/R
Combination meter
EPS control unit

I

J

LHD MODELS
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM

Precautions for Procedures without Cowl Top Cover

K

L
BBS0047Y

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

M

PIIB3706J

On Board Diagnostic (OBD) System of Engine

BBS0034O

The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of
a malfunction causing emission deterioration.
CAUTION:
●
Be sure to turn the ignition switch OFF and disconnect the battery ground cable before any repair
or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will
cause the MI to light up.

EC-455

PRECAUTIONS
[CR (WITHOUT EURO-OBD)]
●

●

●

●

Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)
Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to PG-88, «HARNESS CONNECTOR» .
Be sure to route and secure the harnesses properly after work. The interference of the harness
with a bracket, etc. may cause the MI to light up due to the short circuit.
Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM.

Precaution
●
●

●

●

BBS0034P

Always use a 12 volt battery as power source.
Do not attempt to disconnect battery cables while engine is
running.
Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect negative
battery cable. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned off.
Before removing parts, turn ignition switch OFF and then
disconnect negative battery cable.
SEF289H

●
●

●

–
–
–
–

●

Do not disassemble ECM.
If battery cable is disconnected, the memory will return to
the initial ECM values.
The ECM will now start to self-control at its initial values.
Engine operation can vary slightly when the cable is disconnected. However, this is not an indication of a malfunction. Do not replace parts because of a slight variation.
If the battery is disconnected, the following emission
related diagnostic information will be lost within 24 hours.
Diagnostic trouble codes
1st trip diagnostic trouble codes
Freeze frame data
1st freeze frame data

PBIB1164E

When connecting ECM harness connector, fasten it
securely with levers as far as they will go as shown in the
figure.

PBIB1512E

EC-456

PRECAUTIONS
[CR (WITHOUT EURO-OBD)]
●

●

●

●
●

●

●
●
●

●

●

When connecting or disconnecting pin connectors into or
from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.
Securely connect ECM harness connectors.
A poor connection can cause an extremely high (surge)
voltage to develop in coil and condenser, thus resulting in
damage to ICs.
Keep engine control system harness at least 10 cm (4 in)
away from adjacent harness, to prevent engine control system malfunctions due to receiving external noise, degraded
operation of ICs, etc.
Keep engine control system parts and harness dry.
Before replacing ECM, perform ECM Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-512, «ECM Terminals and Reference Value»
.
Handle manifold absolute pressure sensor carefully to
avoid damage.
Do not clean air clear element with any type of detergent.
Do not disassemble electric throttle control actuator.
Even a slight leak in the air intake system can cause serious incidents.
Do not shock or jar the camshaft position sensor (PHASE),
crankshaft position sensor (POS).
After performing each TROUBLE DIAGNOSIS, perform DTC
Confirmation Procedure or Overall Function Check.
The DTC should not be displayed in the DTC Confirmation
Procedure if the repair is completed. The Overall Function
Check should be a good result if the repair is completed.

A

EC

C
PBIB0090E

D

E

F

G

MEF040D

H

I

J

K

SAT652J

L

M

EC-457

PRECAUTIONS
[CR (WITHOUT EURO-OBD)]
●

●

●

When measuring ECM signals with a circuit tester, connect
a break-out box (SST) and Y-cable adapter (SST) between
the ECM and ECM harness connector.
When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact.
Accidental contact of probes will cause a short circuit and
damage the ECM power transistor.
Do not use ECM ground terminals when measuring input/
output voltage. Doing so may result in damage to the ECM’s
transistor. Use a ground other than ECM terminals, such as
the ground.

SEF348N

●
●

Do not operate fuel pump when there is no fuel in lines.
Tighten fuel hose clamps to the specified torque.

MBIB0291E

●
●

●

Do not depress accelerator pedal when starting.
Immediately after starting, do not rev up engine unnecessarily.
Do not rev up engine just prior to shutdown.

SEF709Y

EC-458

PRECAUTIONS
[CR (WITHOUT EURO-OBD)]
●

–

–

–

–

When installing C.B. ham radio or a mobile phone, be sure
to observe the following as it may adversely affect electronic control systems depending on installation location.
Keep the antenna as far as possible from the electronic
control units.
Keep the antenna feeder line more than 20 cm (8 in) away
from the harness of electronic controls.
Do not let them run parallel for a long distance.
Adjust the antenna and feeder line so that the standingwave radio can be kept smaller.
Be sure to ground the radio to vehicle body.

A

EC

C
SEF708Y

D

E

F

G

H

I

J

K

L

M

EC-459

PREPARATION
[CR (WITHOUT EURO-OBD)]

PREPARATION
Special Service Tools

PFP:00002
BBS0034R

Tool number
Tool name

Description

EG17650301
Radiator cap tester
adapter

Adapting radiator cap tester to radiator cap and
radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
S-NT564

KV10117100
Heated oxygen
sensor wrench

Loosening or tightening heated oxygen sensors
with 22 mm (0.87 in) hexagon nut

S-NT379

KV10114400
Heated oxygen
sensor wrench

Loosening or tightening heated oxygen sensors
a: 22 mm (0.87 in)

S-NT636

KV109E0010
Break-out box

Measuring ECM signals with a circuit tester

NT825

KV109E0080
Y-cable adapter

Measuring ECM signals with a circuit tester

NT826

EC-460

PREPARATION
[CR (WITHOUT EURO-OBD)]

Commercial Service Tools

BBS0034S

A
Tool name

Description

Quick connector
release

Removing fuel tube quick connectors in engine
room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210)

EC

C
PBIC0198E

Fuel filler cap adapter

Checking fuel tank vacuum relief valve opening
pressure

D

E

S-NT653

Socket wrench

Removing and installing engine coolant
temperature sensor

F

G

H

S-NT705

Oxygen sensor thread
cleaner

Reconditioning the exhaust system threads
before installing a new oxygen sensor. Use with
anti-seize lubricant shown below.
a: 18 mm diameter with pitch 1.5 mm for
Zirconia Oxygen Sensor
b: 12 mm diameter with pitch 1.25 mm for
Titania Oxygen Sensor

J

Lubricating oxygen sensor thread cleaning tool
when reconditioning exhaust system threads.

K

I

AEM488

Anti-seize lubricant
i.e.: (PermatexTM
133AR or equivalent
meeting MIL
specification MIL-A907)

L
S-NT779

M

EC-461

ENGINE CONTROL SYSTEM
[CR (WITHOUT EURO-OBD)]

ENGINE CONTROL SYSTEM
System Diagram

PFP:23710
BBS0034T

MBIB1551E

EC-462

ENGINE CONTROL SYSTEM
[CR (WITHOUT EURO-OBD)]

Multiport Fuel Injection (MFI) System

BBS0034W

A

INPUT/OUTPUT SIGNAL CHART
Sensor

Input Signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*3
Piston position

Manifold absolute pressure sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Heated oxygen sensor 1

Density of oxygen in exhaust gas

Throttle position sensor

Throttle position

Accelerator pedal position sensor

Accelerator pedal position

Park/neutral position (PNP) switch

Gear position

Knock sensor

Engine knocking condition

ECM Function

Actuator

EC

C

D
Fuel injection
& mixture ratio
control

Fuel injector

E

voltage*3

Battery

Battery

EPS control unit

Power steering operation*2

Heated oxygen sensor 2*1

Density of oxygen in exhaust gas

Wheel sensor

Vehicle speed*2

Air conditioner switch

Air conditioner operation*2

F

G

*1: This sensor is not used to control the engine system under normal conditions.
*2: This signal is sent to the ECM through CAN communication line.
*3: ECM determines the start signal status by the signals of engine speed and battery voltage.

H

SYSTEM DESCRIPTION
The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of
time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the
ECM memory. The program value is preset by engine operating conditions. These conditions are determined
by input signals (for engine speed and intake air volume) from the crankshaft position sensor (POS), camshaft
position sensor (PHASE) and the manifold absolute pressure sensor.

I

J

VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION
In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below.

●
During warm-up
●
When starting the engine
●
During acceleration
●
Hot-engine operation
●
High-load, high-speed operation

●
During deceleration
●
During high engine speed operation

MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL)

PBIB2938E

EC-463

K

L

M

ENGINE CONTROL SYSTEM
[CR (WITHOUT EURO-OBD)]
The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control.
The three way catalyst (manifold) can then better reduce CO, HC and NOx emissions. This system uses
heated oxygen sensor 1 in the exhaust manifold to monitor whether the engine operation is rich or lean. The
ECM adjusts the injection pulse width according to the sensor voltage signal. For more information about
heated oxygen sensor 1, refer to EC-577 . This maintains the mixture ratio within the range of stoichiometric
(ideal air-fuel mixture).
This stage is referred to as the closed loop control condition.
Heated oxygen sensor 2 is located downstream of the three way catalyst (manifold). Even if the switching
characteristics of heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal
from heated oxygen sensor 2.

Open Loop Control
The open loop system condition refers to when the ECM detects any of the following conditions. Feedback
control stops in order to maintain stabilized fuel combustion.
●
Deceleration and acceleration
●
High-load, high-speed operation
●
Malfunction of heated oxygen sensor 1 or its circuit
●
Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature
●
High engine coolant temperature
●
During warm-up
●
When starting the engine

MIXTURE RATIO SELF-LEARNING CONTROL
The mixture ratio feedback control system monitors the mixture ratio signal transmitted from heated oxygen
sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to
the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. Both manufacturing differences (i.e., manifold absolute pressure sensor silicon diaphragm)
and characteristic changes during operation (i.e., fuel injector clogging) directly affect mixture ratio.
Accordingly, the difference between the basic and theoretical mixture ratios is monitored in this system. This is
then computed in terms of “injection pulse duration” to automatically compensate for the difference between
the two ratios.
“Fuel trim” refers to the feedback compensation value compared against the basic injection duration. Fuel trim
includes short term fuel trim and long term fuel trim.
“Short term fuel trim” is the short-term fuel compensation used to maintain the mixture ratio at its theoretical
value. The signal from heated oxygen sensor 1 indicates whether the mixture ratio is RICH or LEAN compared
to the theoretical value. The signal then triggers a reduction in fuel volume if the mixture ratio is rich, and an
increase in fuel volume if it is lean.
“Long term fuel trim” is overall fuel compensation carried out long-term to compensate for continual deviation
of the short term fuel trim from the central value. Such deviation will occur due to individual engine differences,
wear over time and changes in the usage environment.

FUEL INJECTION TIMING

SEF337W

Two types of systems are used.

Sequential Multiport Fuel Injection System
Fuel is injected into each cylinder during each engine cycle according to the firing order. This system is used
when the engine is running.

EC-464

ENGINE CONTROL SYSTEM
[CR (WITHOUT EURO-OBD)]
Simultaneous Multiport Fuel Injection System
Fuel is injected simultaneously into all four cylinders twice each engine cycle. In other words, pulse signals of A
the same width are simultaneously transmitted from the ECM.
The four fuel injectors will then receive the signals two times for each engine cycle.
This system is used when the engine is being started and/or if the fail-safe system (CPU) is operating.
EC

FUEL SHUT-OFF
Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds or
operation of the vehicle at excessively high speeds.

Electronic Ignition (EI) System

BBS0034X

INPUT/OUTPUT SIGNAL CHART
Sensor

C

D
Input Signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*2
Piston position

Manifold absolute pressure sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Throttle position sensor

Throttle position

Accelerator pedal position sensor

Accelerator pedal position

Knock sensor

Engine knocking

Park/neutral position (PNP) switch

Gear position

Battery

Battery voltage*2

Wheel sensor

Vehicle speed*1

ECM Function

Actuator

E

F
Ignition timing
control

Power transistor

G

H

*1: This signal is sent to the ECM through CAN communication line.
*2: ECM determines the start signal status by the signals of engine speed and battery voltage.

I

SYSTEM DESCRIPTION
Firing order: 1 — 3 — 4 — 2
The ignition timing is controlled by the ECM to maintain the best air-fuel ratio for every running condition of the
engine. The ignition timing data is stored in the ECM.
The ECM receives information such as the injection pulse width and camshaft position sensor signal. Computing this information, ignition signals are transmitted to the power transistor.
During the following conditions, the ignition timing is revised by the ECM according to the other data stored in
the ECM.
●
At starting
●
During warm-up
●
At idle
●
At low battery voltage
●
During acceleration
The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed
within the anti-knocking zone, if recommended fuel is used under dry conditions. The retard system does not
operate under normal driving conditions. If engine knocking occurs, the knock sensor monitors the condition.
The signal is transmitted to the ECM. The ECM retards the ignition timing to eliminate the knocking condition.

Fuel Cut Control (at No Load and High Engine Speed)

BBS0034Z

INPUT/OUTPUT SIGNAL CHART
Sensor

Input Signal to ECM

Park/neutral position (PNP) switch

Neutral position

Accelerator pedal position sensor

Accelerator pedal position

Engine coolant temperature sensor

Engine coolant temperature

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed

Wheel sensor

Vehicle speed*

EC-465

ECM Function

Fuel cut control

Actuator

Fuel injector

J

K

L

M

ENGINE CONTROL SYSTEM
[CR (WITHOUT EURO-OBD)]
*: This signal is sent to the ECM through CAN communication line.

SYSTEM DESCRIPTION
If the engine speed is above 2,500 rpm with no load (for example, the shift position is neutral and engine
speed is over 2,500 rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies
based on engine speed.
Fuel cut will operate until the engine speed reaches 2,000 rpm, then fuel cut is cancelled.
NOTE:
This function is different from deceleration control listed under EC-463, «Multiport Fuel Injection (MFI) System»
.

EC-466

AIR CONDITIONING CUT CONTROL
[CR (WITHOUT EURO-OBD)]

AIR CONDITIONING CUT CONTROL
Input/Output Signal Chart
Sensor

PFP:23710

A
BBS003ZG

Input Signal to ECM

Air conditioner switch

Air conditioner ON signal*

Accelerator pedal position sensor

Accelerator pedal position

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*2

Engine coolant temperature sensor

Engine coolant temperature

Refrigerant pressure sensor

Refrigerant pressure

Actuator

EC

C
Air conditioner
cut control

Air conditioner relay

D

1

Wheel sensor

Vehicle speed*

EPS control unit

Power steering operation*1

Battery

ECM Function

1

E

2

Battery voltage*

*1: This signal is sent to the ECM through CAN communication line.
*2: ECM determines the start signal status by the signals of engine speed and battery voltage.

F

SYSTEM DESCRIPTION
This system improves engine operation when the air conditioner is used.
Under the following conditions, the air conditioner is turned OFF.
●
When the accelerator pedal is fully depressed.
●
When cranking the engine.
●
At high engine speeds.
●
When the engine coolant temperature becomes excessively high.
●
When operating power steering during low engine speed or low vehicle speed.
●
When engine speed is excessively low.
●
When refrigerant pressure is excessively low or high.

G

H

I

J

K

L

M

EC-467

CAN COMMUNICATION
[CR (WITHOUT EURO-OBD)]

CAN COMMUNICATION
System Description

PFP:23710
BBS003ZH

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
Refer to LAN-21, «CAN COMMUNICATION» , about CAN communication for detail.

EC-468

EVAPORATIVE EMISSION SYSTEM
[CR (WITHOUT EURO-OBD)]

EVAPORATIVE EMISSION SYSTEM
Description

PFP:14950

A
BBS003DD

SYSTEM DESCRIPTION
EC

C

D

E

F

G
PBIB0491E

The evaporative emission system is used to reduce hydrocarbons emitted into the atmosphere from the fuel
system. This reduction of hydrocarbons is accomplished by activated charcoals in the EVAP canister.
The fuel vapor in the sealed fuel tank is led into the EVAP canister which contains activated carbon and the
vapor is stored there when the engine is not operating or when refueling to the fuel tank.
The vapor in the EVAP canister is purged by the air through the purge line to the intake manifold when the
engine is operating. EVAP canister purge volume control solenoid valve is controlled by ECM. When the
engine operates, the flow rate of vapor controlled by EVAP canister purge volume control solenoid valve is
proportionally regulated as the air flow increases.
EVAP canister purge volume control solenoid valve also shuts off the vapor purge line during decelerating and
idling.

H

I

J

K

L

M

EC-469

EVAPORATIVE EMISSION SYSTEM
[CR (WITHOUT EURO-OBD)]
EVAPORATIVE EMISSION LINE DRAWING

MBIB0544E

EC-470

EVAPORATIVE EMISSION SYSTEM
[CR (WITHOUT EURO-OBD)]
A

EC

C

D

E

F

G

H

MBIB1450E

: Vehicle front
1.

: To previous page

I

EVAP canister

J

K

L

M

EC-471

EVAPORATIVE EMISSION SYSTEM
[CR (WITHOUT EURO-OBD)]

Component Inspection

BBS003DE

EVAP CANISTER
Check EVAP canister as follows:
1. Block port (B).
2. Blow air into port (A) and check that it flows freely out of port (C).
3. Release blocked port (B).
4. Apply vacuum pressure to port (B) and check that vacuum pressure exists at the ports (A) and (C).
5. Block port (A) and (B).
6. Apply pressure to port (C) and check that there is no leakage.
PBIB2961E

FUEL CHECK VALVE
1.

2.
3.

Blow air through connector on fuel tank side.
A considerable resistance should be felt and a portion of air flow
should be directed toward the EVAP canister side.
Blow air through connector on EVAP canister side.
Air flow should be smoothly directed toward fuel tank side.
If fuel check valve is suspected of not properly functioning in
steps 1 and 2 above, replace it.

SEF552Y

FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP)
1.

Wipe clean valve housing.

SEF989X

2.

Check valve opening pressure and vacuum.
Pressure:
Vacuum:

3.

15.3 — 20.0 kPa (0.153 — 0.200 bar,
0.156 — 0.204 kg/cm2 , 2.22 — 2.90 psi)
−6.0 to −3.4 kPa (−0.060 to −0.034 bar,
−0.061 to −0.035 kg/cm2 , −0.87 to −0.49 psi)

If out of specification, replace fuel filler cap as an assembly.

SEF943S

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
Refer to EC-743, «Component Inspection» .

EC-472

NATS (NISSAN ANTI-THEFT SYSTEM)
[CR (WITHOUT EURO-OBD)]

NATS (NISSAN ANTI-THEFT SYSTEM)
Description
●

●

●

PFP:25386

A
BBS00359

If the security indicator lights up with the ignition switch in
the ON position or “NATS MALFUNCTION” is displayed on
EC
“SELF-DIAG RESULTS” screen, perform self-diagnostic
results mode with CONSULT-II using NATS program card.
Refer to BL-215, «NATS (Nissan Anti-Theft System)» .
C
Confirm no self-diagnostic results of NATS is displayed
before touching “ERASE” in “SELF-DIAG RESULTS” mode
with CONSULT-II.
D
When replacing ECM, initialization of NATS system and registration of all NATS ignition key IDs must be carried out
SEF515Y
with CONSULT-II using NATS program card.
Therefore, be sure to receive all keys from vehicle owner.
E
Regarding the procedures of NATS initialization and all NATS ignition key ID registration, refer to
CONSULT-II Operation Manual, NATS.
F

G

H

I

J

K

L

M

EC-473

POSITIVE CRANKCASE VENTILATION
[CR (WITHOUT EURO-OBD)]

POSITIVE CRANKCASE VENTILATION
Description

PFP:11810
BBS003DF

SYSTEM DESCRIPTION

PBIB0492E

This system returns blow-by gas to the intake manifold.
The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake
manifold. During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the
PCV valve. Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air. The ventilating air is then drawn from the air inlet tubes into the crankcase. In this process the air
passes through the hose connecting air inlet tubes to rocker cover. Under full-throttle condition, the manifold
vacuum is insufficient to draw the blow-by flow through the valve. The flow goes through the hose connection
in the reverse direction.
On vehicles with an excessively high blow-by, the valve does not
meet the requirement. This is because some of the flow will go
through the hose connection to the air inlet tubes under all conditions.

PBIB1588E

Component Inspection

BBS003DG

PCV (POSITIVE CRANKCASE VENTILATION) VALVE
With engine running at idle, remove PCV valve from rocker cover. A
properly working valve makes a hissing noise as air passes through
it. A strong vacuum should be felt immediately when a finger is
placed over valve inlet.

PBIB1589E

EC-474

POSITIVE CRANKCASE VENTILATION
[CR (WITHOUT EURO-OBD)]
PCV VALVE VENTILATION HOSE
1.
2.

A

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

EC

C

S-ET277

D

E

F

G

H

I

J

K

L

M

EC-475

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITHOUT EURO-OBD)]

ON BOARD DIAGNOSTIC (OBD) SYSTEM
Introduction

PFP:00028
BBS00356

The ECM has an on board diagnostic system, which detects malfunctions related to engine sensors or actuators. The ECM also records various emission-related diagnostic information including:
Emission-related diagnostic information
Diagnostic Trouble Code (DTC)
Freeze Frame data
1st Trip Diagnostic Trouble Code (1st Trip DTC)
1st Trip Freeze Frame data

The above information can be checked using procedures listed in the table below.

×: Applicable

—: Not applicable

DTC

1st trip DTC

Freeze Frame data

1st trip Freeze Frame
data

CONSULT-II

×

×

×

×

ECM

×

×*

—

—

*: When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other.

The malfunction indicator (MI) on the instrument panel lights up when the same malfunction is detected in two
consecutive trips (Two trip detection logic), or when the ECM enters fail-safe mode. (Refer to EC-498 .)

Two Trip Detection Logic

BBS00357

When a malfunction is detected for the first time, 1st trip DTC and 1st trip Freeze Frame data are stored in the
ECM memory. The MI will not light up at this stage. <1st trip>
If the same malfunction is detected again during the next drive, the DTC and Freeze Frame data are stored in
the ECM memory, and the MI lights up. The MI lights up at the same time when the DTC is stored. <2nd trip>
The “trip” in the “Two Trip Detection Logic” means a driving mode in which self-diagnosis is performed during
vehicle operation.
When there is an open circuit on MI circuit, the ECM can not warn the driver by lighting up MI when there is a
malfunction on engine control system.
Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as
NG for 5 trips, ECM warns the driver that engine control system has malfunction and MI circuit is open by
means of operating fail-safe function.
The fail-safe function also operate when above diagnoses except MI circuit are detected and demands the
driver to repair the malfunction.
Engine operating condition in fail-safe mode

Engine speed will not rise more than 2,500 rpm due to the fuel cut

Emission-related Diagnostic Information

BBS00358

EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS
Items
(CONSULT-II screen terms)

×: Applicable —: Not applicable

DTC*1
Trip

MI lighting up

Reference page

1001*3

2

—

EC-549

U1010

1010

2

—

EC-552

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

P0000

0000

—

—

—

INT/V TIM CONT-B1

P0011

0011

2

—

EC-554

ABSL PRES SEN/CIRC

P0107

0107

2

×

EC-559

ABSL PRES SEN/CIRC

P0108

0108

2

×

EC-559

ECT SEN/CIRC

P0117

0117

2

×

EC-565

ECT SEN/CIRC

P0118

0118

2

×

EC-565

TP SEN 2/CIRC

P0122

0122

1

×

EC-570

CONSULT-II

ECM*2

CAN COMM CIRCUIT

U1001

CONTROL UNIT(CAN)

EC-476

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITHOUT EURO-OBD)]
Items
(CONSULT-II screen terms)

DTC*1
Trip

MI lighting up

Reference page

0123

1

×

EC-570

P0132

0132

2

×

EC-577

HO2S1 (B1)

P0134

0134

2

×

EC-584

HO2S2 (B1)

P0138

0138

2

×

EC-591

TP SEN 1/CIRC

P0222

0222

1

×

EC-598

CONSULT-II

ECM*2

TP SEN 2/CIRC

P0123

HO2S1 (B1)

TP SEN 1/CIRC

P0223

0223

1

×

EC-598

KNOCK SEN/CIRC-B1

P0327

0327

2

—

EC-605

KNOCK SEN/CIRC-B1

P0328

0328

2

—

EC-605

CKP SEN/CIRCUIT

P0335

0335

2

×

EC-609

CMP SEN/CIRC-B1

P0340

0340

2

×

EC-616

ECM

P0605

0605

1 or 2

× or —

EC-623

ECM BACK UP/CIRCUIT

P1065

1065

2

×

EC-626

INT/V TIM V/CIR-B1

P1111

1111

2

×

EC-630

ETC ACTR

P1121

1121

1

×

EC-635

ETC FUNCTION/CIRC

P1122

1122

1

×

EC-637

ETC MOT PWR

P1124

1124

1

×

EC-643

ETC MOT PWR

P1126

1126

1

×

EC-643

ETC MOT

P1128

1128

1

×

EC-649

INTAKE ERROR

P1171

1171

1

×

EC-654

TCS C/U FUNCTN

P1211

1211

2

—

EC-660

TCS/CIRC

P1212

1212

2

—

EC-661

ENG OVER TEMP

P1217

1217

1

×

EC-662

CTP LEARNING

P1225

1225

2

—

EC-676

CTP LEARNING

P1226

1226

2

—

EC-678

SENSOR POWER/CIRC

P1229

1229

1

×

EC-680

NATS MALFUNCTION

P1610 — P1615

1610 — 1615

2

—

BL-215

P-N POS SW/CIRCUIT

P1706

1706

2

×

EC-688

BRAKE SW/CIRCUIT

P1805

1805

1

×

EC-693

APP SEN 1/CIRC

P2122

2122

1

×

EC-699

APP SEN 1/CIRC

P2123

2123

1

×

EC-699

APP SEN 2/CIRC

P2127

2127

1

×

EC-708

APP SEN 2/CIRC

P2128

2128

1

×

EC-708

TP SENSOR

P2135

2135

1

×

EC-718

APP SENSOR

P2138

2138

1

×

EC-725

*1: 1st trip DTC No. is the same as DTC No.
*2: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN.
*3: The troubleshooting for this DTC needs CONSULT-II.

DTC AND 1ST TRIP DTC
The 1st trip DTC (whose number is the same as the DTC number) is displayed for the latest self-diagnostic
result obtained. If the ECM memory was cleared previously, and the 1st trip DTC did not reoccur, the 1st trip
DTC will not be displayed.
If a malfunction is detected during the 1st trip, the 1st trip DTC is stored in the ECM memory. The MI will not
light up (two trip detection logic). If the same malfunction is not detected in the 2nd trip (meeting the required
driving pattern), the 1st trip DTC is cleared from the ECM memory. If the same malfunction is detected in the
2nd trip, both the 1st trip DTC and DTC are stored in the ECM memory and the MI lights up. In other words,

EC-477

A

EC

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ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITHOUT EURO-OBD)]
the DTC is stored in the ECM memory and the MI lights up when the same malfunction occurs in two consecutive trips. If a 1st trip DTC is stored and a non-diagnostic operation is performed between the 1st and 2nd
trips, only the 1st trip DTC will continue to be stored.
For fail-safe items, DTC is stored in the ECM memory even in the 1st trip.
Procedures for clearing the DTC and the 1st trip DTC from the ECM memory are described in EC-478, «HOW
TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION»
When a 1st trip DTC is detected, check, print out or write down and erase (1st trip) DTC and Freeze Frame
data as specified in Work Flow procedure Step 2, refer to EC-492, «WORK FLOW» . Then perform DTC Confirmation Procedure or Overall Function Check to try to duplicate the malfunction. If the malfunction is duplicated, the item requires repair.

How to Read DTC and 1st Trip DTC
DTC and 1st trip DTC can be read by the following methods.
With CONSULT-II
CONSULT-II displays the DTC in “SEFL-DIAG RESULTS” mode. Examples: P0117, P0340, P1065, etc.
(CONSULT-II also displays the malfunctioning component or system.)
Without CONSULT-II
The number of blinks of the MI in the Diagnostic Test Mode II (Self-Diagnostic Results) indicates the DTC.
Example: 0107, 0340, 1065 etc.
●
1st trip DTC No. is the same as DTC No.
●
Output of a DTC indicates a malfunction. However, the Diagnostic Test Mode II do not indicate
whether the malfunction is still occurring or has occurred in the past and has returned to normal.
CONSULT-II can identify malfunction status as shown below. Therefore, using CONSULT-II (if available) is recommended.
A sample of CONSULT-II display for DTC and 1st trip DTC is shown below. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many times
the vehicle was driven after the last detection of a DTC.
If the DTC is being detected currently, the time data will be [0].
If a 1st trip DTC is stored in the ECM, the time data will be [1t].

PBIB0911E

FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA
The ECM records the driving conditions such as fuel system status, calculated load value, engine coolant temperature, short term fuel trim, long term fuel trim, engine speed, vehicle speed, base fuel schedule and intake
air temperature at the moment a malfunction is detected.
Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data.
The data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II. For
details, see EC-521, «Freeze Frame Data and 1st Trip Freeze Frame Data» .
Only one set of freeze frame data (either 1st trip freeze frame data or freeze frame data) can be stored in the
ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no priority
for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once
freeze frame data (2nd trip detection/MI on) is stored in the ECM memory, 1st trip freeze frame data is no
longer stored. Remember, only one set of freeze frame data can be stored in the ECM. Both 1st trip freeze
frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased. Procedures for clearing the ECM memory are described in EC-478, «HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .

HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION
How to Erase DTC
With CONSULT-II

EC-478

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITHOUT EURO-OBD)]
The emission related diagnostic information in the ECM can be erased by selecting “ERASE” in the “SELFDIAG RESULTS” mode with CONSULT-II.
A
1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once.
Wait at least 10 seconds and then turn it ON (engine stopped) again.
2. Touch “ENGINE”.
EC
3. Touch “SELF-DIAG RESULTS”.
4. Touch “ERASE”. (The DTC in the ECM will be erased.)
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MBIB1303E

Without CONSULT-II
1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once.
2. Wait at least 10 seconds and then turn it ON (engine stopped) again.
3. Change the diagnostic test mode from Mode II to Mode I by depressing the accelerator pedal. Refer to
EC-480, «HOW TO SWITCH DIAGNOSTIC TEST MODE» .
●
If the battery is disconnected, the emission-related diagnostic information will be lost within 24
hours.
●
The following data are cleared when the ECM memory is erased.
–
Diagnostic trouble codes
–
1st trip diagnostic trouble codes
–
Freeze frame data
–
1st trip freeze frame data
Actual work procedures are explained using a DTC as an example. Be careful so that not only the DTC, but all
of the data listed above, are cleared from the ECM memory during work procedures.

Malfunction Indicator (MI)

BBS0035A

DESCRIPTION
The MI is located on the instrument panel.
1. The MI will light up when the ignition switch is turned ON without
the engine running. This is a bulb check.
If the MI does not light up, refer to DI-32, «WARNING LAMPS»
or see EC-800 .
2. When the engine is started, the MI should go off.
If the MI remains on, the on board diagnostic system has
detected an engine system malfunction.

SAT652J

EC-479

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ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITHOUT EURO-OBD)]
ON BOARD DIAGNOSTIC SYSTEM FUNCTION
The on board diagnostic system has the following four functions.
Diagnostic Test
Mode

KEY and ENG.
Status

Function

Explanation of Function

Mode I

Ignition switch in
ON position

BULB CHECK

This function checks the MI bulb for damage (blown, open
circuit, etc.).
If the MI does not come on, check MI circuit.

Engine running

MALFUNCTION
WARNING

This is a usual driving condition. When a malfunction is
detected twice in two consecutive driving cycles (two trip
detection logic), the MI will light up to inform the driver that
a malfunction has been detected.
One trip detection diagnosis will light up or blink the MI in
the 1st trip.

Ignition switch in
ON position

SELF-DIAGNOSTIC
RESULTS

This function allows DTCs and 1st trip DTCs to be read.

HEATED OXYGEN SENSOR 1
MONITOR

This function allows the fuel mixture condition (lean or
rich), monitored by heated oxygen sensor 1, to be read.

Engine stopped

Mode II

Engine stopped

Engine running

When there is an open circuit on MI circuit, the ECM can not warn the driver by lighting up MI when there is
malfunction on engine control system.
Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as
NG for 5 trips, ECM warns the driver that engine control system has a malfunction and MI circuit is open by
means of operating fail-safe function.
The fail-safe function also operate when above diagnoses except MI circuit are detected and demands the
driver to repair the a malfunction.
Engine operating condition in fail-safe mode

Engine speed will not rise more than 2,500 rpm due to the fuel cut

MI Flashing without DTC
If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM diagnostic test mode. EC-480, «HOW TO SWITCH DIAGNOSTIC TEST MODE» .
How to switch the diagnostic test (function) modes, and details of the above functions are described later, EC480, «HOW TO SWITCH DIAGNOSTIC TEST MODE» .
The following emission-related diagnostic information is cleared when the ECM memory is erased.
●
Diagnostic trouble codes
●
1st trip diagnostic trouble codes
●
Freeze frame data
●
1st trip freeze frame data

HOW TO SWITCH DIAGNOSTIC TEST MODE
NOTE:
●
It is better to count the time accurately with a clock.
●
It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit
has a malfunction.

EC-480

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITHOUT EURO-OBD)]
●

Always ECM returns to Diagnostic Test Mode I after ignition switch is turned OFF.
A

How to Set Diagnostic Test Mode II (Self-diagnostic Results)
1.
2.
a.
b.
3.
4.

Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds.
Repeat the following procedure quickly five times within 5 seconds.
EC
Fully depress the accelerator pedal.
Fully release the accelerator pedal.
Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 10 seconds until the MI starts C
blinking.
Fully release the accelerator pedal.
ECM has entered to Diagnostic Test Mode II (Self-diagnostic results).
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PBIB0092E

How to Set Diagnostic Test Mode II (Heated Oxygen Sensor 1 Monitor)
1.
2.

Set the ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-481, «How to Set Diagnostic
Test Mode II (Self-diagnostic Results)» .
Start Engine.
ECM has entered to Diagnostic Test Mode II (Heated oxygen sensor 1 monitor).

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How to Erase Diagnostic Test Mode II (Self-diagnostic Results)
1.
2.
3.

Set ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-481, «How to Set Diagnostic
Test Mode II (Self-diagnostic Results)» .
Fully depress the accelerator pedal and keep it for more than 10 seconds.
The emission-related diagnostic information has been erased from the backup memory in the ECM.
Fully release the accelerator pedal, and confirm the DTC 0000 is displayed.

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DIAGNOSTIC TEST MODE I — BULB CHECK
In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to DI-32,
«WARNING LAMPS» or see EC-800 .

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DIAGNOSTIC TEST MODE I — MALFUNCTION WARNING
MI

●

Condition

ON

When the malfunction is detected.

OFF

No malfunction.

These DTC numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS)

DIAGNOSTIC TEST MODE II — SELF-DIAGNOSTIC RESULTS
In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI as shown below.
The DTC and 1st trip DTC are displayed at the same time. If the MI does not illuminate in diagnostic test mode
I (Malfunction warning), all displayed items are 1st trip DTCs. If only one code is displayed when the MI illuminates in diagnostic test mode II (SELF-DIAGNOSTIC RESULTS), it is a DTC; if two or more codes are dis-

EC-481

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ON BOARD DIAGNOSTIC (OBD) SYSTEM
[CR (WITHOUT EURO-OBD)]
played, they may be either DTCs or 1st trip DTCs. DTC No. is same as that of 1st trip DTC. These unidentified
codes can be identified by using the CONSULT-II. A DTC will be used as an example for how to read a code.

PBIA3905E

A particular trouble code can be identified by the number of four-digit numeral flashes. The “zero” is indicated
by the number of ten flashes. The length of time the 1,000th-digit numeral flashes on and off is 1.2 seconds
consisting of an ON (0.6-second) — OFF (0.6-second) cycle.
The 100th-digit numeral and lower digit numerals consist of a 0.3-second ON and 0.3-second OFF cycle.
A change from one digit numeral to another occurs at an interval of 1.0-second OFF. In other words, the later
numeral appears on the display 1.3 seconds after the former numeral has disappeared.
A change from one trouble code to another occurs at an interval of 1.8-second OFF.
In this way, all the detected malfunctions are classified by their DTC numbers. The DTC 0000 refers to no malfunction. (See EC-451, «INDEX FOR DTC» )

How to Erase Diagnostic Test Mode II (Self-diagnostic Results)
The DTC can be erased from the back up memory in the ECM by depressing accelerator pedal. Refer to EC480, «HOW TO SWITCH DIAGNOSTIC TEST MODE» .
●
If the battery is disconnected, the DTC will be lost from the backup memory within 24 hours.
●
Be careful not to erase the stored memory before starting trouble diagnoses.

DIAGNOSTIC TEST MODE II — HEATED OXYGEN SENSOR 1 MONITOR
In this mode, the MI displays the condition of the fuel mixture (lean or rich) which is monitored by the heated
oxygen sensor 1.
MI

Fuel mixture condition in the exhaust gas

ON

Lean

OFF

Rich

*Remains ON or OFF

Any condition

Air-fuel ratio feedback control condition
Closed loop system
Open loop system

*: Maintains conditions just before switching to open loop.

To check the heated oxygen sensor 1 function, start engine in the Diagnostic Test Mode II and warm it up until
engine coolant temperature indicator points to the middle of the gauge.
Next run engine at about 2,000 rpm for about 2 minutes under no load conditions. Then make sure that the MI
comes ON more than 5 times within 10 seconds with engine running at 2,000 rpm under no load.

EC-482

BASIC SERVICE PROCEDURE
[CR (WITHOUT EURO-OBD)]

BASIC SERVICE PROCEDURE
Basic Inspection

PFP:00018

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BBS0035E

1. INSPECTION START
1.
2.
–
–
–
–
–
–

3.
–
–
–
–

4.

Check service records for any recent repairs that may indicate a related malfunction, or a current need for
scheduled maintenance.
Open engine hood and check the following:
Harness connectors for improper connections
Wiring harness for improper connections, pinches and cut
Vacuum hoses for splits, kinks and improper connections
Hoses and ducts for leaks
Air cleaner clogging
Gasket
Confirm that electrical or mechanical loads are not applied.
Headlamp switch is OFF.
SEF983U
Air conditioner switch is OFF.
Rear window defogger switch is OFF.
Steering wheel is in the straight-ahead position, etc.
Start engine and warm it up until engine coolant temperature
indicator points the middle of gauge.
Ensure engine stays below 1,000 rpm.

EC

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SEF976U

5.

Run engine at about 2,000 rpm for about 2 minutes under no
load.
6. Make sure that no DTC is displayed with CONSULT-II.
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

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SEF977U

2. REPAIR OR REPLACE
Repair or replace components as necessary according to corresponding Diagnostic Procedure.
>> GO TO 3

EC-483

BASIC SERVICE PROCEDURE
[CR (WITHOUT EURO-OBD)]

3. CHECK TARGET IDLE SPEED
1.
2.

With CONSULT-II
Run engine at about 2,000 rpm for about 2 minutes under no load.
Rev engine (2,000 to 3,000 rpm) two or three times under no
load, then run engine at idle speed for about 1 minute.

PBIA8513J

3.

Read idle speed in “DATA MONITOR” mode with CONSULT-II.
Refer to EC-486, «IDLE SPEED» .
650 ± 50 rpm (in Neutral position)

SEF058Y

Without CONSULT-II
Run engine at about 2,000 rpm for about 2 minutes under no load.
Rev engine (2,000 to 3,000 rpm) two or three times under no load, then run engine at idle speed for about
1 minute.
3. Check idle speed. Refer to EC-486, «IDLE SPEED» .
1.
2.

650 ± 50 rpm (in Neutral position)
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 4.

4. PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING
1.
2.

Stop engine.
Perform EC-486, «Accelerator Pedal Released Position Learning» .
>> GO TO 5.

5. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING
Perform EC-486, «Throttle Valve Closed Position Learning» .
>> GO TO 6.

EC-484

BASIC SERVICE PROCEDURE
[CR (WITHOUT EURO-OBD)]

6. PERFORM IDLE AIR VOLUME LEARNING

A

Refer to EC-486, «Idle Air Volume Learning» .
Is Idle Air Volume Learning carried out successfully?
Yes or No
Yes
>> GO TO 7.
No
>> 1. Follow the instruction of Idle Air Volume Learning.
2. GO TO 4.

EC

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7. CHECK TARGET IDLE SPEED AGAIN
With CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Read idle speed in “DATA MONITOR” mode with CONSULT-II.
Refer to EC-486, «IDLE SPEED» .

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650 ± 50 rpm (in Neutral position)
Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Check idle speed. Refer to EC-486, «IDLE SPEED» .

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650 ± 50 rpm (in Neutral position)
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 8.

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8. DETECT MALFUNCTIONING PART

I

Check the following.
●
Check camshaft position sensor (PHASE) and circuit. Refer to EC-616 .
●
Check crankshaft position sensor (POS) and circuit. Refer to EC-609 .
OK or NG
OK
>> GO TO 9.
NG
>> 1. Repair or replace.
2. GO TO 4.

2.

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9. CHECK ECM FUNCTION
1.

J

Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but
this is a rare case.)
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to EC-473,
«Description» .
>> GO TO 4.

EC-485

M

BASIC SERVICE PROCEDURE
[CR (WITHOUT EURO-OBD)]

Idle Speed Check

BBS00351

IDLE SPEED
With CONSULT-II
Check idle speed in “DATA MONITOR” mode with CONSULT-II.

SEF058Y

Without CONSULT-II
Check idle speed by installing the pulse type tachometer clamp on the loop wire or on suitable high-tension
wire which installed between No. 1 ignition coil and No. 1 spark plug.

Accelerator Pedal Released Position Learning

BBS00352

DESCRIPTION
Accelerator Pedal Released Position Learning is an operation to learn the fully released position of the accelerator pedal by monitoring the accelerator pedal position sensor output signal. It must be performed each time
harness connector of accelerator pedal position sensor or ECM is disconnected.

OPERATION PROCEDURE
1.
2.
3.
4.
5.

Make sure that accelerator pedal is fully released.
Turn ignition switch ON and wait at least 2 seconds.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON and wait at least 2 seconds.
Turn ignition switch OFF and wait at least 10 seconds.

Throttle Valve Closed Position Learning

BBS00353

DESCRIPTION
Throttle Valve Closed Position Learning is an operation to learn the fully closed position of the throttle valve by
monitoring the throttle position sensor output signal. It must be performed each time harness connector of
electric throttle control actuator or ECM is disconnected.

OPERATION PROCEDURE
1.
2.
3.

Make sure that accelerator pedal is fully released.
Turn ignition switch ON.
Turn ignition switch OFF and wait at least 10 seconds.
Make sure that throttle valve moves during above 10 seconds by confirming the operating sound.

Idle Air Volume Learning

BBS00354

DESCRIPTION
Idle Air Volume Learning is an operation to learn the idle air volume that keeps each engine within the specific
range. It must be performed under any of the following conditions:
●
Each time electric throttle control actuator or ECM is replaced.
●
Idle speed is out of specification.

PREPARATION
Before performing Idle Air Volume Learning, make sure that all of the following conditions are satisfied.
Learning will be cancelled if any of the following conditions are missed for even a moment.
●
Battery voltage: More than 12.9V (At idle)
●
Engine coolant temperature: 70 — 100°C (158 — 212°F)
●
PNP switch: ON
●
Electric load switch: OFF

EC-486

BASIC SERVICE PROCEDURE
[CR (WITHOUT EURO-OBD)]
(Air conditioner, headlamp, rear window defogger)
On vehicles equipped with daytime light systems, set lighting switch to the 1st position to light A
only small lamps.
Steering wheel: Neutral (Straight-ahead position)
Vehicle speed: Stopped
EC
Transmission: Warmed-up
Drive vehicle for 10 minutes.
C

●
●
●
–

OPERATION PROCEDURE
With CONSULT-II
1.
2.
3.
4.
5.

Perform EC-486, «Accelerator Pedal Released Position Learning» .
Perform EC-486, «Throttle Valve Closed Position Learning» .
Start engine and warm it up to normal operating temperature.
Check that all items listed under the topic PREPARATION (previously mentioned) are in good order.
Select “IDLE AIR VOL LEARN” in “WORK SUPPORT” mode.

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SEF217Z

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Touch “START” and wait 20 seconds.

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SEF454Y

7.

8.

Make sure that “CMPLT” is displayed on CONSULT-II screen. If
“CMPLT” is not displayed, Idle Air Volume Learning will not be
carried out successfully. In this case, find the cause of the incident by referring to the Diagnostic Procedure below.
Rev up the engine two or three times and make sure that idle
speed is within the specifications.

ITEM

SPECIFICATION

Idle speed

650 ± 50 rpm (in Neutral position)

M

MBIB0238E

Without CONSULT-II
NOTE:
●
It is better to count the time accurately with a clock.
●
It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit
has a malfunction.
1. Perform EC-486, «Accelerator Pedal Released Position Learning» .
2. Perform EC-486, «Throttle Valve Closed Position Learning» .

EC-487

L

BASIC SERVICE PROCEDURE
[CR (WITHOUT EURO-OBD)]
3.
4.
5.
6.
7.
a.
b.
8.

Start engine and warm it up to normal operating temperature.
Check that all items listed under the topic PREPARATION (previously mentioned) are in good order.
Turn ignition switch OFF and wait at least 10 seconds.
Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds.
Repeat the following procedure quickly five times within 5 seconds.
Fully depress the accelerator pedal.
Fully release the accelerator pedal.
Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 20 seconds until the MI stops
blinking and turned ON.
9. Fully release the accelerator pedal within 3 seconds after the MI turned ON.
10. Start engine and let it idle.
11. Wait 20 seconds.

PBIB0665E

12. Rev up the engine two or three times and make sure that idle speed is within the specifications.
ITEM

SPECIFICATION

Idle speed

650 ± 50 rpm (in Neutral position)

13. If idle speed is not within the specification, Idle Air Volume Learning will not be carried out successfully. In
this case, find the cause of the incident by referring to the Diagnostic Procedure below.

DIAGNOSTIC PROCEDURE
If idle air volume learning cannot be performed successfully, proceed as follows:
1. Check that throttle valve is fully closed.
2. Check PCV valve operation.
3. Check that downstream of throttle valve is free from air leakage.
4. When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the incident.
It is useful to perform EC-532, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .
5. If any of the following conditions occur after the engine has started, eliminate the cause of the
incident and perform Idle Air Volume Learning all over again:
● Engine stalls.
● Erroneous idle.

Fuel Pressure Check

BBS00355

FUEL PRESSURE RELEASE
With CONSULT-II
1.

Turn ignition switch ON.

EC-488

BASIC SERVICE PROCEDURE
[CR (WITHOUT EURO-OBD)]
2.
3.
4.
5.

Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT”
mode with CONSULT-II.
Start engine.
After engine stalls, crank it two or three times to release all fuel
pressure.
Turn ignition switch OFF.

A

EC

C
SEF214Y

D

Without CONSULT-II
1.
2.
3.
4.
5.

Remove fuel pump fuse located in IPDM E/R.
Start engine.
After engine stalls, crank it two or three times to release all fuel
pressure.
Turn ignition switch OFF.
Reinstall fuel pump fuse after servicing fuel system.

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MBIB0277E

FUEL PRESSURE CHECK

H

CAUTION:
●
Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger.
●
The fuel hose connection method used when taking fuel pressure check must not be used for
other purposes.
●
Be careful not to scratch or put debris around connection area when servicing, so that the quick
connector maintains sealability with O-rings inside.
●
When installing fuel hose quick connector, refer to EM-18, «AIR CLEANER AND AIR DUCT» .
NOTE:
Prepare pans or saucers under the disconnected fuel line because the fuel may spill out. The fuel pressure cannot be completely released because E11 models do not have fuel return system.
1. Release fuel pressure to zero. Refer to EC-488, «FUEL PRESSURE RELEASE» .
2. Prepare fuel hose and fuel hose clamp for fuel pressure check, and connect fuel pressure gauge.
● Use suitable fuel hose for fuel pressure check (genuine NISSAN fuel hose without quick connector).
● To avoid unnecessary force or tension to hose, use moderately long fuel hose for fuel pressure check.
● Do not use the fuel hose for checking fuel pressure with damage or cracks on it.
● Use Pressure Gauge to check fuel pressure.
3. Remove fuel hose. Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
● Do not twist or kink fuel hose because it is plastic hose.
● Do not remove fuel hose from quick connector.
● Keep the original fuel hose to be free from intrusion of dust or foreign substances with a suitable cover.

EC-489

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BASIC SERVICE PROCEDURE
[CR (WITHOUT EURO-OBD)]
4.

Install the fuel pressure gauge as shown in the figure.
● Wipe off oil or dirt from hose insertion part using cloth moistened with gasoline.
● Apply proper amount of gasoline between top of the fuel tube
and No.1 spool.
● Insert fuel hose for fuel pressure check until it touches the
No.1 spool on fuel tube.
● Use NISSAN genuine hose clamp (part number: 16439
N4710 or 16439 40U00).
● When reconnecting fuel line, always use new clamps.
● When reconnecting fuel hose, check the original fuel hose for
damage and abnormality.
● Use a torque driver to tighten clamps.
● Install hose clamp to the position within 1 — 2 mm (0.04 — 0.08
in).
– A: Fuel pressure gauge
Tightening torque:

1 — 1.5 N·m (0.1 — 0.15 kg-m,
9 — 13 in-lb)

Make sure that clamp screw does not contact adjacent parts.
After connecting fuel hose for fuel pressure check, pull the hose
with a force of approximately 98 N (10 kg, 22 lb) to confirm fuel
tube does not come off.
MBIB1495E
Turn ignition switch ON, and check for fuel leakage.
Start engine and check for fuel leakage.
Read the indication of fuel pressure gauge.
● Do not perform fuel pressure check with system operating. Fuel pressure gauge may indicate false
readings.
● During fuel pressure check, confirm for fuel leakage from fuel connection every 3 minutes.
●

5.

6.
7.
8.

PBIB0669E

At idling:

Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi)

9. If result is unsatisfactory, go to next step.
10. Check the following.
● Fuel hoses and fuel tubes for clogging
● Fuel filter for clogging
● Fuel pump
● Fuel pressure regulator for clogging
If OK, replace fuel pressure regulator.
If NG, repair or replace.

EC-490

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

TROUBLE DIAGNOSIS
Trouble Diagnosis Introduction

PFP:00004

A
BBS0035B

INTRODUCTION
The engine has an ECM to control major systems such as fuel control, ignition control, idle air control system, etc. The ECM accepts
input signals from sensors and instantly drives actuators. It is essential that both input and output signals are proper and stable. At the
same time, it is important that there are no malfunctions such as vacuum leaks, fouled spark plugs, or other malfunctions with the engine.

EC

C

D

MEF036D

It is much more difficult to diagnose an incident that occurs intermittently rather than continuously. Most intermittent incidents are
caused by poor electric connections or improper wiring. In this case,
careful checking of suspected circuits may help prevent the replacement of good parts.

E

F

G

H
SEF233G

I

A visual check only may not find the cause of the incidents. A road
test with CONSULT-II or a circuit tester connected should be performed. Follow the Work Flow on EC-492 .
Before undertaking actual checks, take a few minutes to talk with a
customer who approaches with a driveability complaint. The customer can supply good information about such incidents, especially
intermittent ones. Find out what symptoms are present and under
what conditions they occur. A Diagnostic Worksheet like the example
on EC-496 should be used.
Start your diagnosis by looking for conventional malfunctions first.
This will help troubleshoot driveability malfunctions on an electronically controlled engine vehicle.

J

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SEF234G

M

EC-491

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
WORK FLOW
Overall Sequence

PBIB2267E

EC-492

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
Detailed Flow
A

1. GET INFORMATION FOR SYMPTOM

Get the detailed information from the customer about the symptom (the condition and the environment when
EC
the incident/malfunction occurred) using the EC-495, «DIAGNOSTIC WORKSHEET» .
>> GO TO 2.
C

2. CHECK DTC*1
1.

Check DTC*1 .

2.

Perform the following procedure if DTC*1 is displayed.

–

Record DTC*1 and freeze frame data*2 . (Print them out with CONSULT-II.)

–

D

Erase DTC*1 . (Refer to EC-478, «HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .)

Study the relationship between the cause detected by DTC*1 and the symptom described by the customer. (Symptom Matrix Chart is useful. Refer to EC-499, «Symptom Matrix Chart» .)
3. Check related service bulletins for information.
Is any symptom described and any DTC detected?

–

Symptom is described, DTC*1 is displayed>>GO TO 3.
Symptom is described, DTC*1 is not displayed>>GO TO 4.
Symptom is not described, DTC*1 is displayed>>GO TO 5.

E

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3. CONFIRM THE SYMPTOM
I

Try to confirm the symptom described by the customer (except MI ON).
DIAGNOSIS WORK SHEET is useful to verify the incident.
Connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis
results.
Verify relation between the symptom and the condition when the symptom is detected.

J

K

>> GO TO 5.

4. CONFIRM THE SYMPTOM

L

Try to confirm the symptom described by the customer.
DIAGNOSIS WORK SHEET is useful to verify the incident.
Connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis
results.
Verify relation between the symptom and the condition when the symptom is detected.
>> GO TO 6.

EC-493

M

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

5. PERFORM DTC CONFIRMATION PROCEDURE
Perform DTC Confirmation Procedure for the displayed DTC*1 , and then make sure that DTC*1 is detected
again.
At this time, always connect CONSULT-II to the vehicle, and check diagnostic results in real time on “DATA
MONITOR (AUTO TRIG)”.
If two or more DTCs*1 are detected, refer to EC-497, «DTC Inspection Priority Chart» and determine trouble
diagnosis order.
NOTE:
●
Freeze frame data*2 is useful if the DTC*1 is not detected.
●
Perform Overall Function Check if DTC Confirmation Procedure is not included on Service Manual. This
simplified check procedure is an effective alternative though DTC*1 cannot be detected during this check.
If the result of Overall Function Check is NG, it is the same as the detection of DTC*1 by DTC Confirmation Procedure.
Is DTC*1 detected?
Yes
>> GO TO 10.
No
>> Check according to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

6. PERFORM BASIC INSPECTION
Perform EC-483, «Basic Inspection» .
With CONSULT-II>>GO TO 7.
Without CONSULT-II>>GO TO 9.

7. PERFORM DATA MONITOR (SPEC) MODE
With CONSULT-II
Make sure that “B/FUEL SCHDL”, and “A/F ALPHA-B1” are within
the SP value using CONSULT-II “DATA MONITOR (SPEC)” mode.
Refer to EC-533, «Diagnostic Procedure» .
Are they within the SP value?
Yes
>> GO TO 9.
No
>> GO TO 8.

SEF601Z

8. DETECT MALFUNCTIONING PART BY TROUBLE DIAGNOSIS — SPECIFICATION VALUE
Detect malfunctioning part according to EC-532, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .
Is malfunctioning part detected?
Yes
>> GO TO 11.
No
>> GO TO 9.

9. DETECT MALFUNCTIONING SYSTEM BY SYMPTOM MATRIX CHART
Detect malfunctioning system according to EC-499, «Symptom Matrix Chart» based on the confirmed symptom in step 4, and determine the trouble diagnosis order based on possible causes and symptom.
>> GO TO 10.

EC-494

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

10. DETECT MALFUNCTIONING PART BY DIAGNOSTIC PROCEDURE

A
Inspect according to Diagnostic Procedure of the system.
NOTE:
The Diagnostic Procedure in EC section described based on open circuit inspection. A short circuit inspection EC
is also required for the circuit check in the Diagnostic Procedure. For details, refer to Circuit Inspection in GI25, «How to Perform Efficient Diagnosis for an Electrical Incident» .
Is malfunctioning part detected?
C
Yes
>> GO TO 11.
No
>> Monitor input data from related sensors or check voltage of related ECM terminals using CONSULT-II. Refer to EC-512, «ECM Terminals and Reference Value» , EC-527, «CONSULT-II Refer- D
ence Value in Data Monitor Mode» .

11. REPAIR OR REPLACE THE MALFUNCTIONING PART
1.
2.
3.

E

Repair or replace the malfunctioning part.
Reconnect parts or connectors disconnected during Diagnostic Procedure again after repair and replacement.
Check DTC. If DTC is displayed, erase it, refer to EC-478, «HOW TO ERASE EMISSION-RELATED
DIAGNOSTIC INFORMATION» .

F

G

>> GO TO 12.

12. FINAL CHECK

H

When DTC was detected in step 2, perform DTC Confirmation Procedure or Overall Function Check again,
and then make sure that the malfunction have been repaired securely.
When symptom was described from the customer, refer to confirmed symptom in step 3 or 4, and make sure
that the symptom is not detected.
OK or NG

I

NG (DTC*1 is detected)>>GO TO 10.
NG (Symptom remains)>>GO TO 6.
OK
>> 1. Before returning the vehicle to the customer, make sure to erase unnecessary DTC*1 in ECM.
(Refer to EC-478, «HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .)
2. INSPECTION END
*1: Include 1st trip DTC.
*2: Include 1st trip freeze frame data.

DIAGNOSTIC WORKSHEET
Description

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There are many operating conditions that lead to the malfunction of
engine components. A good grasp of such conditions can make troubleshooting faster and more accurate.
In general, each customer feels differently about an incident. It is
important to fully understand the symptoms or conditions for a customer complaint.
Utilize a diagnostic worksheet like the one on the next page in order
to organize all the information for troubleshooting.

SEF907L

EC-495

J

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
Worksheet Sample

MTBL0017

EC-496

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

DTC Inspection Priority Chart

BBS0035C

A
If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
chart.
NOTE:
●
If DTC U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1001. Refer EC
to EC-549, «DTC U1001 CAN COMMUNICATION LINE» .
●
If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer
C
to EC-552, «DTC U1010 CAN COMMUNICATION» .
Priority
1

2

3

Detected items (DTC)
●

U1001 CAN communication line

●

U1010 CAN communication

●

P0107 P0108 Manifold absolute pressure sensor

●

P0117 P0118 Engine coolant temperature sensor

●

P0122 P0123 P0222 P0223 P1225 P1226 P2135 Throttle position sensor

●

P0327 P0328 Knock sensor

●

P0335 Crankshaft position sensor (POS)

●

P0340 Camshaft position sensor (PHASE)

●

P0605 ECM

●

P1171 Intake error

●

P1229 Sensor power supply

●

P1610-P1615 NATS

●

P1706 Park/Neutral position (PNP) switch

●

P2122 P2123 P2127 P2128 P2138 Accelerator pedal position sensor

●

P0132 P0134 Heated oxygen sensor 1

●

P0138 Heated oxygen sensor 2

●

P1065 ECM power supply

●

P1111 Intake valve timing control solenoid valve

●

P1122 Electric throttle control function

●

P1124 P1126 Throttle control motor relay

●

P1128 Throttle control mother

●

P1805 Brake switch

●

P0011 Intake valve timing control

●

P1121 Electric throttle control actuator

●

P1211 ESP control unit

●

P1212 ESP communication line

●

P1217 Engine over temperature (OVERHEAT)

D

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EC-497

M

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

Fail-Safe Chart

BBS0035D

When the DTC listed bellow is detected, the ECM enters fail-safe mode and the MI lights up.
DTC No.

Detected items

Engine operating condition in fail-safe mode

P0122
P0123
P0222
P0223
P2135

Throttle position sensor

The ECM controls the electric throttle control actuator in regulating the throttle opening
in order for the idle position to be within +10 degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

P1121

Electric throttle control
actuator

(When electric throttle control actuator does not function properly due to the return
spring malfunction:)
ECM controls the electric throttle control actuator by regulating the throttle opening
around the idle position. The engine speed will not rise more than 2,000 rpm.
(When throttle valve opening angle in fail-safe mode is not in specified range:)
ECM controls the electric throttle control actuator by regulating the throttle opening to
20 degrees or less.
(When ECM detects the throttle valve is stuck open:)
While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops,
the engine stalls.
The engine can restart in Neutral position and engine speed will not exceed 1,000 rpm
or more.

P1122

Electric throttle control function

ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.

P1124
P1126

Throttle control motor relay

ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.

P1128

Throttle control motor

ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.

P1171
P1229
P1805

P2122
P2123
P2127
P2128
P2138
●

Intake air system
Sensor power supply
Brake switch

Accelerator pedal position
sensor

When accelerator pedal is depressed, engine speed will not rise more than 2,500 rpm
due to fuel cut.
ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.
ECM controls the electric throttle control actuator by regulating the throttle opening to a
small range.
Therefore, acceleration will be poor.
Vehicle condition

Driving condition

When engine is idling

Normal

When accelerating

Poor acceleration

The ECM controls the electric throttle control actuator in regulating the throttle opening
in order for the idle position to be within +10 degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

When there is an open circuit on MI circuit, the ECM can not warn the driver by lighting up MI when there
is a malfunction on engine control system.
Therefore, when electrical controlled throttle and part of ECM related diagnoses is continuously detected
as NG for 5 trips, ECM warns the driver that engine control system has a malfunction and MI circuit is
open by means of operating fail-safe function.
The fail-safe function also operate when above diagnoses except MI circuit are detected and demands
the driver to repair the malfunction.
Engine operating condition in fail-safe mode

Engine speed will not rise more than 2,500 rpm due to the fuel cut

EC-498

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

Symptom Matrix Chart

BBS0035F

A

SYSTEM — BASIC ENGINE CONTROL SYSTEM

1

1

2

3

2

Fuel pressure regulator system

3

3

4

4

4

Fuel injector circuit

1

1

2

3

2

Evaporative emission system

3

3

4

4

4

Air

Positive crankcase ventilation system

3

3

4

4

4

Incorrect idle speed adjustment

3

3

Electric throttle control actuator

1

1

2

3

3

Incorrect ignition timing adjustment

3

3

1

1

Ignition circuit

1

1

2

Main power supply and ground circuit

2

2

Manifold absolute pressure sensor circuit

1

Engine coolant temperature sensor circuit

1

Ignition

Throttle position sensor circuit

AF

AG

AH

AJ

AK

AL

AM

HA

2

2

4

4

2

2

4

4

4

4

4

1

1

4

3
4

2

C
Reference
page

F
EC-750

4

EC-488

2

EC-744

4

4

EC-469

4

4

4

1

1

1

EC-483

2

EC-635,
EC-637 ,
EC-643 ,
EC-649

1

1

1

EC-483

2

2

2

2

2

EC-784

3

3

3

3

3

3

EC-543

1

2

2

2

2

2

2

EC-559

1

2

2

2

2

2

2

EC-565

2

EC-570,
EC-598 ,
EC-676 ,
EC-678 ,
EC-718

Accelerator pedal position sensor circuit

1

Knock sensor circuit

2

3

2

1

2

3

2

2

2

2

2

2

2

2

3

1

2

2

2

EC-680,
EC-699 ,
EC-708 ,
EC-725

2

2

2

EC-577,
EC-584 ,
EC-756

3

EC-605

Crankshaft position sensor (POS) circuit

2

2

EC-609

Camshaft position sensor (PHASE) circuit

2

2

EC-616

Vehicle speed signal circuit
ECM

2

2

3

2

3

3
3

3

EC-499

3

3

3

3

3

G

H

EC-474

1

3

2

1

D

E

2

2

2

EC

2

1

Heated oxygen sensor 1 circuit

BATTERY DEAD (UNDER CHARGE)

Fuel pump circuit

EXCESSIVE OIL CONSUMPTION

Fuel

EXCESSIVE FUEL CONSUMPTION

AE

OVERHEATS/WATER TEMPERATURE HIGH

LACK OF POWER/POOR ACCELERATION

AD

SLOW/NO RETURN TO IDLE

SPARK KNOCK/DETONATION

AC

IDLING VIBRATION

HESITATION/SURGING/FLAT SPOT

AB

ROUGH IDLE/HUNTING

ENGINE STALL

AA

Warranty symptom code

HIGH IDLE/LOW IDLE

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

3

EC-799

3

EC-623,
EC-626

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TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

AF

AG

AH

AJ

AK

AL

AM

HA

2

1

3

2

2

3

3

EC-554

3

3

3

3

3

3

3

EC-688

3

3

3

3

4

EC-794

3

3

3

3

3

3

3

3

HESITATION/SURGING/FLAT SPOT

AE

ENGINE STALL

AD

HARD/NO START/RESTART (EXCP. HA)
Warranty symptom code

SPARK KNOCK/DETONATION

SYMPTOM

AA

AB

AC

3

3

Intake valve timing control solenoid valve circuit
PNP switch circuit
Refrigerant pressure sensor circuit

2

Electrical load signal circuit
Air conditioner circuit

2

2

ABS actuator and electric unit (control unit)

3

3

3

Reference
page

EC-735
3

2

ATC-26 or
MTC-23
BRC-8 or
BRC-49

4

1 — 6: The numbers refer to the order of inspection.
(continued on next page)

SYSTEM — ENGINE MECHANICAL & OTHER

Fuel

ENGINE STALL

HESITATION/SURGING/FLAT SPOT

SPARK KNOCK/DETONATION

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

Warranty symptom code

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

AA

AB

AC

AD

AE

AF

AG

AH

AJ

AK

AL

AM

HA

Fuel tank

FL-8
5

Fuel piping

5

Vapor lock

5

5

5

5

5

FL-3, EM32
—

5

Valve deposit
Poor fuel (Heavy weight gasoline, Low octane)

Reference
page

—
5

5

5

5

EC-500

5

5

5

—

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
SYMPTOM

Air

HARD/NO START/RESTART (EXCP. HA)

ENGINE STALL

HESITATION/SURGING/FLAT SPOT

SPARK KNOCK/DETONATION

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

Warranty symptom code

A

AA

AB

AC

AD

AE

AF

AG

AH

AJ

AK

AL

AM

HA

EC

Reference
page

C

D

E

F

Air duct
Air cleaner
Air leakage from air duct
(Manifold absolute pressure sensor —electric throttle control
actuator)

EM-18
5

5

5

5
5

5

5

5

5
5

H

Electric throttle control actuator
Air leakage from intake manifold/
Collector/Gasket
Cranking

Engine

EM-22

Battery
Alternator circuit

SC-5
1

1

1

1

1

1

1

1

3

SC-45

Signal plate/Flywheel/Drive plate

6

EM-74

PNP switch

4

AT-293,
MT-16

5

5

5

5

5

5

5

Cylinder head gasket

5
4

EM-60

4
6

6

6

6

6

6

6

6

EM-74

Connecting rod
Bearing
Crankshaft
Timing chain

EM-50

Camshaft

EM-38

Intake valve timing control

5

5

5

5

5

5

5

EM-50

5

Intake valve

3

EM-60

Exhaust valve
Exhaust

Exhaust manifold/Tube/Muffler/
Gasket

K

L

Piston

Valve
mechanism

J

3

Cylinder block

Piston ring

I

SC-15

Starter circuit

Cylinder head

G

5

5

5

5

5

Three way catalyst

EC-501

5

5

5

EM-24, EX3

M

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

Lubrication

ENGINE STALL

HESITATION/SURGING/FLAT SPOT

SPARK KNOCK/DETONATION

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

Warranty symptom code

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

AA

AB

AC

AD

AE

AF

AG

AH

AJ

AK

AL

AM

HA

Oil pan/Oil strainer/Oil pump/Oil
filter/Oil gallery

5

5

5

5

5

5

5

5

Oil level (Low)/Filthy oil
Cooling

CO-12

Thermostat

5

CO-19

Water pump

CO-17
5

5

5

5

5

Cooling fan

5

5

2
5

Coolant level (low)/Contaminated
coolant
NATS (Nissan Anti-theft System)

EM-26, LU9 , LU-10 ,
LU-5
LU-6

Radiator/Hose/Radiator filler cap

Water gallery

2

Reference
page

5

CO-7
CO-12
CO-8

1

EC-473 or
BL-215

1

1 — 6: The numbers refer to the order of inspection.

EC-502

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

Engine Control Component Parts Location

BBS0035G

A

EC

C

D

E

F

G

H

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MBIB1491E

1.

Intake valve timing control solenoid
valve

2.

Fuel injector

3.

Refrigerant pressure sensor

4.

Ignition coil (with power transistor)
and spark plug

5.

Heated oxygen sensor 1

6.

Crankshaft position sensor (POS)

7.

Cooling fan motor

8.

IPDM E/R

9.

ECM

10. Camshaft position sensor (PHASE)

11. EVAP canister purge volume control solenoid valve

12. Engine coolant temperature sensor

13. Manifold absolute pressure sensor
(with intake air temperature sensor)

14. Knock sensor

15. Electric throttle control actuator

EC-503

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

MBIB1498E

: Vehicle front
1.

Manifold absolute pressure sensor
(with intake air temperature sensor)

2.

Crankshaft position sensor (POS)

3.

Engine coolant temperature sensor

6.

IPDM E/R

4.

Camshaft position sensor (PHASE)

5.

Battery

7.

Fuel injector

8.

Ignition coil
(with power transistor)

EC-504

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
A

EC

C

D

E

F

G

H

I

J

K

L

M
MBIB1499E

1.

Condenser

2.

Oil filter

3.

Refrigerant pressure sensor

4.

Intake manifold

5.

Knock sensor

6.

Electric throttle control actuator

7.

ECM

8.

Battery

9.

Data link connector

EC-505

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

MBIB0320E

MBIB1460E

: Vehicle front
1.

Exhaust manifold cover

2.

Heated oxygen sensor 1

3.

Heated oxygen sensor 1 harness
connector

4.

Heated oxygen sensor 2 harness
connector

5.

Heated oxygen sensor 2

6.

Oil pan

EC-506

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
A

EC

C

D

E

F

G

H

I

J

K

L

M
MBIB1500E

: Vehicle front
1.

Park/neutral position switch

2.

Cooling fan motor

3.

IPDM E/R

4.

Fuel pump fuse (15A)

5.

Fuel level sensor unit and fuel pump
harness connector

6.

Fuel level sensor unit

7.

Fuel pump and fuel filter

8.

Fuel pressure regulator

9.

Intake valve timing control solenoid
valve

10.

EVAP canister purge volume control solenoid valve

EC-507

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

MBIB1501E

1.

Accelerator pedal position sensor

4.

Brake pedal

2.

Accelerator pedal

EC-508

3.

Stop lamp switch

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

Vacuum Hose Drawing

BBS0034U

A

EC

C

D

E

F

G

H

I

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M

MBIB1440E

: Vehicle front
1.

EVAP canister purge volume control
solenoid valve

2. Intake manifold

NOTE:
Do not use soapy water or any type of solvent while installing vacuum hose or purge hoses.

Refer to EC-462, «System Diagram» for Vacuum Control System.

EC-509

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

Circuit Diagram

BBS0035H

MBWA1500E

EC-510

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1501E

EC-511

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

ECM Harness Connector Terminal Layout

BBS0035I

MBIB0045E

ECM Terminals and Reference Value

BBS0035J

PREPARATION
1.
2.

ECM is located left hand side of the engine room.
Remove ECM harness protector.

MBIB0274E

3.
4.

When disconnecting ECM harness connector, loosen it with
levers as far as they will go as shown in the figure.
Connect a break-out box (SST) and Y-cable adapter (SST)
between the ECM and ECM harness connector.
● Use extreme care not to touch 2 pins at one time.
● Data is for comparison and may not be exact.

PBIB1512E

ECM INSPECTION TABLE
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
1

WIRE
COLOR
B

ITEM

ECM ground

CONDITION
[Engine is running]
●

Idle speed

EC-512

DATA (DC Voltage)

Body ground

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

A

[Engine is running]

2

GR

●

Engine speed: Below 3,800 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load.

Heated oxygen sensor 2
heater

EC
0 — 1.0V

C

[Ignition switch: ON]
●

Engine stopped

[Engine is running]
●

3

LG

Throttle control motor
relay power supply

D
BATTERY VOLTAGE
(11 — 14V)

E

Engine speed: Above 3,800 rpm

[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)

F

0 — 14V
[Ignition switch: ON]
4

L

Throttle control motor
(Close)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

G

PBIB0534E

H

0 — 14V

I

[Ignition switch: ON]
5

P

Throttle control motor
(Open)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

J
PBIB0533E

[Engine is running]
●

Warm-up condition

●

Idle speed

K

Approximately 3.0V

L

NOTE:
The pulse cycle changes depending on rpm
at idle.
13

Y

PBIB0527E

Crankshaft position
sensor (POS)

Approximately 3.0V

[Engine is running]
●

Engine speed: 2,000 rpm

PBIB0528E

EC-513

M

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

[Engine is running]
●

Warm-up condition

●

Idle speed

DATA (DC Voltage)

1.0 — 4.0V

NOTE:
The pulse cycle changes depending on rpm
at idle.
14

R

PBIB0525E

Camshaft position sensor (PHASE)

1.0 — 4.0V

[Engine is running]
●

Engine speed: 2,000 rpm

PBIB0526E

15

W

Knock sensor

[Engine is running]
●

Idle speed

Approximately 2.5V

[Engine is running]

16

LG

Heated oxygen sensor 2

●

Revving engine from idle to 3,000rpm
quickly after the following conditions are
met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load.

0 — Approximately 1.0V

BATTERY VOLTAGE
(11 — 14V)
[Engine is running]
●

19

LG

Idle speed

EVAP canister purge
volume control solenoid
valve

PBIB0050E

Approximately 10V
[Engine is running]
●

Engine speed: About 2,000 rpm (More than
100 seconds after starting engine)

PBIB0520E

EC-514

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

A

BATTERY VOLTAGE
[Engine is running]

22
23
41
42

O
L
R
GR

●

Warm-up condition

●

Idle speed

EC

(11 — 14V)

C

NOTE:
The pulse cycle changes depending on rpm
at idle.

Fuel injector No. 3
Fuel injector No. 1
Fuel injector No. 4
Fuel injector No. 2

PBIB0529E

D

BATTERY VOLTAGE
(11 — 14V)

E
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

F
PBIB0530E

G

Approximately 7.0V
[Engine is running]
24

Y

Heated oxygen sensor 1
heater

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

H

I
PBIB0519E

[Engine is running]
●

29

30

34

B

L

O

Engine speed: Above 3,600 rpm

BATTERY VOLTAGE
(11 — 14V)

Sensor ground
(Camshaft position sensor)

●

Warm-up condition

●

Idle speed

Sensor ground
(Crankshaft position
sensor)

●

Warm-up condition

●

Idle speed

Intake air temperature
sensor

[Engine is running]

Approximately 0V

K

[Engine is running]
Approximately 0V

L
Approximately 0 — 4.8V
Output voltage varies with
intake air temperature.

[Engine is running]
35

45

BR

Heated oxygen sensor 1

J

[Engine is running]

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

L

Sensor power supply

[Ignition switch: ON]

Approximately 5V

46

W

Sensor power supply
(Refrigerant pressure
sensor)

[Ignition switch: ON]

Approximately 5V

47

L

Sensor power supply
(Throttle position sensor)

[Ignition switch: ON]

Approximately 5V

EC-515

M

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch: ON]

49

Y

Throttle position
sensor 1

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

More than 0.36V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

Less than 4.75V

[Engine is running]

51

W

Manifold absolute pressure sensor

●

Warm-up condition

●

Idle speed

Approximately 1.5V

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

Approximately 1.2V

[Engine is running]
54

56

57

—

B

Y

Sensor ground
(Knock sensor)

●

Warm-up condition

●

Idle speed

Sensor ground
(Manifold absolute pressure sensor)

[Engine is running]

Sensor ground
(Refrigerant pressure
sensor)

[Engine is running]

●

Warm-up condition

●

Idle speed

●

Warm-up condition

●

Idle speed

[Engine is running]

60
61
79
80

Y
V
G
BR

●

Warm-up condition

●

Idle speed

Approximately 0V

Approximately 0V

Approximately 0V

0 — 0.1V

NOTE:
The pulse cycle changes depending on rpm
at idle.

Ignition signal No. 3
Ignition signal No. 1
Ignition signal No. 4
Ignition signal No. 2

PBIB0521E

0 — 0.2V
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

PBIB0522E

EC-516

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

A

[Engine is running]
●

Warm-up condition

●

Idle speed

BATTERY VOLTAGE
(11 — 14V)

EC

Approximately 4V — BATTERY
62

LG

Intake valve timing
control solenoid valve

C

VOLTAGE (11 — 14V)
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

D

PBIB1790E

66

B

Sensor ground
(Throttle position sensor)

E

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0V

F

[Ignition switch: ON]

68

R

Throttle position
sensor 2

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

Less than 4.75V

H

[Ignition switch: ON]
●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

G

More than 0.36V

I

[Engine is running]
69

BR

Refrigerant pressure
sensor

●

Warm-up condition

●

Both A/C switch and blower fan switch: ON

1.0 — 4.0V

J

(Compressor operates.)
72

P

Engine coolant temperature sensor

73

B

Sensor ground
(Engine coolant temperature sensor)

[Engine is running]

Approximately 0 — 4.8V
Output voltage varies with
engine coolant temperature.

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

82

B

●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
83

85

B

LG

Sensor ground
(APP sensor 2)

DATA link connector

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]
●

CONSULT-II: Disconnected

Approximately 0V

BATTERY VOLTAGE
(11 — 14V)

86

Y

CAN communication line

[Ignition switch: ON]

1.0 — 2.5V

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

EC-517

L

M
Approximately 0V

[Engine is running]
Sensor ground
(APP sensor 1)

K

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
TERMINAL
NO.
94

WIRE
COLOR
L

ITEM
CAN communication line

CONDITION
[Ignition switch: ON]

DATA (DC Voltage)
2.5 — 4.0V

[Ignition switch: ON]

98

G

Accelerator pedal
position sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

[Ignition switch: OFF]
●

101

R

Stop lamp switch

Brake pedal: Fully released

[Ignition switch: OFF]
●

Brake pedal: Slightly depressed

[Ignition switch: ON]
●

102

GR

PNP switch

G

Throttle control motor
relay

Gear position: Neutral

[Ignition switch: ON]
●

104

0.3 — 0.6V

Except the above gear position

1.95 — 2.4V

Approximately 0V
BATTERY VOLTAGE
(11 — 14V)
Approximately 0V
BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 1.0V

[Ignition switch: ON]

106

109

W

O

Accelerator pedal position sensor 1

Ignition switch

●

Engine stopped

●

Accelerator pedal: Fully released

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed
0V

[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)

●

P

ECM relay
(Self shut-off)

3.9 — 4.7V

[Ignition switch: OFF]

[Engine is running]
[Ignition switch: OFF]
111

0.6 — 0.9V

For a few seconds after turning ignition
switch OFF

[Ignition switch: OFF]
●

More than a few seconds passed after turning ignition switch OFF

0 — 1.0V

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]
●

113

R

Fuel pump relay

For 1 second after turning ignition switch ON

0 — 1.0V

[Engine is running]
[Ignition switch: ON]
●

More than 1 second after turning ignition
switch ON

[Engine is running]

BATTERY VOLTAGE
(11 — 14V)

115
116

B
B

ECM ground

119
120

G
G

Power supply for ECM

[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)

121

BR

Power supply for ECM
(Back-up)

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

●

Idle speed

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-518

Body ground

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

CONSULT-II Function (ENGINE)

BBS0035K

A

FUNCTION
Diagnostic test mode

Function

Work support

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

Self-diagnostic results

Self-diagnostic results such as 1st trip DTC, DTCs and 1st trip freeze frame data or freeze frame data
can be read and erased quickly.*

Data monitor

Input/Output data in the ECM can be read.

Data monitor (SPEC)

Input/Output of the specification for Basic fuel schedule, A/F feedback control value and the other data
monitor items can be read.

CAN diagnostic support
monitor

The results of transmit/receive diagnosis of CAN communication can be read.

Active test

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

Function test

This mode is used to inform customers when their vehicle condition requires periodic maintenance.

ECM part number

ECM part number can be read.

EC

C

D

E

F

*: The following emission-related diagnostic information is cleared when the ECM memory is erased.
●

Diagnostic trouble codes

●

1st trip diagnostic trouble codes

●

Freeze frame data

●

1st trip freeze frame data

G

H

ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
DIAGNOSTIC TEST MODE

WORK SUPPORT

I
DATA
MONITOR

DATA
MONITOR
(SPEC)

DTC*1

FREEZE
FRAME
DATA*2

Crankshaft position sensor (POS)

×

×

×

×

Camshaft position sensor (PHASE)

×

×

×

Manifold absolute pressure sensor

×

×

×

Engine coolant temperature sensor

×

×

×

Heated oxygen sensor 1

×

×

×

Heated oxygen sensor 2

×

×

×

×

×

×

×

Wheel sensor

INPUT

ENGINE CONTROL COMPONENT PARTS

Item

SELF-DIAGNOSTIC
RESULTS

Accelerator pedal position sensor

×

×

×

Throttle position sensor

×

×

×

×

×

Refrigerant pressure sensor

×

×

Closed throttle position switch
(accelerator pedal position sensor
signal)

×

×

Air conditioner switch

×

×

×

Intake air temperature sensor
Knock sensor

×

Park/neutral position (PNP) switch

×

×

×

Stop lamp switch

×

×

×

EPS control unit

×

×

Battery voltage

×

×

Electrical load signal

×

×

EC-519

ACTIVE
TEST

J

K
×

L

M

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
DIAGNOSTIC TEST MODE
SELF-DIAGNOSTIC
RESULTS

DATA
MONITOR

DATA
MONITOR
(SPEC)

ACTIVE
TEST

Fuel injector

×

×

×

Power transistor (Ignition timing)

×

×

×

×

×

EVAP canister purge volume control solenoid valve

×

×

Air conditioner relay

×

×

×

×

×
×

Item

WORK SUPPORT

OUTPUT

ENGINE CONTROL COMPONENT PARTS

DTC*1

Throttle control motor relay

×

Throttle control motor

×

Fuel pump relay

×

×

×

Heated oxygen sensor 1 heater

×

×

Heated oxygen sensor 2 heater

×

×

×

×

Cooling fan relay

Intake valve timing control solenoid
valve

×

FREEZE
FRAME
DATA*2

×

×

×

X: Applicable
*1: This item includes 1st trip DTCs.
*2: This mode includes 1st trip freeze frame data or freeze frame data. The items appear on CONSULT-II screen in freeze frame data
mode only if a 1st trip DTC or DTC is detected. For details, refer to EC-478 .

EC-520

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
INSPECTION PROCEDURE
A

Refer to GI-38, «CONSULT-II Data Link Connector (DLC) Circuit» .

WORK SUPPORT MODE
Work Item

EC

WORK ITEM

CONDITION

FUEL PRESSURE RELEASE

IDLE AIR VOL LEARN

●

●

SELF-LEARNING CONT

●

USAGE

FUEL PUMP WILL STOP BY TOUCHING START DURING IDLING.
CRANK A FEW TIMES AFTER ENGINE STALLS.

When releasing fuel pressure
from fuel line

THE IDLE AIR VOLUME THAT KEEPS THE ENGINE
WITHIN THE SPECIFIED RANGE IS MEMORIZED IN
ECM.

When learning the idle air volume

THE COEFFICIENT OF SELF-LEARNING CONTROL
MIXTURE RATIO RETURNS TO THE ORIGINAL COEFFICIENT.

When clearing the coefficient of
self-learning control value

C

D

TARGET IGN TIM ADJ*

●

IDLE CONDITION

When adjusting target ignition timing

TARGET IDLE RPM ADJ*

●

IDLE CONDITION

When setting target idle speed

E

F

*: This function is not necessary in the usual service procedure.

G

SELF-DIAG RESULTS MODE
Self Diagnostic Item
Regarding items of DTC and 1st trip DTC, refer to EC-476, «EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS» .

H

Freeze Frame Data and 1st Trip Freeze Frame Data
Freeze frame data
item*
DIAG TROUBLE
CODE
[PXXXX]

Description
●

The engine control component part/control system has a trouble code, it is displayed as PXXXX. (Refer to
EC-451, «INDEX FOR DTC» .)

●

Fuel injection system status at the moment a malfunction is detected is displayed.

●

One mode in the following is displayed.
Mode2: Open loop due to detected system malfunction
Mode3: Open loop due to driving conditions (power enrichment, deceleration enleanment)
Mode4: Closed loop — using oxygen sensor(s) as feedback for fuel control
Mode5: Open loop — has not yet satisfied condition to go to closed loop

FUEL SYS-B1

CAL/LD VALUE [%]

●

The calculated load value at the moment a malfunction is detected is displayed.

COOLANT TEMP
[°C] or [°F]

●

The engine coolant temperature at the moment a malfunction is detected is displayed.

●

“Long-term fuel trim” at the moment a malfunction is detected is displayed.

●

The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule
than short-term fuel trim.

L-FUEL TRM-B1 [%]

●

“Short-term fuel trim” at the moment a malfunction is detected is displayed.

S-FUEL TRM-B1 [%]

●

The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel
schedule.

ENGINE SPEED
[rpm]

●

The engine speed at the moment a malfunction is detected is displayed.

VEHICL SPEED
[km/h] or [mph]

●

The vehicle speed at the moment a malfunction is detected is displayed.

B/FUEL SCHDL
[msec]

●

The base fuel schedule at the moment a malfunction is detected is displayed.

INT/A TEMP SE
[°C] or [°F]

●

The intake air temperature at the moment a malfunction is detected is displayed.

*: The items are the same as those of 1st trip freeze frame data.

EC-521

I

J

K

L

M

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
DATA MONITOR MODE
Monitored Item

Monitored item [Unit]

ECM
INPUT
SIGNALS

×: Applicable
MAIN
SIGNALS

Description

●

ENG SPEED [rpm]

×

×

COOLAN TEMP/S
[°C] or [°F]

×

×

HO2S1 (B1) [V]

×

×

HO2S2 (B1) [V]

×

HO2S1 MNTR (B1)
[RICH/LEAN]

×

●

The engine coolant temperature (determined by the signal voltage of the engine
coolant temperature sensor) is displayed.

●

The signal voltage of the heated oxygen
sensor 1 is displayed.

●

The signal voltage of the heated oxygen
sensor 2 is displayed.

●

Display of heated oxygen sensor 1 signal
during air-fuel ratio feedback control:
RICH: means the mixture became “rich”,
and control is being affected toward a
leaner mixture.
LEAN: means the mixture became “lean”,
and control is being affected toward a rich
mixture.

×

●

HO2S2 MNTR (B1)
[RICH/LEAN]

×

A/F ALPHA-B1 [%]

Indicates the engine speed computed from
the signals of the crankshaft position sensor (POS) and camshaft position sensor
(PHASE).

×

●

Display of heated oxygen sensor 2 signal:
RICH: means the amount of oxygen after
three way catalyst is relatively small.
LEAN: means the amount of oxygen after
three way catalyst is relatively large.
The mean value of the air-fuel ratio feedback correction factor per cycle is indicated.

VHCL SPEED SE
[km/h] or [mph]

×

×

●

The vehicle speed computed from the vehicle speed signal is displayed.

BATTERY VOLT [V]

×

×

●

The power supply voltage of ECM is displayed.

●

“Base fuel schedule” indicates the fuel
injection pulse width programmed into
ECM, prior to any learned on board correction.

●

The accelerator pedal position sensor signal voltage is displayed.

●

The throttle position sensor signal voltage
is displayed.

●

The intake air temperature (determined by
the signal voltage of the intake air temperature sensor) is indicated.

●

The signal voltage of the manifold absolute
pressure sensor is displayed.

B/FUEL SCHDL
[msec]

×

ACCEL SEN 1 [V]

×

ACCEL SEN 2 [V]

×

THRTL SEN 1 [V]

×

THRTL SEN 2 [V]

×

INT/A TEMP SE [°C]
or [°F]

×

TURBO BST SEN
[V]

×

×

×

×

EC-522

Remarks

●

Accuracy becomes poor if engine
speed drops below the idle rpm.

●

If the signal is interrupted while the
engine is running, an abnormal value
may be indicated.

●

When the engine coolant temperature sensor is open or short-circuited,
ECM enters fail-safe mode. The
engine coolant temperature determined by the ECM is displayed.

●

After turning ON the ignition switch,
“RICH” is displayed until air-fuel mixture ratio feedback control begins.

●

When the air-fuel ratio feedback is
clamped, the value just before the
clamping is displayed continuously.

●

When the engine is stopped, a certain value is indicated.

●

When the engine is stopped, a certain value is indicated.

●

This data also includes the data for
the air-fuel ratio learning control.

●

ACCEL SEN 2 signal is converted by
ECM internally. Thus, it differs from
ECM terminal voltage signal.

●

THRTL SEN 2 signal is converted by
ECM internally. Thus, it differs from
ECM terminal voltage signal.

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
ECM
INPUT
SIGNALS

MAIN
SIGNALS

START SIGNAL
[ON/OFF]

×

×

CLSD THL POS
[ON/OFF]

×

×

AIR COND SIG [ON/
OFF]

×

×

P/N POSI SW
[ON/OFF]

×

×

PW/ST SIGNAL
[ON/OFF]

×

×

Monitored item [Unit]

Description

Indicates start signal status [ON/OFF] computed by the ECM according to the signals
of engine speed and battery voltage.

●

Indicates idle position [ON/OFF] computed
by the ECM according to the accelerator
pedal position sensor signal.

●

Indicates [ON/OFF] condition of the air conditioner switch as determined by the air
conditioner signal.

●

Indicates [ON/OFF] condition from the park/
neutral position (PNP) switch signal.

E

●

[ON/OFF] condition of the power steering
system (determined by the signal sent from
EPS control unit) is indicated.

F

●

Indicates [ON/OFF] condition from the electrical load signal.
ON: Rear window defogger switch is ON
and/or lighting switch is in 2nd position.
OFF: Both rear window defogger switch
and lighting switch are OFF.

×

IGNITION SW
[ON/OFF]

×

●

Indicates [ON/OFF] condition from ignition
switch.

HEATER FAN SW
[ON/OFF]

×

●

Indicates [ON/OFF] condition from the
heater fan switch signal.

BRAKE SW
[ON/OFF]

×

●

Indicates [ON/OFF] condition from the stop
lamp switch signal.

●

Indicates the actual fuel injection pulse
width compensated by ECM according to
the input signals.

●

Indicates the ignition timing computed by
ECM according to the input signals.

●

Indicates the EVAP canister purge volume
control solenoid valve control value computed by the ECM according to the input
signals.

×

×

IGN TIMING [BTDC]

×

PURG VOL C/V [%]

INT/V TIM (B1) [°CA]

●

The opening becomes larger as the value
increases.

●

Indicates [°CA] of intake camshaft
advanced angle.

●

The control value of the intake valve timing
control solenoid valve (determined by ECM
according to the input signals) is indicated.

●

The advance angle becomes larger as the
value increases.

●

The air conditioner relay control condition
(determined by ECM according to the input
signals) is indicated.

●

Indicates the fuel pump relay control condition determined by ECM according to the
input signals.

INT/V SOL (B1) [%]

AIR COND RLY [ON/
OFF]

×

FUEL PUMP RLY
[ON/OFF]

×

EC-523

●

After starting the engine, [OFF] is displayed regardless of the starter signal.

A

●

LOAD SIGNAL [ON/
OFF]

INJ PULSE-B1
[msec]

Remarks

EC

C

D

G

H

I

J
●

When the engine is stopped, a certain computed value is indicated.

●

When the engine is stopped, a certain value is indicated.

K

L

M

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
Monitored item [Unit]

ECM
INPUT
SIGNALS

THRTL RELAY [ON/
OFF]

MAIN
SIGNALS

Description

●

Indicates the throttle control motor relay
control condition determined by the ECM
according to the input signals.

●

Indicates the condition of the cooling fan
(determined by ECM according to the input
signals).
HI: High speed operation
LOW: Low speed operation
OFF: Stop

●

Indicates [ON/OFF] condition of heated
oxygen sensor 1 heater determined by
ECM according to the input signals.

●

Indicates [ON/OFF] condition of heated
oxygen sensor 2 heater determined by
ECM according to the input signals.

●

Display the condition of idle air volume
learning
YET: Idle air volume learning has not been
performed yet.
CMPLT: Idle air volume learning has
already been performed successfully.

●

Distance traveled while MI is activated.

●

Indicates the heated oxygen sensor 1
heater control valve computed by the ECM
according to the input signals.

●

The signal voltage from the refrigerant
pressure sensor is displayed.

×

COOLING FAN
[HI/LOW/OFF]

×

HO2S1 HTR (B1)
[ON/OFF]
HO2S2 HTR (B1)
[ON/OFF]

IDL A/V LEARN
[YET/CMPLT]

TRVL AFTER MIL
[km] or [mile]
O2 SEN HTR DTY
[%]
AC PRESS SEN [V]

×

Remarks

Voltage [V]
Frequency
[msec], [Hz] or [%]
DUTY-HI
DUTY-LOW

●

Voltage, frequency, duty cycle or pulse
width measured by the probe.

PLS WIDTH-HI

●

Only “#” is displayed if item is unable
to be measured.

●

Figures with “#”s are temporary
ones. They are the same figures as
an actual piece of data which was
just previously measured.

PLS WIDTH-LOW
NOTE:
● Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

EC-524

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
DATA MONITOR (SPEC) MODE
Monitored Item
Monitored item [Unit]

ECM
INPUT
SIGNALS

A

MAIN
SIGNALS

Description

●

×

ENG SPEED [rpm]

●

B/FUEL SCHDL
[msec]

●

×

A/F ALPHA-B1 [%]

Remarks

Indicates the engine speed computed
from the signal of the crankshaft position
sensor (POS) and camshaft position
sensor (PHASE).
“Base fuel schedule” indicates the fuel
injection pulse width programmed into
ECM, prior to any learned on board correction.
The mean value of the air-fuel ratio feedback correction factor per cycle is indicated.

EC

C

●

When engine is running specification
range is indicated.

●

When engine is running specification
range is indicated.

●

This data also includes the data for the
air-fuel ratio learning control.

D

E

F

NOTE:
● Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

G

ACTIVE TEST MODE
Test Item
TEST ITEM

CONDITION
●

FUEL INJECTION

IGNITION TIMING

●

COOLING FAN*

ENG COOLANT
TEMP

FUEL PUMP
RELAY

Change the amount of fuel injection using CONSULT-II.

●

Engine: Return to the original
trouble condition

●

Timing light: Set

●

Retard the ignition timing using
CONSULT-II.

●

POWER BALANCE

Engine: Return to the original
trouble condition

JUDGEMENT
If trouble symptom disappears, see
CHECK ITEM.

If trouble symptom disappears, see
CHECK ITEM.

CHECK ITEM (REMEDY)
●

Harness and connectors

●

Fuel injector

●

Heated oxygen sensor 1

●

Perform Idle Air Volume Learning.

●

Harness and connectors

●

Compression

●

Fuel injector

●

Power transistor

J

●

A/C switch: OFF

●

Shift lever: Neutral

●

Cut off each fuel injector signal
one at a time using CONSULT-II.

●

Spark plug

●

Ignition coil

●

Ignition switch: ON

●

Harness and connectors

●

Turn the cooling fan “HI”, “LOW”
and “OFF” with CONSULT-II.

●

Cooling fan relay

●

Cooling fan motor

●

Harness and connectors

●

Engine coolant temperature sensor

●

Fuel injector

●

Harness and connectors

●

Fuel pump relay

Engine: Return to the original
trouble condition

●

Change the engine coolant temperature using CONSULT-II.

●

Ignition switch: ON (Engine
stopped)

●

Turn the fuel pump relay ON and
OFF using CONSULT-II and listen to operating sound.

I

K

Engine: After warming up, idle
the engine.

●

H

Engine runs rough or dies.

Cooling fan moves and stops.

If trouble symptom disappears, see
CHECK ITEM.

Fuel pump relay makes the operating sound.

EC-525

L

M

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
TEST ITEM

PURG VOL
CONT/V

CONDITION
●

Engine: After warming up, run
engine at 1,500 rpm.

●

Change the EVAP canister purge
volume control solenoid valve
opening percent using CONSULT-II.

●

V/T ASSIGN
ANGLE

●

Engine: Return to the original
trouble condition
Change intake valve timing using
CONSULT-II.

JUDGEMENT

Engine speed changes according to
the opening percent.

If trouble symptom disappears, see
CHECK ITEM.

CHECK ITEM (REMEDY)

●

Harness and connectors

●

Solenoid valve

●

Harness and connectors

●

Intake valve timing control solenoid valve

*: Leaving cooling fan OFF with CONSULT-II while engine is running may cause the engine to overheat.

REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA)
Description
CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR”
mode.
1. “AUTO TRIG” (Automatic trigger):
● The malfunction will be identified on the CONSULT-II screen
in real time.
In other words, DTC/1st trip DTC and malfunction item will be
displayed if the malfunction is detected by ECM.
At the moment a malfunction is detected by ECM, “MONITOR” in “DATA MONITOR” screen is changed to “Recording
Data … xx%” as shown in the figure, and the data after the
malfunction detection is recorded. Then when the percentage
reached 100%, “REAL-TIME DIAG” screen is displayed. If
“STOP” is touched on the screen during “Recording Data …
xx%”, “REAL-TIME DIAG” screen is also displayed.
MBIB0295E
The recording time after the malfunction detection and the
recording speed can be changed by “TRIGGER POINT” and
“Recording Speed”. Refer to CONSULT-II OPERATION MANUAL.
2. “MANU TRIG” (Manual trigger):
● DTC/1st trip DTC and malfunction item will not be displayed
automatically on CONSULT-II screen even though a malfunction is detected by ECM.
DATA MONITOR can be performed continuously even though
a malfunction is detected.
SEF707X

Operation
1.

2.

“AUTO TRIG”
● While trying to detect the DTC/1st trip DTC by performing the DTC Confirmation Procedure, be sure to
select to “DATA MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is
detected.
● While narrowing down the possible causes, CONSULT-II should be set in “DATA MONITOR (AUTO
TRIG)” mode, especially in case the incident is intermittent.
When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components and harness in the DTC Confirmation Procedure, the moment a malfunction is found the DTC/1st
trip DTC will be displayed. (Refer to Incident Simulation Tests in GI-25, «How to Perform Efficient Diagnosis for an Electrical Incident» .)
“MANU TRIG”
● If the malfunction is displayed as soon as “DATA MONITOR” is selected, reset CONSULT-II to “MANU
TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The data can be utilized for further diagnosis, such as a comparison with the value for the normal operating condition.

EC-526

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
A

EC

C

D

E

F

G

H

PBIB0197E

I

CONSULT-II Reference Value in Data Monitor Mode

BBS0035L

Remarks:
● Specification data are reference values.
● Specification data are output/input values which are detected or supplied by the ECM at the connector.
* Specification data may not be directly related to their components signals/values/operations.
MONITOR ITEM
CONDITION
ENG SPEED

●

Run engine and compare CONSULT-II value with the tachometer indication.

B/FUEL SCHDL

See EC-EC-532, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .

A/F ALPHA-B1

See EC-EC-532, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .

COOLAN TEMP/S

●

Engine: After warming up

HO2S1 (B1)

●

Engine: After warming up

●

Revving engine from idle to 3,000 rpm quickly after the following conditions are met.

–

Engine: After warning up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute
and at idle for 1 minute under no load.

●

Engine: After warming up

●

Revving engine from idle to 3,000 rpm quickly after the following conditions are met.

–

Engine: After warning up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute
and at idle for 1 minute under no load.

●

Turn drive wheels and compare CONSULT-II value with the speedometer
indication.

HO2S2 (B1)

HO2S1 MNTR (B1)

HO2S2 MNTR (B1)

VHCL SPEED SE

J
SPECIFICATION

Almost the same speed as the
tachometer indication.

K

L
More than 70°C (158°F)

Maintaining engine speed at 2,000
rpm

0 — 0.3V ←→ Approx. 0.6 — 1.0V

0 — 0.3V ←→ Approx. 0.6 — 1.0V

Maintaining engine speed at 2,000
rpm

LEAN ←→ RICH
Changes more than 5 times during 10 seconds.

LEAN ←→ RICH

EC-527

Almost the same speed as the
speedometer indication.

M

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
MONITOR ITEM
BATTERY VOLT
ACCEL SEN 1

ACCEL SEN 2*1

CONDITION
●

Ignition switch: ON (Engine stopped)

●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

4.0 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

3.9 — 4.8V

●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

More than 0.36V

●

Shift lever: 1st

Accelerator pedal: Fully depressed

Less than 4.75V

●

Engine: After warming up

Idle

Approximately 1.5V

●

Air conditioner switch: OFF

●

Shift lever: Neutral

2,500 rpm

Approximately 1.2V

●

No load

●

Ignition switch: ON → START → ON

THRTL SEN 2*1

TURBO BST SEN

CLSD THL POS

AIR COND SIG

P/N POSI SW

PW/ST SIGNAL

LOAD SIGNAL

IGNITION SW
HEATER FAN SW

BRAKE SW

11 — 14V

●

THRTL SEN 1

START SIGNAL

SPECIFICATION

●

●

●

●

●

●
●

●

Ignition switch: ON
(Engine stopped)
Engine: After warming up, idle
the engine

Ignition switch: ON
Engine: After warming up, idle
the engine

Ignition switch: ON

Ignition switch: ON

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral

●

No load

●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral

●

No load

INJ PULSE-B1

IGN TIMING

PURG VOL C/V

INT/V TIM (B1)

Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates.)

ON

Shift lever: Neutral

ON

Shift lever: Except above

OFF

Steering wheel: Not being turned.

OFF

Steering wheel: Being turned.

ON

Rear window defogger switch is ON
and/or lighting switch is in 2nd.

ON

Rear window defogger switch is OFF
and lighting switch is OFF.

OFF

Ignition switch: ON → OFF → ON
Engine: After warming up, idle
the engine

OFF → ON → OFF

ON → OFF → ON
Heater fan: Operating.

ON

Heater fan: Not operating

OFF

Brake pedal: Fully released

OFF

Brake pedal: Slightly depressed

ON

Idle

2.0 — 3.0 msec

2,000 rpm

1.9 — 2.9 msec

Idle

0° — 10° BTDC

2,000 rpm

25° — 45° BTDC

Idle

0%

2,000 rpm

20 — 30%

Idle

−5° — 5°CA

2,000 rpm

Approx. 0° — 20°CA

EC-528

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral

●

No load

●

Engine: After warming up, idle
the engine

INT/V SOL (B1)

AIR COND RLY

FUEL PUMP RLY

THRTL RELAY

Approx. 0% — 50%

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates)

ON

Engine running or cranking

●

Except above conditions

OFF

●

Ignition switch: ON

ON

●

Engine: After warming up, idle
the engine
Air conditioner switch: OFF

A

EC

C

D

E
OFF

Engine coolant temperature: Between
95°C (203°F) and 104°C (210°F)

LOW*2

Engine coolant temperature: 105°C
(212°F) or more

HIGH*2

F

G

Engine: After warming up

ON

Engine speed: Below 3,600 rpm

●

Engine speed: Above 3,600 rpm

●

Engine speed: Below 3,800 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed at between 3,500 to 4,000 rpm for 1 minute
and at idle for 1 minute under no load

●

Engine speed: Above 3,800 rpm

●

Ignition switch: ON

●

Engine coolant temperature when engine started: More than 80°C
(176°F)

●

Engine speed: Below 3,600 rpm

●

Ignition switch: ON (Engine stopped)

●

Engine: Idle

●

ON

Engine coolant temperature: 94°C
(201°F) or less

●

O2SEN HTR DTY

AC PRESS SEN

2,000 rpm

For 1 second after turning ignition switch ON

●

TRVL AFTER MIL

0% — 2%

●

●

HO2S2 HTR (B1)

Idle

●

COOLING FAN

HO2S1 HTR (B1)

SPECIFICATION

OFF

H

ON

I
OFF

Vehicle has traveled after MI has
turned ON.

0 — 65,535 km
(0 — 40,723 mile)

J

Approx. 50%

K

Approx. 0V

L

Both A/C switch and blower fan switch: ON (Compressor operates)

1.0 — 4.0V

*1: Accelerator pedal position sensor 2 signal and throttle position sensor 2 signal are converted by ECM internally. Thus, they differ
from ECM terminals voltage signal.
*2: Models without air conditioner, cooling fan operates only ON and OFF operation, but CONSULT-II display will change OFF, LOW and
HI depends on engine coolant temperature.

EC-529

M

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]

Major Sensor Reference Graph in Data Monitor Mode

BBS0035M

The following are the major sensor reference graphs in “DATA MONITOR” mode.

CLSD THL POS, ACCEL SEN 1, THRTL SEN 1
Below is the data for “CLSD THL POS”, “ACCEL SEN 1” and “THRTL SEN 1” when depressing the accelerator pedal with the ignition switch ON and with shift lever in 1st position.
The signal of “ACCEL SEN 1” and “THRTL SEN 1” should rise gradually without any intermittent drop or rise
after “CLSD THL POS” is changed from “ON” to “OFF”.

PBIB0198E

ENG SPEED, THRTL SEN 1, HO2S2 (B1), HO2S1 (B1), INJ PULSE-B1
Below is the data for “ENG SPEED”, “THRTL SEN 1”, “HO2S2 (B1)”, “HO2S1 (B1)” and “INJ PULSE-B1”
when revving engine quickly up to 4,800 rpm under no load after warming up engine sufficiently.
Each value is for reference, the exact value may vary.

MBIB0545E

EC-530

TROUBLE DIAGNOSIS
[CR (WITHOUT EURO-OBD)]
A

EC

C

D

E

F

G

H

I

J

K

L

M

PBIB0668E

EC-531

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITHOUT EURO-OBD)]

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
Description

PFP:00031
BBS0035N

The specification (SP) value indicates the tolerance of the value that is displayed in “DATA MONITOR (SPEC)”
mode of CONSULT-II during normal operation of the Engine Control System. When the value in “DATA MONITOR (SPEC)” mode is within the SP value, the Engine Control System is confirmed OK. When the value in
“DATA MONITOR (SPEC)” mode is NOT within the SP value, the Engine Control System may have one or
more malfunctions.
The SP value is used to detect malfunctions that may affect the Engine Control System, but will not light the
MI.
The SP value will be displayed for the following three items:
●
B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board correction)
●
A/F ALPHA-B1 (The mean value of air-fuel ratio feedback correction factor per cycle)

Testing Condition
●
●
●
●
●
●
–
●
–

BBS0035O

Vehicle driven distance: More than 5,000 km (3,107 miles)
Barometric pressure: 98.3 — 104.3 kPa (0.983 — 1.043 bar, 1.003 — 1.064 kg/cm2 , 14.25 — 15.12 psi)
Atmospheric temperature: 20 — 30°C (68 — 86°F)
Engine coolant temperature: 75 — 95°C (167 — 203°F)
Engine speed: Idle
Transmission: Warmed-up
After the engine is warmed up to normal operating temperature, drive vehicle for 5 minutes.
Electrical load: Not applied
Rear window defogger switch, air conditioner switch, lighting switch are OFF. Steering wheel is straight
ahead.

Inspection Procedure

BBS0035P

NOTE:
Perform “DATA MONITOR (SPEC)” mode in maximum scale display.
1. Perform EC-483, «Basic Inspection» .
2. Confirm that the testing conditions indicated above are met.
3. Select “B/FUEL SCHDL” and “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode with CONSULT-II.
4. Make sure that monitor items are within the SP value.
5. If NG, go to EC-533, «Diagnostic Procedure» .

SEF601Z

EC-532

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS0035Q

A

OVERALL SEQUENCE

EC

C

D

E

F

G

H

I

J

K

L

M

PBIB2384E

EC-533

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITHOUT EURO-OBD)]

MBIB1447E

EC-534

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITHOUT EURO-OBD)]
DETAILED PROCEDURE
A

1. CHECK “A/F ALPHA-B1”
1.
2.
3.

Start engine.
Confirm that the testing conditions are met. Refer to EC-532, «Testing Condition» .
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode,
and make sure that the indication is within the SP value.
NOTE:
Check “A/F ALPHA-B1” for approximately 1 minute because
they may fluctuate. It is NG if the indication is out of the SP value
even a little.
OK or NG
OK
>> GO TO 17.
NG (Less than the SP value)>>GO TO 2.
NG (More than the SP value)>>GO TO 3.

EC

C

D

E
PBIB2369E

2. CHECK “B/FUEL SCHDL”

F

Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and
make sure that the indication is within the SP value.
OK or NG
OK
>> GO TO 4.
NG (More than the SP value)>>GO TO 19.

G

H

I
PBIB2332E

J

3. CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and
make sure that the indication is within the SP value.
OK or NG
OK
>> GO TO 6.
NG (More than the SP value)>>GO TO 6.
NG (Less than the SP value)>>GO TO 25.

K

L

M

PBIB2332E

4. CHECK “A/F ALPHA-B1”
1.
2.
3.
4.

Stop the engine.
Disconnect PCV hose, and then plug it.
Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within
the SP value.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 6.

EC-535

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITHOUT EURO-OBD)]

5. CHANGE ENGINE OIL
1.
2.

Stop the engine.
Change engine oil.
NOTE:
This symptom may occur when a large amount of gasoline is mixed with engine oil because of driving
conditions (such as when engine oil temperature does not rise enough since a journey distance is too
short during winter). The symptom will not be detected after changing engine oil or changing driving condition.
>> INSPECTION END

6. CHECK FUEL PRESSURE
Check fuel pressure. (Refer to EC-488, «Fuel Pressure Check» .)
OK or NG
OK
>> GO TO 9.
NG (Fuel pressure is too high)>>Replace fuel pressure regulator, refer to EC-488, «Fuel Pressure Check» .
GO TO 8.
NG (Fuel pressure is too low)>>GO TO 7.

7. DETECT MALFUNCTIONING PART
1.
–
–
–

2.

Check the following.
Clogged and bent fuel hose and fuel tube
Clogged fuel filter
Fuel pump and its circuit (Refer to EC-750, «FUEL PUMP» .)
If NG, repair or replace the malfunctioning part. (Refer to EC-488, «Fuel Pressure Check» .)
If OK, replace fuel pressure regulator.
>> GO TO 8.

8. CHECK “A/F ALPHA-B1”
1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within
the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 9.

9. PERFORM POWER BALANCE TEST
1.
2.

Perform “POWER BALANCE” in “ACTIVE TEST” mode.
Make sure that the each cylinder produces a momentary engine
speed drop.
OK or NG
OK
>> GO TO 12.
NG
>> GO TO 10.

PBIB0133E

EC-536

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITHOUT EURO-OBD)]

10. DETECT MALFUNCTIONING PART
1.
–
–
–
–

2.

A

Check the following.
Ignition coil and its circuit (Refer to EC-784, «IGNITION SIGNAL» .)
Fuel injector and its circuit (Refer to EC-744, «FUEL INJECTOR» .)
Intake air leakage
Low compression pressure (Refer to EM-60, «COMPRESSION PRESSURE INSPECTION» .)
If NG, repair or replace the malfunctioning part.
If OK, replace fuel injector. (It may be caused by leakage from fuel injector or clogging.)

EC

C

D

>> GO TO 11.

11. CHECK “A/F ALPHA-B1”

E

1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within
the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 12.

F

G

12. CHECK HEATED OXYGEN SENSOR 1 FUNCTION
1.
2.
3.

H

Run engine at about 2,000 rpm for about 2 minutes under no load.
Select “HO2S1 MNTR (B1)”, in “DATA MONITOR” mode.
Running engine at 2,000 rpm under no load (The engine is
warmed up to normal operating temperature.), check that the
monitor fluctuates between LEAN and RICH more than 5 times
during 10 seconds.
1 time
2 times

I

J

: RICH → LEAN → RICH
: RICH → LEAN → RICH → LEAN → RICH

K

OK or NG
OK
>> GO TO 15.
NG
>> GO TO 13.
SEF820Y

L

13. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT
Check heated oxygen sensor 1 and its circuit. Refer to EC-577, «DTC P0132 HO2S1» .
>> GO TO 14.

14. CHECK “A/F ALPHA-B1”
1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within
the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 15.

EC-537

M

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITHOUT EURO-OBD)]

15. DISCONNECT AND RECONNECT ECM HARNESS CONNECTOR
1.
2.

Stop the engine.
Disconnect ECM harness connector. Check pin terminal and connector for damage, and then reconnect it.
>> GO TO 16.

16. CHECK “A/F ALPHA-B1”
1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within
the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> Detect malfunctioning part according to EC-499, «Symptom Matrix Chart» .

17. CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and
make sure that the indication is within the SP value.
OK or NG
OK
>> INSPECTION END
NG (More than the SP value)>>GO TO 18.
NG (Less than the SP value)>>GO TO 27.

PBIB2332E

18. DETECT MALFUNCTIONING PART
1.
–
–
–
–
–

2.
–
–
–

Check for the cause of large engine friction. Refer to the following.
Engine oil level too high
Engine oil viscosity
Belt tension of power steering, alternator, A/C compressor, etc. is excessive
Noise from engine
Noise from transmission, etc.
Check for the cause of insufficient combustion. Refer to the following.
Valve clearance malfunction
Intake valve timing control function malfunction
Camshaft sprocket installation malfunction, etc.
>> Repair or replace malfunctioning part, and then GO TO 32.

19. CHECK INTAKE SYSTEM
Check for the cause of unsteady air flow passing through throttle body. Refer to the following.
●
Crushed air ducts
●
Malfunctioning seal of air cleaner element
●
Uneven dirt of air cleaner element
●
Improper specification of intake air system part
OK or NG
OK
>> GO TO 21.
NG
>> Repair or replace malfunctioning part, and then GO TO 20.

EC-538

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITHOUT EURO-OBD)]

20. CHECK “A/F ALPHA-B1”, AND “B/FUEL SCHDL”

A
Select “A/F ALPHA-B1” and “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the
indication is within the SP value.
EC
OK or NG
OK
>> INSPECTION END
NG (“B/FUEL SCHDL” is more, “A/F ALPHA-B1” is less than the SP value)>>GO TO 21.
C
DISCONNECT AND RECONNECT MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR HARNESS
CONNECTOR

21.
1.
2.

Stop the engine.
Disconnect manifold absolute pressure (MAP) sensor harness connector. Check pin terminal and connector for damage and then reconnect it again.

D

E

>> GO TO 22.

22. CHECK “A/F ALPHA-B1”

F

1.
2.

G

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within
the SP value.
OK or NG
OK
>> 1. Detect malfunctioning part of manifold absolute pressure (MAP) sensor circuit and repair it.
Refer to EC-559, «DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR» .
2. GO TO 26.
NG
>> GO TO 23.

H

I

23. CHECK “TURBO BST SEN”
J

Select “TURBO BST SEN” in “DATA MONITOR” mode, and make
sure that the indication is within the specified value as described
below.
Idle:
2,500 rpm:

K

Approximately 1.5V
Approximately 1.2V

OK or NG
OK
>> GO TO 25.
NG (More than the specified value)>>Replace manifold absolute
pressure (MAP) sensor, and then GO TO 24.

L

M
MBIB1448E

EC-539

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITHOUT EURO-OBD)]

24. CHECK INTAKE SYSTEM
Check for the cause of air suction at downstream of throttle body. Refer to the following.
●
Disconnection looseness, or cracks of air duct
●
Looseness of oil filler cap
●
Disconnection of oil level gauge
●
Open sticking, breakage, hose disconnection, or cracks of blow-by gas control valve
●
Disconnection or cracks of EVAP canister purge hose, open sticking of EVAP canister purge volume control valve
●
Malfunctioning sealing of rocker cover gasket
●
Disconnection, looseness, or cracks of hoses, such as vacuum hose, connecting to intake air system
parts.
●
Malfunctioning sealing of intake air system, etc.
>> GO TO 31.

25. REPLACE ECM
1.
2.
3.
4.
5.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs.
Refer to BL-218, «ECM Re-communicating Function» .
Perform EC-486, «Accelerator Pedal Released Position Learning» .
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .
>> GO TO 31.

26. CHECK “TURBO BST SEN”
Select “TURBO BST SEN” in “DATA MONITOR” mode, and make
sure that the indication is within the specified value as described
below.
Idle:
2,500 rpm:

Approximately 1.5V
Approximately 1.2V

OK or NG
OK
>> GO TO 31.
NG (More than the specified value)>>Replace manifold absolute
pressure (MAP) sensor, and then GO TO 32.
MBIB1448E

27. CHECK INTAKE SYSTEM
Check for the cause of uneven air flow passing through throttle body. Refer to the following.
●
Crushed air ducts
●
Malfunctioning seal of air cleaner element
●
Uneven dirt of air cleaner element
●
Improper specification of intake air system
OK or NG
OK
>> GO TO 29.
NG
>> Repair or replace malfunctioning part, and then GO TO 28.

EC-540

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[CR (WITHOUT EURO-OBD)]

28. CHECK “B/FUEL SCHDL”

A
Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the
SP value.
EC
OK or NG
OK
>> INSPECTION END
NG (Less than the SP value)>>GO TO 29.
C
CHECK “TURBO BST SEN”

29.

Select “TURBO BST SEN” in “DATA MONITOR” mode, and make
sure that the indication is within the specified value as described
below.
Idle:
2,500 rpm:

D

Approximately 1.5V
Approximately 1.2V

E

OK or NG
OK
>> GO TO 30.
NG (Less than the specified value)>>Replace manifold absolute
pressure (MAP) sensor, and then GO TO 32.

F

MBIB1448E

30. REPLACE ECM
1.
2.
3.
4.
5.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs.
Refer to BL-218, «ECM Re-communicating Function» .
Perform EC-486, «Accelerator Pedal Released Position Learning» .
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

G

H

I

J

>> GO TO 32.

31. CHECK “A/F ALPHA-B1” AND “B/FUEL SCHDL”
Select “A/F ALPHA-B1” and “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the
indication is within the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> Detect malfunctioning part according to EC-499, «Symptom Matrix Chart» .

32. CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and then make sure that the indication is within
the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> Detect malfunctioning part according to EC-499, «Symptom Matrix Chart» .

EC-541

K

L

M

TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT
[CR (WITHOUT EURO-OBD)]

TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT
Description

PFP:00006
BBS0035R

Intermittent incidents may occur. In many cases, the malfunction resolves itself (the part or circuit function
returns to normal without intervention). It is important to realize that the symptoms described in the customer’s
complaint often do not recur on (1st trip) DTC visits. Realize also that the most frequent cause of intermittent
incident occurrences is poor electrical connections. Because of this, the conditions under which the incident
occurred may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may
not indicate the specific malfunctioning area.
Common Intermittent Incident Report Situations
STEP in Work Flow
2
3 or 4

Situation
The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than [0] or [1t].
The symptom described by the customer does not recur.

5

(1st trip) DTC does not appear during the DTC Confirmation Procedure.

10

The Diagnostic Procedure for PXXXX does not indicate the malfunctioning area.

Diagnostic Procedure

BBS0035S

1. INSPECTION START
Erase (1st trip) DTCs. Refer to EC-478, «HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .
>> GO TO 2.

2. CHECK GROUND TERMINALS
Check ground terminals for corroding or loose connection.
Refer to EC-EC-548, «Ground Inspection» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

3. SEARCH FOR ELECTRICAL INCIDENT
Perform GI-25, «How to Perform Efficient Diagnosis for an Electrical Incident» , “Incident Simulation Tests”.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace.

EC-542

POWER SUPPLY AND GROUND CIRCUIT
[CR (WITHOUT EURO-OBD)]

POWER SUPPLY AND GROUND CIRCUIT
Wiring Diagram

PFP:24110

A
BBS0035T

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1502E

EC-543

POWER SUPPLY AND GROUND CIRCUIT
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
1
115
116
109

WIRE
COLOR
B
B
B
O

ITEM

ECM ground

CONDITION

[Engine is running]
●

Ignition switch

Idle speed

0V

[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)

●

P

ECM relay
(Self shut-off)

G
G

Power supply for
ECM

For a few seconds after turning ignition switch
OFF

[Ignition switch: OFF]
●

119
120

Body ground

[Ignition switch: OFF]

[Engine is running]
[Ignition switch: OFF]
111

DATA (DC Voltage)

More than a few seconds passed after turning
ignition switch OFF

[Ignition switch: ON]

Diagnostic Procedure

0 — 1.0V

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)
BBS0035U

1. INSPECTION START
Start engine.
Is engine running?
Yes or No
Yes
>> GO TO 8.
No
>> GO TO 2.

2. CHECK ECM POWER SUPPLY CIRCUIT-I
1.
2.

Turn ignition switch OFF and then ON.
Check voltage between ECM terminal 109 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

MBIB0015E

3. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors M1, E101
●
Fuse block (J/B) connector M7
●
10A fuse
●
Harness for open or short between ECM and fuse
●

>> Repair harness or connectors.

EC-544

POWER SUPPLY AND GROUND CIRCUIT
[CR (WITHOUT EURO-OBD)]

4. CHECK GROUND CONNECTIONS-I
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body. Refer to EC-548, «Ground Inspection» .
EC

C

D

MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

E

Body ground E28

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace ground connections.

F

5. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-I

G

1.
2.

Disconnect ECM harness connector.
Check harness continuity between ECM terminals 1, 115, 116 and ground.
Refer to Wiring Diagram.

H

Continuity should exist.

I

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

J

6. DETECT MALFUNCTIONING PART

K

Check the following.
●
Harness connectors F1, E48
●
Harness for open or short between ECM and ground

L

>> Repair open circuit or short to power in harness or connectors.

M

7. CHECK ECM POWER SUPPLY CIRCUIT-II
1.
2.
3.

Reconnect ECM harness connector.
Turn ignition switch ON.
Check voltage between IPDM E/R harness connector E7 terminal 33 and ground with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> Go to EC-433, «IGNITION SIGNAL» .
NG
>> GO TO 8.

MBIB1441E

EC-545

POWER SUPPLY AND GROUND CIRCUIT
[CR (WITHOUT EURO-OBD)]

8. CHECK ECM POWER SUPPLY CIRCUIT-III
1.
2.

Turn ignition switch ON and then OFF.
Check voltage between ECM terminals 119, 120 and ground
with CONSULT-II or tester.
Voltage:

After turning ignition switch OFF, battery
voltage will exist for a few seconds, then
drop approximately 0V.

OK or NG
OK
>> GO TO 13.
NG (Battery voltage does not exist.)>>GO TO 9.
NG (Battery voltage exists for more than a few seconds.)>>GO TO
11.

PBIB1630E

9. CHECK ECM POWER SUPPLY CIRCUIT-IV
1.
2.

Turn ignition switch OFF.
Check voltage between ECM terminal 111 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 11.

PBIB1191E

10. CHECK ECM POWER SUPPLY CIRCUIT-VI
1.
2.
3.

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector.
Check harness continuity between ECM terminals 119, 120 and IPDM E/R terminal 32.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 13.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

11. CHECK ECM POWER SUPPLY CIRCUIT-VII
1.
2.
3.

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector.
Check harness continuity between ECM terminal 111 and IPDM E/R terminal 29.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 12.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-546

POWER SUPPLY AND GROUND CIRCUIT
[CR (WITHOUT EURO-OBD)]

12. CHECK 20A FUSE

A

1. Disconnect 20A fuse from IPDM E/R.
2. Check 20A fuse.
OK or NG
OK
>> GO TO 16.
NG
>> Replace 20A fuse.

EC

C

13. CHECK GROUND CONNECTIONS-II
1.

Loosen and retighten ground screws on the body. Refer to EC-548, «Ground Inspection» .

D

E

F

G
MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

OK or NG
OK
>> GO TO 14.
NG
>> Repair or replace ground connections.

14. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-II
1.
2.

Disconnect ECM harness connector.
Check harness continuity between ECM terminals 1, 115, 116 and ground.
Refer to Wiring Diagram.

H

I

J

K

Continuity should exist.
3. Also check harness for short to power.
OK or NG
OK
>> GO TO 16.
NG
>> GO TO 15.

L

15. DETECT MALFUNCTIONING PART

M

Check the following.
●
Harness connectors F1, E48
●
Harness for open or short between ECM and ground
>> Repair open circuit or short to power in harness or connectors.

16. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE
ENGINE ROOM)» .
NG
>> Repair open circuit or short to power in harness or connectors.

EC-547

POWER SUPPLY AND GROUND CIRCUIT
[CR (WITHOUT EURO-OBD)]

Ground Inspection

BBS0035V

Ground connections are very important to the proper operation of electrical and electronic circuits. Ground
connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can
become an unwanted resistance. This unwanted resistance can change the way a circuit works.
Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even
when the ground connection looks clean, there can be a thin film of rust on the surface.
When inspecting a ground connection follow these rules:
●
Remove the ground bolt or screw.
●
Inspect all mating surfaces for tarnish, dirt, rust, etc.
●
Clean as required to assure good contact.
●
Reinstall bolt or screw securely.
●
Inspect for “add-on” accessories which may be interfering with the ground circuit.
●
If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the
wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one
eyelet make sure no ground wires have excess wire insulation.
For detailed ground distribution information, refer to PG-38, «Ground Distribution» .

PBIB1870E

EC-548

DTC U1001 CAN COMMUNICATION LINE
[CR (WITHOUT EURO-OBD)]

DTC U1001 CAN COMMUNICATION LINE
Description

PFP:23710

A
BBS0035W

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- EC
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
C
Each control unit transmits/receives data but selectively reads required data only.

On Board Diagnosis Logic

BBS0035X

D

The MI will not light up for these self-diagnoses.
DTC No.

Trouble diagnosis name

DTC detecting condition
●

U1001
1001

CAN communication line
●

ECM cannot communicate to other control
units.
ECM cannot communicate for more than the
specified time.

DTC Confirmation Procedure
1.
2.
3.

Possible cause
●

Harness or connectors
(CAN communication line is open or
shorted.)

E

F
BBS0035Y

Turn ignition switch ON and wait at least 3 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
If 1st trip DTC is detected, go to EC-551, «Diagnostic Procedure» .

G

H

I

J

K

L

M

EC-549

DTC U1001 CAN COMMUNICATION LINE
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS0035Z

MBWA1503E

EC-550

DTC U1001 CAN COMMUNICATION LINE
[CR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS00360

Go to LAN-3, «Precautions When Using CONSULT-II» .

A

EC

C

D

E

F

G

H

I

J

K

L

M

EC-551

DTC U1010 CAN COMMUNICATION
[CR (WITHOUT EURO-OBD)]

DTC U1010 CAN COMMUNICATION
Description

PFP:23710
BBS003ZM

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

On Board Diagnosis Logic

BBS003ZN

The MI will not light up for this diagnosis.
DTC No.
U1010
1010

Trouble diagnosis name
CAN communication bus

DTC detecting condition
Initializing CAN communication bus is malfunctioning.

DTC Confirmation Procedure

Possible cause
●

ECM

BBS003ZO

WITH CONSULT-II
1.
2.
3.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
If 1st trip DTC is detected, go to EC-553, «Diagnostic Procedure»
.

SEF058Y

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

Turn ignition switch ON.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-553, «Diagnostic Procedure» .

EC-552

DTC U1010 CAN COMMUNICATION
[CR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS003ZP

1. INSPECTION START
1.
2.
3.
4.
5.

A

With CONSULT-II
Turn ignition switch ON.
Select “SELF-DIAG RESULTS” mode with CONSULT-II.
Touch “ERASE”.
Perform DTC Confirmation Procedure.
See EC-552, «DTC Confirmation Procedure» .
Is the DTC U1010 displayed again?

Without CONSULT-II
1. Turn ignition switch ON.
2. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-481, «DIAGNOSTIC
TEST MODE II — SELF-DIAGNOSTIC RESULTS» .
3. Perform DTC Confirmation Procedure.
See EC-552, «DTC Confirmation Procedure» .
4. Is the DTC 1010 displayed again?
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END

2. REPLACE ECM
1.
2.
3.
4.
5.

EC

C

D

E

F

G

H

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
Perform EC-486, «Accelerator Pedal Released Position Learning» .
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .
>> INSPECTION END

I

J

K

L

M

EC-553

DTC P0011 IVT CONTROL
[CR (WITHOUT EURO-OBD)]

DTC P0011 IVT CONTROL
Description

PFP:23796
BBS00361

SYSTEM DESCRIPTION
Sensor
Crankshaft position sensor (POS)

Input Signal to ECM

ECM Function

Actuator

Engine speed and piston position

Camshaft position sensor (PHASE)
Engine coolant temperature sensor

Engine coolant temperature

Wheel sensor

Vehicle speed*

Intake valve
timing control

Intake valve timing control
solenoid valve

*: This signal is sent to the ECM through CAN communication line.

PBIB0540E

This mechanism hydraulically controls cam phases continuously with the fixed operating angle of the intake
valve.
The ECM receives signals such as crankshaft position, camshaft position, engine speed, and engine coolant
temperature. Then, the ECM sends ON/OFF pulse duty signals to the intake valve timing control solenoid
valve depending on driving status. This makes it possible to control the shut/open timing of the intake valve to
increase engine torque in low/mid speed range and output in high-speed range.

CONSULT-II Reference Value in Data Monitor Mode

BBS00362

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

INT/V TIM (B1)

INT/V SOL (B1)

SPECIFICATION

Idle

−5° — 5°CA

2,000 rpm

Approx. 0° — 20°CA

Idle

0% — 2%

2,000 rpm

Approx. 0% — 50%

EC-554

DTC P0011 IVT CONTROL
[CR (WITHOUT EURO-OBD)]

On Board Diagnosis Logic

BBS00363

A

The MI will not light up for this self-diagnosis.
DTC No.

P0011
0011

Trouble diagnosis name

Detecting condition

Intake valve timing control
performance

There is a gap between angle of target and
phase-control angle degree.

Possible cause

EC

●

Crankshaft position sensor (POS)

●

Camshaft position sensor (PHASE)

●

Intake valve control solenoid valve

●

Accumulation of debris to the signal pickup portion of the camshaft

●

Timing chain installation

●

Foreign matter caught in the oil groove for
intake valve timing control

C

D

E

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode.
Detected items

Engine operating condition in fail-safe mode

Intake valve timing control

The signal is not energized to the solenoid valve and the valve control does not function

DTC Confirmation Procedure

F

BBS00364

CAUTION:
Always drive at a safe speed.
NOTE:
●
If DTC P0011 is displayed with DTC P1111, first perform trouble diagnosis for DTC P1111. See EC630 .
●
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
at least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is between 10V and 16V at
idle.

G

H

I

J

WITH CONSULT-II
1.
2.
3.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and warm it up to the normal operating temperature.
Maintain the following conditions from at least 6 consecutive
seconds
Hold the accelerator pedal as steady as possible

ENG SPEED

1,200 — 2,000 rpm (A constant rotation is maintained.)

COOLAN TEMP/S

60 — 120°C (140 — 248°F)

B/FUEL SCHDL

More than 3 msec

Shift lever

Neutral position

4.
5.
6.

K

L

M

PBIB0164E

Let engine idle for 10 seconds.
If the 1st trip DTC is detected, go to EC-556, «Diagnostic Procedure» .
If the 1st trip DTC is not detected, go to next step.
Maintain the following conditions for at least 20 consecutive seconds.

ENG SPEED

1,700 — 3,175 rpm (A constant rotation is maintained.)

COOLAN TEMP/S

70 — 105°C (176 — 194°F)

Shift lever

1st or 2nd position

Driving location uphill

Driving vehicle uphill
(Increased engine load will help maintain the driving
conditions required for this test.)

EC-555

DTC P0011 IVT CONTROL
[CR (WITHOUT EURO-OBD)]
7.

If 1st trip DTC is detected, go to EC-556, «Diagnostic Procedure» .

Overall Function Check

BBS00365

Use this procedure to check the overall function of the intake valve timing control system. During this check, a
1st trip DTC might not be confirmed.

WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON.
Set the tester probe between ECM terminal 62 (IVT control solenoid valve signal) and ground.
Start engine and let it idle.
Check the voltage under the following conditions.
Verify that the oscilloscope screen shows the signal wave as
shown below.
Conditions

Voltage
BATTERY VOLTAGE
(11 — 14V)

At idle

Approximately 4V — BATTERY VOLTAGE(11 — 14V)

2,000 rpm
SEF955V

PBIB1790E

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

7.

If NG, go to EC-556, «Diagnostic Procedure» .

Diagnostic Procedure

BBS00366

1. CHECK OIL PRESSURE WARNING LAMP
1.
2.

Start engine.
Check oil pressure warning lamp and confirm it is not illuminated.
OK or NG
OK
>> GO TO 2.
KG
>> Go to LU-6, «OIL PRESSURE CHECK» .

PBIA8559J

2. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE
Refer to EC-557, «Component Inspection» .
OK or NG
OK
>> GO TO 3.
NG
>> Replace intake valve timing control solenoid valve.

EC-556

DTC P0011 IVT CONTROL
[CR (WITHOUT EURO-OBD)]

3. CHECK CRANKSHAFT POSITION SENSOR (POS)

A

Refer to EC-615, «Component Inspection» .
OK or NG
OK
>> GO TO 4.
NG
>> Replace crankshaft position sensor (POS).

EC

4. CHECK CAMSHAFT POSITION SENSOR (PHASE)

C

Refer to EC-622, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace camshaft position sensor (PHASE).

D

5. CHECK CAMSHAFT (INTAKE)

E

Check the following.
●
Accumulation of debris to the signal plate of camshaft rear end
●
Chipping signal plate of camshaft rear end
OK or NG
OK
>> GO TO 6.
NG
>> Remove debris and clean the signal plate of camshaft
rear end or replace camshaft.

F

G

H

PBIB0565E

I

6. CHECK TIMING CHAIN INSTALLATION
J

Check service records for any recent repairs that may cause timing chain misaligned.
Are there any service records that may cause timing chain misaligned?
Yes or No
Yes
>> Check timing chain installation. Refer to EM-50, «TIMING CHAIN» .
No
>> GO TO 7.

K

7. CHECK LUBRICATION CIRCUIT

L

Refer to EM-47, «Inspection of Camshaft Sprocket (INT) Oil Groove» .
OK or NG
OK
>> GO TO 8.
NG
>> Clean lubrication line.

M

8. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
For Wiring Diagram, refer to EC-611 for CKP sensor (POS), EC-618 for CMP sensor (PHASE).
>> INSPECTION END

Component Inspection

BBS00367

INTAKE VALVE TIMING CONTROL SOLENOID VALVE
1.

Disconnect intake valve timing control solenoid valve harness connector.

EC-557

DTC P0011 IVT CONTROL
[CR (WITHOUT EURO-OBD)]
2.

3.
4.

Check resistance between intake valve timing control solenoid
valve as follows.
Terminal

Resistance

1 and 2

6.7 — 7.7Ω at 20°C (68°F)

1 or 2 and ground

∞Ω
(Continuity should not exist.)

If NG, replace intake valve timing control solenoid valve.
If OK, go to next step.
Remove intake valve timing control solenoid valve.

MBIB0027E

Provide 12V DC between intake valve timing control solenoid
valve terminals and then interrupt it. Make sure that the plunger
moves as shown in the figure.
CAUTION:
Do not apply 12V DC continuously for 5 seconds or more.
Doing so may result in damage to the coil in intake valve
timing control solenoid valve.
If NG, replace intake valve timing control solenoid valve.
NOTE:
Always replace O-ring when intake valve timing control
solenoid valve is removed.

PBIB2388E

Removal and Installation

BBS00368

INTAKE VALVE TIMING CONTROL SOLENOID VALVE
Refer to EM-35, «ROCKER COVER» .

EC-558

DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR
[CR (WITHOUT EURO-OBD)]

DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR
Component Description

PFP:22365

A
BBS00369

The manifold absolute pressure (MAP) sensor is placed intake manifold corrector. It detects intake manifold pressure and sends the
voltage signal to the ECM, ECM uses the signal to compute intake
air volume value.
The sensor uses a silicon diaphragm which is sensitive to the
change in pressure. As the pressure increase, the voltage rises.

EC

C

D
MBIB0278E

E

On Board Diagnosis Logic

BBS0036A

If DTC P0107 or P0108 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229.
Refer to EC-680, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

Trouble diagnosis name

DTC detecting condition

Manifold absolute pressure
sensor circuit low input

An excessively low voltage from the sensor is
sent to ECM.

●

P0107
0107

P0108
0108

Manifold absolute pressure
sensor circuit high input

An excessively high voltage from the sensor is
sent to ECM.

F

Possible cause
Harness or connectors
(The sensor circuit is open or shorted.)

●

Manifold absolute pressure sensor

●

Harness or connectors
(The sensor circuit is open or shorted)

●

Manifold absolute pressure sensor

●

Intake air leaks

G

H

I

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode.
Detected items
Manifold absolute pressure sensor circuit

J

Engine operating condition in fail-safe mode
Engine speed will not rise more than 2,500 rpm due to the fuel cut.

DTC Confirmation Procedure

BBS0036B

K

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

L

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 5 seconds.
If 1st trip DTC is detected, go to EC-561, «Diagnostic Procedure»
.

M

SEF058Y

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

Turn ignition switch ON and wait at least 5 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-561, «Diagnostic Procedure» .

EC-559

DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS0036C

MBWA1506E

EC-560

DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
45

WIRE
COLOR
L

A

EC
ITEM
Sensor power supply

CONDITION
[Ignition switch: ON]

DATA (DC Voltage)
Approximately 5V

C

[Engine is running]

51

56

W

B

Manifold absolute pressure sensor

Sensor ground
(Manifold absolute
pressure sensor)

●

Warm-up condition

●

Idle speed

Approximately 1.5V

D

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

Approximately 1.2V

E

[Engine is running]
●

Warm-up condition

●

Idle speed

Diagnostic Procedure

Approximately 0V

F
BBS0036D

1. INSPECTION START

G

Which malfunction (P0107 or P0108) is duplicated?
P0107 or P0108
P0107 >> GO TO 3.
P0108 >> GO TO 2.

H

I

2. CHECK INTAKE SYSTEM
Check the following for connection.
●
Air duct
●
Vacuum hoses
●
Intake air passage between air duct and intake manifold
OK or NG
OK
>> GO TO 3.
NG
>> Reconnect the parts.

J

K

L

M

EC-561

DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR
[CR (WITHOUT EURO-OBD)]

3. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace ground connections.

4. CHECK MAP SENSOR POWER SUPPLY CIRCUIT
1.
2.

Disconnect manifold absolute pressure (MAP) sensor harness
connector.
Turn ignition switch ON.

MBIB0276E

3.

Check voltage between MAP sensor terminal 2 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 5.
NG
>> Repair harness or connectors.

MBIB0602E

EC-562

DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR
[CR (WITHOUT EURO-OBD)]

5. CHECK MAP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between MAP sensor terminal 4 and ECM terminal 56
Refer to Wiring Diagram.

EC

Continuity should exist.

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D

6. CHECK MAP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

E

Check harness continuity between MAP sensor terminal 1 and ECM terminal 51.
Refer to Wiring Diagram
F

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

G

H

7. CHECK MAP SENSOR
Refer to EC-563, «Component Inspection» .
OK or NG
OK
>> GO TO 8.
NG
>> Replace manifold absolute pressure sensor.

I

J

8. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

K

>> INSPECTION END
L

Component Inspection

BBS0036E

MANIFOLD ABSOLUTE PRESSURE SENSOR
1.
2.
3.
4.

5.

Reconnect all harness connectors disconnected.
Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF, wait at least 5 seconds and then turn ON.
Check voltage between ECM terminal 51 (manifold absolute
pressure sensor signal) and ground.
NOTE:
● To avoid the affection of intake manifold vacuum, check the
voltage 1 or more minutes past after engine is stopped.
● Because the sensor is absolute pressure sensor, output value
may differ depends on atmospheric pressure and altitude.
Measure the atmospheric pressure.
NOTE:
As atmospheric pressure describe on synoptic chart is value at
sea level, please compensate the actual pressure with the following chart.

EC-563

M

SEF006P

DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR
[CR (WITHOUT EURO-OBD)]

6.

Altitude

Compensated pressure

0m

0hPa

200m

-24hPa

400m

-47hPa

600m

-70hPa

800m

-92hPa

1,000m

-114hPa

1,500m

-168hPa

2,000m

-218hPa

Check the manifold absolute pressure sensor value corresponds to the atmospheric pressure.
Atmospheric pressure

Voltage

800hPa

3.2 — 3.6V

850hPa

3.4 — 3.8V

900hPa

3.7 — 4.1V

960hPa

3.9 — 4.3V

1,000hPa

4.1 — 4.5V

1,050hPa

4.3 — 4.7V

7.

Start engine and let it idle.

8.

Check the voltage between ECM terminal 51 and ground at
idling and confirm the voltage difference between engine is
stopped and at idling is within following chart.

MBIB0655E

Intake manifold vacuum

Voltage difference

-40kPa (-300mmHg)

1.6 — 2.0V

-53.3kPa (-400mmHg)

2.2 — 2.6V

-66.7kPa (-500mm)

2.8 — 3.2V

-80kPa (-600mmHg)

3.4 — 3.8V
SEF487R

Removal and Installation

BBS0036F

MANIFOLD ABSOLUTE PRESSURE SENSOR
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

EC-564

DTC P0117, P0118 ECT SENSOR
[CR (WITHOUT EURO-OBD)]

DTC P0117, P0118 ECT SENSOR
Component Description

PFP:22630

A
BBS0036G

The engine coolant temperature sensor is used to detect the engine
coolant temperature. The sensor modifies a voltage signal from the
ECM. The modified signal returns to the ECM as the engine coolant
temperature input. The sensor uses a thermistor which is sensitive to
the change in temperature. The electrical resistance of the thermistor decreases as temperature increases.

EC

C

D
SEF594K

E

Engine coolant
temperature °C (°F)

Voltage* V

−10 (14)

4.4

Resistance

F

kΩ

7.0 — 11.4

20 (68)

3.5

2.1 — 2.9

50 (122)

2.2

0.68 — 1.00

90 (194)

0.9

0.236 — 0.260

G

H

*: This data is reference value and is measured between ECM terminal 72 (Engine
coolant temperature sensor) and ground.

SEF012P

CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.

On Board Diagnosis Logic
DTC No.

BBS0036H

Trouble Diagnosis Name

DTC Detecting Condition

I

J

Possible Cause

P0117
0117

Engine coolant temperature
sensor circuit low input

An excessively low voltage from the sensor
is sent to ECM.

●

Harness or connectors
(The sensor circuit is open or shorted.)

P0118
0118

Engine coolant temperature
sensor circuit high input

An excessively high voltage from the sensor
is sent to ECM.

●

Engine coolant temperature sensor

K

L

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode.
Detected items

Engine operating condition in fail-safe mode
Engine coolant temperature will be determined by ECM based on the time after turning ignition switch ON
or START. CONSULT-II displays the engine coolant temperature decided by ECM.
Engine coolant temperature decided
(CONSULT-II display)

Condition
Engine coolant temperature sensor circuit

Just as ignition switch is turned ON or START

40°C (104°F)

More than approx. 4 minutes after ignition ON or
START

80°C (176°F)
40 — 80°C (104 — 176°F)
(Depends on the time)

Except as shown above

When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates
while engine is running.

EC-565

M

DTC P0117, P0118 ECT SENSOR
[CR (WITHOUT EURO-OBD)]

DTC Confirmation Procedure

BBS0036I

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 5 seconds.
If 1st trip DTC is detected, go to EC-568, «Diagnostic Procedure»
.

SEF058Y

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

Turn ignition switch ON and wait at least 5 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-568, «Diagnostic Procedure» .

EC-566

DTC P0117, P0118 ECT SENSOR
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS0036J

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1508E

EC-567

DTC P0117, P0118 ECT SENSOR
[CR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS0036K

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

2. CHECK ECT SENSOR POWER SUPPLY CIRCUIT
1.
2.

Disconnect engine coolant temperature (ECT) sensor harness
connector.
Turn ignition switch ON.

MBIB0279E

3.

Check voltage between ECT sensor terminal 1 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

PBIB0080E

EC-568

DTC P0117, P0118 ECT SENSOR
[CR (WITHOUT EURO-OBD)]

3. CHECK ECT SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECT sensor terminal 2 and ECM terminal 73.
Refer to Wiring Diagram.

EC

Continuity should exist.

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D

4. CHECK ENGINE COOLANT TEMPERATURE SENSOR

E

Refer to EC-569, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace engine coolant temperature sensor.

F

5. CHECK INTERMITTENT INCIDENT

G

Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
H

>> INSPECTION END

Component Inspection

BBS0036L

ENGINE COOLANT TEMPERATURE SENSOR
1.

I

Check resistance between engine coolant temperature sensor
terminals 1 and 2 as shown in the figure.
J

K

L
PBIB2005E

M

Engine coolant temperature

2.

°C (°F)

Resistance

kΩ

20 (68)

2.1 — 2.9

50 (122)

0.68 — 1.00

90 (194)

0.236 — 0.260

If NG, replace engine coolant temperature sensor.

SEF012P

Removal and Installation

BBS0036M

ENGINE COOLANT TEMPERATURE SENSOR
Refer to CO-19, «THERMOSTAT» .

EC-569

DTC P0122, P0123 TP SENSOR
[CR (WITHOUT EURO-OBD)]

DTC P0122, P0123 TP SENSOR
Component Description

PFP:16119
BBS0036N

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

PBIB0145E

CONSULT-II Reference Value in Data Monitor Mode

BBS0036O

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

More than 0.36V

●

Shift lever: 1st

Accelerator pedal: Fully depressed

Less than 4.75V

THRTL SEN 1
THRTL SEN 2*

*: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic

BBS0036P

These self-diagnoses have the one trip detection logic.
DTC No.

Trouble diagnosis name

DTC detecting condition

Possible cause

P0122
0122

Throttle position sensor 2
circuit low input

An excessively low voltage from the TP sensor 2
is sent to ECM.

●

Harness or connectors
(TP sensor 2 circuit is open or
shorted.)
(APP sensor 2 circuit is shorted.)

P0123
0123

Throttle position sensor 2
circuit high input

An excessively high voltage from the TP sensor 2
is sent to ECM.

●

Electric throttle control actuator
(TP sensor 2)

●

Accelerator pedal position sensor
(APP sensor 2)

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-570

DTC P0122, P0123 TP SENSOR
[CR (WITHOUT EURO-OBD)]

DTC Confirmation Procedure

BBS0036Q

A
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
EC
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

C

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-573, «Diagnostic Procedure» .

D

E

F
SEF058Y

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

G

Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-573, «Diagnostic Procedure» .

H

I

J

K

L

M

EC-571

DTC P0122, P0123 TP SENSOR
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS0036R

MBWA1509E

EC-572

DTC P0122, P0123 TP SENSOR
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL NO.
47

WIRE
COLOR
L

ITEM

CONDITION

Sensor power supply
(Throttle position sensor)

EC

DATA (DC Voltage)

[Ignition switch: ON]

A

Approximately 5V

C

[Ignition switch: ON]

49

Y

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

Throttle position sensor 1

More than 0.36V

D

[Ignition switch: ON]
●

E

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

Less than 4.75V

F

[Engine is running]
66

B

Sensor ground
(Throttle position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

G

[Ignition switch: ON]

68

R

Throttle position sensor 2

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

BR

Sensor power supply
(APP sensor 2)

H

[Ignition switch: ON]
●

91

Less than 4.75V

I

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

More than 0.36V

J

[Ignition switch: ON]

Approximately 5V

Diagnostic Procedure

BBS0036S

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

K

L

M

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-573

3.

Body ground E28

DTC P0122, P0123 TP SENSOR
[CR (WITHOUT EURO-OBD)]

2. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-I
1.
2.

Disconnect electric throttle control actuator harness connector.
Turn ignition switch ON.

MBIB0308E

3.

Check voltage between electric throttle control actuator terminal
1 and ground with CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.

PBIB0082E

3. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between electric throttle control actuator terminal 1 and ECM terminal 47.
Refer to Wiring Diagram.
Continuity should exist.

OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit.

4. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-III
Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

47

Electric throttle control actuator terminal 1

EC-572

91

APP sensor terminal 5

EC-710

OK or NG
OK
>> GO TO 5.
NG
>> Repair short to ground or short to power in harness or connectors.

5. CHECK APP SENSOR
Refer to EC-716, «Component Inspection» .
OK or NG
OK
>> GO TO 11
NG
>> GO TO 6.

EC-574

DTC P0122, P0123 TP SENSOR
[CR (WITHOUT EURO-OBD)]

6. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace accelerator pedal assembly.
Perform EC-486, «Accelerator Pedal Released Position Learning» .
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

7. CHECK THROTTLE POSITION SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT
Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 66 and electric throttle control actuator terminal 5.
Refer to Wiring Diagram.
Continuity should exist.

8. CHECK THROTTLE POSITION SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

E

G

H

Check harness continuity between ECM terminal 68 and electric throttle control actuator terminal 2.
Refer to Wiring Diagram.
I

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 9.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

J

K

9. CHECK THROTTLE POSITION SENSOR
Refer to EC-576, «Component Inspection» .
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

L

10. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

D

F

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

1.

EC

C

>> INSPECTION END

1.
2.
3.

A

Replace the electric throttle control actuator.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .
>> INSPECTION END

11. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-575

M

DTC P0122, P0123 TP SENSOR
[CR (WITHOUT EURO-OBD)]

Component Inspection

BBS0036T

THROTTLE POSITION SENSOR
1.
2.
3.
4.
5.

Reconnect all harness connectors disconnected.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Turn ignition switch ON.
Set shift lever to 1st position.
Check voltage between ECM terminals 49 (TP sensor 1 signal),
68 (TP sensor 2 signal) and ground under the following conditions.
Terminal

Accelerator pedal

Voltage

49
(Throttle position sensor 1)

Fully released

More than 0.36V

Fully depressed

Less than 4.75V

Fully released

Less than 4.75V

Fully depressed

More than 0.36V

68
(Throttle position sensor 2)

6.
7.
8.

If NG, replace electric throttle control actuator and go to the next
step.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

Removal and Installation

MBIB1443E

BBS0036U

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

EC-576

DTC P0132 HO2S1
[CR (WITHOUT EURO-OBD)]

DTC P0132 HO2S1
Component Description

PFP:22690

A
BBS0036V

The heated oxygen sensor 1 is placed into the exhaust manifold. It
detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.

EC

C

D
SEF463R

E

F

G

H
SEF288D

CONSULT-II Reference Value in Data Monitor Mode

BBS0036W

I

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

J

0 — 0.3V ←→ Approx. 0.6 — 1.0V

HO2S1 (B1)
●

HO2S1 MNTR (B1)

Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN ←→ RICH
Changes more than 5 times during
10 seconds.

On Board Diagnosis Logic

K

BBS0036X

L

To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 output is not inordinately high.

M

SEF301UA

DTC No.
P0132
0132

Trouble diagnosis name
Heated oxygen sensor 1
circuit high voltage

DTC detecting condition

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 1

An excessively high voltage from the sensor
is sent to ECM.

EC-577

DTC P0132 HO2S1
[CR (WITHOUT EURO-OBD)]

DTC Confirmation Procedure

BBS0036Y

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Restart engine and let it idle for 2 minutes.
If 1st trip DTC is detected, go to EC-580, «Diagnostic Procedure»
.

SEF174Y

WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Restart engine and let it idle for 2 minutes.
Turn ignition switch OFF and wait at least 10 seconds.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-580, «Diagnostic Procedure» .

EC-578

DTC P0132 HO2S1
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS0036Z

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1510E

EC-579

DTC P0132 HO2S1
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Approximately 7.0V
[Engine is running]
24

Y

Heated oxygen sensor 1
heater

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

PBIB0519E

[Engine is running]
●

BATTERY VOLTAGE
(11 — 14V)

Engine speed: Above 3,600 rpm

[Engine is running]
35

BR

Heated oxygen sensor 1

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS00370

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-580

3.

Body ground E28

DTC P0132 HO2S1
[CR (WITHOUT EURO-OBD)]

2. RETIGHTEN HEATED OXYGEN SENSOR 1

A

Loosen and retighten heated oxygen sensor 1 (2).
●
●

: Vehicle front
Exhaust manifold cover (1)

EC

Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb)
C

>> GO TO 3.
D

E
MBIB1493E

3. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT
F

1.
2.
3.

Disconnect heated oxygen sensor 1 harness connector (1).
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 74 and HO2S1
terminal 1.
Refer to Wiring Diagram.

G

H

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

I
MBIB1494E

J

4. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 35 and HO2S1 terminal 4.
Refer to Wiring Diagram.

K

Continuity should exist.
2.

Check harness continuity between ECM terminal 35 or HO2S1 terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

L

M

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK HO2S1 CONNECTOR FOR WATER
Check connectors for water
Water should not exist.
OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace harness or connectors.

EC-581

DTC P0132 HO2S1
[CR (WITHOUT EURO-OBD)]

6. CHECK HEATED OXYGEN SENSOR 1
Refer to EC-582, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace heated oxygen sensor 1.

7. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS00371

HEATED OXYGEN SENSOR 1
With CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULTII.
Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch “RECORD” on CONSULT-II screen.

MBIB0301E

6.

Check the following.
● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes
from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds.
5 times (cycles) are counted as shown in the figure.
● “HO2S1 (B1)” voltage goes above 0.6V at least once.
● “HO2S1 (B1)” voltage goes below 0.3V at least once.
● “HO2S1 (B1)” voltage never exceeds 1.0V.
SEF217YA

SEF648Y

CAUTION:
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.

●

EC-582

DTC P0132 HO2S1
[CR (WITHOUT EURO-OBD)]
●

Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

A

Without CONSULT-II
1.
2.
3.

Start engine and warm it up to normal operating temperature.
EC
Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground.
Check the following with engine speed held at 2,000 rpm constant under no load.
C
● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
● The maximum voltage is over 0.6V at least one time.
D
● The minimum voltage is below 0.3V at least one time.
● The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
E
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V → 0 0.3V
MBIB0018E
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 F
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
G
Cleaner and approved anti-seize lubricant.

Removal and Installation

BBS00372

HEATED OXYGEN SENSOR 1

H

Refer to EM-24, «EXHAUST MANIFOLD AND THREE WAY CATALYST» .
I

J

K

L

M

EC-583

DTC P0134 HO2S1
[CR (WITHOUT EURO-OBD)]

DTC P0134 HO2S1
Component Description

PFP:22690
BBS00373

The heated oxygen sensor 1 is placed into the exhaust manifold. It
detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.

SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

BBS00374

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION
0 — 0.3V ←→ Approx. 0.6 — 1.0V

HO2S1 (B1)
●

HO2S1 MNTR (B1)

Engine: After warming up

Maintaining engine speed at 2,000
rpm

LEAN ←→ RICH
Changes more than 5 times during 10 seconds.

On Board Diagnosis Logic

BBS00375

Under the condition in which the heated oxygen sensor 1 signal is
not input, the ECM circuits will read a continuous approximately
0.3V. Therefore, for this diagnosis, the time that output voltage is
within 200 to 400 mV range is monitored, and the diagnosis checks
that this time is not inordinately long.

SEF237U

DTC No.
P0134
0134

Trouble diagnosis name
Heated oxygen sensor 1
circuit no activity detected

DTC detecting condition

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 1

The voltage from the sensor is constantly
approx. 0.3V.

EC-584

DTC P0134 HO2S1
[CR (WITHOUT EURO-OBD)]

Overall Function Check

BBS00376

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a
1st trip DTC might not be confirmed.

WITH CONSULT-II
1.
2.
3.
4.
5.

A

EC

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” in “DATA MONITOR” mode with CONSULT-II, and select “HO2S1 (B1)”.
Hold engine speed at 2,000 rpm under no load.
Make sure that the indications do not remain in the range
between 0.2V to 0.4V.
If NG, go to EC-587, «Diagnostic Procedure» .

C

D

E
SEF646Y

F

WITHOUT CONSULT-II
1.
2.
3.
●

4.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground.
Check the following with engine speed held at 2,000 rpm constant under no load.
The voltage does not remain in the range of 0.2 — 0.4V.
If NG, go to EC-587, «Diagnostic Procedure» .

G

H

I

J
MBIB0018E

K

L

M

EC-585

DTC P0134 HO2S1
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS00377

MBWA1510E

EC-586

DTC P0134 HO2S1
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
Approximately 7.0V
[Engine is running]

24

Y

Heated oxygen sensor 1
heater

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

D

E
PBIB0519E

[Engine is running]
●

BATTERY VOLTAGE
(11 — 14V)

Engine speed Above 3,600 rpm

F

[Engine is running]
35

BR

Heated oxygen sensor 1

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

G

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

H

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

I

Diagnostic Procedure

BBS00378

1. CHECK GROUND CONNECTIONS
1.
2.

J

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

K

L

M

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-587

3.

Body ground E28

DTC P0134 HO2S1
[CR (WITHOUT EURO-OBD)]

2. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Disconnect heated oxygen sensor 1 harness connector (1).
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 74 and HO2S1
terminal 1. Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

3. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 35 and HO2S1 terminal 4.
Refer to Wiring Diagram.
Continuity should exist.

2.

Check harness continuity between ECM terminal 35 or HO2S1 terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK HEATED OXYGEN SENSOR 1
Refer to EC-589, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace heated oxygen sensor 1.

5. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-588

MBIB1494E

DTC P0134 HO2S1
[CR (WITHOUT EURO-OBD)]

Component Inspection

BBS00379

A

HEATED OXYGEN SENSOR 1
With CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC
II.
Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
C
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch “RECORD” on CONSULT-II screen.
D

E

MBIB0301E

F

6.

Check the following.
● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes
from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds.
5 times (cycles) are counted as shown in the figure.
● “HO2S1 (B1)” voltage goes above 0.6V at least once.
● “HO2S1 (B1)” voltage goes below 0.3V at least once.
● “HO2S1 (B1)” voltage never exceeds 1.0V.

G

H

I
SEF217YA

J

K

L

SEF648Y

CAUTION:
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.
●

Without CONSULT-II
1.
2.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground.

EC-589

M

DTC P0134 HO2S1
[CR (WITHOUT EURO-OBD)]
3.

Check the following with engine speed held at 2,000 rpm constant under no load.
● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
● The maximum voltage is over 0.6V at least one time.
● The minimum voltage is below 0.3V at least one time.
● The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V → 0 0.3V
MBIB0018E
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

Removal and Installation

BBS0037A

HEATED OXYGEN SENSOR 1
Refer to EM-24, «EXHAUST MANIFOLD AND THREE WAY CATALYST» .

EC-590

DTC P0138 HO2S2
[CR (WITHOUT EURO-OBD)]

DTC P0138 HO2S2
Component Description

PFP:226A0

A
BBS0037B

The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.

EC

C

D
SEF327R

E

CONSULT-II Reference Value in Data Monitor Mode

BBS0037C

Specification data are reference values.
MONITOR ITEM
HO2S2 (B1)

HO2S2 MNTR (B1)

F

CONDITION

SPECIFICATION

●

Revving engine from idle to 3,000 rpm quickly after the following conditions are met.

0 — 0.3V ←→ Approx. 0.6 — 1.0V

–

Engine: After warning up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute
and at idle for 1 minute under no load.

G

LEAN ←→ RICH

H

On Board Diagnosis Logic

BBS0037D

The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity before the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the voltage is unusually high during
the various driving condition such as fuel-cut.

I

J

K
SEF305UA

L
DTC No.
P0138
0138

Trouble diagnosis name
Heated oxygen sensor 2
circuit high voltage

DTC detecting condition

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 2

An excessively high voltage from the sensor
is sent to ECM.

DTC Confirmation Procedure

BBS0037E

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

EC-591

M

DTC P0138 HO2S2
[CR (WITHOUT EURO-OBD)]
WITH CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least 1 minute under no load.
Let engine idle for 2 minutes.
If 1st trip DTC is detected, go to EC-594, «Diagnostic Procedure»
.

SEF189Y

WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.
7.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 2 minutes.
Turn ignition switch OFF and wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-594, «Diagnostic Procedure» .

EC-592

DTC P0138 HO2S2
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS0037F

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1511E

EC-593

DTC P0138 HO2S2
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]

2

GR

●

Engine speed: Below 3,800 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and
4,000 rpm for 1 minute and at idle for 1 minute
under no load.

Heated oxygen sensor 2
heater

0 — 1.0V

[Ignition switch ON]
●

Engine stopped

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
●

Engine speed: Above 3,800 rpm

[Engine is running]

16

LG

Heated oxygen sensor 2

●

Revving engine from idle to 3,000rpm quickly
after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and
4,000 rpm for 1 minute and at idle for 1 minute
under no load.

0 — Approximately 1.0V

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

Diagnostic Procedure

BBS0037G

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-594

3.

Body ground E28

DTC P0138 HO2S2
[CR (WITHOUT EURO-OBD)]

2. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT
1.

Disconnect heated oxygen sensor 2 harness connector (1).

–

: Vehicle front
Heated oxygen sensor 2 (2)
Oil pan (3)
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 74 and HO2S2
terminal 4.
Refer to Wiring Diagram.

–
–

2.
3.

Continuity should exist.

EC

C

D
MBIB1459E

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

A

Check harness continuity between ECM terminal 16 and HO2S2 terminal 1.
Refer to Wiring Diagram.

E

F

G

Continuity should exist.
2.

Check harness continuity between ECM terminal 16 or HO2S2 terminal 1 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

H

I

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK HO2S2 CONNECTOR FOR WATER

J

K

Check connectors for water.
Water should not exist.

L

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace harness or connectors.

5. CHECK HEATED OXYGEN SENSOR 2
Refer to EC-596, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 2.

6. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-595

M

DTC P0138 HO2S2
[CR (WITHOUT EURO-OBD)]

Component Inspection

BBS0037H

HEATED OXYGEN SENSOR 2
With CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
SEF174Y

6.

Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select
“HO2S2(B1)” as the monitor item with CONSULT-II.

SEF662Y

7.

Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%.

MBIB1402E

“HO2S2 (B1)” should be above 0.61V at least once when the “FUEL INJECTION” is +25%.
“HO2S2 (B1)” should be below 0.52V at least once when the “FUEL INJECTION” is −25%.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

Without CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground.

EC-596

DTC P0138 HO2S2
[CR (WITHOUT EURO-OBD)]
6.

Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
A
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.61V at least once during this
procedure.
EC
If the voltage is above 0.61V at step 6, step 7 is not necessary.
7. Keep vehicle idling for 10 minutes, then check voltage. Or check
C
the voltage when coasting from 80 km/h (50 MPH) in 3rd gear
position.
The voltage should be below 0.52V at least once during this
MBIB0020E
procedure.
D
8. If NG, replace heated oxygen sensor 2.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 E
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.
F

Removal and Installation

BBS0037I

HEATED OXYGEN SENSOR 2
G

Refer to EX-3, «EXHAUST SYSTEM» .

H

I

J

K

L

M

EC-597

DTC P0222, P0223 TP SENSOR
[CR (WITHOUT EURO-OBD)]

DTC P0222, P0223 TP SENSOR
Component Description

PFP:16119
BBS0037J

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. the throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

PBIB0145E

CONSULT-II Reference Value in Data Monitor Mode

BBS0037K

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

More than 0.36V

●

Shift lever: 1st

Accelerator pedal: Fully depressed

Less than 4.75V

THRTL SEN 1
THRTL SEN 2*

*: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic

BBS0037L

These self-diagnoses have the one trip detection logic.
DTC No.

Trouble diagnosis name

DTC detecting condition

P0222
0222

Throttle position sensor 1
circuit low input

An excessively low voltage from the TP sensor 1
is sent to ECM.

P0223
0223

Throttle position sensor 1
circuit high input

An excessively high voltage from the TP sensor
1 is sent to ECM.

Possible cause
●

Harness or connectors
(TP sensor 1 circuit is open or shorted.)
(APP sensor 2 circuit is shorted.)

●

Electric throttle control actuator
(TP sensor 1)

●

Accelerator pedal position sensor
(APP sensor 2)

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

DTC Confirmation Procedure

BBS0037M

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

EC-598

DTC P0222, P0223 TP SENSOR
[CR (WITHOUT EURO-OBD)]
WITH CONSULT-II
1.
2.
3.
4.

A

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-601, «Diagnostic Procedure» .

EC

C

D
SEF058Y

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

Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-601, «Diagnostic Procedure» .

E

F

G

H

I

J

K

L

M

EC-599

DTC P0222, P0223 TP SENSOR
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS0037N

MBWA1513E

EC-600

DTC P0222, P0223 TP SENSOR
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
47

EC

WIRE
COLOR
L

A

ITEM

CONDITION

Sensor power supply
(Throttle position sensor)

DATA (DC Voltage)

[Ignition switch: ON]

C

Approximately 5V

[Ignition switch: ON]

49

Y

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

Throttle position sensor 1

D

More than 0.36V

E

[Ignition switch: ON]
●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

Less than 4.75V

F

[Engine is running]
66

B

Sensor ground
(Throttle position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

G

[Ignition switch: ON]

68

91

R

BR

Throttle position sensor 2

Sensor power supply
(APP sensor 2)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

H

Less than 4.75V

I

[Ignition switch: ON]
●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

More than 0.36V

J

[Ignition switch ON]

Approximately 5V

K

Diagnostic Procedure

BBS0037O

1. RETIGHTEN GROUND CONNECTIONS
1.
2.

L

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

M

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-601

3.

Body ground E28

DTC P0222, P0223 TP SENSOR
[CR (WITHOUT EURO-OBD)]

2. CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT-I
1.
2.

Disconnect electric throttle control actuator harness connector.
Turn ignition switch ON.

MBIB0308E

3.

Check voltage between electric throttle control actuator terminal
1 and ground with CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.

PBIB0082E

3. CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between electric throttle control actuator terminal 1 and ECM terminal 47.
Refer to Wiring Diagram.
Continuity should exist.

OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit.

4. CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT-III
Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

47

Electric throttle control actuator terminal 1

EC-600

91

APP sensor terminal 5

EC-710

OK or NG
OK
>> GO TO 5.
NG
>> Repair short to ground or short to power in harness or connectors.

5. CHECK APP SENSOR
Refer to EC-716, «Component Inspection» .
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 6.

EC-602

DTC P0222, P0223 TP SENSOR
[CR (WITHOUT EURO-OBD)]

6. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace accelerator pedal assembly.
Perform EC-486, «Accelerator Pedal Released Position Learning» .
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

7. CHECK THROTTLE POSITION SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT
Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 66 and electric throttle control actuator terminal 5.
Refer to Wiring Diagram.
Continuity should exist.

8. CHECK THROTTLE POSITION SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

E

G

H

Check harness continuity between ECM terminal 49 and electric throttle control actuator terminal 4.
Refer to Wiring Diagram.
I

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 9.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

J

K

9. CHECK THROTTLE POSITION SENSOR
Refer to EC-604, «Component Inspection» .
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

L

10. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

D

F

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

1.

EC

C

>> INSPECTION END

1.
2.
3.

A

Replace the electric throttle control actuator.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .
>> INSPECTION END

11. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-603

M

DTC P0222, P0223 TP SENSOR
[CR (WITHOUT EURO-OBD)]

Component Inspection

BBS0037P

THROTTLE POSITION SENSOR
1.
2.
3.
4.
5.

Reconnect all harness connectors disconnected.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Turn ignition switch ON.
Set shift lever to 1st position.
Check voltage between ECM terminals 49 (TP sensor 1 signal),
68 (TP sensor 2 signal) and ground under the following conditions.
Terminal

Accelerator pedal

Voltage

49
(Throttle position sensor 1)

Fully released

More than 0.36V

Fully depressed

Less than 4.75V

Fully released

Less than 4.75V

Fully depressed

More than 0.36V

68
(Throttle position sensor 2)

6.
7.
8.

If NG, replace electric throttle control actuator and go to the next
step.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

Removal and Installation

MBIB1443E

BBS0037Q

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

EC-604

DTC P0327, P0328 KS
[CR (WITHOUT EURO-OBD)]

DTC P0327, P0328 KS
Component Description

PFP:22060

A
BBS0037R

The knock sensor is attached to the cylinder block. It senses engine
knocking using a piezoelectric element. A knocking vibration from
the cylinder block is sensed as vibrational pressure. This pressure is
converted into a voltage signal and sent to the ECM.

EC

C

D
MBIB0306E

E

On Board Diagnosis Logic

BBS0037S

The MI will not light up for these self-diagnoses.
DTC No.

Trouble Diagnosis Name

DTC Detected Condition

F

Possible Cause

P0327
0327

Knock sensor circuit low
input

An excessively low voltage from the sensor is
sent to ECM.

●

Harness or connectors
(The sensor circuit is open or shorted.)

P0328
0328

Knock sensor circuit high
input

An excessively high voltage from the sensor is
sent to ECM.

●

Knock sensor

DTC Confirmation Procedure

BBS0037T

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

WITH CONSULT-II
1.
2.
3.

G

H

I

J

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and run it for at least 5 seconds at idle speed.
If 1st trip DTC is detected, go to EC-607, «Diagnostic Procedure»
.

K

L

M
SEF058Y

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

Start engine and run it for at least 5 seconds at idle speed.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-607, «Diagnostic Procedure» .

EC-605

DTC P0327, P0328 KS
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS0037U

MBWA0571E

EC-606

DTC P0327, P0328 KS
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
15

WIRE
COLOR
W

A

EC
ITEM

Knock sensor

CONDITION
[Engine is running]
●

Idle speed

DATA (DC Voltage)

C

Approximately 2.5V

[Engine is running]
54

—

Sensor ground
(Knock sensor)

●

Warm-up condition

●

Idle speed

D

Approximately 0V

Diagnostic Procedure

BBS0037V

1. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-I
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check resistance between ECM terminal 15 and ground. Refer to Wiring Diagram.
NOTE:
It is necessary to use an ohmmeter which can measure more than 10 MΩ.

E

F

G

Resistance: Approximately 530 — 590kΩ [at 20°C (68°F)]
H

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 2.

I

2. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-II
1.
2.

J

Disconnect knock sensor harness connector.
Check harness continuity between ECM terminal 15 and knock
sensor terminal 2.
Refer to Wiring Diagram.

K

Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

3. CHECK KNOCK SENSOR
Refer to EC-608, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace knock sensor.

EC-607

L

M
MBIB0306E

DTC P0327, P0328 KS
[CR (WITHOUT EURO-OBD)]

4. CHECK GROUND CONNECTIONS
1.

Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace ground connections.

5. CHECK KNOCK SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 54 and knock sensor terminal 1.
Refer to Wiring Diagram.
Continuity should exist

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS0037W

KNOCK SENSOR
Check resistance between knock sensor terminal 2 and ground.
NOTE:
It is necessary to use an ohmmeter which can measure more
than 10 MΩ.
Resistance: Approximately 530 — 590kΩ [at 20°C (68°F)]
CAUTION:
Do not use any knock sensors that have been dropped or physically damaged. Use only new ones.
PBIB0253E

Removal and Installation

BBS0037X

KNOCK SENSOR
Refer to EM-74, «CYLINDER BLOCK» .

EC-608

DTC P0335 CKP SENSOR (POS)
[CR (WITHOUT EURO-OBD)]

DTC P0335 CKP SENSOR (POS)
Component Description

PFP:23731

A
BBS0037Y

The crankshaft position sensor (POS) is located on the cylinder
block rear housing facing the gear teeth (cogs) of the signal plate at
the end of the crankshaft. It detects the fluctuation of the engine revolution.
The sensor consists of a permanent magnet and Hall IC.
When the engine is running, the high and low parts of the teeth
cause the gap with the sensor to change.
The changing gap causes the magnetic field near the sensor to
change.
Due to the changing magnetic field, the voltage from the sensor
changes.
The ECM receives the voltage signal and detects the fluctuation of
the engine revolution.
ECM receives the signals as shown in the figure.

EC

C

D
PBIB0562E

E

F

G

H

PBIB2382E

I

CONSULT-II Reference Value in Data Monitor Mode

BBS0037Z

Specification data are reference values.
MONITOR ITEM
ENG SPEED

CONDITION
●

J

SPECIFICATION

Run engine and compare CONSULT-II value with the tachometer indication.

Almost the same speed as the
tachometer indication.

K

On Board Diagnosis Logic
DTC No.

Trouble diagnosis name

DTC detecting condition
●

P0335
0335

Crankshaft position
sensor (POS) circuit

BBS00380

●

●

The crankshaft position sensor (POS) signal is not
detected by the ECM during the first few seconds of
engine cranking.
The proper pulse signal from the crankshaft position
sensor (POS) is not sent to ECM while the engine is
running.
The crankshaft position sensor (POS) signal is not in
the normal pattern during engine running.

DTC Confirmation Procedure

Possible cause

●

L

Harness or connectors
(The sensor circuit is open or
shorted.)

M

●

Crankshaft position sensor (POS)

●

Signal plate

BBS00381

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON.

EC-609

DTC P0335 CKP SENSOR (POS)
[CR (WITHOUT EURO-OBD)]
WITH CONSULT-II
1.
2.
3.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed.
If 1st trip DTC is detected, go to EC-613, «Diagnostic Procedure»
.

SEF058Y

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

Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-613, «Diagnostic Procedure» .

EC-610

DTC P0335 CKP SENSOR (POS)
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS00382

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1515E

EC-611

DTC P0335 CKP SENSOR (POS)
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

[Engine is running]
●

Warm-up condition

●

Idle speed

DATA (DC Voltage)

Approximately 3.0V

NOTE:
The pulse cycle changes depending on rpm at
idle.
13

Y

PBIB0527E

Crankshaft position
sensor (POS)

Approximately 3.0V

[Engine is running]
●

Engine speed: 2,000 rpm

PBIB0528E

30

L

Sensor ground
(Crankshaft position
sensor)

[Engine is running]
●

Warm-up condition

●

Idle speed

[Engine is running]
[Ignition switch: OFF]
●

111

P

ECM relay
(Self shut-off)

For a few seconds after turning ignition switch
OFF

[Ignition switch: OFF]
●

119
120

G
G

Power supply for
ECM

More than a few seconds passed after turning
ignition switch OFF

[Ignition switch: ON]

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-612

Approximately 0V

0 — 1.0V

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

DTC P0335 CKP SENSOR (POS)
[CR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS00383

1. CHECK GROUND CONNECTIONS
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

EC

C

D

E
MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

F

Body ground E28

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

G

2. CHECK CRANKSHAFT POSITION (CKP) SENSOR (POS) POWER SUPPLY CIRCUIT
1.
2.

H

Disconnect crankshaft position (CKP) sensor (POS) harness
connector.
Turn ignition switch ON.

I

J

K
MBIB1078E

3.

L

Check voltage between CKP sensor (POS) terminal 3 and
ground with CONSULT-II or tester.
Voltage: Battery voltage

M

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

SEF479Y

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors F1, E48
●
Harness for open or short between crankshaft position sensor (POS) and ECM
●
Harness for open or short between crankshaft position sensor (POS) and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-613

DTC P0335 CKP SENSOR (POS)
[CR (WITHOUT EURO-OBD)]

4. CHECK CKP SENSOR (POS) GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 30 and CKP sensor (POS) terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK CKP SENSOR (POS) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 13 and CKP sensor (POS) terminal 2.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK CRANKSHAFT POSITION SENSOR (POS)
Refer to EC-615, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace crankshaft position sensor (POS).

7. CHECK GEAR TOOTH
Visually check for chipping signal plate gear tooth.
OK or NG
OK
>> GO TO 8.
NG
>> Replace the signal plate.

8. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-614

DTC P0335 CKP SENSOR (POS)
[CR (WITHOUT EURO-OBD)]

Component Inspection

BBS00384

A

CRANKSHAFT POSITION SENSOR (POS)
1.
2.
3.
4.

Loosen the fixing bolt of the sensor.
Disconnect crankshaft position sensor (POS) harness connector.
Remove the sensor.
Visually check the sensor for chipping.

EC

C

D

E
PBIB0563E

5.

F

Check resistance as shown in the figure.
Terminal No. (Polarity)

Resistance Ω [at 25°C (77°F)]

3 (+) — 1 (-)
3 (+) — 2 (-)

G
Except 0 or ∞

2 (+) — 1 (-)

6.

H

If NG, replace crankshaft position sensor (POS).

MBIB0024E

Removal and Installation

I

BBS00385

CRANKSHAFT POSITION SENSOR (POS)

J

Refer to EM-74, «CYLINDER BLOCK» .

K

L

M

EC-615

DTC P0340 CMP SENSOR (PHASE)
[CR (WITHOUT EURO-OBD)]

DTC P0340 CMP SENSOR (PHASE)
Component Description

PFP:23731
BBS00386

The camshaft position sensor (PHASE) senses the retraction with
camshaft (intake) to identify a particular cylinder. The camshaft position sensor (PHASE) senses the piston position.
When the crankshaft position sensor (POS) system becomes inoperative, the camshaft position sensor (PHASE) provides various controls of engine parts instead, utilizing timing of cylinder identification
signals.
The sensor consists of a permanent magnet and Hall IC.
When engine is running, the high and low parts of the teeth cause
the gap with the sensor to change.
The changing gap causes the magnetic field near the sensor to
change.
Due to the changing magnetic field, the voltage from the sensor changes.
ECM receives the signals as shown in the figure.

PBIB0562E

PBIB2382E

On Board Diagnosis Logic
DTC No.

Trouble diagnosis name

DTC detecting condition
●

P0340
0340

Camshaft position sensor
(PHASE) circuit

BBS00387

The cylinder No. signal is not sent to ECM
for the first few seconds during engine
cranking.

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Camshaft position sensor (PHASE)
Camshaft (Intake)

●

The cylinder No. signal is not set to ECM
during engine running.

●
●

Starter motor (Refer to SC-45 .)

●

The cylinder No. signal is not in the normal
pattern during engine running.

●

Starting system circuit (Refer to SC-45 .)

●

Dead (Weak) battery

DTC Confirmation Procedure

BBS00388

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON.

WITH CONSULT-II
1.

Turn ignition switch ON.

EC-616

DTC P0340 CMP SENSOR (PHASE)
[CR (WITHOUT EURO-OBD)]
2.
3.
4.

5.
6.

Select “DATA MONITOR” mode with CONSULT-II.
Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed.
If 1st trip DTC is detected, go to EC-619, «Diagnostic Procedure»
.
If 1st trip DTC is not detected, go to next step.
Maintain engine speed at more than 800 rpm for at least 5 seconds.
If 1st trip DTC is detected, go to EC-619, «Diagnostic Procedure»
.

5.
6.
7.
8.
9.

EC

C
SEF058Y

D

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

A

Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-619, «Diagnostic Procedure» .
If 1st trip DTC is not detected, go to next step.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and maintain engine speed at more than 800 rpm for at least 5 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-619, «Diagnostic Procedure» .

E

F

G

H

I

J

K

L

M

EC-617

DTC P0340 CMP SENSOR (PHASE)
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS00389

MBWA1516E

EC-618

DTC P0340 CMP SENSOR (PHASE)
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
[Engine is running]
●

Warm-up condition

●

Idle speed

1.0 — 4.0V

D

NOTE:
The pulse cycle changes depending on rpm at
idle.
14

R

E
PBIB0525E

Camshaft position
sensor (PHASE)

1.0 — 4.0V

F
[Engine is running]
●

Engine speed: 2,000 rpm

G
PBIB0526E

29

B

Sensor ground
(Camshaft position
sensor)

●

Warm-up condition

●

Idle speed

●

P

ECM relay
(Self shut-off)

For a few seconds after turning ignition switch
OFF

[Ignition switch: OFF]
●

119
120

G
G

Power supply for
ECM

Approximately 0V

I

[Engine is running]
[Ignition switch: OFF]
111

H

[Engine is running]

More than a few seconds passed after turning
ignition switch OFF

[Ignition switch: ON]

0 — 1.0V

J
BATTERY VOLTAGE
(11 — 14V)

K

BATTERY VOLTAGE
(11 — 14V)

L

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS0038A

M

1. CHECK STARTING SYSTEM
Turn ignition switch to START position.
Does the engine turn over?
Does the starter motor operate?
Yes or No
Yes
>> GO TO 2.
No
>> Check starting system. (Refer to SC-45, «STARTING SYSTEM» .)

EC-619

DTC P0340 CMP SENSOR (PHASE)
[CR (WITHOUT EURO-OBD)]

2. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace ground connections.

3. CHECK CAMSHAFT POSITION (CMP) SENSOR (PHASE) POWER SUPPLY CIRCUIT
1.
2.

Disconnect camshaft position (CMP) sensor (PHASE) harness
connector.
Turn ignition switch ON.

MBIB0279E

3.

Check voltage between CMP sensor (PHASE) terminal 3 and
ground with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

SEF479Y

4. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors F1, E48
●
Harness for open or short between camshaft position sensor (PHASE) and ECM
●
Harness for open or short between camshaft position sensor (PHASE) and IPDM E/R
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-620

DTC P0340 CMP SENSOR (PHASE)
[CR (WITHOUT EURO-OBD)]

5. CHECK CMP SENSOR (PHASE) GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 29 and CMP sensor (PHASE) terminal 1.
Refer to Wiring Diagram.

EC

Continuity should exist.

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D

6. CHECK CMP SENSOR (PHASE) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

E

Check harness continuity between ECM terminal 14 and CMP sensor (PHASE) terminal 2.
Refer to Wiring Diagram.
F

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

G

H

7. CHECK CAMSHAFT POSITION SENSOR (PHASE)
Refer to EC-622, «Component Inspection» .
OK or NG
OK
>> GO TO 8.
NG
>> Replace camshaft position sensor (PHASE).

I

J

8. CHECK CAMSHAFT (INTAKE)
Check the following.
●
Accumulation of debris to the signal plate of camshaft rear end
●
Chipping signal plate of camshaft rear end
OK or NG
OK
>> GO TO 9.
NG
>> Remove debris and clean the signal plate of camshaft
rear end or replace camshaft.

K

L

M

PBIB0565E

9. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-621

DTC P0340 CMP SENSOR (PHASE)
[CR (WITHOUT EURO-OBD)]

Component Inspection

BBS0038B

CAMSHAFT POSITION SENSOR (PHASE)
1.
2.
3.
4.

Loosen the fixing bolt of the sensor.
Disconnect camshaft position sensor (PHASE) harness connector.
Remove the sensor.
Visually check the sensor for chipping.

PBIB0563E

5.

Check resistance as shown in the figure.
Terminal No. (Polarity)

Resistance Ω [at 25°C (77°F)]

3 (+) — 1 (-)
3 (+) — 2 (-)

Except 0 or ∞

2 (+) — 1 (-)

MBIB0024E

Removal and Installation

BBS0038C

CAMSHAFT POSITION SENSOR (PHASE)
Refer to EM-38, «CAMSHAFT» .

EC-622

DTC P0605 ECM
[CR (WITHOUT EURO-OBD)]

DTC P0605 ECM
Component Description

PFP:23710

A
BBS0038D

The ECM consists of a microcomputer and connectors for signal
input and output and for power supply. The ECM controls the engine.

EC

C

D
PBIB1164E

E

On Board Diagnosis Logic

BBS0038E

This self-diagnosis has one or two trip detection logic.
DTC No.
P0605
0605

Trouble diagnosis name

Engine control module

DTC detecting condition
A)

ECM calculation function is malfunctioning.

B)

ECM EEP-ROM system is malfunctioning.

C)

ECM self shut-off function is malfunctioning.

F

Possible cause

●

ECM

G

FAIL-SAFE MODE

H

ECM enters fail-safe mode when malfunction A is detected.
Detected items
Malfunction A

Engine operation condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5
degrees) by the return spring.

DTC Confirmation Procedure

BBS0038F

Perform PROCEDURE FOR MALFUNCTION A first. If the DTC cannot be confirmed, perform PROCEDURE FOR MALFUNCTION B. If there is no malfunction on PROCEDURE FOR MALFUNCTION B, perform PROCEDURE FOR MALFUNCTION C.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

PROCEDURE FOR MALFUNCTION A
With CONSULT-II
1.
2.
3.

Without CONSULT-II
Turn ignition switch ON.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.

EC-623

J

K

L

M

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
If 1st DTC is detected, go to EC-625, «Diagnostic Procedure» .

SEF058Y

1.
2.
3.

I

DTC P0605 ECM
[CR (WITHOUT EURO-OBD)]
4.

If DTC is detected, go to EC-625, «Diagnostic Procedure» .

PROCEDURE FOR MALFUNCTION B
With CONSULT-II
1.
2.
3.
4.

Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch OFF, wait at least 10 seconds, and then turn
ON.
If 1st trip DTC is detected, go to EC-625, «Diagnostic Procedure»
.

SEF058Y

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

Turn ignition switch ON and wait at least 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-625, «Diagnostic Procedure» .

PROCEDURE FOR MALFUNCTION C
With CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch OFF, wait at least 10 seconds, and then turn
ON.
Repeat step 3 for 32 times.
If 1st trip DTC is detected, go to EC-625, «Diagnostic Procedure»
.

SEF058Y

Without CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and wait at least 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Repeat step 2 for 32 times.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-625, «Diagnostic Procedure» .

EC-624

DTC P0605 ECM
[CR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS0038G

1. INSPECTION START
1.
2.
3.
4.
5.

A

With CONSULT-II
Turn ignition switch ON.
Select “SELF DIAG RESULTS” mode with CONSULT-II.
Touch “ERASE”.
Perform DTC Confirmation Procedure.
See EC-623, «DTC Confirmation Procedure» .
Is the 1st trip DTC P0605 displayed again?

Without CONSULT-II
1. Turn ignition switch ON.
2. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-478, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .
3. Perform DTC Confirmation Procedure.
See EC-623, «DTC Confirmation Procedure» .
4. Is the 1st trip DTC 0605 displayed again?
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END

2. REPLACE ECM
1.
2.
3.
4.
5.

EC

C

D

E

F

G

H

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
Perform EC-486, «Accelerator Pedal Released Position Learning» .
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .
>> INSPECTION END

I

J

K

L

M

EC-625

DTC P1065 ECM POWER SUPPLY
[CR (WITHOUT EURO-OBD)]

DTC P1065 ECM POWER SUPPLY
Component Description

PFP:23710
BBS0038H

Battery voltage is supplied to the ECM even when the ignition switch
is turned OFF for the ECM memory function of the DTC memory, the
air-fuel ratio feedback compensation value memory, the idle air volume learning value memory, etc.

PBIB1164E

On Board Diagnosis Logic
DTC No.
P1065
1065

Trouble diagnosis name

ECM power supply circuit

BBS0038I

DTC detecting condition

Possible cause
●

Harness or connectors
[ECM power supply (back-up) circuit is
open or shorted.]

●

ECM

ECM back-up RAM system does not function
properly.

DTC Confirmation Procedure

BBS0038J

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn
ON.
Repeat steps 3 and 4 for 4 times.
If 1st trip DTC is detected, go to EC-628, «Diagnostic Procedure»
.

SEF058Y

WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.
7.

Turn ignition switch ON and wait at least 1 second.
Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Repeat steps 2 and 3 for 4 times.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-628, «Diagnostic Procedure» .

EC-626

DTC P1065 ECM POWER SUPPLY
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS0038K

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1518E

EC-627

DTC P1065 ECM POWER SUPPLY
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
121

WIRE
COLOR
BR

ITEM
Power supply for ECM
(Back-up)

CONDITION

[Ignition switch: OFF]

Diagnostic Procedure

DATA (DC Voltage)
BATTERY VOLTAGE
(11 — 14V)
BBS0038L

1. CHECK ECM POWER SUPPLY
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check voltage between ECM terminal 121 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

MBIB0026E

2. DETECT MALFUNCTIONING PART
Check the following.
●
20A fuse
●
IPDM E/R harness connector E7
●
Harness for open or short between ECM and IPDM E/R
>> Repair or replace harness or connectors.

3. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace harness or connectors.

EC-628

DTC P1065 ECM POWER SUPPLY
[CR (WITHOUT EURO-OBD)]

4. PERFORM DTC CONFIRMATION PROCEDURE
With CONSULT-II
Turn ignition switch ON.
Select “SELF DIAG RESULTS” mode with CONSULT-II.
Touch “ERASE”.
Perform DTC Confirmation Procedure.
See EC-626, «DTC Confirmation Procedure» .
5. Is the 1st trip DTC P1065 displayed again?
1.
2.
3.
4.

Without CONSULT-II
Turn ignition switch ON.
Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-478, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .
3. Perform DTC Confirmation Procedure.
See EC-626, «DTC Confirmation Procedure» .
4. Is the 1st trip DTC 1065 displayed again?
Yes or No
Yes
>> GO TO 5.
No
>> INSPECTION END

A

EC

C

D

1.
2.

E

F

G

5. REPLACE ECM
1.
2.
3.
4.
5.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to EC-473,
«Description» .
Perform EC-486, «Accelerator Pedal Released Position Learning» .
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

H

I

J

>> INSPECTION END
K

L

M

EC-629

DTC P1111 IVT CONTROL SOLENOID VALVE
[CR (WITHOUT EURO-OBD)]

DTC P1111 IVT CONTROL SOLENOID VALVE
Component Description

PFP:23796
BBS0038M

Intake valve timing control solenoid valve is activated by ON/OFF
pulse duty (ratio) signals from the ECM.
The intake valve timing control solenoid valve changes the oil
amount and direction of flow through intake valve timing control unit
or stops oil flow.
The longer pulse width advances valve angle.
The shorter pulse width retards valve angle.
When ON and OFF pulse widths become equal, the solenoid valve
stops oil pressure flow to fix the intake valve angle at the control
position.
PBIB1842E

CONSULT-II Reference Value in Data Monitor Mode

BBS0038N

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

INT/V SOL (B1)

SPECIFICATION

Idle

0% — 2%

2,000 rpm

Approx. 0% — 50%

On Board Diagnosis Logic
DTC No.
P1111
1111

Trouble diagnosis name
Intake valve timing control
solenoid valve circuit

BBS0038O

DTC detecting condition

Possible cause
●

Harness or connectors
(Intake valve timing control solenoid valve
circuit is open or shorted.)

●

Intake valve timing control solenoid valve

An improper voltage is sent to the ECM
through intake valve timing control solenoid
valve.

DTC Confirmation Procedure

BBS0038P

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If 1st trip DTC is detected, go to EC-633, «Diagnostic Procedure»
.

SEF058Y

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

Start engine and let it idle for 5 seconds.
Turn ignition switch OFF and wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-633, «Diagnostic Procedure» .

EC-630

DTC P1111 IVT CONTROL SOLENOID VALVE
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS0038Q

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1519E

EC-631

DTC P1111 IVT CONTROL SOLENOID VALVE
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]
●

Warm-up condition

●

Idle speed

BATTERY VOLTAGE
(11 — 14V)
Approximately 4V — BATTERY

62

LG

Intake valve timing
control solenoid valve

VOLTAGE (11 — 14V)
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

PBIB1790E

[Engine is running]
[Ignition switch: OFF]
●

111

P

ECM relay
(Self shut-off)

For a few seconds after turning ignition switch
OFF

[Ignition switch: OFF]
●

119
120

G
G

Power supply for ECM

More than a few seconds passed after turning
ignition switch OFF

[Ignition switch: ON]

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-632

0 — 1.0V

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

DTC P1111 IVT CONTROL SOLENOID VALVE
[CR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS0038R

1. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect intake valve timing control solenoid valve harness
connector.
Turn ignition switch ON.

EC

C

D

MBIB0284E

4.

Check voltage between intake valve timing control solenoid
valve terminal 1 and ground with CONSULT-II or tester.

E

F

Voltage: Battery voltage
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

G

H

PBIB0285E

2. DETECT MALFUNCTION PART
Check the following.
●
Harness connectors E48, F1
●
Harness for open or short between intake valve timing control solenoid valve and IPDM E/R

I

J

K

>> Repair or replace harness or connectors.

3. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR

L

OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 62 and intake valve timing control solenoid valve terminal 2. Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE
Refer to EC-634, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace intake valve timing control solenoid valve.

EC-633

M

DTC P1111 IVT CONTROL SOLENOID VALVE
[CR (WITHOUT EURO-OBD)]

5. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS0038S

INTAKE VALVE TIMING CONTROL SOLENOID VALVE
1.
2.

3.
4.

Disconnect intake valve timing control solenoid valve harness connector.
Check resistance between intake valve timing control solenoid
valve as follows.
Terminal

Resistance

1 and 2

6.7 — 7.7Ω at 20°C (68°F)

1 or 2 and ground

∞Ω
(Continuity should not exist.)

If NG, replace intake valve timing control solenoid valve.
If OK, go to next step.
Remove intake valve timing control solenoid valve.

MBIB0027E

Provide 12V DC between intake valve timing control solenoid
valve terminals and then interrupt it. Make sure that the plunger
moves as shown in the figure.
CAUTION:
Do not apply 12V DC continuously for 5 seconds or more.
Doing so may result in damage to the coil in intake valve
timing control solenoid valve.
If NG, replace intake valve timing control solenoid valve.
NOTE:
Always replace O-ring when intake valve timing control
solenoid valve is removed.

PBIB2388E

Removal and Installation

BBS0038T

INTAKE VALVE TIMING CONTROL SOLENOID VALVE
Refer to EM-35, «ROCKER COVER» .

EC-634

DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR
[CR (WITHOUT EURO-OBD)]

DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR
Component Description

PFP:16119

A
BBS0038U

Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc.
The throttle control motor is operated by the ECM and it opens and closes the throttle valve.
EC
The throttle position sensor detects the throttle valve position, and the opening and closing speed of the throttle valve and feeds the voltage signals to the ECM. The ECM judges the current opening angle of the throttle
valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening
C
angle properly in response to driving condition.

On Board Diagnosis Logic

BBS0038V

D

This self-diagnosis has the one trip detection logic.
DTC No.

P1121
1121

Trouble diagnosis name

Electric throttle control
actuator

DTC detecting condition
A)

Electric throttle control actuator does not function
properly due to the return spring malfunction.

B)

Throttle valve opening angle in fail-safe mode is
not in specified range.

C)

ECM detect the throttle valve is stuck open.

Possible cause

E
●

Electric throttle control actuator

F

FAIL-SAFE MODE

G

When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Detected items

Engine operating condition in fail-safe mode

Malfunction A

The ECM controls the electric throttle actuator by regulating the throttle opening around the idle position.
The engine speed will not rise more than 2,000 rpm.

Malfunction B

ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less.

Malfunction C

While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls.
The engine can restart in Neutral position, and engine speed will not exceed 1,000 rpm or more.

DTC Confirmation Procedure

H

I

BBS0038W

J

NOTE:
●
Perform PROCEDURE FOR MALFUNCTION A AND B first. If the DTC cannot be confirmed, perform
PROCEDURE FOR MALFUNCTION C.
●
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
at least 10 seconds before conducting the next test.

K

L

PROCEDURE FOR MALFUNCTION A AND B
With CONSULT-II
1.
2.
3.
4.
5.
6.
7.
8.
9.

Turn ignition witch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Set shift lever to 1st position and wait at least 2 seconds.
Set shift lever to Neutral position.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition witch ON and wait at least 1 second.
Set shift lever to 1st position and wait at least 2 seconds.
Set shift lever to Neutral position.
Turn ignition switch OFF, wait at least 10 seconds, and then turn
ON.
10. If DTC is detected, go to EC-636, «Diagnostic Procedure» .

Without CONSULT-II
1.
2.
3.

Turn ignition switch ON and wait at least 1 second.
Set shift lever to 1st position and wait at least 2 seconds.
Set shift lever to Neutral position.

EC-635

M

SEF058Y

DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR
[CR (WITHOUT EURO-OBD)]
4.
5.
6.
7.
8.
9.
10.

Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition witch ON and wait at least 1 second.
Set shift lever to 1st position and wait at least 2 seconds.
Set shift lever to Neutral position.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-636, «Diagnostic Procedure» .

PROCEDURE FOR MALFUNCTION C
With CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Set shift lever to 1st position and wait at least 2 seconds.
Set shift lever to Neutral position.
Start engine and let it idle for 3 seconds.
If DTC is detected, go to EC-636, «Diagnostic Procedure» .

SEF058Y

Without CONSULT-II
1.
2.
3.
4.
5.
6.
7.

Turn ignition switch ON and wait at least 1 second.
Set shift lever to 1st position and wait at least 2 seconds.
Set shift lever to Neutral position.
Start engine and let it idle for the 3 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-636, «Diagnostic Procedure» .

Diagnostic Procedure

BBS0038X

1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY
1.
2.

Remove the intake air duct.
Check if a foreign matter is caught between the throttle valve
and the housing.
OK or NG
OK
>> GO TO 2.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.

MBIB0307E

2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .
>> INSPECTION END

EC-636

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[CR (WITHOUT EURO-OBD)]

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
Description

PFP:16119

A
BBS0038Y

NOTE:
If DTC P1122 is displayed with DTC P1121 or P1126, first perform the trouble diagnosis for DTC P1121 EC
or P1126. Refer to EC-635 or EC-643 .
Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc.
The throttle control motor is operated by the ECM and it opens and closes the throttle valve.
The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feed- C
back to the ECM to control the throttle control motor to make the throttle valve opening angle properly in
response to driving condition.
D

On Board Diagnosis Logic

BBS0038Z

This self-diagnosis has the one trip detection logic.
DTC No.

Trouble diagnosis name

P1122
1122

Electric throttle control
performance

DTC detecting condition

E

Possible cause
●

Electric throttle control function does not
operate properly.
●

Harness or connectors
(Throttle control motor circuit is open or
shorted.)

F

Electric throttle control actuator

G

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode

H

ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.

DTC Confirmation Procedure

BBS00390

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 11V when engine
is running.

I

J

K

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

Turn ignition switch ON and wait at least 2 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If DTC is detected, go to EC-639, «Diagnostic Procedure» .

L

M

SEF058Y

WITHOUT CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and wait at least 2 seconds.
Start engine and let it idle for 5 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-639, «Diagnostic Procedure» .

EC-637

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS00391

MBWA1520E

EC-638

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.
3

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
LG

Throttle control motor relay
power supply

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 14V

D

[Ignition switch: ON]
4

L

Throttle control motor
(Close)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

E

PBIB0534E

F

0 — 14V
[Ignition switch: ON]
5

P

Throttle control motor
(Open)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

G

H
PBIB0533E

104

G

Throttle control motor relay

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 1.0V

I

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

J

Diagnostic Procedure

BBS00392

1. CHECK GROUND CONNECTIONS
1.
2.

K

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

L

M

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-639

3.

Body ground E28

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[CR (WITHOUT EURO-OBD)]

2. CHECK THROTTLE CONTROL MOTOR RELAY SIGNAL CIRCUIT-I
Check voltage between ECM terminal 3 and ground under the following conditions with CONSULT-II or tester.
Ignition switch

Voltage

OFF

Approximately 0V

ON

Battery voltage
(11 — 14V)

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 3.

MBIB0028E

3. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-I
1.
2.

Turn ignition switch OFF.
Check voltage between ECM terminal 104 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 4.

PBIB1171E

4. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-II
1.
2.
3.

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E5.
Check continuity between ECM terminal 104 and IPDM E/R terminal 70.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK FUSE
1. Disconnect 20A fuse.
2. Check 20A fuse for blown.
OK or NG
OK
>> GO TO 8.
NG
>> Replace 20A fuse.

EC-640

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[CR (WITHOUT EURO-OBD)]

6. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-II
1.
2.
3.

A

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between ECM terminal 3 and IPDM E/R terminal 28.
Refer to Wiring Diagram.

EC

Continuity should exist.

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

D

7. DETECT MALFUNCTIONING PART

E

Check the following.
●
Harness connectors E48, F1
●
Harness for open or short between ECM and IPDM E/R

F

>> Repair open circuit or short to ground or short to power in harness or connectors.

G

8. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connectors.

9. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT
1.
2.
3.
4.

3

6

ECM terminal

I

J

Turn ignition switch OFF.
Disconnect electric throttle control actuator harness connector.
Disconnect ECM harness connector.
Check harness continuity between the following terminals.
Refer to Wiring Diagram.
Electric throttle control
actuator terminal

H

K

L

Continuity

5

Should not exist

4

Should exist

5

Should exist

4

Should not exist

5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 10.
NG
>> Repair or replace.

EC-641

M

MBIB0308E

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[CR (WITHOUT EURO-OBD)]

10. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY
1.
2.

Remove the intake air duct.
Check if foreign matter is caught between the throttle valve and
the housing.
OK or NG
OK
>> GO TO 11.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.

MBIB0307E

11. CHECK THROTTLE CONTROL MOTOR
Refer to EC-642, «Component Inspection» .
OK or NG
OK
>> GO TO 12.
NG
>> GO TO 13.

12. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> GO TO 13.
NG
>> Repair or replace harness or connectors.

13. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .
>> INSPECTION END

Component Inspection

BBS00393

THROTTLE CONTROL MOTOR
1.
2.

Disconnect electric throttle control actuator harness connector.
Check resistance between terminals 3 and 6.
Resistance: Approximately 1 — 15 Ω [at 25 °C (77°F)]

3.
4.
5.

If NG, replace electric throttle control actuator and go to next
step.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

PBIB0095E

Removal and Installation

BBS00394

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

EC-642

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[CR (WITHOUT EURO-OBD)]

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
Component Description

PFP:16119

A
BBS00395

Power supply for the throttle control motor is provided to the ECM via throttle control motor relay. The throttle
control motor relay is ON/OFF controlled by the ECM. When the ignition switch is turned ON, the ECM sends EC
an ON signal to throttle control motor relay and battery voltage is provided to the ECM. When the ignition
switch is turned OFF, the ECM sends an OFF signal to throttle control motor relay and battery voltage is not
provided to the ECM.
C

CONSULT-II Reference Value in Data Monitor Mode

BBS00396

Specification data are reference values.
MONITOR ITEM
THRTL RELAY

CONDITION
●

D

SPECIFICATION

Ignition switch: ON

ON

On Board Diagnosis Logic

BBS00397

E

These self-diagnoses have the one trip detection logic.
DTC No.
P1124
1124

P1126
1126

Trouble diagnosis name
Throttle control motor
relay circuit short

Throttle control motor
relay circuit open

DTC detecting condition

F

Possible cause
●

Harness or connectors
(Throttle control motor relay circuit is shorted.)

●

Throttle control motor relay

●

Harness or connectors
(Throttle control motor relay circuit is open.)

●

Throttle control motor relay

ECM detects the throttle control motor relay
is stuck ON.

ECM detects a voltage of power source for
throttle control motor is excessively low.

G

H

FAIL-SAFE MODE
I

When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.

DTC Confirmation Procedure

BBS00398

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

PROCEDURE FOR DTC P1124
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 8V.
Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
If DTC is detected, go to EC-646, «Diagnostic Procedure» .

SEF058Y

EC-643

K

L

M

With CONSULT-II
1.
2.
3.

J

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[CR (WITHOUT EURO-OBD)]
Without CONSULT-II
1.
2.
3.

Turn ignition switch ON and wait at least 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
If DTC is detected, go to EC-646, «Diagnostic Procedure» .

PROCEDURE FOR DTC P1126
With CONSULT-II
1.
2.
3.
4.

Turn ignition switch ON and wait at least 2 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If DTC is detected, go to EC-646, «Diagnostic Procedure» .

SEF058Y

Without CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and wait at least 2 second.
Start engine and let it idle for 5 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-646, «Diagnostic Procedure» .

EC-644

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS00399

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1521E

EC-645

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
3

WIRE
COLOR
LG

ITEM
Throttle control motor relay
power supply

CONDITION

[Ignition switch: ON]

DATA (DC Voltage)
BATTERY VOLTAGE
(11 — 14V)
0 — 14V

[Ignition switch: ON]
4

L

Throttle control motor
(Close)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released
PBIB0534E

0 — 14V
[Ignition switch: ON]
5

P

Throttle control motor
(Open)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed
PBIB0533E

104

G

Throttle control motor relay

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 1.0V

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS0039A

1. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-I
1.
2.

Turn ignition switch OFF.
Check voltage between ECM terminal 104 and ground with
CONSULT-II or tester.
Voltage: Battery voltage.

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 2.

PBIB1171E

EC-646

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[CR (WITHOUT EURO-OBD)]

2. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-II
1.
2.
3.

A

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E5.
Check continuity between ECM terminal 104 and IPDM E/R terminal 70.

EC

Continuity should exist.
C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D

3. CHECK FUSE
E

1. Disconnect 20A fuse.
2. Check 20A fuse for blown.
OK or NG
OK
>> GO TO 7.
NG
>> Replace 20A fuse.

F

4. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-I
1.
2.

G

Reconnect all disconnected connectors.
Check voltage between ECM terminal 3 and ground under the
following conditions with CONSULT-II or tester.
Ignition switch

Voltage

OFF

Approximately 0V

ON

Battery voltage
(11 — 14V)

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 5.

H

I

J

MBIB0028E

K

5. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-II
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E7.
Check continuity between ECM terminal 3 and IPDM E/R terminal 28.
Refer to Wiring Diagram.
Continuity should exist.

5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

6. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F1
●
Harness for open or short between ECM and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-647

L

M

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[CR (WITHOUT EURO-OBD)]

7. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connectors.

EC-648

DTC P1128 THROTTLE CONTROL MOTOR
[CR (WITHOUT EURO-OBD)]

DTC P1128 THROTTLE CONTROL MOTOR
Component Description

PFP:16119

A
BBS0039B

The throttle control motor is operated by the ECM and it opens and closes the throttle valve.
The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feed- EC
back to the ECM to control the throttle control motor to make the throttle valve opening angle properly in
response to driving condition.

On Board Diagnosis Logic

BBS0039C

C

This self-diagnosis has the one trip detection logic.
DTC No.
P1128
1128

Trouble diagnosis name
Throttle control motor
circuit short

DTC detecting condition
ECM detects short in both circuits between
ECM and throttle control motor.

Possible cause

D

●

Harness or connectors
(Throttle control motor circuit is shorted.)

●

Electric throttle control actuator
(Throttle control motor)

E

FAIL-SAFE MODE

F

When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.

DTC Confirmation Procedure

BBS0039D

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

G

H

I

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

Turn ignition switch ON and wait at least 2 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If DTC is detected, go to EC-651, «Diagnostic Procedure» .

J

K

L

SEF058Y

WITHOUT CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and wait at least 2 second.
Start engine and let it idle for 5 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-651, «Diagnostic Procedure» .

EC-649

M

DTC P1128 THROTTLE CONTROL MOTOR
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS0039E

MBWA1522E

EC-650

DTC P1128 THROTTLE CONTROL MOTOR
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.
3

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
LG

Throttle control motor
relay power supply

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 14V

D

[Ignition switch: ON]
4

L

Throttle control motor
(Close)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

E

PBIB0534E

F

0 — 14V
[Ignition switch: ON]
5

P

Throttle control motor
(Open)

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

G

H
PBIB0533E

104

G

Throttle control motor
relay

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 1.0V

I

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

J

Diagnostic Procedure

BBS0039F

1. CHECK GROUND CONNECTIONS
1.
2.

K

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

L

M

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-651

3.

Body ground E28

DTC P1128 THROTTLE CONTROL MOTOR
[CR (WITHOUT EURO-OBD)]

2. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT
1.
2.
3.

Disconnect electric throttle control actuator harness connector.
Disconnect ECM harness connector.
Check harness continuity between the following terminals.
Refer to Wiring Diagram.
Electric throttle control
actuator terminal

ECM terminal

3

6

Continuity

4

Should exist

5

Should not exist

4

Should not exist

5

Should exist

MBIB0308E

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

3. CHECK THROTTLE CONTROL MOTOR
Refer to EC-652, «Component Inspection» .
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 5.

4. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace harness or connectors.

5. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .
>> INSPECTION END

Component Inspection

BBS0039G

THROTTLE CONTROL MOTOR
1.
2.

Disconnect electric throttle control actuator harness connector.
Check resistance between terminals 3 and 6.
Resistance: Approximately 1 — 15 Ω [at 25 °C (77°F)]

3.
4.
5.

If NG, replace electric throttle control actuator and go to next
step.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

PBIB0095E

EC-652

DTC P1128 THROTTLE CONTROL MOTOR
[CR (WITHOUT EURO-OBD)]

Removal and Installation

BBS0039H

ELECTRIC THROTTLE CONTROL ACTUATOR

A

Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
EC

C

D

E

F

G

H

I

J

K

L

M

EC-653

DTC P1171 INTAKE ERROR
[CR (WITHOUT EURO-OBD)]

DTC P1171 INTAKE ERROR
On Board Diagnosis Logic

PFP:22365
BBS0039I

NOTE:
●
If DTC P1171 is displayed with DTC P0108, first perform the trouble diagnosis for DTC P0108.
Refer to EC-559, «DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR» .
●
If DTC P1171 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229.
Refer to EC-680, «DTC P1229 SENSOR POWER SUPPLY» .
ECM computes two intake air volume values.
1: Computed from manifold absolute pressure signal and intake air temperature signal.
2: Computed from engine revolution signal and throttle position signal.
In normal condition, value 1 is used for engine control.
If intake air leak occurred between throttle valve and intake air port, manifold absolute pressure sensor signal
might increase, and then ECM increases amount of fuel injected. In this case, ECM uses value 2 for engine
control instead of value1.
ECM monitors the difference between value 1 and value 2. If the difference is extremely large, ECM judges
intake air leak occurs and light up the MI
This diagnosis has one trip detection logic.
DTC No.

P1171
1171

Trouble diagnosis name

Intake error

DTC detecting condition

A high voltage from the sensor is sent to
ECM under light load driving condition.

Possible cause
●

Harness or connectors
(The manifold absolute pressure sensor
circuit is open or shorted.)

●

Manifold absolute pressure

●

Intake air leaks

●

Vacuum hoses

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and MI lights up.
Detected items
Intake air system

Engine operating condition in fail-safe mode
When accelerator pedal is depressed, engine speed will not rise more than 2,500 rpm
due to fuel cut.

DTC Confirmation Procedure

BBS0039J

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and wait at least 5 seconds.
If DTC is detected, go to EC-657, «Diagnostic Procedure» .

SEF058Y

EC-654

DTC P1171 INTAKE ERROR
[CR (WITHOUT EURO-OBD)]
WITHOUT CONSULT-II
1.
2.
3.
4.

Turn ignition switch ON and wait at least 5 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-657, «Diagnostic Procedure» .

A

EC

C

D

E

F

G

H

I

J

K

L

M

EC-655

DTC P1171 INTAKE ERROR
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS0039K

MBWA1506E

EC-656

DTC P1171 INTAKE ERROR
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
45

WIRE
COLOR

L

EC
ITEM
Sensor power supply
(Manifold absolute
pressure sensor)

CONDITION

DATA (DC Voltage)

C
[Ignition switch: ON]

Approximately 5V

[Engine is running]

51

56

W

B

A

Manifold absolute pressure sensor

Sensor ground
(Manifold absolute
pressure sensor)

●

Warm-up condition

●

Idle speed

D
Approximately 1.5V

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

E
Approximately 1.2V

F

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0V

G

Diagnostic Procedure

BBS0039L

1. CHECK INTAKE AIR LEAK
Listen for an intake air leak after the air cleaner element.
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace.

2. CHECK VACUUM HOSE

H

I

J

Check intake manifold vacuum hoses for clogging or disconnection. Refer to EC-509, «Vacuum Hose
Drawing» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

1.

K

L

M

EC-657

DTC P1171 INTAKE ERROR
[CR (WITHOUT EURO-OBD)]

3. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace ground connections.

4. CHECK MAP SENSOR POWER SUPPLY CIRCUIT
1.
2.

Disconnect manifold absolute pressure sensor harness connector.
Turn ignition switch ON.

MBIB0276E

3.

Check voltage between manifold absolute pressure sensor terminal 2 and ground with CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 5.
NG
>> Repair harness or connectors.

MBIB0602E

EC-658

DTC P1171 INTAKE ERROR
[CR (WITHOUT EURO-OBD)]

5. CHECK MAP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between manifold absolute pressure sensor terminal 4 and ECM terminal 56.
Refer to Wiring Diagram.
Continuity should exist.

EC

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK MAP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

A

D

E

Check harness continuity between manifold absolute pressure sensor terminal 1 and ECM terminal 51.
Refer to Wiring Diagram.
F

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

G

H

7. CHECK MAP SENSOR
Refer to EC-563, «Component Inspection» .
OK or NG
OK
>> GO TO 8.
NG
>> Replace manifold absolute pressure sensor.

I

J

8. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

K

>> INSPECTION END
L

M

EC-659

DTC P1211 TCS CONTROL UNIT
[CR (WITHOUT EURO-OBD)]

DTC P1211 TCS CONTROL UNIT
Description

PFP:47850
BBS003ZQ

The malfunction information related to TCS is transferred through the CAN communication line from “ABS
actuator and electric unit (control unit)” to ECM.
Be sure to erase the malfunction information such as DTC not only for “ABS actuator and electric unit
(control unit)” but also for ECM after TCS related repair.

On Board Diagnosis Logic

BBS003ZR

Freeze frame data is not stored in the ECM for this self-diagnosis. The MI will not light up for this selfdiagnosis.
DTC No.
P1211
1211

Trouble diagnosis name
TCS control unit

DTC detecting condition

Possible cause
●

ABS actuator and electric unit (control
unit)

●

TCS related parts

ECM receives a malfunction information from
“ABS actuator and electric unit (Control unit)”.

DTC Confirmation Procedure

BBS003ZS

TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for at least 60 seconds.
If 1st trip DTC is detected, go to EC-660, «Diagnostic Procedure»
.

SEF058Y

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

Start engine and let it idle for at least 60 seconds.
Turn ignition switch OFF, wait at least 10 seconds and turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-660, «Diagnostic Procedure» .

Diagnostic Procedure

BBS003ZT

Go to BRC-49, «TROUBLE DIAGNOSIS» .

EC-660

DTC P1212 TCS COMMUNICATION LINE
[CR (WITHOUT EURO-OBD)]

DTC P1212 TCS COMMUNICATION LINE
Description

PFP:47850

A
BBS0039M

NOTE:
●
If DTC P1212 is displayed with DTC U1001, first perform the trouble diagnosis for DTC U1001. EC
Refer to EC-549, «DTC U1001 CAN COMMUNICATION LINE» .
●
If DTC P1212 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010.
Refer to EC-552, «DTC U1010 CAN COMMUNICATION» .
C
This CAN communication line is used to control the smooth engine operation during the TCS operation. Pulse
signals are exchanged between ECM and “ABS actuator and electric unit (control unit)”.
Be sure to erase the malfunction information such as DTC not only for “ABS actuator and electric unit
D
(control unit)” but also for ECM after TCS related repair.

On Board Diagnosis Logic

BBS0039N

E

The MI will not light up for this self-diagnosis.
Freeze frame data is not stored in the ECM for this self-diagnosis.
DTC No.

P1212
1212

Trouble diagnosis name

TCS communication
line

DTC detecting condition

ECM can not receive the information from
“ABS actuator and electric unit (control
unit)” continuously.

Possible cause

F

●

Harness or connectors
(The CAN communication line is open or
shorted.)

●

ABS actuator and electric unit (control unit).

●

Dead (Weak) battery

DTC Confirmation Procedure

BBS0039O

G

H

TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle.
I

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for at least 10 seconds.
If 1st trip DTC is detected, go to EC-661, «Diagnostic Procedure»
.

J

K

L

SEF058Y

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

Start engine and let it idle for at least 10 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-661, «Diagnostic Procedure» .

Diagnostic Procedure

BBS0039P

Refer to BRC-49, «TROUBLE DIAGNOSIS» .

EC-661

M

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITHOUT EURO-OBD)]

DTC P1217 ENGINE OVER TEMPERATURE
System Description

PFP:00000
BBS0047Z

NOTE:
●
If DTC P1217 is displayed with DTC U1001, first perform the trouble diagnosis for DTC U1001.
Refer to EC-549, «DTC U1001 CAN COMMUNICATION LINE» .
●
If DTC P1217 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010.
Refer to EC-552, «DTC U1010 CAN COMMUNICATION» .

COOLING FAN CONTROL
Sensor

Input Signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*1

Battery

Battery voltage*1

Wheel sensor

Vehicle speed*2

Engine coolant temperature sensor

Engine coolant temperature

Air conditioner switch*3

Air conditioner ON signal*2

Refrigerant pressure sensor*3

Refrigerant pressure

ECM Function

Cooling fan
control

Actuator

IPDM E/R
(Cooling fan relay)

*1: ECM determines the start signal status by the signals of engine speed and battery voltage.
*2: This signal is sent to ECM through CAN communication line.
*3: Models with air conditioner.

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, refrigerant
pressure, and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF] (models with
A/C) or 2 step control [ON/OFF] (models without A/C).
The ECM controls cooling fan relays through CAN communication line.

OPERATION
Models with A/C

MBIB0650E

EC-662

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITHOUT EURO-OBD)]
Models without A/C
A

EC

C

MBIB0656E

CONSULT-II Reference Value in Data Monitor Mode

BBS00480

Specification data are reference values.

E

MONITOR ITEM
AIR COND SIG

CONDITION
●

●

COOLING FAN
●

Engine: After warming up, idle
the engine

Engine: After warming up, idle
the engine
Air conditioner switch: OFF

SPECIFICATION

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates.)

ON

Engine coolant temperature: 94°C
(201°F) or less

OFF

Engine coolant temperature: Between
95°C (203°F) and 104°C (210°F)

LOW*

Engine coolant temperature: 105°C
(212°F) or more

HI*

F

G

H

*: Models without air conditioner, cooling fan operates only ON and OFF operation, but CONSULT-II display will change OFF, LOW and
HI depends on engine coolant temperature.

On Board Diagnosis Logic

Trouble diagnosis name

DTC detecting condition

●

P1217
1217

Engine over temperature (Overheat)

Harness or connectors
(The cooling fan circuit is open or
shorted.)

●

Cooling fan

Cooling fan does not operate properly (Overheat).

●

IPDM E/R (Cooling fan relay)

●

Radiator hose

Cooling fan system does not operate properly (Overheat).

●

Radiator

●

Reservoir tank cap
(Models with A/C)

●

Radiator cap
(Models without A/C)

●

Water pump

●

Thermostat

●

Engine coolant was not added to the system
using the proper filling method.

●

Engine coolant is not within the specified
range.

For more information, refer to EC-674,
«Main 12 Causes of Overheating» .

CAUTION:
When a malfunction is indicated, be sure to replace the coolant. Refer to CO-9, «Changing Engine
coolant» . Also, replace the engine oil. Refer to LU-7, «Changing Engine Oil» .
1. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to
use coolant with the proper mixture ratio. Refer to MA-26, «Engine Coolant Mixture Ratio» .

EC-663

J

K

Possible cause
●

●

I

BBS00481

If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise. When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction
is indicated.
This self-diagnosis has the one trip detection logic.
DTC No.

D

L

M

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITHOUT EURO-OBD)]
2.

After refilling coolant, run engine to ensure that no water-flow noise is emitted.

Overall Function Check

BBS00482

Use this procedure to check the overall function of the cooling fan. During this check, a DTC might not be confirmed.
WARNING:
Never remove the radiator cap (Models without A/C) or reservoir tank cap (Models with A/C) when the
engine is hot. Serious burns could be caused by high pressure fluid escaping from the radiator (Models without A/C) or reservoir tank (Models with A/C).
Wrap a thick cloth around cap. Carefully remove the cap by turning it a quarter turn to allow built-up
pressure to escape. Then turn the cap all the way off.

WITH CONSULT-II
1.

2.

3.

Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to EC-668,
«Diagnostic Procedure» .
Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to EC-668,
«Diagnostic Procedure» .
Turn ignition switch ON.
SEF621W

4.
5.

Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II.
If the results are NG, go to EC-668, «Diagnostic Procedure» .

SEF784Z

WITHOUT CONSULT-II
Models with Air Conditioner
1.

2.

3.

4.
5.
6.
7.

Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to EC-668,
«Diagnostic Procedure» .
Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to EC-668,
«Diagnostic Procedure» .
Start engine.
CAUTION:
Be careful not to overheat engine.
Set temperature control lever to full cold position.
Turn air conditioner switch ON.
Turn blower fan switch ON.
Run engine at idle for a few minutes with air conditioner operating.
CAUTION:
Be careful not to overheat engine.

EC-664

SEF621W

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITHOUT EURO-OBD)]
8.

Make sure that cooling fans operates at low speed.
If NG, go to EC-668, «Diagnostic Procedure» .
If OK, go to the following step.
9. Turn ignition switch OFF.
10. Turn air conditioner switch and blower fan switch OFF.
11. Disconnect engine coolant temperature sensor harness connector.
12. Connect 150Ω resistor to engine coolant temperature sensor
harness connector.

A

EC

C
MBIB0651E

D

13. Restart engine and make sure that cooling fan operates at
higher speed than low speed.
CAUTION:
Be careful not to overheat engine.
14. If NG, go to EC-668, «Diagnostic Procedure» .

E

F

G
SEF023R

Models without Air Conditioner
1.

2.

3.
4.
5.
6.

Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to EC-668,
«Diagnostic Procedure» .
Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to EC-668,
«Diagnostic Procedure» .
Disconnect engine coolant temperature sensor harness connector.
Connect 150Ω resistor to engine coolant temperature sensor
harness connector.
Start engine and make that cooling fan operates. Be careful not
to overheat engine.
If NG, go to EC-668, «Diagnostic Procedure» .

H

I

J

K
SEF621W

L

M

SEF023R

EC-665

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS00483

MODELS WITH AIR CONDITIONER

MBWA1523E

EC-666

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITHOUT EURO-OBD)]
MODELS WITHOUT AIR CONDITIONER
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1524E

EC-667

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS00484

PROCEDURE FOR MODELS WITH AIR CONDITIONER

1. INSPECTION START
Do you have CONSULT-II?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 4.

2. CHECK COOLING FAN LOW SPEED OPERATION
With CONSULT-II
Turn ignition switch ON.
Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II and touch “LOW” on the CONSULT-II screen.
3. Make sure that cooling fan operates at low speed.
OK or NG
OK
>> GO TO 3.
NG
>> Check cooling fan low speed control circuit. (Go to EC670, «Procedure A» .)
1.
2.

SEF784Z

3. CHECK COOLING FAN HIGH SPEED OPERATION
With CONSULT-II
1. Touch “HIGH” on the CONSULT-II screen.
2. Make sure that cooling fan operate at higher speed than low
speed.
OK or NG
OK
>> GO TO 6.
NG
>> Check cooling fan high speed control circuit. (Go to EC671, «Procedure B» .)

SEF785Z

4. CHECK COOLING FAN LOW SPEED OPERATION
Without CONSULT-II
1. Start engine and let it idle.
2. Turn air conditioner switch ON.
3. Turn blower fan switch ON.
4. Make sure that cooling fan operates at low speed.
OK or NG
OK
>> GO TO 5.
NG
>> Check cooling fan low speed control circuit. (Go to EC670, «Procedure A» .)

MBIB0651E

EC-668

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITHOUT EURO-OBD)]

5. CHECK COOLING FAN HIGH SPEED OPERATION

A

Without CONSULT-II
Turn ignition switch OFF.
Turn air conditioner switch and blower fan switch OFF.
Disconnect engine coolant temperature sensor harness connector.
Connect 150Ω resistor to engine coolant temperature sensor harness connector.
Restart engine and make sure that cooling fan operate at higher
speed than low speed.
OK or NG
OK
>> GO TO 6.
NG
>> Check cooling fan high speed control circuit. (Go to EC671, «Procedure B» .)

1.
2.
3.
4.
5.

EC

C

D

E

F
SEF023R

6. CHECK COOLING SYSTEM FOR LEAK

G

Refer to CO-8, «ENGINE COOLANT» .
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

H

7. DETECT MALFUNCTIONING PART

I

Check the following for leak.
●
Hose
●
Radiator
●
Water pump (Refer to CO-17, «WATER PUMP» .)

J

K

>> Repair or replace.

8. CHECK RESERVOIR TANK CAP

L

Refer to CO-16, «Checking Reservoir Tank Cap (Models with A/C)» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace reservoir tank cap.

9. CHECK COMPONENT PARTS
Check the following.
●
Thermostat. Refer to CO-19, «THERMOSTAT» .
●
Engine coolant temperature sensor. Refer to EC-569, «Component Inspection» .
OK or NG
OK
>> GO TO 10.
NG
>> Replace malfunctioning component.

10. CHECK MAIN 12 CAUSES
If the cause cannot be isolated, go to EC-674, «Main 12 Causes of Overheating» .
>> INSPECTION END

EC-669

M

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITHOUT EURO-OBD)]
Procedure A

1. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E6.
Check voltage between IPDM E/R terminal 14 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

MBIB1307E

2. DETECT MALFUNCTIONING PART
Check the following.
●
40A fusible link
●
Harness for open or short between IPDM E/R and battery
>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK COOLING FAN MOTORS CIRCUIT
1.
2.

Disconnect cooling fan motor harness connector.
Check harness continuity between cooling fan motor terminal 1
and IPDM E/R terminal 10, cooling fan motor terminal 2 and
ground. Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness for open or short between cooling fan motor and IPDM E/R
●
Harness for open or short between cooling fan motor and ground
●
Harness for open or short between resistor and IPDM E/R
●
Harness for open or short between resistor and cooling fan motor
●
Resistor E62
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK COOLING FAN MOTOR
Refer to EC-675, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace cooling fan motor.

EC-670

MBIB1074E

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITHOUT EURO-OBD)]

6. CHECK INTERMITTENT INCIDENT

A
Perform EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MOD- EC
ULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connector.
C
Procedure B

1. CHECK COOLING FAN MOTORS CIRCUIT
1.
2.
3.
4.

D

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E6.
Disconnect cooling fan motor harness connector.
Check harness continuity between IPDM E/R terminal 12 and
cooling fan motor terminal 1, cooling fan motor terminal 2 and
ground. Refer to Wiring Diagram.

E

F

Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

G

MBIB1074E

H

2. DETECT MALFUNCTIONING PART
Check the following.
●
Harness for open or short between cooling fan motor and IPDM E/R
●
Harness for open or short between cooling fan motor and ground

I

J

>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK COOLING FAN MOTOR

K

Refer to EC-675, «Component Inspection» .
OK or NG
OK
>> GO TO 4.
NG
>> Replace cooling fan motor.

L

M

4. CHECK INTERMITTENT INCIDENT
Perform EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connector.

EC-671

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITHOUT EURO-OBD)]
PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER

1. INSPECTION START
Do you have CONSULT-II?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.

2. CHECK COOLING FAN OPERATION
With CONSULT-II
1. Turn ignition switch ON.
2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II and touch “LOW” on the CONSULT-II screen.
3. Make sure that cooling fan operates.
OK or NG
OK
>> GO TO4.
NG
>> Check cooling fan control circuit. (Go to EC-673, «Procedure A» .)

SEF784Z

3. CHECK COOLING FAN OPERATION
Without CONSULT-II
1. Turn ignition switch OFF.
2. Disconnect engine coolant temperature sensor harness connector.
3. Connect 150Ω resistor to engine coolant temperature sensor harness connector.
4. Restart engine and make sure that cooling fan operates.
OK or NG
OK
>> GO TO 4.
NG
>> Check cooling fan control circuit. (Go to EC-673, «Procedure A» .)

SEF023R

4. CHECK COOLING SYSTEM FOR LEAK
Refer to CO-8, «ENGINE COOLANT» .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

EC-672

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITHOUT EURO-OBD)]

5. DETECT MALFUNCTIONING PART

A

Check the following for leak.
●
Hose
●
Radiator
●
Water pump (Refer to CO-17, «WATER PUMP» .)

EC

C

>> Repair or replace.

6. CHECK RADIATOR CAP

D

Refer to CO-15, «Checking Radiator Cap (Models without A/C)» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace radiator cap.

E

7. CHECK THERMOSTAT

F

Check the following.
●
Thermostat. Refer to CO-19, «THERMOSTAT» .
●
Engine coolant temperature sensor. Refer to EC-569, «Component Inspection» .
OK or NG
OK
>> GO TO 8.
NG
>> Replace malfunctioning component.

G

H

8. CHECK MAIN 12 CAUSES

I

If the cause cannot be isolated, go to EC-674, «Main 12 Causes of Overheating» .
J

>> INSPECTION END

Procedure A

1. CHECK POWER SUPPLY CIRCUIT

K

1.
2.
3.

L

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E6.
Check voltage between IPDM E/R terminal 14 and ground with
CONSULT-II or tester.

M

Voltage: Battery voltage
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

MBIB1307E

2. DETECT MALFUNCTIONING PART
Check the following.
●
40A fusible link
●
Harness for open or short between IPDM E/R and battery
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-673

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITHOUT EURO-OBD)]

3. CHECK COOLING FAN MOTORS CIRCUIT
1.
2.

Disconnect cooling fan motor harness connector.
Check harness continuity between cooling fan motor terminal 1
and IPDM E/R terminal 10, cooling fan motor terminal 2 and
ground.
Refer to wiring diagram.
Continuity should exist.

3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

MBIB1074E

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness for open or short between cooling fan motor and IPDM E/R
●
Harness for open or short between cooling fan motor and ground
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK COOLING FAN MOTOR
Refer to EC-675, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace cooling fan motor.

6. CHECK INTERMITTENT INCIDENT
Perform EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connector.

Main 12 Causes of Overheating
Engine

Step

OFF

1

Inspection item
●

Blocked radiator

●

Blocked condenser

●

Blocked radiator grille

●

Blocked bumper

2

●

3

4*5

BBS00485

Equipment

Standard

Visual

No blocking

Coolant mixture

●

Coolant tester

50 — 50% coolant mixture

See MA-26, «Engine
Coolant Mixture Ratio» .

●

Coolant level

●

Visual

Coolant up to MAX level
in reservoir tank and radiator filler neck

See CO-8, «LEVEL
CHECK» .

●

Radiator cap

●

Pressure tester

59 — 98 kPa
(0.59 — 0.98 bar, 0.6 — 1.0

See CO-15, «Checking
Radiator Cap (Models
without A/C)» .

kg/cm2 , 9 — 14 psi) (Limit)
4*6

Reference page

●

●

Reservoir tank cap

●

Pressure tester

EC-674

88 kPa (0.88 bar, 0.90 kg/
2

cm , 12.8psi)

—

See CO-16, «Checking
Reservoir Tank Cap
(Models with A/C)» .

DTC P1217 ENGINE OVER TEMPERATURE
[CR (WITHOUT EURO-OBD)]
Engine

Step

Inspection item

Equipment

Standard

Reference page

ON*2

5

●

Coolant leaks

●

Visual

No leaks

See CO-8, «LEAK
CHECK» .

ON*2

6

●

Thermostat

●

Touch the upper and
lower radiator hoses

Both hoses should be hot

See CO-19, «THERMOSTAT» , and CO-12,
«RADIATOR» .

ON*1

7

●

Cooling fan

●

CONSULT-II

Operating

See trouble diagnosis for
DTC P1217 (EC-662 ).

OFF

8

●

Combustion gas leak

●

Color checker chemical
tester 4 Gas analyzer

Negative

—

ON*3

9

●

Coolant temperature
gauge

●

Visual

Gauge less than 3/4
when driving

—

●

Coolant overflow to
reservoir tank

●

Visual

No overflow during driving
and idling

See CO-9, «Changing
Engine coolant» .

A

C

D

OFF*4

10

●

Coolant return from
reservoir tank to radiator

●

Visual

Should be initial level in
reservoir tank

See CO-8, «LEVEL
CHECK» .

OFF

11

●

Cylinder head

●

Straight gauge feeler
gauge

0.1 mm (0.004 in) Maximum distortion (warping)

See EM-60, «CYLINDER
HEAD» .

12

●

Cylinder block and pistons

●

Visual

No scuffing on cylinder
walls or piston

See EM-74, «CYLINDER
BLOCK» .

E

F

*1: Turn the ignition switch ON.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
*5: Models without A/C.
*6: Models with A/C.
For more information, refer to CO-5, «OVERHEATING CAUSE ANALYSIS» .

Component Inspection

G

H

I

BBS00486

COOLING FAN MOTOR
1.
2.

EC

Disconnect cooling fan motor harness connector.
Supply cooling fan motor terminals with battery voltage and
check operation.

J

K

Terminals

Cooling fan motor

(+)

(-)

1

2

L

M
MBIB0607E

EC-675

DTC P1225 TP SENSOR
[CR (WITHOUT EURO-OBD)]

DTC P1225 TP SENSOR
Component Description

PFP:16119
BBS0039Y

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

PBIB0145E

On Board Diagnosis Logic

BBS0039Z

The MI will not light up for this self-diagnosis.
DTC No.
P1225
1225

Trouble diagnosis name
Closed throttle position learning
performance

DTC detecting condition
Closed throttle position learning value is
excessively low.

DTC Confirmation Procedure

Possible cause
●

Electric throttle control actuator
(TP sensor 1 and 2)
BBS003A0

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON.
If 1st trip DTC is detected, go to EC-677, «Diagnostic Procedure»
.

SEF058Y

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

Turn ignition switch ON.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-677, «Diagnostic Procedure» .

EC-676

DTC P1225 TP SENSOR
[CR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS003A1

1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY

A

1.
2.
3.

Turn ignition switch OFF.
Remove the intake air duct.
Check if foreign matter is caught between the throttle valve and
the housing.
OK or NG
OK
>> GO TO 2.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.

EC

C

D

E
MBIB0307E

2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR

F

1.
2.
3.

G

Replace the electric throttle control actuator.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

H

>> INSPECTION END

Removal and Installation

BBS003A2

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

I

J

K

L

M

EC-677

DTC P1226 TP SENSOR
[CR (WITHOUT EURO-OBD)]

DTC P1226 TP SENSOR
Component Description

PFP:16119
BBS003A3

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

PBIB0145E

On Board Diagnosis Logic

BBS003A4

The MI will not light up for this self-diagnosis.
DTC No.
P1226
1226

Trouble diagnosis name
Closed throttle position learning
performance

DTC detecting condition
Closed throttle position learning is not
performed successfully, repeatedly.

DTC Confirmation Procedure

Possible cause
●

Electric throttle control actuator
(TP sensor 1 and 2)
BBS003A5

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON.
Repeat steps 3 and 4 for 32 times.
If 1st trip DTC is detected, go to EC-679, «Diagnostic Procedure»
.

SEF058Y

WITHOUT CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Repeat step 2 for 32 times.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-679, «Diagnostic Procedure» .

EC-678

DTC P1226 TP SENSOR
[CR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS003A6

1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY

A

1.
2.
3.

Turn ignition switch OFF.
Remove the intake air duct.
Check if foreign matter is caught between the throttle valve and
the housing.
OK or NG
OK
>> GO TO 2.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.

EC

C

D

E
MBIB0307E

2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR

F

1.
2.
3.

G

Replace the electric throttle control actuator.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

H

>> INSPECTION END

Removal and Installation

BBS003A7

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

I

J

K

L

M

EC-679

DTC P1229 SENSOR POWER SUPPLY
[CR (WITHOUT EURO-OBD)]

DTC P1229 SENSOR POWER SUPPLY
On Board Diagnosis Logic

PFP:16119
BBS003A8

This self-diagnosis has the one trip detection logic.
DTC No.

P1229
1229

Trouble diagnosis name

Sensor power supply circuit
short

DTC detecting condition

Possible cause
●

Harness or connectors
(APP sensor 1 circuit is shorted.)
(Manifold absolute pressure sensor is
shorted.)
(Refrigerant pressure sensor circuit is
shorted.)

●

Accelerator pedal position sensor
(APP sensor 1)

●

Manifold absolute pressure sensor

●

Refrigerant pressure sensor

ECM detects a voltage of power source
for sensor is excessively low or high.

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.

DTC Confirmation Procedure

BBS003A9

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-685, «Diagnostic Procedure» .

SEF058Y

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

Start engine and let it idle for 1 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-685, «Diagnostic Procedure» .

EC-680

DTC P1229 SENSOR POWER SUPPLY
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003AA

A

LHD MODELS

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1525E

EC-681

DTC P1229 SENSOR POWER SUPPLY
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

45

L

Sensor power supply
(Manifold absolute pressure sensor)

[Ignition switch: ON]

Approximately 5V

46

W

Sensor power supply
(Refrigerant pressure
sensor)

[Ignition switch: ON]

Approximately 5V

B

Sensor ground
(APP sensor 1)

[Engine is running]
82

●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
83

B

Sensor ground
(APP sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

98

G

Accelerator pedal
position sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Ignition switch: ON]

106

W

Accelerator pedal position sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

EC-682

3.9 — 4.7V

DTC P1229 SENSOR POWER SUPPLY
[CR (WITHOUT EURO-OBD)]
RHD MODELS
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1526E

EC-683

DTC P1229 SENSOR POWER SUPPLY
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

45

L

Sensor power supply
(Manifold absolute pressure sensor)

[Ignition switch: ON]

Approximately 5V

46

W

Sensor power supply
(Refrigerant pressure
sensor)

[Ignition switch: ON]

Approximately 5V

B

Sensor ground
(APP sensor 1)

[Engine is running]
82

●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
83

B

Sensor ground
(APP sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

98

G

Accelerator pedal
position sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Ignition switch: ON]

106

W

Accelerator pedal position sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

EC-684

3.9 — 4.7V

DTC P1229 SENSOR POWER SUPPLY
[CR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS003AB

1. CHECK GROUND CONNECTIONS
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

EC

C

D

E
MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

F

Body ground E28

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

G

2. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT-I
1.
2.

H

Disconnect accelerator pedal position sensor (APP) sensor harness connector.
Turn ignition switch ON.

I

J

K
MBIB0285E

3.

L

Check voltage between APP sensor terminal 4 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

M

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.

MBIB0304E

EC-685

DTC P1229 SENSOR POWER SUPPLY
[CR (WITHOUT EURO-OBD)]

3. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between APP sensor terminal 4 and ECM terminal 90.
Refer to Wiring Diagram.
Continuity should exist.

OK or NG
OK
>> GO TO 5.
NG (LHD models)>>Repair open circuit.
NG (RHD models)>>GO TO 4.

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M201, M8
●
Harness connectors M1, E101
●
Harness for open or short between APP sensor and ECM
>> Repair open circuit.

5. CHECK SENSOR POWER SUPPLY CIRCUIT
Check harness for short to power and short to ground, between the following terminals
ECM terminal

Sensor terminal

Reference Wiring Diagram

90

APP sensor terminal 4

EC-681

45

Manifold absolute pressure sensor terminal 2

EC-560

46

Refrigerant pressure sensor terminal 3

EC-795

OK or NG
OK
>> GO TO 6.
NG
>> Repair short to ground or short to power in harness or connectors.

6. CHECK COMPONENTS
Check the following.
●
Manifold absolute pressure sensor (Refer to EC-563, «Component Inspection» .)
●
Refrigerant pressure sensor (Refer to ATC-85, «COMPONENT INSPECTION» or MTC-51, «COMPONENT INSPECTION» .)
OK or NG
OK
>> GO TO 9.
NG
>> Replace malfunctioning component.

7. CHECK APP SENSOR
Refer to EC-716, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.

EC-686

DTC P1229 SENSOR POWER SUPPLY
[CR (WITHOUT EURO-OBD)]

8. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace accelerator pedal assembly.
Perform EC-486, «Accelerator Pedal Released Position Learning» .
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

A

EC

C

>> INSPECTION END

9. CHECK INTERMITTENT INCIDENT

D

Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
E

>> INSPECTION END

F

G

H

I

J

K

L

M

EC-687

DTC P1706 PNP SWITCH
[CR (WITHOUT EURO-OBD)]

DTC P1706 PNP SWITCH
Component Description

PFP:32006
BBS003AC

When the shift lever position is Neutral, park/neutral position (PNP) switch is ON.
ECM detects the position because the continuity of the line (the ON signal) exists.

CONSULT-II Reference Value in Data Monitor Mode

BBS003AD

Specification data are reference values.
MONITOR ITEM
P/N POSI SW

CONDITION
●

Ignition switch: ON

SPECIFICATION

Shift lever: Neutral

ON

Shift lever: Except above

OFF

On Board Diagnosis Logic
DTC No.
P1706
1706

BBS003AE

Trouble diagnosis name

DTC detecting condition

Park/neutral position switch

The signal of the park/neutral position (PNP)
switch is not changed in the process of
engine starting and driving.

Overall Function Check

Possible cause
●

Harness or connectors
[The park/neutral position (PNP) switch
circuit is open or shorted.]

●

Park/neutral position (PNP) switch
BBS003AF

Use this procedure to check the overall function of the park/neutral position (PNP) switch circuit. During this
check, a 1st trip DTC might not be confirmed.

WITH CONSULT-II
1.
2.

Turn ignition switch ON.
Select “P/N POSI SW” in “DATA MONITOR” mode with CONSULT-II. Then check the “P/N POSI SW” signal under the following conditions.
Position (Shift lever)

Known-good signal

Neutral position

ON

Except the above position

OFF

If NG, go to EC-690, «Diagnostic Procedure» .
SEF212Y

WITHOUT CONSULT-II
1.
2.

Turn ignition switch ON.
Check voltage between ECM terminal 102 (PNP switch signal)
and ground under the following conditions.
Condition (Gear position)

Neutral position
Except the above position

3.

Voltage V (Known-good data)
Approx. 0
BATTERY VOLTAGE
(11 — 14V)

If NG, go to EC-690, «Diagnostic Procedure» .
MBIB0043E

EC-688

DTC P1706 PNP SWITCH
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003AG

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1527E

EC-689

DTC P1706 PNP SWITCH
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION
[Ignition switch: ON]
●

102

GR

PNP switch

Shift lever position: Neutral

[Ignition switch: ON]
●

Except the above gear position

Diagnostic Procedure

DATA (DC Voltage)

Approximately 0V
BATTERY VOLTAGE
(11 — 14V)
BBS003AH

1. CHECK PNP SWITCH CIRCUIT
1.
2.

Turn ignition switch ON.
Check voltage between IPDM E/R terminal 31 and ground under
following condition.
Shift lever position

Voltage

Neutral

Battery voltage (11- 14V)

Except above position

Approximately 0V

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 2.
MBIB0652E

2. CHECK PNP SWITCH POWER SUPPLY CIRCUIT
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect PNP switch harness connector.
Turn ignition switch ON.
Check voltage between PNP switch terminal 2 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

MBIB1444E

3. DETECT MALFUNCTIONING PARTS
Check the following.
●
10A fuse
●
Harness connectors E48, F1
●
IPDM E/R connector E7
●
Harness for short or open between PNP switch and fuse
>> Repair or replace harness or connectors.

EC-690

DTC P1706 PNP SWITCH
[CR (WITHOUT EURO-OBD)]

4. CHECK HARNESS CONTINUTY BETWEEN PNP SWITCH AND IPDM E/R
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between IPDM E/R terminal 31 and PNP switch terminal 3.
Refer to Wiring Diagram.
Continuity should exist.

A

EC

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. DETECT MALFUNCTIONING PARTS

D

E

Check the following.
●
Harness connectors E48, F1
●
Harness for short or open between PNP switch and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

F

G

6. CHECK PNP SWITCH
H

Refer to MT-16, «Park/Neutral Position Switch» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace PNP switch.

I

7. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

J

K

8. CHECK PNP SWITCH GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connectors E11 and E12.
Check harness continuity between IPDM E/R terminal 3, 54 and ground.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to power.
OK or NG
OK
>> GO TO 9.
NG
>> Repair open circuit or short to power in harness or connectors.

EC-691

L

M

DTC P1706 PNP SWITCH
[CR (WITHOUT EURO-OBD)]

9. CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Disconnect IPDM E/R harness connector E5
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 102 and IPDM E/R terminal 64.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 10.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

10. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace.

EC-692

DTC P1805 BRAKE SWITCH
[CR (WITHOUT EURO-OBD)]

DTC P1805 BRAKE SWITCH
Description

PFP:25320

A
BBS003AI

Brake switch signal is applied to the ECM through the stop lamp
switch when the brake pedal is depressed. This signal is used
mainly to decrease the engine speed when the vehicle is driving.

EC

C

D
MBIB0286E

E

CONSULT-II Reference Value in Data Monitor Mode

BBS003AJ

Specification data are reference values.
MONITOR ITEM
BRAKE SW

CONDITION
●

Ignition switch: ON

F

SPECIFICATION

Brake pedal: Fully released

OFF

Brake pedal: Slightly depressed

ON

On Board Diagnosis Logic

G
BBS003AK

This self-diagnosis has the one trip detection logic.
DTC No.

Trouble diagnosis name

P1805
1805

Brake switch

H

DTC detecting condition
A brake switch signal is not sent to ECM for
extremely long time while the vehicle is driving.

Possible cause
●

Harness or connectors
(Stop lamp switch circuit is open or shorted.)

●

Stop lamp switch

FAIL-SAFE MODE

I

J

When the malfunction is detected, the ECM enters fail-safe mode and the MI light up.
Engine operating condition in fail-safe mode

K

ECM controls the electric throttle control actuator by regulating the throttle opening to a small range.
Therefore, acceleration will be poor.
Vehicle condition

Driving condition

When engine is idling

Normal

When accelerating

Poor acceleration

DTC Confirmation Procedure

L

BBS003AM

WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON.
Fully depress the brake pedal for at least 5 seconds.
Erase the DTC with CONSULT-II.
Select “DATA MONITOR” mode with CONSULT-II.
If DTC is detected, go to EC-696, «Diagnostic Procedure» .

SEF058Y

EC-693

M

DTC P1805 BRAKE SWITCH
[CR (WITHOUT EURO-OBD)]
WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch ON.
Fully depress the brake pedal at least 5 seconds.
Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-478 .
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-696, «Diagnostic Procedure» .

EC-694

DTC P1805 BRAKE SWITCH
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003AN

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1528E

EC-695

DTC P1805 BRAKE SWITCH
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION
[Ignition switch: OFF]
●

101

R

Stop lamp switch

Brake pedal: Fully released

[Ignition switch: OFF]
●

Brake pedal: Slightly depressed

Diagnostic Procedure

DATA (DC Voltage)

Approximately 0V
BATTERY VOLTAGE
(11 — 14V)
BBS003AO

1. CHECK STOP LAMP SWITCH CIRCUIT
1.
2.

Turn ignition switch OFF.
Check the stop lamp when depressing and releasing the brake pedal.
Brake pedal

Stop lamp

Fully released

Not illuminated

Slightly depressed

Illuminated

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 2.

2. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT
1.

Disconnect stop lamp switch harness connector.

MBIB0286E

2.

Check voltage between stop lamp switch terminal 1 and ground
with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

PBIB0117E

EC-696

DTC P1805 BRAKE SWITCH
[CR (WITHOUT EURO-OBD)]

3. DETECT MALFUNCTIONING PART

A

Check the following.
●
10A fuse
●
Fuse block (J/B) connector M7
●
Harness connectors M1, E101 (LHD models)
●
Harness connectors M8, M201 (RHD models)
●
Harness for open and short between stop lamp switch and battery
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC

C

D

4. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Disconnect ECM harness connector.
Disconnect stop lamp switch harness connector.
Check harness continuity between ECM terminal 101 and stop lamp switch terminal 2.
Refer to Wiring Diagram.

E

F

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 5.

5. DETECT MALFUNCTIONING PART

G

H

I

Check the following.
●
Harness connectors M8, M201
●
Harness connectors M1, E101
●
Harness for open or short between ECM and stop lamp switch
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK STOP LAMP SWITCH

J

K

L

Refer to EC-698, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace stop lamp switch.

M

7. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-697

DTC P1805 BRAKE SWITCH
[CR (WITHOUT EURO-OBD)]

Component Inspection

BBS003AP

STOP LAMP SWITCH
1.

Disconnect stop lamp switch harness connector.

MBIB0286E

2.

Check continuity between stop lamp switch terminals 1 and 2
under the following conditions.
Conditions

Brake pedal: Fully released
Brake pedal: Slightly depressed

Continuity
Should not exist.
Should exist.

If NG, adjust brake pedal installation, refer to BR-6, «BRAKE
PEDAL» , and perform step 2 again.
PBIB0118E

EC-698

DTC P2122, P2123 APP SENSOR
[CR (WITHOUT EURO-OBD)]

DTC P2122, P2123 APP SENSOR
Component Description

PFP:18002

A
BBS003AQ

The accelerator pedal position sensor is installed on the upper end
of the accelerator pedal assembly. The sensor detects the acceleraEC
tor position and sends a signal to the ECM.
Accelerator pedal position sensor has two sensors. These sensors
are a kind of potentiometers which transform the accelerator pedal
C
position into output voltage, and emit the voltage signal to the ECM.
In addition, these sensors detect the opening and closing speed of
the accelerator pedal and feed the voltage signals to the ECM. The
ECM judges the current opening angle of the accelerator pedal from
D
these signals and controls the throttle control motor based on these
signals.
PBIB1741E
Idle position of the accelerator pedal is determined by the ECM
E
receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut.

CONSULT-II Reference Value in Data Monitor Mode

BBS003AR

F

Specification data are reference values.
MONITOR ITEM
ACCEL SEN 1

ACCEL SEN 2*

CLSD THL POS

CONDITION
●

●

●

SPECIFICATION

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

4.0 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

3.9 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

G

H

I

*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage.

On Board Diagnosis Logic

BBS003AS

These self-diagnoses have the one trip detection logic.
NOTE:
If DTC P2122 or P2123 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229.
Refer to EC-680, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

Trouble diagnosis name

DTC detecting condition

P2122
2122

Accelerator pedal position
sensor 1 circuit low input

An excessively low voltage from the APP sensor 1
is sent to ECM.

P2123
2123

Accelerator pedal position
sensor 1 circuit high input

An excessively high voltage from the APP sensor 1
is sent to ECM.

Possible cause
Harness or connectors
(APP sensor 1 circuit is open or
shorted.)

●

Accelerator pedal position sensor
(APP sensor 1)

When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.
BBS003AT

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:

EC-699

K

L

●

FAIL-SAFE MODE

DTC Confirmation Procedure

J

M

DTC P2122, P2123 APP SENSOR
[CR (WITHOUT EURO-OBD)]
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-704, «Diagnostic Procedure» .

SEF058Y

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

Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-704, «Diagnostic Procedure» .

EC-700

DTC P2122, P2123 APP SENSOR
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003AU

A

LHD MODELS

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1529E

EC-701

DTC P2122, P2123 APP SENSOR
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]
82

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Ignition switch: ON]
83

B

Sensor ground
(APP sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

98

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Ignition switch: ON]

106

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

EC-702

3.9 — 4.7V

DTC P2122, P2123 APP SENSOR
[CR (WITHOUT EURO-OBD)]
RHD MODELS
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1530E

EC-703

DTC P2122, P2123 APP SENSOR
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]
82

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Ignition switch: ON]
83

B

Sensor ground
(APP sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

98

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Ignition switch: ON]

106

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

Diagnostic Procedure

BBS003AV

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-704

3.

Body ground E28

DTC P2122, P2123 APP SENSOR
[CR (WITHOUT EURO-OBD)]

2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT
1.
2.

A

Disconnect accelerator pedal position (APP) sensor harness
connector.
Turn ignition switch ON.

EC

C

D
MBIB0285E

3.

Check voltage between APP sensor terminal 4 and ground with
CONSULT-II or tester.

E

Voltage: Approximately 5V
F

G

MBIB0304E

H

OK or NG
OK
>> GO TO 4.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 3.

I

3. DETECT MALFUNCTIONING PART

J

Check the following.
●
Harness connectors M1, E101
●
Harness connectors M8, M201
●
Harness for open or short between ECM and accelerator pedal position sensor

K

L

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK APP SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 82 and APP sensor terminal 2.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 5.

EC-705

M

DTC P2122, P2123 APP SENSOR
[CR (WITHOUT EURO-OBD)]

5. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M1, E101
●
Harness connectors M8, M201
●
Harness for open or short between ECM and accelerator pedal position sensor
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK APP SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 106 and APP sensor terminal 3.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 7.

7. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors M1, E101
●
Harness connectors M8, M201
●
Harness for open or short between ECM and accelerator pedal position sensor
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK APP SENSOR
Refer to EC-706, «Component Inspection» .
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 9.

9. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace the accelerator pedal assembly.
Perform EC-486, «Accelerator Pedal Released Position Learning» .
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .
>> INSPECTION END

10. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS003AW

ACCELERATOR PEDAL POSITION SENSOR
1.
2.

Reconnect all harness connectors disconnected.
Turn ignition switch ON.

EC-706

DTC P2122, P2123 APP SENSOR
[CR (WITHOUT EURO-OBD)]
3.

Check voltage between ECM terminals 106 (APP sensor 1 signal), 98 (APP sensor 2 signal) and ground under the following
conditions.
Terminal

Accelerator pedal

Voltage

106
(Accelerator pedal position
sensor 1)

Fully released

0.6 — 0.9V

Fully depressed

3.9 — 4.7V

Fully released

0.3 — 0.6V

Fully depressed

1.95 — 2.4V

98
(Accelerator pedal position
sensor 2)

4.
5.
6.
7.

A

EC

C
MBIB0023E

D

If NG, replace accelerator pedal assembly and go to the next
step.
Perform EC-486, «Accelerator Pedal Released Position Learning» .
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

Removal and Installation

E

BBS003AX

ACCELERATOR PEDAL

F

Refer to ACC-2, «ACCELERATOR CONTROL SYSTEM» .
G

H

I

J

K

L

M

EC-707

DTC P2127, P2128 APP SENSOR
[CR (WITHOUT EURO-OBD)]

DTC P2127, P2128 APP SENSOR
Component Description

PFP:18002
BBS003AY

The accelerator pedal position sensor is installed on the upper end
of the accelerator pedal assembly. The sensor detects the accelerator position and sends a signal to the ECM.
Accelerator pedal position sensor has two sensors. These sensors
are a kind of potentiometers which transform the accelerator pedal
position into output voltage, and emit the voltage signal to the ECM.
In addition, these sensors detect the opening and closing speed of
the accelerator pedal and feed the voltage signals to the ECM. The
ECM judges the current opening angle of the accelerator pedal from
these signals and controls the throttle control motor based on these
signals.
PBIB1741E
Idle position of the accelerator pedal is determined by the ECM
receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut.

CONSULT-II Reference Value in Data Monitor Mode

BBS003AZ

Specification data are reference values.
MONITOR ITEM
ACCEL SEN 1

ACCEL SEN 2*

CLSD THL POS

CONDITION
●

●

●

SPECIFICATION

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

4.0 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

3.9 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differ from ECM terminal voltage signal.

On Board Diagnosis Logic

BBS003B0

These self-diagnoses have the one trip detection logic.
DTC No.

Trouble diagnosis name

DTC detecting condition

Possible cause

P2127
2127

Accelerator pedal position
sensor 2 circuit low input

An excessively low voltage from the APP sensor 2
is sent to ECM.

●

Harness or connectors
(APP sensor 2 circuit is open or
shorted.)
(TP sensor circuit is shorted.)

P2128
2128

Accelerator pedal position
sensor 2 circuit high input

An excessively high voltage from the APP sensor 2
is sent to ECM.

●

Accelerator pedal position sensor
(APP sensor 2)

●

Electric throttle control actuator
(TP sensor 1 and 2)

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

DTC Confirmation Procedure

BBS003B1

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

EC-708

DTC P2127, P2128 APP SENSOR
[CR (WITHOUT EURO-OBD)]
WITH CONSULT-II
1.
2.
3.
4.

A

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-713, «Diagnostic Procedure» .

EC

C

D
SEF058Y

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

Start engine and let it idle for 1 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-713, «Diagnostic Procedure» .

E

F

G

H

I

J

K

L

M

EC-709

DTC P2127, P2128 APP SENSOR
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003B2

LHD MODELS

MBWA1531E

EC-710

DTC P2127, P2128 APP SENSOR
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

A

EC
ITEM

47

G

Sensor power supply
(Throttle position sensor)

82

B

Sensor ground
(APP sensor 1)

CONDITION

[Ignition switch: ON]

DATA (DC Voltage)

Approximately 5V

C

Approximately 0V

D

Approximately 0V

E

F

[Engine is running]
●

Warm-up condition

●

Idle speed

[Ignition switch: ON]
83

B

Sensor ground
(APP sensor 2)

●

Warm-up condition

●

Idle speed

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

G

[Ignition switch: ON]

98

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

H

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

I

[Ignition switch: ON]

106

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

J

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

K

L

M

EC-711

DTC P2127, P2128 APP SENSOR
[CR (WITHOUT EURO-OBD)]
RHD MODELS

MBWA1532E

EC-712

DTC P2127, P2128 APP SENSOR
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

A

EC

WIRE
COLOR

ITEM

CONDITION

47

G

Sensor power supply
(Throttle position sensor)

82

B

Sensor ground
(APP sensor 1)

DATA (DC Voltage)

[Ignition switch: ON]

Approximately 5V

C

Approximately 0V

D

Approximately 0V

E

F

[Engine is running]
●

Warm-up condition

●

Idle speed

[Ignition switch: ON]
83

B

Sensor ground
(APP sensor 2)

●

Warm-up condition

●

Idle speed

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

G

[Ignition switch: ON]

98

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

H

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

I

[Ignition switch: ON]

106

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

J

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

K

Diagnostic Procedure

BBS003B3

1. CHECK GROUND CONNECTIONS
1.
2.

L

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

M

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-713

3.

Body ground E28

DTC P2127, P2128 APP SENSOR
[CR (WITHOUT EURO-OBD)]

2. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I
1.
2.

Disconnect accelerator pedal position (APP) sensor harness
connector.
Turn ignition switch ON.

MBIB0285E

3.

Check voltage between APP sensor terminal 5 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 3.

MBIB0309E

3. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between APP sensor terminal 5 and ECM terminal 91.
Refer to Wiring Diagram.
Continuity should exist.

OK or NG
OK
>> GO TO 5.
NG (LHD models)>>Repair open circuit.
NG (RHD models)>>GO TO 4.

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M201, M8
●
Harness connectors M1, E101
●
Harness for open or short between accelerator pedal position sensor and ECM
>> Repair open circuit.

EC-714

DTC P2127, P2128 APP SENSOR
[CR (WITHOUT EURO-OBD)]

5. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III

A

Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

91

APP sensor terminal 5

EC-710

47

Electric throttle control actuator terminal 1

EC-720

OK or NG
OK
>> GO TO 6.
NG
>> Repair short to ground or short to power in harness or connectors.

EC

C

D

6. CHECK THROTTLE POSITION SENSOR
Refer to EC-724, «Component Inspection» .
OK or NG
OK
>> GO TO 14.
NG
>> GO TO 7.

E

F

7. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

G

H

>> INSPECTION END

8. CHECK APP SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT

I

1.
2.
3.

J

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 83 and APP sensor terminal 1.
Refer to Wiring Diagram.

K

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 10.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 9.

9. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M8, M201
●
Harness connectors M1, E101
●
Harness for open or short between accelerator pedal position sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-715

L

M

DTC P2127, P2128 APP SENSOR
[CR (WITHOUT EURO-OBD)]

10. CHECK APP SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 98 and APP sensor terminal 6.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 12.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 11.

11. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors M8, M201
●
Harness connectors M1, E101
●
Harness for open or short between ECM and accelerator pedal position sensor
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

12. CHECK APP SENSOR
Refer to EC-716, «Component Inspection» .
OK or NG
OK
>> GO TO 14.
NG
>> GO TO 13.

13. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace the accelerator pedal assembly.
Perform EC-486, «Accelerator Pedal Released Position Learning» .
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .
>> INSPECTION END

14. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS003B4

ACCELERATOR PEDAL POSITION SENSOR
1.
2.

Reconnect all harness connectors disconnected.
Turn ignition switch ON.

EC-716

DTC P2127, P2128 APP SENSOR
[CR (WITHOUT EURO-OBD)]
3.

Check voltage between ECM terminals 106 (APP sensor 1 signal), 98 (APP sensor 2 signal) and ground under the following
conditions.
Terminal

Accelerator pedal

Voltage

106
(Accelerator pedal position
sensor 1)

Fully released

0.6 — 0.9V

Fully depressed

3.9 — 4.7V

Fully released

0.3 — 0.6V

Fully depressed

1.95 — 2.4V

98
(Accelerator pedal position
sensor 2)

4.
5.
6.
7.

A

EC

C
MBIB0023E

D

If NG, replace accelerator pedal assembly and go to the next
step.
Perform EC-486, «Accelerator Pedal Released Position Learning» .
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

Removal and Installation

E

BBS003B5

ACCELERATOR PEDAL

F

Refer to ACC-2, «ACCELERATOR CONTROL SYSTEM» .
G

H

I

J

K

L

M

EC-717

DTC P2135 TP SENSOR
[CR (WITHOUT EURO-OBD)]

DTC P2135 TP SENSOR
Component Description

PFP:16119
BBS003B6

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

PBIB0145E

CONSULT-II Reference Value in Data Monitor Mode

BBS003B7

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

More than 0.36V

●

Shift lever: 1st

Accelerator pedal: Fully depressed

Less than 4.75V

THRTL SEN 1
THRTL SEN 2*

*: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic

BBS003B8

This self-diagnosis has the one trip detection logic.
DTC No.

P2135
2135

Trouble diagnosis name

Throttle position sensor
circuit range/performance

DTC detecting condition

Rationally incorrect voltage is sent to ECM
compared with the signals from TP sensor 1
and TP sensor 2.

Possible cause
●

Harness or connector
(TP sensor 1 and 2 circuit is open or
shorted.)
(APP sensor 2 circuit is shorted.)

●

Electric throttle control actuator
(TP sensor 1 and 2)

●

Accelerator pedal position sensor
(APP sensor 2)

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

DTC Confirmation Procedure

BBS003B9

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

EC-718

DTC P2135 TP SENSOR
[CR (WITHOUT EURO-OBD)]
WITH CONSULT-II
1.
2.
3.
4.

A

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-721, «Diagnostic Procedure» .

EC

C

D
SEF058Y

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

Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-721, «Diagnostic Procedure» .

E

F

G

H

I

J

K

L

M

EC-719

DTC P2135 TP SENSOR
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003BA

MBWA1533E

EC-720

DTC P2135 TP SENSOR
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL NO.
47

WIRE
COLOR
L

ITEM

CONDITION

Sensor power supply
(Throttle position sensor)

EC

DATA (DC Voltage)

[Ignition switch: ON]

A

Approximately 5V

C

[Ignition switch: ON]

49

Y

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

Throttle position sensor 1

More than 0.36V

D

[Ignition switch: ON]
●

E

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

Less than 4.75V

F

[Engine is running]
66

B

Sensor ground
(Throttle position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

G

[Ignition switch: ON]

68

R

Throttle position sensor 2

●

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully released

BR

Sensor power supply
(APP sensor 2)

H

[Ignition switch: ON]
●

91

Less than 4.75V

I

Engine stopped

●

Shift lever position: 1st

●

Accelerator pedal: Fully depressed

More than 0.36V

J

[Ignition switch: ON]

Approximately 5V

Diagnostic Procedure

BBS003BB

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

K

L

M

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-721

3.

Body ground E28

DTC P2135 TP SENSOR
[CR (WITHOUT EURO-OBD)]

2. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT
1.
2.

Disconnect electric throttle control actuator harness connector.
Turn ignition switch ON.

MBIB0308E

3.

Check voltage between electric throttle control actuator terminal
1 and ground with CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.

PBIB0082E

3. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between electric throttle control actuator terminal 1 and ECM terminal 47.
Refer to Wiring Diagram.
Continuity should exist.

OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit.

4. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT-III
Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

47

Electric throttle control actuator terminal 1

EC-720

91

APP sensor terminal 5

EC-710

OK or NG
OK
>> GO TO 5.
NG
>> Repair short to ground or short to power in harness or connectors.

5. CHECK APP SENSOR
Refer to EC-716, «Component Inspection» .
OK or NG
OK
>> GO TO 11
NG
>> GO TO 6.

EC-722

DTC P2135 TP SENSOR
[CR (WITHOUT EURO-OBD)]

6. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace accelerator pedal assembly.
Perform EC-486, «Accelerator Pedal Released Position Learning» .
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

7. CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 66 and electric throttle control actuator terminal 5.
Refer to Wiring Diagram.
Continuity should exist.

D

E

F

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

EC

C

>> INSPECTION END

1.
2.
3.

A

Check harness continuity between ECM terminal 49 and electric throttle control actuator terminal 4, ECM
terminal 68 and electric throttle control actuator terminal 2.
Refer to Wiring Diagram.

G

H

I

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 9.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

J

K

9. CHECK THROTTLE POSITION SENSOR
L

Refer to EC-724, «Component Inspection» .
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

M

10. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .
>> INSPECTION END

11. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-723

DTC P2135 TP SENSOR
[CR (WITHOUT EURO-OBD)]

Component Inspection

BBS003BC

THROTTLE POSITION SENSOR
1.
2.
3.
4.
5.

Reconnect all harness connectors disconnected.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Turn ignition switch ON.
Set shift lever to 1st position.
Check voltage between ECM terminals 49 (TP sensor 1 signal),
68 (TP sensor 2 signal) and ground under the following conditions.
Terminal

Accelerator pedal

Voltage

49
(Throttle position sensor 1)

Fully released

More than 0.36V

Fully depressed

Less than 4.75V

Fully released

Less than 4.75V

Fully depressed

More than 0.36V

68
(Throttle position sensor 2)

6.
7.
8.

If NG, replace electric throttle control actuator and go to the next
step.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

Removal and Installation

MBIB1443E

BBS003BD

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

EC-724

DTC P2138 APP SENSOR
[CR (WITHOUT EURO-OBD)]

DTC P2138 APP SENSOR
Component Description

PFP:18002

A
BBS003BE

The accelerator pedal position sensor is installed on the upper end
of the accelerator pedal assembly. The sensor detects the acceleraEC
tor position and sends a signal to the ECM.
Accelerator pedal position sensor has two sensors. These sensors
are a kind of potentiometers which transform the accelerator pedal
C
position into output voltage, and emit the voltage signal to the ECM.
In addition, these sensors detect the opening and closing speed of
the accelerator pedal and feed the voltage signals to the ECM. The
ECM judges the current opening angle of the accelerator pedal from
D
these signals and controls the throttle control motor based on these
signals.
PBIB1741E
Idle position of the accelerator pedal is determined by the ECM
E
receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut.

CONSULT-II Reference Value in Data Monitor Mode

BBS003BF

F

Specification data are reference values.
MONITOR ITEM
ACCEL SEN 1

ACCEL SEN 2*

CLSD THL POS

CONDITION
●

●

●

SPECIFICATION

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

4.0 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

3.9 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

G

H

I

*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage.

On Board Diagnosis Logic

BBS003BG

This self-diagnosis has the one trip detection logic.
NOTE:
If DTC P2138 is displayed with DTC P1229, first perform trouble diagnosis for DTC P1229. Refer to EC680, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

Trouble diagnosis name

DTC detecting condition

Possible cause
●

P2138
2138

Accelerator pedal position sensor
circuit range/performance

Rationally incorrect voltage is sent to ECM
compared with the signals from APP sensor
1 and APP sensor 2.

Harness or connector
(APP sensor 1 and 2 circuit is open
or shorted.)
(TP sensor circuit is shorted.)

●

Accelerator pedal position sensor
(APP sensor 1 and 2)

●

Electric throttle control actuator
(TP sensor 1 and 2)

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-725

J

K

L

M

DTC P2138 APP SENSOR
[CR (WITHOUT EURO-OBD)]

DTC Confirmation Procedure

BBS003BH

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-730, «Diagnostic Procedure» .

SEF058Y

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

Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-730, «Diagnostic Procedure» .

EC-726

DTC P2138 APP SENSOR
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003BI

A

LHD MODELS

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1534E

EC-727

DTC P2138 APP SENSOR
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

47

G

Sensor power supply
(Throttle position sensor)

[Ignition switch: ON]

82

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

DATA (DC Voltage)

Approximately 5V

[Engine is running]
Approximately 0V

[Ignition switch: ON]
83

B

Sensor ground
(APP sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

98

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Ignition switch: ON]

106

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

EC-728

3.9 — 4.7V

DTC P2138 APP SENSOR
[CR (WITHOUT EURO-OBD)]
RHD MODELS
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1535E

EC-729

DTC P2138 APP SENSOR
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

47

G

Sensor power supply
(Throttle position sensor)

[Ignition switch: ON]

82

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

DATA (DC Voltage)

Approximately 5V

[Engine is running]
Approximately 0V

[Ignition switch: ON]
83

B

Sensor ground
(APP sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

90

O

Sensor power supply
(APP sensor 1)

[Ignition switch: ON]

Approximately 5V

91

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

98

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Ignition switch: ON]

106

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

Diagnostic Procedure

BBS003BJ

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-730

3.

Body ground E28

DTC P2138 APP SENSOR
[CR (WITHOUT EURO-OBD)]

2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT
1.
2.

A

Disconnect accelerator pedal position (APP) sensor harness
connector.
Turn ignition switch ON.

EC

C

D
MBIB0285E

3.

Check voltage between APP sensor terminal 4 and ground with
CONSULT-II or tester.

E

Voltage: Approximately 5V
F

G

MBIB0304E

H

OK or NG
OK
>> GO TO 4.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 3.

I

3. DETECT MALFUNCTIONING PART

J

Check the following.
●
Harness connectors M1, E101
●
Harness connectors M8, M201
●
Harness for open or short between ECM and accelerator pedal position sensor

K

L

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I

M

Check voltage between APP sensor terminal 5 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 5.

MBIB0309E

EC-731

DTC P2138 APP SENSOR
[CR (WITHOUT EURO-OBD)]

5. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between APP sensor terminal 5 and ECM terminal 91.
Refer to Wiring Diagram.
Continuity should exist.

OK or NG
OK
>> GO TO 7.
NG (LHD models)>>Repair open circuit.
NG (RHD models)>>GO TO 6.

6. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M1, E101
●
Harness connectors M8, M201
●
Harness for open or short between accelerator pedal position sensor and ECM
>> Repair open circuit.

7. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III
Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

91

APP sensor terminal 5

EC-727

47

Electric throttle control actuator terminal 1

EC-720

OK or NG
OK
>> GO TO 8.
NG
>> Repair short to ground or short to power in harness or connectors.

8. CHECK THROTTLE POSITION SENSOR
Refer to EC-724, «Component Inspection» .
OK or NG
OK
>> GO TO 16.
NG
>> GO TO 9.

9. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .
>> INSPECTION END

EC-732

DTC P2138 APP SENSOR
[CR (WITHOUT EURO-OBD)]

10. CHECK APP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

A
Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 82 and APP sensor terminal 2, ECM terminal 83 and EC
APP sensor terminal 1.
Refer to Wiring Diagram.
C
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 12.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 11.

D

E

11. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M1, E101
●
Harness connectors M8, M201
●
Harness for open or short between ECM and accelerator pedal position sensor
>> Repair open circuit or short to ground or short to power in harness or connectors.

F

G

H

12. CHECK APP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 106 and APP sensor terminal 3, ECM terminal 98 and
APP sensor terminal 6.
Refer to Wiring Diagram.

I

J

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 14.
NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors.
NG (RHD models)>>GO TO 13.

13. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M1, E101
●
Harness connectors M8, M201
●
Harness for open or short between ECM and accelerator pedal position sensor
>> Repair open circuit or short to ground or short to power in harness or connectors.

14. CHECK APP SENSOR
Refer to EC-734, «Component Inspection» .
OK or NG
OK
>> GO TO 16.
NG
>> GO TO 15.

EC-733

K

L

M

DTC P2138 APP SENSOR
[CR (WITHOUT EURO-OBD)]

15. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace the accelerator pedal assembly.
Perform EC-486, «Accelerator Pedal Released Position Learning» .
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .
>> INSPECTION END

16. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS003BK

ACCELERATOR PEDAL POSITION SENSOR
1.
2.
3.

Reconnect all harness connectors disconnected.
Turn ignition switch ON.
Check voltage between ECM terminals 106 (APP sensor 1 signal), 98 (APP sensor 2 signal) and ground under the following
conditions.
Terminal

Accelerator pedal

Voltage

106
(Accelerator pedal position
sensor 1)

Fully released

0.6 — 0.9V

Fully depressed

3.9 — 4.7V

Fully released

0.3 — 0.6V

Fully depressed

1.95 — 2.4V

98
(Accelerator pedal position
sensor 2)

4.
5.
6.
7.

MBIB0023E

If NG, replace accelerator pedal assembly and go to the next
step.
Perform EC-486, «Accelerator Pedal Released Position Learning» .
Perform EC-486, «Throttle Valve Closed Position Learning» .
Perform EC-486, «Idle Air Volume Learning» .

Removal and Installation

BBS003BL

ACCELERATOR PEDAL
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

EC-734

ELECTRICAL LOAD SIGNAL
[CR (WITHOUT EURO-OBD)]

ELECTRICAL LOAD SIGNAL
Description

PFP:25350

A
BBS003D8

The electrical load signal (Headlamp switch signal, rear window defogger switch signal, etc.) is transferred
through the CAN communication line from IPDM E/R to ECM.
EC

CONSULT-II Reference Value in Data Monitor Mode

BBS003D9

Specification data are reference values.
MONITOR ITEM

LOAD SIGNAL

C
CONDITION

●

●

HEATER FAN SW

Ignition switch: ON

Engine: After warming up, idle the
engine

SPECIFICATION

Rear window defogger switch is ON and/or
lighting switch is 2nd.

ON

Rear window defogger switch is OFF and lighting switch is OFF.

OFF

Heater fan: Operating

ON

Heater fan: Not operating

OFF

Diagnostic Procedure

D

E

BBS003DA

F

1. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-I
1.
2.
3.

Turn ignition switch ON.
Connect CONSULT-II and select “DATA MONITOR” mode.
Select “LOAD SIGNAL” and check indication under the following
conditions.
Condition

G

H

Indication

Rear window defogger switch: ON

ON

Rear window defogger switch: OFF

OFF

I

OK or NG
OK
>> GO TO 2.
NG
>> GO TO 4.

J

PBIB0103E

K

2. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-II
Check “LOAD SIGNAL” indication under the following conditions.
Condition

L

Indication

Lighting switch: 2nd position

ON

Lighting switch: OFF

OFF

M

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 5.
PBIB0103E

EC-735

ELECTRICAL LOAD SIGNAL
[CR (WITHOUT EURO-OBD)]

3. CHECK HEATER FAN SIGNAL CIRCUIT OVERALL FUNCTION
With CONSULT-II
Check “HEATER FAN SW” in “DATA MONITOR” mode with CONSULT-II under the following conditions.
Condition

HEATER FAN SW

Heater fan control switch: ON

ON

Heater fan control switch: OFF

OFF

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.

PBIB1995E

4. CHECK REAR WINDOW DEFOGGER SYSTEM
Refer to GW-12, «REAR WINDOW DEFOGGER» .
>> INSPECTION END

5. CHECK HEADLAMP SYSTEM
Refer to LT-7, «HEADLAMP -CONVENTIONAL TYPE-» or LT-35, «HEADLAMP — DAYTIME LIGHT SYSTEM «.
>> INSPECTION END

6. CHECK HEATER FAN CONTROL SYSTEM
Refer to ATC-26, «TROUBLE DIAGNOSIS» or MTC-23, «TROUBLE DIAGNOSIS» .
>> INSPECTION END

EC-736

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[CR (WITHOUT EURO-OBD)]

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
Description

PFP:14920

A
BBS003CK

SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*1

Manifold absolute pressure sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Battery

Battery voltage*1

Throttle position sensor

Throttle position

Accelerator pedal position sensor

Accelerator pedal position

Heated oxygen sensors 1

Density of oxygen in exhaust gas
(Mixture ratio feedback signal)

Wheel sensor

Vehicle speed*2

ECM Function

Actuator

EC

C

EVAP canister
purge flow control

EVAP canister purge volume
control solenoid valve

D

E

F

*1: ECM determines the start signal status by the signals of engine speed and battery voltage.
*2: This signal is sent to the ECM through CAN communication line.

This system controls flow rate of fuel vapor from the EVAP canister. The opening of the vapor by-pass passage in the EVAP canister purge volume control solenoid valve changes to control the flow rate. The EVAP
canister purge volume control solenoid valve repeats ON/OFF operation according to the signal sent from the
ECM. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is
determined by considering various engine conditions. When the engine is operating, the flow rate of fuel vapor
from the EVAP canister is regulated as the air flow changes.

G

H

COMPONENT DESCRIPTION
I

The EVAP canister purge volume control solenoid valve uses a ON/
OFF duty to control the flow rate of fuel vapor from the EVAP canister. The EVAP canister purge volume control solenoid valve is
moved by ON/OFF pulses from the ECM. The longer the ON pulse,
the greater the amount of fuel vapor that will flow through the valve.

J

K

L
SEF337U

CONSULT-II Reference Value in Data Monitor Mode

BBS003CL

M

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

PURG VOL C/V

SPECIFICATION

Idle

0%

2,000 rpm

20 — 30%

EC-737

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003CM

MBWA1545E

EC-738

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
BATTERY VOLTAGE
(11 — 14V)

D
[Engine is running]
●

Idle speed

E
19

LG

EVAP canister purge
volume control solenoid
valve

PBIB0050E

F

Approximately 10V
[Engine is running]
●

G

Engine speed: About 2,000 rpm
(More than 100 seconds after starting engine)

PBIB0520E

[Engine is running]
[Ignition switch: OFF]
●

111

P

ECM relay
(Self shut-off)

[Ignition switch: OFF]
●

119
120

G
G

Power supply for ECM

For a few seconds after turning ignition switch
OFF

More than a few seconds passed after turning
ignition switch OFF

[Ignition switch: ON]

0 — 1.0V

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

H

I

J

K

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

L

M

EC-739

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[CR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS003CN

1. CHECK OVERALL FUNCTION
1.
2.
3.
4.

With CONSULT-II
Turn ignition switch OFF.
Disconnect the EVAP purge hose connected to the EVAP canister.
Turn ignition switch ON, and select “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II.
Start engine and let it idle.

PBIB0569E

5.

Change the valve opening percentage with touching “Qu” or
“Qd” on CONSULT-II screen, and check for vacuum existence at
the EVAP purge hose (2) under the following conditions.

–

: Vehicle front
EVAP canister (1)

–

Conditions
(PURG VOL CONT/V value)
0%

Vacuum
Should not exist

100%

Should exist
MBIB1497E

1.
2.
3.
4.
–
–

Without CONSULT-II
Turn ignition switch OFF.
Disconnect the EVAP purge hose connected to the EVAP canister.
Start engine and let it idle for at least 80 seconds.
Check for vacuum existence at the EVAP purge hose (2) under
the following conditions.
: Vehicle front
EVAP canister (1)
Conditions

At idle
Engine speed: About 2,000 rpm

Vacuum
Should not exist
Should exist

OK or NG
OK
>> GO TO 2.
NG
>> GO TO 3.

MBIB1497E

2. CHECK EVAP CANISTER
Refer to EC-472, «Component Inspection» .
OK or NG
OK
>> INSPECTION END
NG
>> Replace EVAP canister.

EC-740

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[CR (WITHOUT EURO-OBD)]

3. CHECK EVAP PURGE LINE

A

Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks or improper connection.
Refer to EC-469, «EVAPORATIVE EMISSION SYSTEM» .
OK or NG
OK
>> GO TO 4.
NG
>> Repair or reconnect the hose.

4. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIR-

EC

C

CUIT
1.
2.
3.

D

Turn ignition switch OFF.
Disconnect EVAP canister purge volume control solenoid valve
harness connector.
Turn ignition switch ON.

E

F

G
MBIB1076E

4.

H

Check voltage between EVAP canister purge volume control
solenoid valve terminal 1 and ground with CONSULT-II or tester.
Voltage: Battery voltage

I

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

J

K
PBIB0148E

5. DETECT MALFUNCTIONING PART

L

Check the following.
●
Harness connectors E48, F1
●
Harness for open or short between EVAP canister purge volume control solenoid valve and IPDM E/R
●
Harness for open or short between EVAP canister purge volume control solenoid valve and ECM
>> Repair harness or connectors.

EC-741

M

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[CR (WITHOUT EURO-OBD)]

6. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 19 and EVAP canister purge volume control solenoid
valve terminal 2. Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK (With CONSULT-II)>>GO TO 7.
OK (Without CONSULT-II)>>GO TO 8.
NG
>> Repair open circuit or short to ground and short to power in harness or connectors.

7. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION
With CONSULT-II
1. Reconnect all harness connectors disconnected.
2. Start engine.
3. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with
CONSULT-II. Check that engine speed varies according to the
valve opening.
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.

PBIB0569E

8. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
Refer to EC-743, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace EVAP canister purge volume control solenoid valve.

9. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-742

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[CR (WITHOUT EURO-OBD)]

Component Inspection

BBS003CO

A

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
With CONSULT-II
Check air passage continuity of EVAP canister purge volume control
solenoid valve under the following conditions.
Condition
(PURG VOL CONT/V value)

EC

Air passage continuity
between A and B

100%

Yes

0%

No

C

D

PBIB0149E

Without CONSULT-II
Check air passage continuity of EVAP canister purge volume control
solenoid valve under the following conditions.
Condition

Air passage continuity
between A and B

12V direct current supply between terminals 1 and 2

Yes

No supply

No

E

F

G

H
PBIB0150E

Removal and Installation

BBS003CP

I

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

J

K

L

M

EC-743

FUEL INJECTOR
[CR (WITHOUT EURO-OBD)]

FUEL INJECTOR
Component Description

PFP:16600
BBS003CS

The fuel injector is a small, precise solenoid valve. When the ECM
supplies a ground to the fuel injector circuit, the coil in the fuel injector is energized. The energized coil pulls the ball valve back and
allows fuel to flow through the fuel injector into the intake manifold.
The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the fuel injector remains
open. The ECM controls the injection pulse duration based on
engine fuel needs.

SEF375Z

CONSULT-II Reference Value in Data Monitor Mode

BBS003CT

Specification data are reference values.
MONITOR ITEM
B/FUEL SCHDL

CONDITION
●

See EC-532, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .

●

Engine: After warming up

●

Shift lever: Neutral

●

Air conditioner switch: OFF

●

No load

INJ PULSE-B1

SPECIFICATION

Idle

2.0 — 3.0 msec

2,000 rpm

1.9 — 2.9 msec

EC-744

FUEL INJECTOR
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003CU

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1538E

EC-745

FUEL INJECTOR
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)
BATTERY VOLTAGE

[Engine is running]

22
23
41
42

O
L
R
GR

●

Warm-up condition

●

Idle speed

(11 — 14V)

NOTE:
The pulse cycle changes depending on
rpm at idle.

Fuel injector No. 3
Fuel injector No. 1
Fuel injector No. 4
Fuel injector No. 2

PBIB0529E

BATTERY VOLTAGE
(11 — 14V)
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

PBIB0530E

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS003CV

1. INSPECTION START
Turn ignition switch to START.
Is any cylinder ignited?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.

EC-746

FUEL INJECTOR
[CR (WITHOUT EURO-OBD)]

2. CHECK OVERALL FUNCTION

A

With CONSULT-II
Start engine.
Perform “POWER BALANCE” in “ACTIVE TEST” mode with
CONSULT-II.
3. Make sure that each circuit produces a momentary engine
speed drop.
1.
2.

EC

C

D

E
MBIB0302E

Without CONSULT-II
1. Start engine.
2. Listen to each fuel injector operating sound.
Clicking noise should be heard.

F

G

H

I
PBIB1986E

J

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 3.

K

L

M

EC-747

FUEL INJECTOR
[CR (WITHOUT EURO-OBD)]

3. CHECK FUEL INJECTOR POWER SUPPLY CIRCUIT
1.
2.

Turn ignition switch OFF.
Disconnect fuel injector harness connector (1).

–

: Vehicle front
Turn ignition switch ON.

3.

MBIB1458E

4.

Check voltage between fuel injector terminal 1 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

PBIB0582E

4. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors E48, F1
●
10A fuse
●
Harness for open or short between fuel injector and fuse
●

>> Repair harness or connectors.

5. CHECK FUEL INJECTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between fuel injector terminal 2 and ECM terminals 22, 23, 41, 42.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK FUEL INJECTOR
Refer to EC-749, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace fuel injector.

EC-748

FUEL INJECTOR
[CR (WITHOUT EURO-OBD)]

7. CHECK INTERMITTENT INCIDENT

A

Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
EC

>> INSPECTION END

Component Inspection

BBS003CW

FUEL INJECTOR
1.
2.

C

Disconnect fuel injector harness connector.
Check resistance between terminals as shown in the figure.
Resistance: 10.4 — 15.3Ω [at 10 — 60°C (50 — 140°F)]

D

E

F
PBIB1727E

Removal and Installation

BBS003CX

G

FUEL INJECTOR
Refer to EM-32, «FUEL INJECTOR AND FUEL TUBE» .
H

I

J

K

L

M

EC-749

FUEL PUMP
[CR (WITHOUT EURO-OBD)]

FUEL PUMP
Description

PFP:17042
BBS003CY

SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*

Battery

Battery voltage*

ECM Function

Actuator

Fuel pump control

Fuel pump relay

*: ECM determines the start signal status by the signals of engine speed and battery voltage.

The ECM activates the fuel pump for several seconds after the ignition switch is turned on to improve engine
startability. If the ECM receives a engine speed signal from the crankshaft position sensor (POS) and camshaft position sensor (PHASE), it knows that the engine is rotating, and causes the pump to operate. If the
engine speed signal is not received when the ignition switch is ON, the engine stalls. The ECM stops pump
operation and prevents battery discharging, thereby improving safety. The ECM does not directly drive the fuel
pump. It controls the ON/OFF fuel pump relay, which in turn controls the fuel pump.
Condition

Fuel pump operation

Ignition switch is turned to ON.

Operates for 1 second.

Engine running and cranking

Operates.

When engine is stopped

Stops in 1.5 seconds.

Except as shown above

Stops.

COMPONENT DESCRIPTION
A turbine type design fuel pump is used in the fuel tank.

MBIB0291E

CONSULT-II Reference Value in Data Monitor Mode

BBS003CZ

Specification data are reference values.
MONITOR ITEM

FUEL PUMP RLY

CONDITION
●

For 1 second after turning ignition switch ON

●

Engine running or cranking

●

Except above conditions

SPECIFICATION
ON
OFF

EC-750

FUEL PUMP
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003D0

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1539E

EC-751

FUEL PUMP
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch: ON]
●

113

R

Fuel pump relay

For 1 second after turning ignition switch ON

0 — 1.0V

[Engine is running]
[Ignition switch: ON]
●

More than 1 second after turning ignition switch
ON

Diagnostic Procedure

BATTERY VOLTAGE
(11 — 14V)

BBS003D1

1. CHECK OVERALL FUNCTION
1.
2.

Turn ignition switch ON.
Pinch fuel feed hose (1) with two fingers.
Fuel pressure pulsation should be felt on the fuel hose for 1
second after ignition switch is turned ON.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

MBIB1496E

2. CHECK FUEL PUMP RELAY POWER SUPPLY CIRCUIT
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Turn ignition switch ON.
Check voltage between ECM terminals 113 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.

PBIB1187E

EC-752

FUEL PUMP
[CR (WITHOUT EURO-OBD)]

3. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-I

A

Check voltage between IPDM E/R terminal 69 and ground with
CONSULT-II or tester.
EC

Voltage: Battery voltage
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 11.

C

D
MBIB1445E

4. DETECT MALFUNCTIONING PART

E

Check harness for open or short between IPDM E/R and ECM
F

>> Repair harness or connectors.

5. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-I
1.
2.
3.
4.

G

Turn ignition switch OFF.
Reconnect all harness connectors disconnected.
Disconnect “fuel level sensor unit and fuel pump” harness connector.
Turn ignition switch ON.

H

I

J

MBIB0288E

5.

Check voltage between “Fuel level sensor unit and fuel pump”
terminal 1 and ground with CONSULT-II or tester.
Voltage:

L

Battery voltage should exist for 1 second
after ignition switch is turned ON.

M

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 6.

MBIB1446E

6. CHECK 15A FUSE
1. Turn ignition switch OFF.
2. Disconnect 15A fuse.
3. Check 15A fuse.
OK or NG
OK
>> GO TO 7.
NG
>> Replace fuse.

EC-753

K

FUEL PUMP
[CR (WITHOUT EURO-OBD)]

7. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-II
1.
2.

Disconnect IPDM E/R harness connector E10.
Check harness continuity between IPDM E/R terminal 20 and “fuel level sensor unit and fuel pump” terminal 1. Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 8.

8. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E101, M1
●
Harness connectors M72, B21
●
Harness for open or short between “fuel level sensor unit and fuel pump” and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

9. CHECK FUEL PUMP GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.

Turn ignition switch OFF.
Check harness continuity between “fuel level sensor unit and fuel pump” terminal 3 and ground.
Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 10.
NG
>> Repair open circuit or short to power in harness or connectors.

10. CHECK FUEL PUMP
Refer to EC-754, «Component Inspection» .
OK or NG
OK
>> GO TO 11.
NG
>> Replace “fuel level sensor unit and fuel pump”.

11. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connector.
>> INSPECTION END

Component Inspection

BBS003D2

FUEL PUMP
1.

Disconnect “fuel level sensor unit and fuel pump” harness connector.

EC-754

FUEL PUMP
[CR (WITHOUT EURO-OBD)]
2.

Check resistance between “fuel level sensor unit and fuel pump”
terminals 1 and 3.

A

Resistance: Approximately 0.2 — 5.0Ω [at 25°C (77°F)]
EC

C
MBIB0311E

D

Removal and Installation

BBS003D3

FUEL PUMP
Refer to FL-4, «FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY» .

E

F

G

H

I

J

K

L

M

EC-755

HO2S1
[CR (WITHOUT EURO-OBD)]

HO2S1
Component Description

PFP:22690
BBS003C3

The heated oxygen sensor 1 is placed into the exhaust manifold. It
detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.

SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

BBS003C4

Specification data are reference values.
MONITOR ITEM

CONDITION

0 — 0.3V ←→ Approx. 0.6 — 1.0V

HO2S1 (B1)
●

HO2S1 MNTR (B1)

SPECIFICATION

Engine: After warming up

Maintaining engine speed at 2,000 rpm

EC-756

LEAN ←→ RICH
Changes more than 5 times during
10 seconds.

HO2S1
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003C5

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1542E

EC-757

HO2S1
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Approximately 7.0V
[Engine is running]
24

Y

Heated oxygen sensor 1
heater

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

PBIB0519E

[Engine is running]
●

Engine speed: Above 3,600 rpm

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
35

BR

Heated oxygen sensor 1

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-758

Approximately 0V

HO2S1
[CR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS003C6

1. CHECK OVERALL FUNCTION

A

With CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Select “HO2S1 MNTR (B1)” in “DATA MONITOR” mode with CONSULT-II.
3. Keep the engine speed at 2,000 rpm under no load, and make
sure that the monitors fluctuates between LEAN and RICH more
than 5 times in 10 seconds.

EC

C

1 time: RICH → LEAN → RICH
2 times: RICH → LEAN → RICH → LEAN →RICH

D

E

SEF820Y

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Stop engine and wait at least 10 seconds.
3. Set ECM in Diagnostic test mode — II (Heated oxygen sensor 1 monitor).
Refer to EC-480, «HOW TO SWITCH DIAGNOSTIC TEST MODE» .
4. Keep the engine speed at 2,000 rpm under no load, and make
sure that the MI comes ON more than 5 times in 10 seconds.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

F

G

H

I

J

K
SAT652J

2. CHECK GROUND CONNECTIONS
1.
2.

L

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

M

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace ground connections.

EC-759

3.

Body ground E28

HO2S1
[CR (WITHOUT EURO-OBD)]

3. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Disconnect heated oxygen sensor 1 harness connector (1).
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 74 and HO2S1
terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

MBIB1494E

4. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 35 and HO2S1 terminal 4.
Refer to Wiring Diagram.
Continuity should exist.

2.

Check harness continuity between ECM terminal 35 or HO2S1 terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK HEATED OXYGEN SENSOR 1
Refer to EC-760, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 1.

6. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS003C7

HEATED OXYGEN SENSOR 1
With CONSULT-II
1.
2.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULTII.

EC-760

HO2S1
[CR (WITHOUT EURO-OBD)]
3.
4.
5.

Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch “RECORD” on CONSULT-II screen.

A

EC

C
MBIB0301E

D

6.

Check the following.
● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes
from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds.
5 times (cycles) are counted as shown in the figure.
● “HO2S1 (B1)” voltage goes above 0.6V at least once.
● “HO2S1 (B1)” voltage goes below 0.3V at least once.
● “HO2S1 (B1)” voltage never exceeds 1.0V.

E

F

G
SEF217YA

H

I

J

SEF648Y

CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

K

L

M

Without CONSULT-II
1.
2.
3.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 35 [HO2S1 (B1) signal] and ground.
Check the following with engine speed held at 2,000 rpm constant under no load.
● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
● The maximum voltage is over 0.6V at least one time.
● The minimum voltage is below 0.3V at least one time.
● The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V → 0 0.3V
MBIB0018E
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.

EC-761

HO2S1
[CR (WITHOUT EURO-OBD)]
●

Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

Removal and Installation

BBS003C8

HEATED OXYGEN SENSOR 1
Refer to EM-24, «EXHAUST MANIFOLD AND THREE WAY CATALYST» .

EC-762

HO2S1 HEATER
[CR (WITHOUT EURO-OBD)]

HO2S1 HEATER
Description

PFP:22690

A
BBS003BM

SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Camshaft position sensor (PHASE)
Crankshaft position sensor (POS)

Engine speed

Engine coolant temperature sensor

Engine coolant temperature

ECM Function

Actuator

Heated oxygen sensor 1
heater control

EC

Heated oxygen sensor 1
heater

The ECM performs ON/OFF duty control of the heated oxygen sensor 1 heater corresponding to the engine
speed and engine coolant temperature. The duty percent varies with engine coolant temperature when engine
is started.

C

D

OPERATION
Engine speed rpm

Heated oxygen sensor 1 heater

Above 3,600

OFF

Below 3,600 after warming up

ON

E

F

CONSULT-II Reference Value in Data Monitor Mode

BBS003BN

Specification data are reference values.
MONITOR ITEM

HO2S1 HTR (B1)

CONDITION
●

Engine: After warming up

●

Engine speed: Below 3,600 rpm

●

Engine speed: Above 3,600 rpm

SPECIFICATION

G

ON

H
OFF

I

J

K

L

M

EC-763

HO2S1 HEATER
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003BO

MBWA1542E

EC-764

HO2S1 HEATER
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
Approximately 7.0V
[Engine is running]

24

Y

Heated oxygen sensor 1 heater

D

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

E
PBIB0519E

[Engine is running]
●

Engine speed: Above 3,600 rpm

BATTERY VOLTAGE
(11 — 14V)

F

[Engine is running]
35

BR

74

B

Heated oxygen sensor 1
Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

G

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0V

H

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

I

Diagnostic Procedure

BBS003BP

1. CHECK OVERALL FUNCTION
1.
2.
3.
4.
5.
6.

J

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON.
Set tester prove between ECM terminal 24 (HO2S1 heater signal) and ground.
Start engine and let it idle.
Check the voltage under the following conditions.
Verify that the oscilloscope screen shows the signal waves as
shown below.
Conditions

K

L

M

Voltage
Approximately 7.0V

At idle

MBIB0038E
PBIB0519E

Engine speed: Above 3,600 rpm

BATTERY VOLTAGE
(11 — 14V)

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

EC-765

HO2S1 HEATER
[CR (WITHOUT EURO-OBD)]

2. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace ground connections.

3. CHECK HO2S1 POWER SUPPLY CIRCUIT
1.
2.

Disconnect heated oxygen sensor 1 harness connector (1).
Turn ignition switch ON.

MBIB1494E

3.

Check voltage between HO2S1 terminal 2 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

PBIA9576J

4. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors E48, F1
●
IPDM E/R connector E10
●
10A fuse
●
Harness for open or short between heated oxygen sensor 1 and fuse
●

>> Repair harness or connectors.

EC-766

HO2S1 HEATER
[CR (WITHOUT EURO-OBD)]

5. CHECK HO2S1 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 24 and HO2S1 terminal 3.
Refer to Wiring Diagram.

EC

Continuity should exist.

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D

6. CHECK HEATED OXYGEN SENSOR 1 HEATER

E

Refer to EC-767, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace heated oxygen sensor 1.

F

7. CHECK INTERMITTENT INCIDENT

G

Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
H

>> INSPECTION END

Component Inspection

BBS003BQ

HEATED OXYGEN SENSOR 1 HEATER
1.

I

Check resistance between HO2S1 terminals as follows.
Terminal No.

Resistance

2 and 3

3.3 — 4.4 Ω at 25°C (77°F)

1 and 2, 3, 4

∞Ω
(Continuity should not exist)

4 and 1, 2, 3

J

K

2. If NG, replace heated oxygen sensor 1.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped
from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system
threads using Oxygen Sensor Thread Cleaner and
approved anti-seize lubricant.

L

M

MBIB1306E

Removal and Installation

BBS003BR

HEATED OXYGEN SENSOR 1
Refer to EM-24, «EXHAUST MANIFOLD AND THREE WAY CATALYST» .

EC-767

HO2S2
[CR (WITHOUT EURO-OBD)]

HO2S2
Component Description

PFP:226A0
BBS003C9

The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas on each bank.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
SEF327R

CONSULT-II Reference Value in Data Monitor Mode

BBS003CA

Specification data are reference values.
MONITOR ITEM
HO2S2 (B1)

HO2S2 MNTR (B1)

CONDITION

SPECIFICATION

●

Revving engine from idle to 3,000 rpm quickly after the following conditions are met.

0 — 0.3V ←→ Approx. 0.6 — 1.0V

–

Engine: After warning up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute
and at idle for 1 minute under no load.

EC-768

LEAN ←→ RICH

HO2S2
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003CB

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1543E

EC-769

HO2S2
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]

2

GR

●

Engine speed: Below 3,800 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and
4,000 rpm for 1 minute and at idle for 1 minute
under no load.

Heated oxygen sensor 2
heater

0 — 1.0V

[Ignition switch: ON]
●

Engine stopped

[Engine is running]
●

BATTERY VOLTAGE
(11 — 14V)

Engine speed: Above 3,800 rpm

[Engine is running]

16

LG

Heated oxygen sensor 2

●

Revving engine from idle to 3,000rpm quickly
after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and
4,000 rpm for 1 minute and at idle for 1 minute
under no load.

0 — Approximately 1.0V

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

Diagnostic Procedure

Approximately 0V

BBS003CC

1. CHECK OVERALL FUNCTION-I
1.
2.
3.
4.
5.
6.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground.
Check the voltage while revving up to 4,000 rpm under no load
at least 10 times. (Depress and release the accelerator pedal as
quickly as possible.)
The voltage does not remain in the range of 0.2 — 0.4V

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

MBIB0020E

EC-770

HO2S2
[CR (WITHOUT EURO-OBD)]

2. CHECK OVERALL FUNCTION-II

A

Keep engine at idle for 10 minutes, then check the voltage between ECM terminal 16 and ground, or check
voltage when coasting 80 km/h (50 MPH) in 3rd gear position.
EC

The voltage does not remain in the range of 0.2 — 0.4V
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 3.

C

3. CHECK GROUND CONNECTIONS
1.
2.

D

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

E

F

G

H
MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

I

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace ground connections.

J

4. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT
1.

Disconnect heated oxygen sensor 2 harness connector (1).

–

: Vehicle front
Heated oxygen sensor 2 (2)
Oil pan (3)
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 74 and HO2S2
terminal 4. Refer to Wiring Diagram.

–
–

2.
3.

K

L

M

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-771

MBIB1459E

HO2S2
[CR (WITHOUT EURO-OBD)]

5. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 16 and HO2S2 terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

2.

Check harness continuity between ECM terminal 16 or HO2S2 terminal 1 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK HEATED OXYGEN SENSOR 2
Refer to EC-772, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace heated oxygen sensor 2.

7. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS003CD

HEATED OXYGEN SENSOR 2
With CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
SEF174Y

6.

Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select
“HO2S2 (B1)” as the monitor item with CONSULT-II.

SEF662Y

EC-772

HO2S2
[CR (WITHOUT EURO-OBD)]
7.

Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%.
A

EC

C

MBIB1402E

“HO2S2 (B1)” should be above 0.61V at least once when the “FUEL INJECTION” is +25%.
“HO2S2 (B1)” should be below 0.52V at least once when the “FUEL INJECTION” is −25%.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

D

E

F

Without CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground.
Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.61V at least once during this
procedure.
If the voltage is above 0.61V at step 6, step 7 is not necessary.
7. Keep vehicle idling for 10 minutes, then check voltage. Or check
the voltage when coasting from 80 km/h (50 MPH) in 3rd gear
position.
The voltage should be below 0.52V at least once during this
MBIB0020E
procedure.
8. If NG, replace heated oxygen sensor 2.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.

Removal and Installation

BBS003CE

HEATED OXYGEN SENSOR 2
Refer to EX-3, «EXHAUST SYSTEM» .

EC-773

G

H

I

J

K

L

M

HO2S2 HEATER
[CR (WITHOUT EURO-OBD)]

HO2S2 HEATER
Description

PFP:226A0
BBS003BS

SYSTEM DESCRIPTION
Sensor
Camshaft position sensor (PHASE)

Input Signal to ECM

ECM Function

Actuator

Engine speed

Crankshaft position sensor (POS)
Engine coolant temperature sensor

Engine coolant temperature

Manifold absolute pressure (MAP) sensor

Amount of intake air

Heated oxygen sensor 2
heater control

Heated oxygen sensor 2
heater

The ECM performs ON/OFF control of the heated oxygen sensor 2 heater corresponding to the engine speed,
amount of intake air and engine coolant temperature.

OPERATION
Engine speed rpm

Heated oxygen sensor 2 heater

Above 3,800

OFF

●

Below 3,800 rpm after the following conditions are met.

●

Engine: After warming up

●

Keeping the engine speed between 3,500 and 4,000 rpm for 1
minute and at idle for 1 minute under no load

ON

CONSULT-II Reference Value in Data Monitor Mode

BBS003BT

Specification data are reference values.
MONITOR ITEM

HO2S2 HTR (B1)

CONDITION
●

Engine speed: Below 3,800 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed at between 3,500 to 4,000 rpm for 1 minute
and at idle for 1 minute under no load

●

Engine speed: Above 3,800 rpm

SPECIFICATION

ON

OFF

EC-774

HO2S2 HEATER
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003BU

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1543E

EC-775

HO2S2 HEATER
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]

2

GR

●

Engine speed: Below 3,800 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and
4,000 rpm for 1 minute and at idle for 1 minute
under no load.

Heated oxygen sensor 2
heater

0 — 1.0V

[Ignition switch: ON]
●

Engine stopped

[Engine is running]
●

BATTERY VOLTAGE
(11 — 14V)

Engine speed: Above 3,800 rpm

[Engine is running]

16

LG

Heated oxygen sensor 2

●

Revving engine from idle to 3,000rpm quickly
after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and
4,000 rpm for 1 minute and at idle for 1 minute
under no load.

0 — Approximately 1.0V

[Engine is running]
74

B

Sensor ground
(Heated oxygen sensor)

●

Warm-up condition

●

Idle speed

Diagnostic Procedure

Approximately 0V

BBS003BV

1. CHECK OVERALL FUNCTION
1.
2.
3.
4.
5.
6.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter proves between ECM terminal 2 (HO2S2 heater signal) and ground.
Check the voltage under the following conditions.
Conditions

At idle
Engine speed: Above 3,800 rpm

Voltage
0 — 1V
Battery voltage

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
PBIB0673E

EC-776

HO2S2 HEATER
[CR (WITHOUT EURO-OBD)]

2. CHECK GROUND CONNECTIONS
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

EC

C

D

E
MBIB1502E

1.

Body ground E44

2.

Body ground E45

3.

Body ground E28

F

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace ground connections.

G

3. CHECK HO2S2 POWER SUPPLY CIRCUIT
1.

Disconnect heated oxygen sensor 2 harness connector (1).

H

–

: Vehicle front
Heated oxygen sensor 2 (2)
Oil pan (3)
Turn ignition switch ON.

I

–
–

2.

J

MBIB1459E

3.

Check voltage between HO2S2 terminal 2 and ground with
CONSULT-II or tester.

K

L

Voltage: Battery voltage
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

M

MBIB1442E

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F1
●
IPDM E/R connector E10
●
10A fuse
●
Harness for open or short between heated oxygen sensor 2 and fuse
>> Repair harness or connectors.

EC-777

HO2S2 HEATER
[CR (WITHOUT EURO-OBD)]

5. CHECK HO2S2 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 2 and HO2S2 terminal 3.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK HEATED OXYGEN SENSOR 2 HEATER
Refer to EC-778, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace heated oxygen sensor 2.

7. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS003BW

HEATED OXYGEN SENSOR 2 HEATER
1.

Check resistance between HO2S2 terminals as follows.
Terminal No.

Resistance

2 and 3

8.0 — 10.0 Ω at 25°C (77°F)

1 and 2, 3, 4

∞Ω
(Continuity should not exist)

4 and 1, 2, 3

2. If NG, replace heated oxygen sensor 2.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped
from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system
threads using Oxygen Sensor Thread Cleaner and
approved anti-seize lubricant.

SEF249Y

Removal and Installation

BBS003BX

HEATED OXYGEN SENSOR 2
Refer to EX-3, «EXHAUST SYSTEM» .

EC-778

IAT SENSOR
[CR (WITHOUT EURO-OBD)]

IAT SENSOR
Component Description

PFP:22630

A
BBS003BY

The intake air temperature sensor is built into manifold absolute
pressure sensor. The sensor detects intake air temperature and
transmits a signal to the ECM.
The temperature sensing unit uses a thermistor which is sensitive to
the change in temperature. Electrical resistance of the thermistor
decreases in response to the temperature rise.

EC

C

D
MBIB0276E

E

Intake air
temperature °C (°F)

Voltage*

V

Resistance

F

kΩ

25 (77)

3.32

1.9 — 2.1

80 (176)

1.23

0.31 — 0.37

G

*: This data is reference value and is measured between ECM terminal 34 (Intake air
temperature sensor) and ground.

CAUTION:
Do not use ECM ground terminals when measuring input/output
voltage. Doing so may result in damage to the ECM’s transistor.
Use a ground other than ECM terminals, such as the ground.

H
SEF012P

I

J

K

L

M

EC-779

IAT SENSOR
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003BZ

MBWA1544E

EC-780

IAT SENSOR
[CR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS003C0

1. CHECK OVERALL FUNCTION
1.
2.

A

Turn ignition switch ON.
Check voltage between ECM terminal 34 and ground with CONSULT-II or tester.

EC

Voltage: Approximately 0 — 4.8V

C

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

D

MBIB0041E

E

2. CHECK GROUND CONNECTIONS
1.
2.

F

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

G

H

I

J
MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace ground connections.

3.

Body ground E28

K

L

M

EC-781

IAT SENSOR
[CR (WITHOUT EURO-OBD)]

3. CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT
1.
2.

Disconnect manifold absolute pressure (MAP) sensor (with
intake air temperature sensor) harness connector.
Turn ignition switch ON.

MBIB0276E

3.

Check voltage between MAP sensor terminal 3 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 4.
NG
>> Repair harness or connectors.

MBIB0300E

4. CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between MAP sensor terminal 4 and ECM terminal 56.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK INTAKE AIR TEMPERATURE SENSOR
Refer to EC-783, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace manifold absolute pressure sensor (with intake air temperature sensor).

6. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-782

IAT SENSOR
[CR (WITHOUT EURO-OBD)]

Component Inspection

BBS003C1

A

INTAKE AIR TEMPERATURE SENSOR
1.

2.

Check resistance between manifold absolute pressure sensor
terminals 3 and 4 under the following conditions.
Intake air temperature °C (°F)

Resistance kΩ

25 (77)

1.9 — 2.1

EC

If NG, replace manifold absolute pressure sensor (with intake air
temperature sensor).

C

D
MBIB0276E

E

F

G

SEF012P

Removal and Installation

H

BBS003C2

MANIFOLD ABSOLUTE PRESSURE SENSOR
Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

I

J

K

L

M

EC-783

IGNITION SIGNAL
[CR (WITHOUT EURO-OBD)]

IGNITION SIGNAL
Component Description

PFP:22448
BBS003CF

IGNITION COIL & POWER TRANSISTOR
The ignition signal from the ECM is sent to and amplified by the
power transistor. The power transistor turns ON and OFF the ignition
coil primary circuit. This ON-OFF operation induces the proper high
voltage in the coil secondary circuit.

MBIB0272E

EC-784

IGNITION SIGNAL
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003CG

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1536E

EC-785

IGNITION SIGNAL
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION
[Engine is running]
[Ignition switch: OFF]
●

111

P

ECM relay
(Self shut-off)

[Ignition switch: OFF]
●

119
120

G
G

Power supply for ECM

For a few seconds after turning ignition
switch OFF

More than a few seconds passed after turning ignition switch OFF

[Ignition switch: ON]

EC-786

DATA (DC Voltage)

0 — 1.0V

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

IGNITION SIGNAL
[CR (WITHOUT EURO-OBD)]
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1537E

EC-787

IGNITION SIGNAL
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

[Engine is running]

60
61
79
80

Y
V
G
BR

●

Warm-up condition

●

Idle speed

DATA (DC Voltage)

0 — 0.1V

NOTE:
The pulse cycle changes depending on rpm
at idle.

Ignition signal No. 3
Ignition signal No. 1
Ignition signal No. 4
Ignition signal No. 2

PBIB0521E

0 — 0.2V
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

PBIB0522E

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS003CH

1. CHECK ENGINE START
Turn ignition switch OFF and restart engine.
Is engine running?
Yes or No
Yes (With CONSULT-II)>>GO TO 2.
Yes (Without CONSULT-II)>>GO TO 3.
No
>> GO TO 4.

2. CHECK OVERALL FUNCTION
With CONSULT-II
Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.
Make sure that each circuit produces a momentary engine
speed drop.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 10.
1.
2.

MBIB0302E

EC-788

IGNITION SIGNAL
[CR (WITHOUT EURO-OBD)]

3. CHECK OVERALL FUNCTION

A

Without CONSULT-II
Let engine idle.
Read the voltage signal between ECM terminals 60, 61, 79, 80
and ground with an oscilloscope.
3. Verify that the oscilloscope screen shows the signal wave as
shown in the figure.
NOTE:
The pulse cycle changes depending on rpm at idle.
1.
2.

EC

C

D

E
MBIB0033E

PBIB0521E

F

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 10.

G

4. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-I
1.
2.

Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Check voltage between ECM terminals 119, 120 and ground
with CONSULT-II or tester.

H

Voltage: Battery voltage

I

OK or NG
OK
>> GO TO 5.
NG
>> Go to EC-543, «POWER SUPPLY AND GROUND CIRCUIT» .

J

K
MBIB0034E

5. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-II
1.
2.
3.
4.

L

Turn ignition switch OFF.
Disconnect condenser harness connector.
Turn ignition switch ON.
Check voltage between condenser terminal 1 and ground with
CONSULT-II or tester.

M

Voltage: Battery voltage
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 6.

PBIB0624E

EC-789

IGNITION SIGNAL
[CR (WITHOUT EURO-OBD)]

6. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-III
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector.
Check harness continuity between condenser terminal 1 and IPDM terminal 33.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to power and short to ground.
OK or NG
OK
>> GO TO 15.
NG
>> GO TO 7.

7. DETECT MALFUNCTION PART
Check the following.
●
Harness connectors E48, F1
●
Harness for open or short between IPDM E/R and condenser
>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK CONDENSER GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.

Turn ignition switch OFF.
Check harness continuity between condenser terminal 2 and ground.
Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 9.
NG
>> Repair open circuit or short to power in harness or connector.

9. CHECK CONDENSER
Refer to EC-792, «Component Inspection» .
OK or NG
OK
>> GO TO 10.
NG
>> Replace condenser.

EC-790

IGNITION SIGNAL
[CR (WITHOUT EURO-OBD)]

10. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-V
1.
2.
3.
4.

A

Turn ignition switch OFF.
Reconnect all harness connectors disconnected.
Disconnect ignition coil harness connector.
Turn ignition switch ON.

EC

C

D

MBIB0272E

5.

Check voltage between ignition coil terminal 1 and ground with
CONSULT-II or tester.

E

F

Voltage: Battery voltage
OK or NG
OK
>> GO TO 12.
NG
>> GO TO 11.

G

H
SEF107S

I

11. DETECT MALFUNCTIONING PART
Check harness for open or short between ignition coil and harness connector F1.

J

>> Repair open circuit or short to ground or short to power in harness or connectors.

12. CHECK IGNITION COIL GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.

Turn ignition switch OFF.
Check harness continuity between ignition coil terminal 2 and ground.
Refer to Wiring Diagram.
Continuity should exist.

L

M

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 13.
NG
>> Repair open circuit or short to power in harness or connectors.

13. CHECK IGNITION COIL OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

K

Disconnect ECM harness connector.
Check harness continuity between ECM terminals 60, 61, 79, 80 and ignition coil terminal 3.
Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 14.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-791

IGNITION SIGNAL
[CR (WITHOUT EURO-OBD)]

14. CHECK IGNITION COIL WITH POWER TRANSISTOR
Refer to EC-792, «Component Inspection» .
OK or NG
OK
>> GO TO 15.
NG
>> Replace malfunctioning ignition coil with power transistor.

15. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace.

Component Inspection

BBS003CI

IGNITION COIL WITH POWER TRANSISTOR
CAUTION:
Do the following procedure in the place where ventilation is good without the combustible.
1. Turn ignition switch OFF.
2. Disconnect ignition coil harness connector.
3. Check resistance between ignition coil terminals as follows.
Terminal No.

Resistance Ω [at 25°C (77°F)]

2 and 3

Except 0 or ∞

1 and 2
1 and 3

4.
5.
6.
7.

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

Except 0

If NG, replace ignition coil with power transistor.
If OK, go to next step.
Turn ignition switch OFF.
Reconnect all harness connectors disconnected.
Remove fuel pump fuse in IPDM E/R to release fuel pressure.
NOTE:
Do not use CONSULT-II to release fuel pressure, or fuel pressure applies again during the following procedure.
Start engine.
After engine stalls, crank it two or three times to release all fuel
pressure.
Turn ignition switch OFF.
Remove ignition coil harness connectors to avoid the electrical
discharge from the ignition coils.
Remove ignition coil and spark plug of the cylinder to be
checked.
Crank engine for 5 seconds or more to remove combustion gas in the cylinder.
Connect spark plug and harness connector to ignition coil.

EC-792

MBIB0032E

MBIB0277E

IGNITION SIGNAL
[CR (WITHOUT EURO-OBD)]
15. Fix ignition coil using a rope etc. with gap of 13 — 17 mm
between the edge of the spark plug and grounded metal portion
as shown in the figure.
16. Crank engine for about 3 seconds, and check whether spark is
generated between the spark plug and the grounded part.

A

EC

Spark should be generated.
CAUTION:
● Do not approach to the spark plug and the ignition coil
within 50cm. Be careful not to get an electrical shock
while checking, because the electrical discharge voltage
PBIB2325E
becomes 20kV or more.
● If might cause to damage the ignition coil if the gap of more than 17 mm is taken.
NOTE:
When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning.
17. If NG, replace ignition coil with power transistor.

CONDENSER
1.
2.
3.

C

D

E

F

Turn ignition switch OFF.
Disconnect condenser harness connector.
Check resistance between condenser terminals 1 and 2.

G

Resistance: Above 1 MΩ at 25°C (77°F)
H

I

MBIB0031E

Removal and Installation

J

BBS003CJ

IGNITION COIL WITH POWER TRANSISTOR
Refer to EM-29, «IGNITION COIL» .

K

L

M

EC-793

REFRIGERANT PRESSURE SENSOR
[CR (WITHOUT EURO-OBD)]

REFRIGERANT PRESSURE SENSOR
Component Description

PFP:92136
BBS003D4

The refrigerant pressure sensor (1) is installed at the condenser of
the air conditioner system. The sensor uses an electrostatic volume
pressure transducer to convert refrigerant pressure to voltage. The
voltage signal is sent to ECM, and ECM controls cooling fan system.

MBIB1492E

PBIB2657E

EC-794

REFRIGERANT PRESSURE SENSOR
[CR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS003D5

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1540E

EC-795

REFRIGERANT PRESSURE SENSOR
[CR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

46

W

Sensor power supply
(Refrigerant pressure sensor)

57

Y

Sensor ground
(Refrigerant pressure sensor)

DATA (DC Voltage)

[Ignition switch: ON]

Approximately 5V

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
69

BR

●

Warm-up condition

●

Both A/C switch and blower fan switch: ON.

Refrigerant pressure sensor

1.0 — 4.0V

(Compressor operates.)

Diagnostic Procedure

BBS003D6

1. CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION
1.
2.
3.

Start engine and warm it up to normal operating temperature.
Turn A/C switch and blower fan switch ON.
Check voltage between ECM terminal 69 and ground with CONSULT-II or tester.
Voltage: 1.0 — 4.0V

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

MBIB0035E

2. CHECK GROUND CONNECTIONS
1.
2.
3.

Turn A/C switch and blower fan switch OFF.
Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-548, «Ground Inspection» .

MBIB1502E

1.

Body ground E44

2.

Body ground E45

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace ground connections.

EC-796

3.

Body ground E28

REFRIGERANT PRESSURE SENSOR
[CR (WITHOUT EURO-OBD)]

3. CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT
1.
2.

A

Disconnect refrigerant pressure sensor (1) harness connector.
Turn ignition switch ON.
EC

C

D
MBIB1492E

3.

E

Check voltage between refrigerant pressure sensor terminal 3
and ground with CONSULT-II or tester.
Voltage: Approximately 5V

F

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

G

SEF479Y

H

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F1
●
Harness for open or short between ECM and refrigerant pressure sensor

I

J

>> Repair harness or connectors.

5. CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 57 and refrigerant pressure sensor terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

6. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F1
●
Harness for open or short between ECM and refrigerant pressure sensor
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-797

K

L

M

REFRIGERANT PRESSURE SENSOR
[CR (WITHOUT EURO-OBD)]

7. CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 69 and refrigerant pressure sensor terminal 2.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.

8. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors E48, F1
●
Harness for open or short between ECM and refrigerant pressure sensor
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

9. CHECK INTERMITTENT INCIDENT
Refer to EC-542, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace refrigerant pressure sensor.
NG
>> Repair or replace.

Removal and Installation

BBS003D7

REFRIGERANT PRESSURE SENSOR
Refer to ATC-142, «Removal and Installation for Refrigerant Pressure Sensor» (Models with A/C) or MTC-88,
«Removal and Installation for Refrigerant Pressure Sensor» .

EC-798

VSS
[CR (WITHOUT EURO-OBD)]

VSS
Description

PFP:32702

A
BBS003CQ

The vehicle speed signal is sent to the combination meter from the “ABS actuator and electric unit (control
unit)” through CAN communication line. The combination meter then sends a signal to the ECM through CAN EC
communication line.

Diagnostic Procedure

BBS003CR

1. INSPECTION START

C

Do you have CONSULT-II?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.

D

E

2. CHECK OVERRALL FUNCTION
1.
2.
3.
4.
5.

Turn ignition switch OFF.
Lift up the vehicle.
Start engine and let it idle
Select “VHCL SPEED SE” in“DATA MONITOR” mode with
CONSULT-II.
Select “VHCL SPEED SE” indication when rotating wheels with
suitable gear position.

F

G

H

“VHCL SPEED SE” indication should
exceed 10km/h (6MPH).
I

OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 3.
PBIB0164E

J

3. CHECK DTC WITH “ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)”
Refer to BRC-8, «TROUBLE DIAGNOSIS»
(models with ESP).
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace.

(models without ESP) or BRC-49, «TROUBLE DIAGNOSIS»

K

L

4. CHECK COMBINATION METER

M

Check combination meter function.
Refer to DI-4, «COMBINATION METERS» .
>> INSPECTION END

EC-799

MI & DATA LINK CONNECTORS
[CR (WITHOUT EURO-OBD)]

MI & DATA LINK CONNECTORS
Wiring Diagram

PFP:24814
BBS003DB

MBWA1541E

EC-800

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR (WITHOUT EURO-OBD)]

SERVICE DATA AND SPECIFICATIONS (SDS)
Fuel Pressure

PFP:00030

A
BBS0048B

Approximately 350 kPa (3.5bar, 3.57kg/cm2 , 51psi)

Fuel pressure at idle

EC

Idle Speed

BBS0048C

Target idle speed

No load* (in Neutral position)

Air conditioner: ON

In Neutral position

650 ± 50 rpm

C

900 rpm or more

*: Under the following conditions:
●

Air conditioner switch: OFF

●

Electric load: OFF (Lights, heater fan & rear window defogger)

●

Steering wheel: Kept in straight-ahead position

D

Manifold Absolute Pressure Sensor

BBS0048E

Supply voltage

E

Approximately 5.0V

Output voltage at idle

F

1.4 – 1.5 V*

*: Engine is warmed up to normal operating temperature and running under no load.

Intake Air Temperature Sensor

BBS0048F

Temperature °C (°F)

G

Resistance kΩ

25 (77)

1.9 – 2.1

H

Engine Coolant Temperature Sensor
Temperature °C (°F)

BBS0048G

Resistance kΩ

20 (68)

2.1 – 2.9

50 (122)

0.68 – 1.00

90 (194)

0.236 – 0.260

Knock Sensor

I

J
BBS0048H

Resistance [at 20°C (68°F)]

Approximately 530 – 590kΩ

Crankshaft Position Sensor (POS)

K
BBS0048I

Refer to EC-615, «Component Inspection» .

L

Camshaft Position Sensor (PHASE)

BBS0048J

Refer to EC-622, «Component Inspection» .

M

Heated Oxygen Sensor 1 Heater

BBS0048K

Resistance [at 25°C (77°F)]

3.4 – 4.4Ω

Heated Oxygen Sensor 2 Heater

BBS0048L

Resistance [at 25°C (77°F)]

8.0 – 10.0Ω

Intake Valve Timing Control Solenoid Valve
Resistance [at 20°C (68°F)]

BBS0048M

6.7 – 7.7Ω

Throttle Control Motor

BBS0048N

Resistance [at 25°C (77°F)]

Approximately 1 – 15Ω

Fuel Injector

BBS0048O

Resistance [at 10 — 60°C (50 — 140°F)]

10.4 – 15.3Ω

EC-801

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR (WITHOUT EURO-OBD)]

Fuel Pump

BBS0048P

Resistance [at 25°C (77°F)]

Approximately 0.2 – 5.0Ω

EC-802

INDEX FOR DTC
[HR (WITH EURO-OBD)]

INDEX FOR DTC
DTC No. Index
[HR (WITH EURO-OBD)]

PFP:00024

A
BBS0048Q

NOTE:
●
If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC EC
U1000, U1001. Refer to EC-925, «DTC U1000, U1001 CAN COMMUNICATION LINE» .
●
If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer
to EC-928, «DTC U1010 CAN COMMUNICATION» .
C
DTC*1
CONSULT-II

Items
(CONSULT-II screen terms)

Reference page

2

ECM*3

U1000

1000*4

CAN COMM CIRCUIT

EC-925

U1001

1001*4

CAN COMM CIRCUIT

EC-925

U1010

1010

CONTROL UNIT(CAN)

EC-928

P0000

Flashing*5

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

EC-844

F

P0000

0000

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

—

G

P0011

0011

INT/V TIM CONT-B1

EC-930

P0102

0102

MAF SEN/CIRCUIT

EC-935

P0103

0103

MAF SEN/CIRCUIT

EC-935

P0112

0112

IAT SEN/CIRCUIT

EC-942

P0113

0113

IAT SEN/CIRCUIT

EC-942

P0117

0117

ECT SEN/CIRC

EC-947

P0118

0118

ECT SEN/CIRC

EC-947

P0122

0122

TP SEN 2/CIRC

EC-953

P0123

0123

TP SEN 2/CIRC

EC-953

P0132

0132

HO2S1 (B1)

EC-959

P0133

0133

HO2S1 (B1)

EC-967

P0134

0134

HO2S1 (B1)

EC-977

P0135

0135

HO2S1 HTR (B1)

EC-985

P0138

0138

HO2S2 (B1)

EC-991

P0139

0139

HO2S2 (B1)

EC-998

P0141

0141

HO2S2 HTR (B1)

EC-1006

P0171

0171

FUEL SYS-LEAN-B1

EC-1012

GST*

D

P0172

0172

FUEL SYS-RICH-B1

EC-1019

P0222

0222

TP SEN 1/CIRC

EC-1026

P0223

0223

TP SEN 1/CIRC

EC-1026

P0300

0300

MULTI CYL MISFIRE

EC-1032

P0301

0301

CYL 1 MISFIRE

EC-1032

P0302

0302

CYL 2 MISFIRE

EC-1032

P0303

0303

CYL 3 MISFIRE

EC-1032

P0304

0304

CYL 4 MISFIRE

EC-1032

P0327

0327

KNOCK SEN/CIRC-B1

EC-1038

P0328

0328

KNOCK SEN/CIRC-B1

EC-1038

P0335

0335

CKP SEN/CIRCUIT

EC-1042

EC-803

E

H

I

J

K

L

M

INDEX FOR DTC
[HR (WITH EURO-OBD)]
DTC*1
CONSULT-II

Items
(CONSULT-II screen terms)

3

Reference page

2

ECM*

P0340

0340

CMP SEN/CIRC-B1

EC-1049

P0420

0420

TW CATALYST SYS-B1

EC-1056

P0444

0444

PURG VOLUME CONT/V

EC-1063

P0500

0500

VEH SPEED SEN/CIRC*

6

EC-1070

P0605

0605

ECM

P0705

0705

PNP SW/CIRC

P0710

0710

ATF TEMP SEN/CIRC

GST*

EC-1072
AT-105
AT-110
6

P0720

0720

VEH SPD SEN/CIR AT*

AT-115

P0725

0725

ENGINE SPEED SIG

AT-121

P0731

0731

A/T 1ST GR FNCTN

AT-125

P0732

0732

A/T 2ND GR FNCTN

AT-129

P0733

0733

A/T 3RD GR FNCTN

AT-132

P0734

0734

A/T 4TH GR FNCTN

AT-136

P0740

0740

TCC SOLENOID/CIRC

AT-142

P0744

0744

A/T TCC S/V FNCTN

AT-147

P0745

0745

L/PRESS SOL/CIRC

AT-153

P0750

0750

SFT SOL A/CIRC

AT-159

P0755

0755

SFT SOL B/CIRC

AT-164
*7

P1065

1065

ECM BACK UP/CIRCUIT

EC-1075

P1111

1111

INT/V TIM V/CIR-B1

EC-1077

P1121

1121

ETC ACTR

EC-1082

P1122

1122

ETC FUNCTION/CIRC

EC-1084

P1124

1124

ETC MOT PWR

EC-1090

P1126

1126

ETC MOT PWR

EC-1090

P1128

1128

ETC MOT

EC-1096

P1143

1143

HO2S1 (B1)

EC-1101

P1144

1144

HO2S1 (B1)

EC-1107

P1146

1146

HO2S2 (B1)

EC-1113

P1147

1147

HO2S2 (B1)

EC-1121

P1212

1212

TCS/CIRC

EC-1129

P1217

1217

ENG OVER TEMP

EC-1130

P1225

1225

CTP LEARNING

EC-1146

P1226

1226

CTP LEARNING

EC-1148

P1229

1229

SENSOR POWER/CIRC

EC-1150

P1610 — P1615

1610 — 1615

P1705

NATS MALFUNCTION

BL-215

1705

TP SEN/CIRC A/T

AT-169

P1706

1706

P-N POS SW/CIRCUIT

EC-1158

P1760

1760

O/R CLTCH SOL/CIRC

AT-171

P1805

1805

BRAKE SW/CIRCUIT

EC-1167

P2122

2122

APP SEN 1/CIRC

EC-1172

P2123

2123

APP SEN 1/CIRC

EC-1172

P2127

2127

APP SEN 2/CIRC

EC-1181

EC-804

INDEX FOR DTC
[HR (WITH EURO-OBD)]
DTC*1
CONSULT-II

3

Items
(CONSULT-II screen terms)

Reference page

GST*2

ECM*

P2128

2128

APP SEN 2/CIRC

EC-1181

P2135

2135

TP SENSOR

EC-1191

P2138

2138

APP SENSOR

EC-1197

*1: 1st trip DTC No. is the same as DTC No.
*2: This number is prescribed by ISO 15031-5.
*3: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN.
*4: The troubleshooting for this DTC needs CONSULT-II.
*5: When engine is running, MI may flash. For details, refer to EC-844, «MI Flashing Without DTC» .
*6: When the fail-safe operations for both self-diagnoses occur, the MI illuminates.
*7:This self-diagnosis is not for ECM power supply circuit, even though “ECM BACK UP/CIRCUIT” is displayed on CONSULT-II screen.

A

EC

C

D

E

F

G

H

I

J

K

L

M

EC-805

INDEX FOR DTC
[HR (WITH EURO-OBD)]

Alphabetical Index

BBS0048R

NOTE:
●
If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC
U1000, U1001. Refer to EC-925, «DTC U1000, U1001 CAN COMMUNICATION LINE» .
●
If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer
to EC-928, «DTC U1010 CAN COMMUNICATION» .
Items
(CONSULT-II screen terms)

DTC*1
CONSULT-II
2

GST*

Reference page
ECM*3

A/T 1ST GR FNCTN

P0731

0731

AT-125

A/T 2ND GR FNCTN

P0732

0732

AT-129

A/T 3RD GR FNCTN

P0733

0733

AT-132

A/T 4TH GR FNCTN

P0734

0734

AT-136

A/T TCC S/V FNCTN

P0744

0744

AT-147

APP SEN 1/CIRC

P2122

2122

EC-1172

APP SEN 1/CIRC

P2123

2123

EC-1172

APP SEN 2/CIRC

P2127

2127

EC-1181

APP SEN 2/CIRC

P2128

2128

EC-1181

APP SENSOR

P2138

2138

EC-1197

ATF TEMP SEN/CIRC

P0710

0710

AT-110

BRAKE SW/CIRCUIT

P1805

1805

EC-1167

4

CAN COMM CIRCUIT

U1000

1000*

EC-925

CAN COMM CIRCUIT

U1001

1001*4

EC-925

CONTROL UNIT(CAN)

U1010

1010

EC-928

CKP SEN/CIRCUIT

P0335

0335

EC-1042

CMP SEN/CIRC-B1

P0340

0340

EC-1049

CTP LEARNING

P1225

1225

EC-1146

CTP LEARNING

P1226

1226

EC-1148

CYL 1 MISFIRE

P0301

0301

EC-1032

CYL 2 MISFIRE

P0302

0302

EC-1032

CYL 3 MISFIRE

P0303

0303

EC-1032

CYL 4 MISFIRE

P0304

0304

EC-1032

ECM

P0605

0605

EC-1072

ECM BACK UP/CIRCUIT*7

P1065

1065

EC-1075

ECT SEN/CIRC

P0117

0117

EC-947

ECT SEN/CIRC

P0118

0118

EC-947

ENG OVER TEMP

P1217

1217

EC-1130

ENGINE SPEED SIG

P0725

0725

AT-121

ETC ACTR

P1121

1121

EC-1082

ETC FUNCTION/CIRC

P1122

1122

EC-1084

ETC MOT

P1128

1128

EC-1096

ETC MOT PWR

P1124

1124

EC-1090

ETC MOT PWR

P1126

1126

EC-1090

FUEL SYS-LEAN-B1

P0171

0171

EC-1012

FUEL SYS-RICH-B1

P0172

0172

EC-1019

EC-806

INDEX FOR DTC
[HR (WITH EURO-OBD)]
DTC*1
Items
(CONSULT-II screen terms)

CONSULT-II

Reference page

GST*2

ECM*

HO2S1 (B1)

P0132

0132

EC-959

HO2S1 (B1)

P0133

0133

EC-967

HO2S1 (B1)

P0134

0134

EC-977

HO2S1 (B1)

P1143

1143

EC-1101

HO2S1 (B1)

P1144

1144

EC-1107

HO2S1 HTR (B1)

P0135

0135

EC-985

HO2S2 (B1)

P0138

0138

EC-991

HO2S2 (B1)

P0139

0139

EC-998

HO2S2 (B1)

P1146

1146

EC-1113

HO2S2 (B1)

P1147

1147

EC-1121

HO2S2 HTR (B1)

P0141

0141

EC-1006

IAT SEN/CIRCUIT

P0112

0112

EC-942

IAT SEN/CIRCUIT

P0113

0113

EC-942

INT/V TIM CONT-B1

P0011

0011

EC-930

INT/V TIM V/CIR-B1

P1111

1111

EC-1077

KNOCK SEN/CIRC-B1

P0327

0327

EC-1038

KNOCK SEN/CIRC-B1

P0328

0328

EC-1038

L/PRESS SOL/CIRC

P0745

0745

AT-153

MAF SEN/CIRCUIT

P0102

0102

EC-935

MAF SEN/CIRCUIT

P0103

0103

EC-935

MULTI CYL MISFIRE

P0300

0300

EC-1032

P1610 — P1615

1610 — 1615

BL-215

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

No DTC

Flashing*5

EC-844

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

P0000

0000

—

O/R CLTCH SOL/CIRC

P1760

1760

AT-171

P-N POS SW/CIRCUIT

P1706

1706

EC-1158

PNP SW/CIRC

P0705

0705

AT-105

PURG VOLUME CONT/V

P0444

0444

EC-1063

SENSOR POWER/CIRC

P1229

1229

EC-1150

SFT SOL A/CIRC

P0750

0750

AT-159

SFT SOL B/CIRC

P0755

0755

AT-164

TCC SOLENOID/CIRC

P0740

0740

AT-142

TCS/CIRC

P1212

1212

EC-1129

TP SEN 1/CIRC

P0222

0222

EC-1026

TP SEN 1/CIRC

P0223

0223

EC-1026

TP SEN 2/CIRC

P0122

0122

EC-953

TP SEN 2/CIRC

P0123

0123

EC-953

TP SENSOR

P2135

2135

EC-1191

TP SEN/CIRC A/T

P1705

1705

AT-169

TW CATALYST SYS-B1

P0420

0420

EC-1056

NATS MALFUNCTION

A

3

EC

C

D

E

F

G

H

I

J

K

L

EC-807

M

INDEX FOR DTC
[HR (WITH EURO-OBD)]
DTC*1
Items
(CONSULT-II screen terms)

CONSULT-II
2

GST*

Reference page
ECM*3

VEH SPD SEN/CIR AT*6

P0720

0720

AT-115

VEH SPEED SEN/CIRC*6

P0500

0500

EC-1070

*1: 1st trip DTC No. is the same as DTC No.
*2: This number is prescribed by ISO 15031-5.
*3: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN.
*4: The troubleshooting for this DTC needs CONSULT-II.
*5: When engine is running, MI may flash. For details, refer to EC-844, «MI Flashing Without DTC» .
*6: When the fail-safe operation for both self-diagnoses occur, the MI illuminates.
*7:This self-diagnosis is not for ECM power supply circuit, even though “ECM BACK UP/CIRCUIT” is displayed on CONSULT-II screen.

EC-808

PRECAUTIONS
[HR (WITH EURO-OBD)]

PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

A

BBS0048S

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along EC
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
C
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be perD
formed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
E
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
F

Maintenance Information

BBS005AS

If any of following part is replaced, always replace with new* one.
If it’s not (or fail to do so), the electrical system may not be operated properly.
*: New one means a virgin control unit that has never been energized on-board.

G

RHD MODELS

H

●
●
●
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM
IPDM E/R
Combination meter
EPS control unit

I

J

LHD MODELS
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM

Precautions for Procedures without Cowl Top Cover

K

L
BBS00583

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

M

PIIB3706J

On Board Diagnostic (OBD) System of Engine and A/T

BBS0048U

The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of
a malfunction causing emission deterioration.
CAUTION:
●
Be sure to turn the ignition switch OFF and disconnect the negative battery cable before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves,
etc. will cause the MI to light up.

EC-809

PRECAUTIONS
[HR (WITH EURO-OBD)]
●

●

●

●

●

Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)
Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to PG-88, «HARNESS CONNECTOR» .
Be sure to route and secure the harnesses properly after work. The interference of the harness
with a bracket, etc. may cause the MI to light up due to the short circuit.
Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MI to light up due to the malfunction of the fuel injection system, etc.
Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM and
TCM (Transmission control module) before returning the vehicle to the customer.

Precaution
●
●

●

●

BBS0048V

Always use a 12 volt battery as power source.
Do not attempt to disconnect battery cables while engine is
running.
Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect negative
battery cable. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned OFF.
Before removing parts, turn ignition switch OFF and then
disconnect negative battery cable.
SEF289H

●
●

●

–
–
–
–
–
–
●

–
–

Do not disassemble ECM.
If a battery cable is disconnected, the memory will return to
the ECM value.
The ECM will now start to self-control at its initial value.
Engine operation can vary slightly when the terminal is disconnected. However, this is not an indication of a malfunction. Do not replace parts because of a slight variation.
If the battery is disconnected, the following emissionrelated diagnostic information will be lost within 24 hours.
Diagnostic trouble codes
1st trip diagnostic trouble codes
Freeze frame data
1st trip freeze frame data
System readiness test (SRT) codes
Test values
When connecting ECM harness connector, fasten (B) it
securely with a lever (1) as far as it will go as shown in the
figure.
ECM (2)
Loosen (A)

PBIA9222J

PBIB2947E

EC-810

PRECAUTIONS
[HR (WITH EURO-OBD)]
●

●

●

●
●

●
●

●
●

●

●

When connecting or disconnecting pin connectors into or
from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.
Securely connect ECM harness connectors.
A poor connection can cause an extremely high (surge)
voltage to develop in coil and condenser, thus resulting in
damage to ICs.
Keep engine control system harness at least 10 cm (4 in)
away from adjacent harness, to prevent engine control system malfunctions due to receiving external noise, degraded
operation of ICs, etc.
Keep engine control system parts and harness dry.
Before replacing ECM, perform ECM Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-883, «ECM Terminals and Reference Value»
.
Handle mass air flow sensor carefully to avoid damage.
Do not clean mass air flow sensor with any type of detergent.
Do not disassemble electric throttle control actuator.
Even a slight leak in the air intake system can cause serious incidents.
Do not shock or jar the camshaft position sensor (PHASE),
crankshaft position sensor (POS).
After performing each TROUBLE DIAGNOSIS, perform DTC
Confirmation Procedure or Overall Function Check.
The DTC should not be displayed in the DTC Confirmation
Procedure if the repair is completed. The Overall Function
Check should be a good result if the repair is completed.

A

EC

C
PBIB0090E

D

E

F

G

MEF040D

H

I

J

K

SAT652J

L

M

EC-811

PRECAUTIONS
[HR (WITH EURO-OBD)]
●

●

When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact.
Accidental contact of probes will cause a short circuit and
damage the ECM power transistor.
Do not use ECM ground terminals when measuring input/
output voltage. Doing so may result in damage to the ECM’s
transistor. Use a ground other than ECM terminals, such as
the ground.

SEF348N

●
●

Do not operate fuel pump when there is no fuel in lines.
Tighten fuel hose clamps to the specified torque.

MBIB0291E

●
●

●

Do not depress accelerator pedal when starting.
Immediately after starting, do not rev up engine unnecessarily.
Do not rev up engine just prior to shutdown.

SEF709Y

●

–

–

–

When installing C.B. ham radio or a mobile phone, be sure
to observe the following as it may adversely affect electronic control systems depending on installation location.
Keep the antenna as far as possible from the electronic
control units.
Keep the antenna feeder line more than 20 cm (8 in) away
from the harness of electronic controls.
Do not let them run parallel for a long distance.
Adjust the antenna and feeder line so that the standingwave radio can be kept smaller.
SEF708Y

EC-812

PRECAUTIONS
[HR (WITH EURO-OBD)]
–

Be sure to ground the radio to vehicle body.
A

EC

C

D

E

F

G

H

I

J

K

L

M

EC-813

PREPARATION
[HR (WITH EURO-OBD)]

PREPARATION
Special Service Tools

PFP:00002
BBS0048W

Tool number
Tool name

Description

KV10117100
Heated oxygen
sensor wrench

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

S-NT379

KV10114400
Heated oxygen
sensor wrench

Loosening or tightening heated oxygen sensor
a: 22 mm (0.87 in)

S-NT636

EG17650301
Radiator cap tester
adapter

Adapting radiator cap tester to radiator cap and
radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
S-NT564

EG17550000
Break-out box

Measuring ECM signals with a circuit tester

ZZA1194D

EG17680000
Y-cable adapter

Measuring ECM signals with a circuit tester

PBIA9379J

KV10118400
Fuel tube adapter

Measuring fuel pressure

PBIB3043E

EC-814

PREPARATION
[HR (WITH EURO-OBD)]

Commercial Service Tools

BBS0048X

A
Tool name

Description

Quick connector
release

Removing fuel tube quick connectors in engine
room
(Available in SEC. 164 of PARTS CATALOG: Part
No. 16441 6N210)

EC

C
PBIC0198E

Fuel filler cap adapter

Checking fuel tank vacuum relief valve opening
pressure

D

E

S-NT653

Socket wrench

Removing and installing engine coolant
temperature sensor

F

G

H

S-NT705

Oxygen sensor thread
cleaner

Reconditioning the exhaust system threads
before installing a new oxygen sensor. Use with
anti-seize lubricant shown below.
a: 18 mm diameter with pitch 1.5 mm for
Zirconia Oxygen Sensor
b: 12 mm diameter with pitch 1.25 mm for
Titania Oxygen Sensor

J

Lubricating oxygen sensor thread cleaning tool
when reconditioning exhaust system threads.

K

I

AEM488

Anti-seize lubricant
i.e.: (PermatexTM
133AR or equivalent
meeting MIL
specification MIL-A907)

L
S-NT779

M

EC-815

ENGINE CONTROL SYSTEM
[HR (WITH EURO-OBD)]

ENGINE CONTROL SYSTEM
System Diagram

PFP:23710
BBS0048Y

MBIB1449E

EC-816

ENGINE CONTROL SYSTEM
[HR (WITH EURO-OBD)]

Multiport Fuel Injection (MFI) System

BBS0048Z

A

INPUT/OUTPUT SIGNAL CHART
Sensor
Crankshaft position sensor (POS)

Input Signal to ECM

Camshaft position sensor (PHASE)

Engine speed*3
Piston position

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Heated oxygen sensor 1

Density of oxygen in exhaust gas

Throttle position sensor

Throttle position

Accelerator pedal position sensor

Accelerator pedal position

Park/neutral position (PNP) switch

Gear position

Battery

Battery voltage*3

Knock sensor

Engine knocking condition

EPS control unit

Power steering operation*2

Heated oxygen sensor 2*1

Density of oxygen in exhaust gas

Air conditioner switch

Air conditioner operation*2

Wheel sensor

Vehicle speed*2

ECM function

Actuator

EC

C

D
Fuel injection
& mixture ratio
control

Fuel injector

*1: This sensor is not used to control the engine system under normal conditions.
*2: This signal is sent to the ECM through CAN communication line.
*3: ECM determines the start signal status by the signals of engine speed and battery voltage.

E

F

G

H

SYSTEM DESCRIPTION
The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of
time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the
ECM memory. The program value is preset by engine operating conditions. These conditions are determined
by input signals (for engine speed and intake air) from the crankshaft position sensor (POS), camshaft position
sensor (PHASE) and the mass air flow sensor.

I

J

VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION
In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below.

●
During warm-up
●
When starting the engine
●
During acceleration
●
Hot-engine operation
●
When shift lever is changed from N to D (A/T models)
●
High-load, high-speed operation

●
During deceleration
●
During high engine speed operation

EC-817

K

L

M

ENGINE CONTROL SYSTEM
[HR (WITH EURO-OBD)]
MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL)

PBIB2953E

The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control.
The three way catalyst (manifold) can then better reduce CO, HC and NOx emissions. This system uses
heated oxygen sensor 1 in the exhaust manifold to monitor whether the engine operation is rich or lean. The
ECM adjusts the injection pulse width according to the sensor voltage signal. For more information about
heated oxygen sensor 1, refer to EC-967, «DTC P0133 HO2S1» . This maintains the mixture ratio within the
range of stoichiometric (ideal air-fuel mixture).
This stage is referred to as the closed loop control condition.
Heated oxygen sensor 2 is located downstream of the three way catalyst (manifold). Even if the switching
characteristics of heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal
from heated oxygen sensor 2.

Open Loop Control
The open loop system condition refers to when the ECM detects any of the following conditions. Feedback
control stops in order to maintain stabilized fuel combustion.
●
Deceleration and acceleration
●
High-load, high-speed operation
●
Malfunction of heated oxygen sensor 1 or its circuit
●
Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature
●
High engine coolant temperature
●
During warm-up
●
After shifting from N to D (A/T models)
●
When starting the engine

MIXTURE RATIO SELF-LEARNING CONTROL
The mixture ratio feedback control system monitors the mixture ratio signal transmitted from heated oxygen
sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to
the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. Both manufacturing differences (i.e., mass air flow sensor hot wire) and characteristic
changes during operation (i.e., fuel injector clogging) directly affect mixture ratio.
Accordingly, the difference between the basic and theoretical mixture ratios is monitored in this system. This is
then computed in terms of “injection pulse duration” to automatically compensate for the difference between
the two ratios.
“Fuel trim” refers to the feedback compensation value compared against the basic injection duration. Fuel trim
includes short term fuel trim and long term fuel trim.
“Short term fuel trim” is the short-term fuel compensation used to maintain the mixture ratio at its theoretical
value. The signal from heated oxygen sensor 1 indicates whether the mixture ratio is RICH or LEAN compared
to the theoretical value. The signal then triggers a reduction in fuel volume if the mixture ratio is rich, and an
increase in fuel volume if it is lean.
“Long term fuel trim” is overall fuel compensation carried out long-term to compensate for continual deviation
of the short term fuel trim from the central value. Such deviation will occur due to individual engine differences,
wear over time and changes in the usage environment.

EC-818

ENGINE CONTROL SYSTEM
[HR (WITH EURO-OBD)]
FUEL INJECTION TIMING
A

EC

C

SEF337W

D

Two types of systems are used.

Sequential Multiport Fuel Injection System
Fuel is injected into each cylinder during each engine cycle according to the firing order. This system is used
when the engine is running.

Simultaneous Multiport Fuel Injection System
Fuel is injected simultaneously into all four cylinders twice each engine cycle. In other words, pulse signals of
the same width are simultaneously transmitted from the ECM.
The four fuel injectors will then receive the signals two times for each engine cycle.
This system is used when the engine is being started and/or if the fail-safe system (CPU) is operating.

E

F

G

FUEL SHUT-OFF
Fuel to each cylinder is cut off during deceleration, operation of the engine at excessively high speeds or operation of the vehicle at excessively high speeds.

Electronic Ignition (EI) System

BBS00490

INPUT/OUTPUT SIGNAL CHART
Sensor
Crankshaft position sensor (POS)

I
Input Signal to ECM

Camshaft position sensor (PHASE)

Engine speed*2
Piston position

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Throttle position sensor

Throttle position

Accelerator pedal position sensor

Accelerator pedal position

Battery

Battery voltage*2

Knock sensor

Engine knocking

Park/neutral position (PNP) switch

Gear position

Wheel sensor

H

ECM function

Actuator

J

K
Ignition timing
control

Power transistor

L

M
1

Vehicle speed*

*1: This signal is sent to the ECM through CAN communication line.
*2: ECM determines the start signal status by the signals of engine speed and battery voltage.

SYSTEM DESCRIPTION
Firing order: 1 — 3 — 4 — 2
The ignition timing is controlled by the ECM to maintain the best air-fuel ratio for every running condition of the
engine. The ignition timing data is stored in the ECM.
The ECM receives information such as the injection pulse width and camshaft position sensor (PHASE) signal. Computing this information, ignition signals are transmitted to the power transistor.
During the following conditions, the ignition timing is revised by the ECM according to the other data stored in
the ECM.
●
At starting
●
During warm-up
●
At idle
●
At low battery voltage

EC-819

ENGINE CONTROL SYSTEM
[HR (WITH EURO-OBD)]
●
During acceleration
The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed
within the anti-knocking zone, if recommended fuel is used under dry conditions. The retard system does not
operate under normal driving conditions. If engine knocking occurs, the knock sensor monitors the condition.
The signal is transmitted to the ECM. The ECM retards the ignition timing to eliminate the knocking condition.

Fuel Cut Control (at No Load and High Engine Speed)

BBS00491

INPUT/OUTPUT SIGNAL CHART
Sensor

Input Signal to ECM

Park/neutral position (PNP) switch

Neutral position

Accelerator pedal position sensor

Accelerator pedal position

Engine coolant temperature sensor

Engine coolant temperature

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed

Wheel sensor

Vehicle speed*

ECM function

Fuel cut control

Actuator

Fuel injector

*: This signal is sent to the ECM through CAN communication line.

SYSTEM DESCRIPTION
If the engine speed is above 2,500 rpm under no load (for example, the shift lever position is neutral and
engine speed is over 2,500 rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies based on engine speed.
Fuel cut will be operated until the engine speed reaches 2,000 rpm, then fuel cut will be cancelled.
NOTE:
This function is different from deceleration control listed under EC-817, «Multiport Fuel Injection (MFI) System»
.

EC-820

AIR CONDITIONING CUT CONTROL
[HR (WITH EURO-OBD)]

AIR CONDITIONING CUT CONTROL
Input/Output Signal Chart
Sensor

PFP:23710

A
BBS00492

Input Signal to ECM

Air conditioner switch

Air conditioner ON signal*

Accelerator pedal position sensor

Accelerator pedal position

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*2

Engine coolant temperature sensor

Engine coolant temperature

Battery

Battery voltage*2

Refrigerant pressure sensor

Refrigerant pressure

EPS control unit

Power steering operation*1

Wheel sensor

ECM function

Actuator

EC

1

C
Air conditioner
cut control

Air conditioner relay

D

E

1

Vehicle speed*

*1: This signal is sent to the ECM through CAN communication line.
*2: ECM determines the start signal status by the signals of engine speed and battery voltage.

System Description

F
BBS00493

This system improves engine operation when the air conditioner is used.
Under the following conditions, the air conditioner is turned OFF.
●
When the accelerator pedal is fully depressed.
●
When cranking the engine.
●
At high engine speeds.
●
When the engine coolant temperature becomes excessively high.
●
When operating power steering during low engine speed or low vehicle speed.
●
When engine speed is excessively low.
●
When refrigerant pressure is excessively low or high.

G

H

I

J

K

L

M

EC-821

CAN COMMUNICATION
[HR (WITH EURO-OBD)]

CAN COMMUNICATION
System Description

PFP:23710
BBS00494

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
Refer to LAN-21, «CAN COMMUNICATION» , about CAN communication for detail.

EC-822

EVAPORATIVE EMISSION SYSTEM
[HR (WITH EURO-OBD)]

EVAPORATIVE EMISSION SYSTEM
Description

PFP:14950

A
BBS00495

SYSTEM DESCRIPTION
EC

C

D

E

F

G
PBIB3039E

The evaporative emission system is used to reduce hydrocarbons emitted into the atmosphere from the fuel
system. This reduction of hydrocarbons is accomplished by activated charcoals in the EVAP canister.
The fuel vapor in the sealed fuel tank is led into the EVAP canister which contains activated carbon and the
vapor is stored there when the engine is not operating or when refueling to the fuel tank.
The vapor in the EVAP canister is purged by the air through the purge line to the intake manifold when the
engine is operating. EVAP canister purge volume control solenoid valve is controlled by ECM. When the
engine operates, the flow rate of vapor controlled by EVAP canister purge volume control solenoid valve is
proportionally regulated as the air flow increases.
EVAP canister purge volume control solenoid valve also shuts off the vapor purge line during decelerating.

H

I

J

K

L

M

EC-823

EVAPORATIVE EMISSION SYSTEM
[HR (WITH EURO-OBD)]
EVAPORATIVE EMISSION LINE DRAWING

PBIB2946E

: Vehicle front
1.

Intake manifold

: From next page
2.

EVAP canister purge volume control
solenoid valve

3.

EVAP purge resonator

NOTE:
Do not use soapy water or any type of solvent while installing vacuum hose or purge hoses.

EC-824

EVAPORATIVE EMISSION SYSTEM
[HR (WITH EURO-OBD)]
A

EC

C

D

E

F

G

H

MBIB1450E

: Vehicle front
1.

: To previous page

I

EVAP canister

J

K

L

M

EC-825

EVAPORATIVE EMISSION SYSTEM
[HR (WITH EURO-OBD)]

Component Inspection

BBS00496

EVAP CANISTER
Check EVAP canister as follows:
1. Block port (B).
2. Blow air into port (A) and check that it flows freely out of port (C).
3. Release blocked port (B).
4. Apply vacuum pressure to port (B) and check that vacuum pressure exists at the ports (A) and (C).
5. Block port (A) and (B).
6. Apply pressure to port (C) and check that there is no leakage.
PBIB2961E

FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP)
1.

Wipe clean valve housing.

SEF989X

2.

Check valve opening pressure and vacuum.
Pressure:
Vacuum:

3.

15.3 — 20.0 kPa (0.153 — 0.200 bar,
0.156 — 0.204 kg/cm2 , 2.22 — 2.90 psi)
−6.0 to −3.3 kPa (−0.060 to −0.034 bar,
−0.061 to −0.035 kg/cm2 , −0.87 to −0.49 psi)

If out of specification, replace fuel filler cap as an assembly.

SEF943S

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
Refer to EC-1063, «DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE» .

EC-826

NATS (NISSAN ANTI-THEFT SYSTEM)
[HR (WITH EURO-OBD)]

NATS (NISSAN ANTI-THEFT SYSTEM)
Description
●

●

●

PFP:25386

A
BBS00497

If the security indicator lights up with the ignition switch in
the ON position or “NATS MALFUNCTION” is displayed on
EC
“SELF-DIAG RESULTS” screen, perform self-diagnostic
results mode with CONSULT-II using NATS program card.
Refer to BL-215, «NATS (Nissan Anti-Theft System)» .
C
Confirm no self-diagnostic results of NATS is displayed
before touching “ERASE” in “SELF-DIAG RESULTS” mode
with CONSULT-II.
D
When replacing ECM, initialization of NATS system and registration of all NATS ignition key IDs must be carried out
SEF515Y
with CONSULT-II using NATS program card.
Therefore, be sure to receive all keys from vehicle owner.
E
Regarding the procedures of NATS initialization and all NATS ignition key ID registration, refer to
CONSULT-II operation manual, NATS.
F

G

H

I

J

K

L

M

EC-827

POSITIVE CRANKCASE VENTILATION
[HR (WITH EURO-OBD)]

POSITIVE CRANKCASE VENTILATION
Description

PFP:11810
BBS00498

SYSTEM DESCRIPTION

PBIB2962E

This system returns blow-by gas to the intake manifold.
The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake
manifold.
During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the PCV
valve.
Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air.
The ventilating air is then drawn from the air inlet tubes into the crankcase. In this process the air passes
through the hose connecting air inlet tubes to rocker cover.
Under full-throttle condition, the manifold vacuum is insufficient to draw the blow-by flow through the valve.
The flow goes through the hose connection in the reverse direction.
On vehicles with an excessively high blow-by, the valve does not
meet the requirement. This is because some of the flow will go
through the hose connection to the air inlet tubes under all conditions.

PBIB1588E

Component Inspection

BBS00499

PCV (POSITIVE CRANKCASE VENTILATION) VALVE
With engine running at idle, remove PCV valve from rocker cover. A
properly working valve makes a hissing noise as air passes through
it. A strong vacuum should be felt immediately when a finger is
placed over valve inlet.

PBIB1589E

EC-828

POSITIVE CRANKCASE VENTILATION
[HR (WITH EURO-OBD)]
PCV VALVE VENTILATION HOSE
1.
2.

A

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

EC

C

S-ET277

D

E

F

G

H

I

J

K

L

M

EC-829

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]

ON BOARD DIAGNOSTIC (OBD) SYSTEM
Introduction

PFP:00028
BBS0049A

The ECM has an on board diagnostic system, which detects malfunctions related to engine sensors or actuators. The ECM also records various emission-related diagnostic information including:
Emission-related diagnostic information

Diagnostic service

Diagnostic Trouble Code (DTC)

Service $03 of ISO 15031-5

Freeze Frame data

Service $02 of ISO 15031-5

System Readiness Test (SRT) code

Service $01 of ISO 15031-5

1st Trip Diagnostic Trouble Code (1st Trip DTC)

Service $07 of ISO 15031-5

1st Trip Freeze Frame data
Test values and Test limits

Service $06 of ISO 15031-5

The above information can be checked using procedures listed in the table below.

×: Applicable

—: Not applicable

DTC

1st trip DTC

Freeze Frame
data

1st trip Freeze
Frame data

SRT code

Test value

CONSULT-II

×

×

×

×

×

—

GST

×

×

×

—

×

×

ECM

×

×*

—

—

—

—

*: When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other.

The malfunction indicator (MI) on the instrument panel lights up when the same malfunction is detected in two
consecutive trips (Two trip detection logic), or when the ECM enters fail-safe mode. (Refer to EC-870, «FailSafe Chart» .)

Two Trip Detection Logic

BBS0049B

When a malfunction is detected for the first time, 1st trip DTC and 1st trip Freeze Frame data are stored in the
ECM memory. The MI will not light up at this stage. <1st trip>
If the same malfunction is detected again during the next drive, the DTC and Freeze Frame data are stored in
the ECM memory, and the MI lights up. The MI lights up at the same time when the DTC is stored. <2nd trip>
The “trip” in the “Two Trip Detection Logic” means a driving mode in which self-diagnosis is performed during
vehicle operation. Specific on board diagnostic items will cause the ECM to light up or blink the MI, and store
DTC and Freeze Frame data, even in the 1st trip, as shown below.
×: Applicable

MI

DTC

1st trip

Items

2nd trip

—: Not applicable
1st trip DTC

1st trip
displaying

2nd trip
displaying

1st trip
displaying

2nd trip
displaying

—

—

—

×

—

×

—

—

×

—

—

×

—

—

×

—

—

—

—

—

×

—

×

×

—

Blinking

Lighting
up

Blinking

Lighting
up

Misfire (Possible three way catalyst damage) — DTC: P0300 P0304 is being detected

×

—

—

Misfire (Possible three way catalyst damage) — DTC: P0300 P0304 is being detected

—

—

One trip detection diagnoses
(Refer to EC-831, «EMISSIONRELATED DIAGNOSTIC INFORMATION ITEMS» .)

—

Except above

—

When there is an open circuit on MI circuit, the ECM cannot warn the driver by lighting up MI when there is
malfunction on engine control system.
Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as
NG for 5 trips, ECM warns the driver that engine control system malfunctions and MI circuit is open by means
of operating fail-safe function.

EC-830

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
The fail-safe function also operates when above diagnoses except MI circuit are detected and demands the
driver to repair the malfunction.
Engine operating condition in fail-safe mode

Engine speed will not rise more than 2,500 rpm due to the fuel cut

Emission-related Diagnostic Information

BBS0049C

EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS
DTC*
Items
(CONSULT-II screen terms)

CONSULT-II
GST*2

1

EC

×:Applicable —: Not applicable

SRT code

Test value/
Test limit
(GST only)

Trip

MI

Reference
page

C

D

ECM*3

U1000

1000*4

—

—

1

×

EC-925

CAN COMM CIRCUIT

U1001

4

1001*

—

—

2

—

EC-925

CONTROL UNIT(CAN)

U1010

1010

—

—

1 (A/T)
2 (M/T)

× (A/T)
— (M/T)

EC-928

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

P0000

0000

—

—

—

Flashing*5

EC-844

INT/V TIM CONT-B1

P0011

0011

—

—

2

—

EC-930

MAF SEN/CIRCUIT

P0102

0102

—

—

1

×

EC-935

MAF SEN/CIRCUIT

P0103

0103

—

—

1

×

EC-935

IAT SEN/CIRCUIT

P0112

0112

—

—

2

×

EC-942

IAT SEN/CIRCUIT

P0113

0113

—

—

2

×

EC-942

ECT SEN/CIRC

P0117

0117

—

—

1

×

EC-947

ECT SEN/CIRC

P0118

0118

—

—

1

×

EC-947

TP SEN 2/CIRC

P0122

0122

—

—

1

×

EC-953

TP SEN 2/CIRC

P0123

0123

—

—

1

×

EC-953

HO2S1 (B1)

P0132

0132

—

×

2

×

EC-959

HO2S1 (B1)

P0133

0133

×

×

2

×

EC-967

HO2S1 (B1)

P0134

0134

—

×

2

×

EC-977

HO2S1 HTR (B1)

P0135

0135

×

×

2

×

EC-985

HO2S2 (B1)

P0138

0138

—

×

2

×

EC-991

HO2S2 (B1)

P0139

0139

×

×

2

×

EC-998

HO2S2 HTR (B1)

P0141

0141

×

×

2

×

EC-1006

FUEL SYS-LEAN-B1

P0171

0171

—

—

2

×

EC-1012

FUEL SYS-RICH-B1

P0172

0172

—

—

2

×

EC-1019

TP SEN 1/CIRC

P0222

0222

—

—

1

×

EC-1026

TP SEN 1/CIRC

P0223

0223

—

—

1

×

EC-1026

MULTI CYL MISFIRE

P0300

0300

—

—

2

×

EC-1032

CYL 1 MISFIRE

P0301

0301

—

—

2

×

EC-1032

CYL 2 MISFIRE

P0302

0302

—

—

2

×

EC-1032

CYL 3 MISFIRE

P0303

0303

—

—

2

×

EC-1032

CAN COMM CIRCUIT

A

F

CYL 4 MISFIRE

P0304

0304

—

—

2

×

EC-1032

KNOCK SEN/CIRC-B1

P0327

0327

—

—

2

—

EC-1038

KNOCK SEN/CIRC-B1

P0328

0328

—

—

2

—

EC-1038

CKP SEN/CIRCUIT

P0335

0335

—

—

2

×

EC-1042

CMP SEN/CIRC-B1

P0340

0340

—

—

2

×

EC-1049

TW CATALYST SYS-B1

P0420

0420

×

×

2

×

EC-1056

PURG VOLUME CONT/V

P0444

0444

—

—

2

×

EC-1063

EC-831

E

G

H

I

J

K

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M

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
DTC*1
Items
(CONSULT-II screen terms)

CONSULT-II

SRT code

Test value/
Test limit
(GST only)

Trip

MI

Reference
page

3

GST*2

ECM*

VEH SPEED SEN/CIRC*6

P0500

0500

—

—

2

×

EC-1070

ECM

P0605

0605

—

—

1 or 2

× or —

EC-1072

PNP SW/CIRC

P0705

0705

—

—

2

×

AT-105

ATF TEMP SEN/CIRC

P0710

0710

—

—

2

×

AT-110

VEH SPD SEN/CIR AT*6

P0720

0720

—

—

2

×

AT-115

ENGINE SPEED SIG

P0725

0725

—

—

2

×

AT-121

A/T 1ST GR FNCTN

P0731

0731

—

—

2

×

AT-125

A/T 2ND GR FNCTN

P0732

0732

—

—

2

×

AT-129

A/T 3RD GR FNCTN

P0733

0733

—

—

2

×

AT-132

A/T 4TH GR FNCTN

P0734

0734

—

—

2

×

AT-136

TCC SOLENOID/CIRC

P0740

0740

—

—

2

×

AT-142

A/T TCC S/V FNCTN

P0744

0744

—

—

2

×

AT-147

L/PRESS SOL/CIRC

P0745

0745

—

—

2

×

AT-153

SHIFT SOL A/CIRC

P0750

0750

—

—

1

×

AT-159

SHIFT SOL B/CIRC

P0755

0755

—

—

1

×

AT-164

ECM BACK UP/CIRCUIT*7

P1065

1065

—

—

2

×

EC-1075

INT/V TIM V/CIR-B1

P1111

1111

—

—

2

×

EC-1077

ETC ACTR

P1121

1121

—

—

1

×

EC-1082

ETC FUNCTION/CIRC

P1122

1122

—

—

1

×

EC-1084

ETC MOT PWR

P1124

1124

—

—

1

×

EC-1090

ETC MOT PWR

P1126

1126

—

—

1

×

EC-1090

ETC MOT

P1128

1128

—

—

1

×

EC-1096

HO2S1 (B1)

P1143

1143

×

×

2

×

EC-1101

HO2S1 (B1)

P1144

1144

×

×

2

×

EC-1107

HO2S2 (B1)

P1146

1146

×

×

2

×

EC-1113

HO2S2 (B1)

P1147

1147

×

×

2

×

EC-1121

TCS/CIRC

P1212

1212

—

—

2

—

EC-1129

ENG OVER TEMP

P1217

1217

—

—

1

×

EC-1130

CTP LEARNING

P1225

1225

—

—

2

—

EC-1146

CTP LEARNING

P1226

1226

—

—

2

—

EC-1148

SENSOR POWER/CIRC

P1229

1229

—

—

1

×

EC-1150

NATS MALFUNCTION

P1610 — P1615

1610 — 1615

—

—

2

—

BL-215

TP SEN/CIRC A/T

P1705

1705

—

—

1

×

AT-169

P-N POS SW/CIRCUIT

P1706

1706

—

—

2

×

EC-1158

O/R CLTCH SOL/CIRC

P1760

1760

—

—

2

×

AT-171

BRAKE SW/CIRCUIT

P1805

1805

—

—

2

—

EC-1167

APP SEN 1/CIRC

P2122

2122

—

—

1

×

EC-1172

APP SEN 1/CIRC

P2123

2123

—

—

1

×

EC-1172

APP SEN 2/CIRC

P2127

2127

—

—

1

×

EC-1181

APP SEN 2/CIRC

P2128

2128

—

—

1

×

EC-1181

TP SENSOR

P2135

2135

—

—

1

×

EC-1191

APP SENSOR

P2138

2138

—

—

1

×

EC-1197

EC-832

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
*1: 1st trip DTC No. is the same as DTC No.
*2: This number is prescribed by ISO 15031-5.
*3: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN.
*4: The troubleshooting for this DTC needs CONSULT-II.
*5: When engine is running, MI may flash. For details, refer to EC-844, «MI Flashing Without DTC» .
*6: When the fail-safe operations for both self-diagnoses occur at the same time, the MI illuminates.
*7:This self-diagnosis is not for ECM power supply circuit, even though “ECM BACK UP/CIRCUIT” is displayed on CONSULT-II screen.

DTC AND 1ST TRIP DTC
The 1st trip DTC (whose number is the same as the DTC number) is displayed for the latest self-diagnostic
result obtained. If the ECM memory was cleared previously, and the 1st trip DTC did not reoccur, the 1st trip
DTC will not be displayed.
If a malfunction is detected during the 1st trip, the 1st trip DTC is stored in the ECM memory. The MI will not
light up (two trip detection logic). If the same malfunction is not detected in the 2nd trip (meeting the required
driving pattern), the 1st trip DTC is cleared from the ECM memory. If the same malfunction is detected in the
2nd trip, both the 1st trip DTC and DTC are stored in the ECM memory and the MI lights up. In other words,
the DTC is stored in the ECM memory and the MI lights up when the same malfunction occurs in two consecutive trips. If a 1st trip DTC is stored and a non-diagnostic operation is performed between the 1st and 2nd
trips, only the 1st trip DTC will continue to be stored. For malfunctions that blink or light up the MI during the
1st trip, the DTC and 1st trip DTC are stored in the ECM memory.
Procedures for clearing the DTC and the 1st trip DTC from the ECM memory are described in EC-841, «HOW
TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .
For malfunctions in which 1st trip DTCs are displayed, refer to EC-831, «EMISSION-RELATED DIAGNOSTIC
INFORMATION ITEMS» . These items are required by legal regulations to continuously monitor the system/
component. In addition, the items monitored non-continuously are also displayed on CONSULT-II.
1st trip DTC is specified in Service $07 of ISO 15031-5. 1st trip DTC detection occurs without lighting up the
MI and therefore does not warn the driver of a malfunction. However, 1st trip DTC detection will not prevent
the vehicle from being tested, for example during Inspection/Maintenance (I/M) tests.
When a 1st trip DTC is detected, check, print out or write down and erase (1st trip) DTC and Freeze Frame
data as specified in Work Flow procedure Step 2, refer to EC-864, «WORK FLOW» . Then perform DTC Confirmation Procedure or Overall Function Check to try to duplicate the malfunction. If the malfunction is duplicated, the item requires repair.

How to Read DTC and 1st Trip DTC

A

EC

C

D

E

F

G

H

I

J

DTC and 1st trip DTC can be read by the following methods.
With CONSULT-II
With GST
CONSULT-II or GST (Generic Scan Tool) Examples: P0340, P0740, P1217, etc.
These DTCs are prescribed by ISO 15031-5.
(CONSULT-II also displays the malfunctioning component or system.)
No Tools
The number of blinks of the MI in the Diagnostic Test Mode II (Self-Diagnostic Results) indicates the DTC.
Example: 0340, 0740, 1217, etc.
These DTCs are controlled by NISSAN.
●
1st trip DTC No. is the same as DTC No.
●
Output of a DTC indicates a malfunction. However, GST or the Diagnostic Test Mode II do not indicate whether the malfunction is still occurring or has occurred in the past and has returned to normal. CONSULT-II can identify malfunction status as shown below. Therefore, using CONSULT-II (if
available) is recommended.
A sample of CONSULT-II display for DTC and 1st trip DTC is shown below. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many times
the vehicle was driven after the last detection of a DTC.
If the DTC is being detected currently, the time data will be [0].

EC-833

K

L

M

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
If a 1st trip DTC is stored in the ECM, the time data will be [1t].

PBIB0911E

FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA
The ECM records the driving conditions such as fuel system status, calculated load value, engine coolant temperature, short term fuel trim, long term fuel trim, engine speed, vehicle speed, base fuel schedule and intake
air temperature at the moment a malfunction is detected.
Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data.
The data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II or
GST. The 1st trip freeze frame data can only be displayed on the CONSULT-II screen, not on the GST. For
details, see EC-893, «Freeze Frame Data and 1st Trip Freeze Frame Data» .
Only one set of freeze frame data (either 1st trip freeze frame data or freeze frame data) can be stored in the
ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no priority
for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once
freeze frame data (2nd trip detection/MI on) is stored in the ECM memory, 1st trip freeze frame data is no
longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the following priorities to update the data.
Priority
1
2
3

Items
Freeze frame data

Misfire — DTC: P0300 — P0304
Fuel Injection System Function — DTC: P0171, P0172
Except the above items (Includes A/T related items)

1st trip freeze frame data

For example, the EGR malfunction (Priority: 2) was detected and the freeze frame data was stored in the 2nd
trip. After that when the misfire (Priority: 1) is detected in another trip, the freeze frame data will be updated
from the EGR malfunction to the misfire. The 1st trip freeze frame data is updated each time a different malfunction is detected. There is no priority for 1st trip freeze frame data. However, once freeze frame data is
stored in the ECM memory, 1st trip freeze data is no longer stored (because only one freeze frame data or 1st
trip freeze frame data can be stored in the ECM). If freeze frame data is stored in the ECM memory and freeze
frame data with the same priority occurs later, the first (original) freeze frame data remains unchanged in the
ECM memory.
Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased. Procedures for clearing the ECM memory are described in EC-841, «HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .

SYSTEM READINESS TEST (SRT) CODE
System Readiness Test (SRT) code is specified in Service $01 of ISO 15031-5.
As part of an enhanced emissions test for Inspection & Maintenance (I/M), certain states require the status of
SRT be used to indicate whether the ECM has completed self-diagnosis of major emission systems and components. Completion must be verified in order for the emissions inspection to proceed.
If a vehicle is rejected for a State emissions inspection due to one or more SRT items indicating “INCMP”, use
the information in this Service Manual to set the SRT to “CMPLT”.
In most cases the ECM will automatically complete its self-diagnosis cycle during normal usage, and the SRT
status will indicate “CMPLT” for each application system. Once set as “CMPLT”, the SRT status remains
“CMPLT” until the self-diagnosis memory is erased.
Occasionally, certain portions of the self-diagnostic test may not be completed as a result of the customer’s
normal driving pattern; the SRT will indicate “INCMP” for these items.
NOTE:
The SRT will also indicate “INCMP” if the self-diagnosis memory is erased for any reason or if the ECM memory power supply is interrupted for several hours.

EC-834

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
If, during the state emissions inspection, the SRT indicates “CMPLT” for all test items, the inspector will continue with the emissions test. However, if the SRT indicates “INCMP” for one or more of the SRT items the A
vehicle is returned to the customer untested.
NOTE:
If MI is ON during the state emissions inspection, the vehicle is also returned to the customer untested even EC
though the SRT indicates “CMPLT” for all test items. Therefore, it is important to check SRT (“CMPLT”) and
DTC (No DTCs) before the inspection.

SRT Item

C

The table below shows required self-diagnostic items to set the SRT to “CMPLT”.
SRT item
(CONSULT-II indication)

Performance
Priority*

Required self-diagnostic items to set the SRT to “CMPLT”

Corresponding
DTC No.

CATALYST

2

Three way catalyst function

P0420

HO2S

1

Heated oxygen sensor 1

P0133

Heated oxygen sensor 1

P1143

Heated oxygen sensor 1

P1144

Heated oxygen sensor 2

P0139

Heated oxygen sensor 2

P1146

Heated oxygen sensor 2

P1147

Heated oxygen sensor 1 heater

P0135

Heated oxygen sensor 2 heater

P0141

HO2S HTR

1

D

E

F

G

*: If completion of several SRTs is required, perform driving patterns (DTC confirmation procedure), one by one based on the priority for
models with CONSULT-II.

H

SRT Set Timing
SRT is set as “CMPLT” after self-diagnosis has been performed one or more times. Completion of SRT is
done regardless of whether the result is OK or NG. The set timing is different between OK and NG results and
is shown in the table below.

J

Example
Self-diagnosis result
All OK

Case 1

Case 2

NG exists

Case 3

Ignition cycle
← ON → OFF ← ON →

Diagnosis

← ON →

P0400

OK (1)

— (1)

OK (2)

— (2)

P0402

OK (1)

— (1)

— (1)

OK (2)

P1402

OK (1)

OK (2)

— (2)

— (2)

SRT of EGR

“CMPLT”

“CMPLT”

“CMPLT”

“CMPLT”

P0400

OK (1)

— (1)

— (1)

— (1)

P0402

— (0)

— (0)

OK (1)

— (1)

P1402

OK (1)

OK (2)

— (2)

— (2)

SRT of EGR

“INCMP”

“INCMP”

“CMPLT”

“CMPLT”

P0400

OK

OK

—

—

P0402

—

—

—

—

P1402

NG

—

NG

NG
(Consecutive
NG)

(1st trip)
DTC

1st trip DTC

—

1st trip DTC

DTC
(= MI ON)

SRT of EGR

“INCMP”

“INCMP”

“INCMP”

“CMPLT”

OFF

OFF

← ON →

OK: Self-diagnosis is carried out and the result is OK.
NG: Self-diagnosis is carried out and the result is NG.
—: Self-diagnosis is not carried out.

When all SRT related self-diagnoses showed OK results in a single cycle (Ignition OFF-ON-OFF), the SRT will
indicate “CMPLT”. → Case 1 above

EC-835

I

K

L

M

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
When all SRT related self-diagnoses showed OK results through several different cycles, the SRT will indicate
“CMPLT” at the time the respective self-diagnoses have at least one OK result. → Case 2 above
If one or more SRT related self-diagnoses showed NG results in 2 consecutive cycles, the SRT will also indicate “CMPLT”. → Case 3 above
The table above shows that the minimum number of cycles for setting SRT as “INCMP” is one (1) for each
self-diagnosis (Case 1 & 2) or two (2) for one of self-diagnoses (Case 3). However, in preparation for the state
emissions inspection, it is unnecessary for each self-diagnosis to be executed twice (Case 3) for the following
reasons:
●
The SRT will indicate “CMPLT” at the time the respective self-diagnoses have one (1) OK result.
●
The emissions inspection requires “CMPLT” of the SRT only with OK self-diagnosis results.
●
When, during SRT driving pattern, 1st trip DTC (NG) is detected prior to “CMPLT” of SRT, the self-diagnosis memory must be erased from ECM after repair.
●
If the 1st trip DTC is erased, all the SRT will indicate “INCMP”.
NOTE:
SRT can be set as “CMPLT” together with the DTC(s). Therefore, DTC check must always be carried out
prior to the state emission inspection even though the SRT indicates “CMPLT”.

SRT Service Procedure
If a vehicle has failed the state emissions inspection due to one or more SRT items indicating “INCMP”, review
the flowchart diagnostic sequence on the next page.

EC-836

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
A

EC

C

D

E

F

G

H

I

J

K

L

M
SEF573XB

*1

EC-833, «How to Read DTC and 1st
Trip DTC»

*2

EC-837, «How to Display SRT Code» *3

EC-838, «How to Set SRT Code»

How to Display SRT Code
WITH CONSULT-II
Selecting “SRT STATUS” in “DTC & SRT CONFIRMATION” mode
with CONSULT-II.
For items whose SRT codes are set, a “CMPLT” is displayed on the
CONSULT-II screen; for items whose SRT codes are not set,
“INCMP” is displayed.
A sample of CONSULT-II display for SRT code is shown in the figure.
“INCMP” means the self-diagnosis is incomplete and SRT is not set.
“CMPLT” means the self-diagnosis is complete and SRT is set.
PBIB0666E

EC-837

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
WITH GST
Selecting Service $01 with GST (Generic Scan Tool)

How to Set SRT Code
To set all SRT codes, self-diagnosis for the items indicated above must be performed one or more times. Each
diagnosis may require a long period of actual driving under various conditions.
WITH CONSULT-II
Perform corresponding DTC Confirmation Procedure one by one based on Performance Priority in the table
on EC-835, «SRT Item» .
WITHOUT CONSULT-II
The most efficient driving pattern in which SRT codes can be properly set is explained on the next page. The
driving pattern should be performed one or more times to set all SRT codes.

EC-838

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
Driving Pattern
A

EC

C

D

E

F

G

H

I

J

K

L

M

PBIB2451E

EC-839

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
The time required for each diagnosis varies with road surface conditions, weather, altitude, individual driving habits, etc.
Zone A refers to the range where the time, required for the diagnosis under normal conditions*, is the
shortest.
Zone B refers to the range where the diagnosis can still be performed if the diagnosis is not completed
within zone A.
*: Normal conditions refer to the following:
●
Sea level
●
Flat road
●
Ambient air temperature: 20 — 30°C (68 — 86°F)
●
Diagnosis is performed as quickly as possible under normal conditions.
Under different conditions [For example: ambient air temperature other than 20 — 30°C (68 — 86°F)], diagnosis may also be performed.
Pattern 1:
●
The engine is started at the engine coolant temperature of −10 to 35°C (14 to 95°F)
(where the voltage between the ECM terminal 38 and ground is 3.0 — 4.3V).
●
The engine must be operated at idle speed until the engine coolant temperature is greater than
70°C (158°F) (where the voltage between the ECM terminal 38 and ground is lower than 1.4V).
Pattern 2:
●
When steady-state driving is performed again even after it is interrupted, each diagnosis can be conducted. In this case, the time required for diagnosis may be extended.
*1: Depress the accelerator pedal until vehicle speed is 90 km/h (56 MPH), then release the accelerator pedal
and keep it released for more than 10 seconds. Depress the accelerator pedal until vehicle speed is 90 km/h
(56 MPH) again.
*2: Checking the vehicle speed with GST is advised.
●

Suggested Transmission Gear Position
Set the shift lever in the D position with the overdrive switch turned ON.

EC-840

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II)
A
The following is the information specified in Service $06 of ISO 15031-5.
The test value is a parameter used to determine whether a system/circuit diagnostic test is OK or NG while
being monitored by the ECM during self-diagnosis. The test limit is a reference value which is specified as the
maximum or minimum value and is compared with the test value being monitored.
EC
These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be displayed on the GST screen.
SRT item

CATALYST

Self-diagnostic test item

Three way catalyst function

Heated oxygen sensor 1

HO2S

Heated oxygen sensor 2

Test value
(GST display)

DTC

C
Test limit

TID

CID

P0420

01H

01H

Max.

P0420

02H

81H

Min.

P0133

09H

04H

Max.

P1143

0AH

84H

Min.

P1144

0BH

04H

Max.

P0132

0CH

04H

Max.

P0134

0DH

04H

Max.

P0139

19H

86H

Min.

P1147

1AH

86H

Min.

P1146

1BH

06H

Max.

P0138

1CH

06H

Max.

29H

08H

Max.

2AH

88H

Min.

2DH

0AH

Max.

2EH

8AH

Min.

Heated oxygen sensor 1 heater

P0135

Heated oxygen sensor 2 heater

P0141

HO2S HTR

HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION
How to Erase DTC
WITH CONSULT-II
The emission related diagnostic information in the ECM can be erased by selecting “ERASE” in the “SELFDIAG RESULTS” mode with CONSULT-II.
If DTCs are displayed for both ECM and TCM (Transmission control module), they need to be erased individually from the ECM and TCM (Transmission control module).
NOTE:
If the DTC is not for A/T related items (see EC-803, «INDEX FOR DTC» ), skip steps 2 through 4.
1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10
seconds and then turn it ON (engine stopped) again.
2. Turn CONSULT-II ON and touch “A/T”.
3. Touch “SELF-DIAG RESULTS”.
4. Touch “ERASE”. [The DTC in the TCM (Transmission control module) will be erased.] Then touch “BACK”
twice.
5. Touch “ENGINE”.
6. Touch “SELF-DIAG RESULTS”.
7. Touch “ERASE”. (The DTC in the ECM will be erased.)

EC-841

D

E

F

G

H

I

J

K

L

M

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]

SCIA5680E

WITH GST
The emission related diagnostic information in the ECM can be erased by selecting Service $04 with GST.
NOTE:
If the DTC is not for A/T related items (see EC-803, «INDEX FOR DTC» ), skip step 2.
1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10
seconds and then turn it ON (engine stopped) again.
2. Perform AT-98, «OBD Diagnostic Trouble Code (DTC)» . (The DTC in TCM will be erased)
3. Select Service $04 with GST (Generic Scan Tool).
No Tools
NOTE:
If the DTC is not for AT related items (see EC-803, «INDEX FOR DTC» ), skip step 2.
1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once.
Wait at least 10 seconds and then turn it ON (engine stopped) again.
2. Perform AT-98, «OBD Diagnostic Trouble Code (DTC)» . (The DTC in the TCM will be erased.)
3. Change the diagnostic test mode from Mode II to Mode I by depressing the accelerator pedal. Refer to
EC-1269, «HOW TO SWITCH DIAGNOSTIC TEST MODE» .
●
If the battery is disconnected, the emission-related diagnostic information will be lost within 24
hours.
●
The following data are cleared when the ECM memory is erased.
–
Diagnostic trouble codes
–
1st trip diagnostic trouble codes
–
Freeze frame data
–
1st trip freeze frame data
–
System readiness test (SRT) codes

EC-842

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
Test values
Actual work procedures are explained using a DTC as an example. Be careful so that not only the DTC, but all
of the data listed above, are cleared from the ECM memory during work procedures.

–

Malfunction Indicator (MI)

BBS0049D

DESCRIPTION
The MI is located on the instrument panel.
1. The MI will light up when the ignition switch is turned ON without
the engine running. This is a bulb check.
If the MI does not light up, check MI circuit. Refer to DI-32,
«WARNING LAMPS» , or see EC-1236, «MI & DATA LINK CONNECTORS» .
2. When the engine is started, the MI should go off.
If the MI remains on, the on board diagnostic system has
detected an engine system malfunction.

A

EC

C

D

E
SAT652J

ON BOARD DIAGNOSTIC SYSTEM FUNCTION

F

The on board diagnostic system has the following four functions.
Diagnostic Test
Mode

KEY and ENG.
Status

Function

Mode I

Ignition switch in
ON position

BULB CHECK

Explanation of Function

G
This function checks the MI bulb for damage (blown, open
circuit, etc.).
If the MI does not come on, check MI circuit.

Engine stopped

Engine running

Mode II

Ignition switch in
ON position

H

I

MALFUNCTION
WARNING

This is a usual driving condition. When a malfunction is
detected twice in two consecutive driving cycles (two trip
detection logic), the MI will light up to inform the driver that
a malfunction has been detected.
The following malfunctions will light up or blink the MI in
the 1st trip.

SELF-DIAGNOSTIC
RESULTS

●

Misfire (Possible three way catalyst damage)

●

One trip detection diagnoses

J

K

L

This function allows DTCs and 1st trip DTCs to be read.

M

Engine stopped

Engine running

HEATED OXYGEN SENSOR 1
MONITOR

This function allows the fuel mixture condition (lean or
rich), monitored by heated oxygen sensor 1, to be read.

When there is an open circuit on MI circuit, the ECM cannot warn the driver by lighting up MI when there is
malfunction on engine control system.
Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as
NG for 5 trips, ECM warns the driver that engine control system malfunctions and MI circuit is open by means
of operating fail-safe function.

EC-843

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
The fail-safe function also operates when above diagnoses except MI circuit are detected and demands the
driver to repair the malfunction.
Engine operating condition in fail-safe mode

Engine speed will not rise more than 2,500 rpm due to the fuel cut

MI Flashing Without DTC
If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM diagnostic test mode. How to switch the diagnostic test (function) modes, and details of the above functions are
described later. Refer to EC-1269, «HOW TO SWITCH DIAGNOSTIC TEST MODE» .
The following emission-related diagnostic information is cleared when the ECM memory is erased.
●
Diagnostic trouble codes
●
1st trip diagnostic trouble codes
●
Freeze frame data
●
1st trip freeze frame data
●
System readiness test (SRT) codes
●
Test values

HOW TO SWITCH DIAGNOSTIC TEST MODE
NOTE:
●
It is better to count the time accurately with a clock.
●
It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit
has a malfunction.
●
Always ECM returns to Diagnostic Test Mode I after ignition switch is turned OFF.

How to Set Diagnostic Test Mode II (Self-diagnostic Results)
1.
2.
a.
b.
3.
4.

Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds.
Repeat the following procedure quickly five times within 5 seconds.
Fully depress the accelerator pedal.
Fully release the accelerator pedal.
Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 10 seconds until the MI starts
blinking.
Fully release the accelerator pedal.
ECM has entered to Diagnostic Test Mode II (Self-diagnostic results).
NOTE:
Wait until the same DTC (or 1st trip DTC) appears to confirm all DTCs certainly.

PBIB0092E

How to Set Diagnostic Test Mode II (Heated Oxygen Sensor 1 Monitor)
1.
2.

Set the ECM in Diagnostic Test Mode II (Self-diagnostic results).
Refer to EC-1269, «How to Set Diagnostic Test Mode II (Self-diagnostic Results)» .
Start Engine.
ECM has entered to Diagnostic Test Mode II (Heated oxygen sensor 1 monitor).

How to Erase Diagnostic Test Mode II (Self-diagnostic Results)
1.
2.

Set ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-1269, «How to Set Diagnostic
Test Mode II (Self-diagnostic Results)» .
Fully depress the accelerator pedal and keep it for more than 10 seconds.
The emission-related diagnostic information has been erased from the backup memory in the ECM.

EC-844

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
3.

Fully release the accelerator pedal, and confirm the DTC 0000 is displayed.
A

DIAGNOSTIC TEST MODE I — BULB CHECK
In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check MI circuit. Refer to DI32, «WARNING LAMPS» or see EC-1236, «MI & DATA LINK CONNECTORS» .

EC

DIAGNOSTIC TEST MODE I — MALFUNCTION WARNING
MI

Condition

ON

When the malfunction is detected.

OFF

No malfunction.

C

This DTC number is clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS)

D

DIAGNOSTIC TEST MODE II — SELF-DIAGNOSTIC RESULTS
In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI as shown below.
The DTC and 1st trip DTC are displayed at the same time. If the MI does not illuminate in diagnostic test mode
I (Malfunction warning), all displayed items are 1st trip DTCs. If only one code is displayed when the MI illuminates in diagnostic test mode II (SELF-DIAGNOSTIC RESULTS), it is a DTC; if two or more codes are displayed, they may be either DTCs or 1st trip DTCs. DTC No. is same as that of 1st trip DTC. These unidentified
codes can be identified by using the CONSULT-II or GST. A DTC will be used as an example for how to read a
code.

E

F

G

H

I

J

K

L
PBIA3905E

A particular trouble code can be identified by the number of four-digit numeral flashes. The “zero” is indicated
by the number of ten flashes. The length of time the 1,000th-digit numeral flashes on and off is 1.2 seconds
consisting of an ON (0.6-second) — OFF (0.6-second) cycle.
The 100th-digit numeral and lower digit numerals consist of a 0.3-second ON and 0.3-second OFF cycle.
A change from one digit numeral to another occurs at an interval of 1.0-second OFF. In other words, the later
numeral appears on the display 1.3 seconds after the former numeral has disappeared.
A change from one trouble code to another occurs at an interval of 1.8-second OFF.
In this way, all the detected malfunctions are classified by their DTC numbers. The DTC 0000 refers to no malfunction. (See EC-803, «INDEX FOR DTC» .)

How to Erase Diagnostic Test Mode II (Self-diagnostic Results)
The DTC can be erased from the back up memory in the ECM by depressing accelerator pedal. Refer to EC1269, «How to Erase Diagnostic Test Mode II (Self-diagnostic Results)» .
●
If the battery is disconnected, the DTC will be lost from the backup memory within 24 hours.
●
Be careful not to erase the stored memory before starting trouble diagnoses.

DIAGNOSTIC TEST MODE II — HEATED OXYGEN SENSOR 1 MONITOR
In this mode, the MI displays the condition of the fuel mixture (lean or rich) which is monitored by the heated
oxygen sensor 1.

EC-845

M

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
MI

Fuel mixture condition in the exhaust gas

ON

Lean

OFF

Rich

*Remains ON or OFF

Any condition

Air fuel ratio feedback control condition
Closed loop system
Open loop system

*: Maintains conditions just before switching to open loop.

To check the heated oxygen sensor 1 function, start engine in the Diagnostic Test Mode II and warm it up until
engine coolant temperature indicator points to the middle of the gauge.
Next run engine at about 2,000 rpm for about 2 minutes under no load conditions. Then make sure that the MI
comes ON more than 5 times within 10 seconds with engine running at 2,000 rpm under no load.

OBD System Operation Chart

BBS0049E

RELATIONSHIP BETWEEN MI, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS
●

●

●

●

●

When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data are
stored in the ECM memory.
When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data are
stored in the ECM memory, and the MI will come on. For details, refer to EC-830, «Two Trip Detection
Logic» .
The MI will go off after the vehicle is driven 3 times (driving pattern B) with no malfunction. The drive is
counted only when the recorded driving pattern is met (as stored in the ECM). If another malfunction
occurs while counting, the counter will reset.
The DTC and the freeze frame data will be stored until the vehicle is driven 40 times (driving pattern A)
without the same malfunction recurring (except for Misfire and Fuel Injection System). For Misfire and
Fuel Injection System, the DTC and freeze frame data will be stored until the vehicle is driven 80 times
(driving pattern C) without the same malfunction recurring. The “TIME” in “SELF-DIAGNOSTIC
RESULTS” mode of CONSULT-II will count the number of times the vehicle is driven.
The 1st trip DTC is not displayed when the self-diagnosis results in OK for the 2nd trip.

SUMMARY CHART
Items

Fuel Injection System

Misfire

Other

MI (goes off)

3 (pattern B)

3 (pattern B)

3 (pattern B)

DTC, Freeze Frame Data (no
display)

80 (pattern C)

80 (pattern C)

40 (pattern A)

1 (pattern C), *1

1 (pattern C), *1

1 (pattern B)

*1, *2

*1, *2

1 (pattern B)

1st Trip DTC (clear)
1st Trip Freeze Frame Data
(clear)

For details about patterns B and C under “Fuel Injection System” and “Misfire”, see EC-848, «EXPLANATION FOR DRIVING PATTERNS FOR “MISFIRE ”, “FUEL INJECTION SYSTEM”» .
For details about patterns A and B under Other, see EC-850, «EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR “MISFIRE
”, “FUEL INJECTION SYSTEM”» .
*1: Clear timing is at the moment OK is detected.
*2: Clear timing is when the same malfunction is detected in the 2nd trip.

EC-846

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS FOR “MISFIRE ”
, “FUEL INJECTION SYSTEM”

A

EC

C

D

E

F

G

H

I

J

K

L

M

SEF392SA

*1: When the same malfunction is
detected in two consecutive trips, MI
will light up.

*2: MI will go off after vehicle is driven 3
times (pattern B) without any malfunctions.

*3: When the same malfunction is
detected in two consecutive trips, the
DTC and the freeze frame data will
be stored in ECM.

*4: The DTC and the freeze frame data
will not be displayed any longer after
vehicle is driven 80 times (pattern C)
without the same malfunction. (The
DTC and the freeze frame data still
remain in ECM.)

*5: When a malfunction is detected for
the first time, the 1st trip DTC and
the 1st trip freeze frame data will be
stored in ECM.

*6: The 1st trip DTC and the 1st trip
freeze frame data will be cleared at
the moment OK is detected.

*7: When the same malfunction is
detected in the 2nd trip, the 1st trip
freeze frame data will be cleared.

*8: 1st trip DTC will be cleared when
vehicle is driven once (pattern C)
without the same malfunction after
DTC is stored in ECM.

EC-847

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
EXPLANATION FOR DRIVING PATTERNS FOR “MISFIRE ”, “FUEL INJECTION SYSTEM”

Driving pattern B means the vehicle operation as follows:
All components and systems should be monitored at least once by the OBD system.
●
The B counter will be cleared when the malfunction is detected once regardless of the driving pattern.
●
The B counter will be counted up when driving pattern B is satisfied without any malfunction.
●
The MI will go off when the B counter reaches 3. (*2 in “OBD SYSTEM OPERATION CHART”)

Driving pattern C means the vehicle operation as follows:
The following conditions should be satisfied at the same time:
Engine speed: (Engine speed in the freeze frame data) ±375 rpm
Calculated load value: (Calculated load value in the freeze frame data) x (1±0.1) [%]
Engine coolant temperature (T) condition:
●
When the freeze frame data shows lower than 70°C (158°F), T should be lower than 70°C (158°F).
●
When the freeze frame data shows higher than or equal to 70°C (158°F), T should be higher than or equal
to 70°C (158°F).
Example:
If the stored freeze frame data is as follows:
Engine speed: 850 rpm, Calculated load value: 30%, Engine coolant temperature: 80°C (176°F)
To be satisfied with driving pattern C, the vehicle should run under the following conditions:
Engine speed: 475 — 1,225 rpm, Calculated load value: 27 — 33%, Engine coolant temperature: more than 70°C
(158°F)
●
The C counter will be cleared when the malfunction is detected regardless of vehicle conditions above.
●
The C counter will be counted up when vehicle conditions above is satisfied without the same malfunction.
●
The DTC will not be displayed after C counter reaches 80.
●
The 1st trip DTC will be cleared when C counter is counted once without the same malfunction after DTC
is stored in ECM.

EC-848

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS EXCEPT FOR
“MISFIRE ”, “FUEL INJECTION SYSTEM”

A

EC

C

D

E

F

G

H

I

J

K

L

M

PBIB2551E

*1: When the same malfunction is
detected in two consecutive trips, MI
will light up.

*2: MI will go off after vehicle is driven 3
times (pattern B) without any malfunctions.

*3: When the same malfunction is
detected in two consecutive trips, the
DTC and the freeze frame data will
be stored in ECM.

*4: The DTC and the freeze frame data
will not be displayed any longer after
vehicle is driven 40 times (pattern A)
without the same malfunction.
(The DTC and the freeze frame data
still remain in ECM.)

*5: When a malfunction is detected for
the first time, the 1st trip DTC and
the 1st trip freeze frame data will be
stored in ECM.

*6: 1st trip DTC will be cleared after
vehicle is driven once (pattern B)
without the same malfunction.

*7: When the same malfunction is
detected in the 2nd trip, the 1st trip
freeze frame data will be cleared.

EC-849

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITH EURO-OBD)]
EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR “MISFIRE ”, “FUEL INJECTION SYSTEM”

AEC574

●
●
●

The A counter will be cleared when the malfunction is detected regardless of (1) — (4).
The A counter will be counted up when (1) — (4) are satisfied without the same malfunction.
The DTC will not be displayed after the A counter reaches 40.

Driving pattern B means the vehicle operation as follows:
All components and systems should be monitored at least once by the OBD system.
●
The B counter will be cleared when the malfunction is detected once regardless of the driving pattern.
●
The B counter will be counted up when driving pattern B is satisfied without any malfunctions.
●
The MI will go off when the B counter reaches 3 (*2 in OBD SYSTEM OPERATION CHART).

EC-850

BASIC SERVICE PROCEDURE
[HR (WITH EURO-OBD)]

BASIC SERVICE PROCEDURE
Basic Inspection

PFP:00018

A
BBS0049F

1. INSPECTION START
1.
2.
–
–
–
–
–
–

3.
–
–
–
–

4.

Check service records for any recent repairs that may indicate a related malfunction, or a current need for
scheduled maintenance.
Open engine hood and check the following:
Harness connectors for improper connections
Wiring harness for improper connections, pinches and cut
Vacuum hoses for splits, kinks and improper connections
Hoses and ducts for leaks
Air cleaner clogging
Gasket
Confirm that electrical or mechanical loads are not applied.
Headlamp switch is OFF.
SEF983U
Air conditioner switch is OFF.
Rear window defogger switch is OFF.
Steering wheel is in the straight-ahead position, etc.
Start engine and warm it up until engine coolant temperature
indicator points the middle of gauge.
Ensure engine stays below 1,000 rpm.

EC

C

D

E

F

G

H

I

J
SEF976U

5.

Run engine at about 2,000 rpm for about 2 minutes under no
load.
6. Make sure that no DTC is displayed with CONSULT-II or GST.
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

K

L

M

SEF977U

2. REPAIR OR REPLACE
Repair or replace components as necessary according to corresponding Diagnostic Procedure.
>> GO TO 3

EC-851

BASIC SERVICE PROCEDURE
[HR (WITH EURO-OBD)]

3. CHECK TARGET IDLE SPEED
1.
2.

With CONSULT-II
Run engine at about 2,000 rpm for about 2 minutes under no load.
Rev engine (2,000 to 3,000 rpm) two or three times under no
load, then run engine at idle speed for about 1 minute.

PBIA8513J

3.

Read idle speed in “DATA MONITOR” mode with CONSULT-II.
Refer to EC-856, «IDLE SPEED» .
A/T:
M/T:

700 ± 50 rpm (in P or N position)
650 ± 50 rpm (in Neutral position)

SEF058Y

Without CONSULT-II
Run engine at about 2,000 rpm for about 2 minutes under no load.
Rev engine (2,000 to 3,000 rpm) two or three times under no load, then run engine at idle speed for about
1 minute.
3. Check idle speed.
Refer to EC-856, «IDLE SPEED» .
1.
2.

A/T:
M/T:

700 ± 50 rpm (in P or N position)
650 ± 50 rpm (in Neutral position)

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 4.

4. PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING
1.
2.

Stop engine.
Perform EC-857, «Accelerator Pedal Released Position Learning» .
>> GO TO 5.

5. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING
Perform EC-857, «Throttle Valve Closed Position Learning» .
>> GO TO 6.

EC-852

BASIC SERVICE PROCEDURE
[HR (WITH EURO-OBD)]

6. PERFORM IDLE AIR VOLUME LEARNING

A

Refer to EC-858, «Idle Air Volume Learning» .
Is Idle Air Volume Learning carried out successfully?
Yes or No
Yes
>> GO TO 7.
No
>> 1. Follow the instruction of Idle Air Volume Learning.
2. GO TO 4.

EC

C

7. CHECK TARGET IDLE SPEED AGAIN
D

With CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Read idle speed in “DATA MONITOR” mode with CONSULT-II.
Refer to EC-856, «IDLE SPEED» .
A/T:
M/T:

E

700 ± 50 rpm (in P or N position)
650 ± 50 rpm (in Neutral position)

F

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Check idle speed.
Refer to EC-856, «IDLE SPEED» .
A/T:
M/T:

700 ± 50 rpm (in P or N position)
650 ± 50 rpm (in Neutral position)

G

SEF174Y

H

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 8.

I

8. DETECT MALFUNCTIONING PART

J

Check the Following.
●
Check camshaft position sensor (PHASE) and circuit. Refer to EC-1049, «DTC P0340 CMP SENSOR
(PHASE)» .
●
Check crankshaft position sensor (POS) and circuit. Refer to EC-1042, «DTC P0335 CKP SENSOR
(POS)» .
OK or NG
OK
>> GO TO 9.
NG
>> 1. Repair or replace.
2. GO TO 4.

9. CHECK ECM FUNCTION
1.
2.

Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but
this is a rare case.)
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
>> GO TO 4.

EC-853

K

L

M

BASIC SERVICE PROCEDURE
[HR (WITH EURO-OBD)]

10. CHECK IGNITION TIMING
1.
2.
–

Run engine at idle.
Check ignition timing with a timing light.
Refer to EC-856, «IGNITION TIMING» .
Timing indicator (1)
A/T:
M/T:

6 ± 5° BTDC (in P or N position)
6 ± 5° BTDC (in Neutral position)

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 11.
MBIB1331E

11. PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING
1.
2.

Stop engine.
Perform EC-857, «Accelerator Pedal Released Position Learning» .
>> GO TO 12.

12. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING
Perform EC-857, «Throttle Valve Closed Position Learning» .
>> GO TO 13.

13. PERFORM IDLE AIR VOLUME LEARNING
Refer to EC-858, «Idle Air Volume Learning» .
Is Idle Air Volume Learning carried out successfully?
Yes or No
Yes
>> GO TO 14.
No
>> 1. Follow the instruction of Idle Air Volume Learning.
2. GO TO 4.

14. CHECK TARGET IDLE SPEED AGAIN
With CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Read idle speed in “DATA MONITOR” mode with CONSULT-II.
Refer to EC-856, «IDLE SPEED» .
A/T:
M/T:

700 ± 50 rpm (in P or N position)
650 ± 50 rpm (in Neutral position)

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Check idle speed.
Refer to EC-856, «IDLE SPEED» .
A/T:
M/T:

700 ± 50 rpm (in P or N position)
650 ± 50 rpm (in Neutral position)

OK or NG
OK
>> GO TO 15.
NG
>> GO TO 17.

EC-854

SEF174Y

BASIC SERVICE PROCEDURE
[HR (WITH EURO-OBD)]

15. CHECK IGNITION TIMING AGAIN
1.
2.
–

A

Run engine at idle.
Check ignition timing with a timing light.
Refer to EC-856, «IGNITION TIMING» .
Timing indicator (1)
A/T:
M/T:

EC

6 ± 5° BTDC (in P or N position)
6 ± 5° BTDC (in Neutral position)

C

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 16.

D
MBIB1331E

E

16. CHECK TIMING CHAIN INSTALLATION
Check timing chain installation. Refer to EM-142, «TIMING CHAIN» .
OK or NG
OK
>> GO TO 17.
NG
>> 1. Repair the timing chain installation.
2. GO TO 4.

17. DETECT MALFUNCTIONING PART

F

G

H

Check the following.
●
Check camshaft position sensor (PHASE) and circuit. Refer to EC-1049, «DTC P0340 CMP SENSOR
(PHASE)» .
●
Check crankshaft position sensor (POS) and circuit. Refer to EC-1042, «DTC P0335 CKP SENSOR
(POS)» .
OK or NG
OK
>> GO TO 18.
NG
>> 1. Repair or replace.
2. GO TO 4.

I

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18. CHECK ECM FUNCTION
1.
2.

Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but
this is a rare case.)
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
>> GO TO 4.

EC-855

L

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BASIC SERVICE PROCEDURE
[HR (WITH EURO-OBD)]

Idle Speed and Ignition Timing Check

BBS0049G

IDLE SPEED
With CONSULT-II
Check idle speed in “DATA MONITOR” mode with CONSULT-II.

SEF058Y

With GST
Check idle speed with GST.

IGNITION TIMING
Any of following two methods may be used.

Method A
1.

Attach timing light A to loop wire (1) as shown.
●

: Vehicle front

PBIB2955E

2.

Check ignition timing.
● Timing indicator (1)

MBIB1331E

Method B
1.

Remove ignition coil No. 4 (1).
●

: Vehicle front

MBIB1457E

EC-856

BASIC SERVICE PROCEDURE
[HR (WITH EURO-OBD)]
2.

Connect ignition coil No. 4 (1) and spark plug No. 4 with suitable
high-tension wire A as shown, and attach timing light clamp B to
this wire.

A

EC

C
MBIB1541E

D

E

F

G
SEF166Y

3.

Check ignition timing.
● Timing indicator (1)

H

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MBIB1331E

Accelerator Pedal Released Position Learning

BBS0049H

DESCRIPTION
Accelerator Pedal Released Position Learning is an operation to learn the fully released position of the accelerator pedal by monitoring the accelerator pedal position sensor output signal. It must be performed each time
harness connector of accelerator pedal position sensor or ECM is disconnected.
Make sure that accelerator pedal is fully released.
Turn ignition switch ON and wait at least 2 seconds.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON and wait at least 2 seconds.
Turn ignition switch OFF and wait at least 10 seconds.

Throttle Valve Closed Position Learning

BBS0049I

DESCRIPTION
Throttle Valve Closed Position Learning is an operation to learn the fully closed position of the throttle valve by
monitoring the throttle position sensor output signal. It must be performed each time harness connector of
electric throttle control actuator or ECM is disconnected.

OPERATION PROCEDURE
1.
2.
3.

L

M

OPERATION PROCEDURE
1.
2.
3.
4.
5.

K

Make sure that accelerator pedal is fully released.
Turn ignition switch ON.
Turn ignition switch OFF and wait at least 10 seconds.

EC-857

BASIC SERVICE PROCEDURE
[HR (WITH EURO-OBD)]
Make sure that throttle valve moves during above 10 seconds by confirming the operating sound.

Idle Air Volume Learning

BBS0049J

DESCRIPTION
Idle Air Volume Learning is an operation to learn the idle air volume that keeps each engine within the specific
range. It must be performed under any of the following conditions:
●
Each time electric throttle control actuator or ECM is replaced.
●
Idle speed or ignition timing is out of specification.

PREPARATION
Before performing Idle Air Volume Learning, make sure that all of the following conditions are satisfied.
Learning will be cancelled if any of the following conditions are missed for even a moment.
●
Battery voltage: More than 12.9V (At idle)
●
Engine coolant temperature: 70 — 95°C (158 — 203°F)
●
PNP switch: ON
●
Electric load switch: OFF
(Air conditioner, headlamp, rear window defogger)
On vehicles equipped with daytime light systems, set lighting switch to the 1st position to light
only small lamps.
●
Steering wheel: Neutral (Straight-ahead position)
●
Vehicle speed: Stopped
●
Transmission: Warmed-up
–
A/T models
•
With CONSULT-II: Drive vehicle until “FLUID TEMP SE” in “DATA MONITOR” mode of “A/T” system indicates less than 0.9V.
•
Without CONSULT-II: Drive vehicle for 10 minutes.
–
M/T models
•
Drive vehicle for 10 minutes.

OPERATION PROCEDURE
With CONSULT-II
1.
2.
3.
4.
5.

Perform EC-857, «Accelerator Pedal Released Position Learning» .
Perform EC-857, «Throttle Valve Closed Position Learning» .
Start engine and warm it up to normal operating temperature.
Check that all items listed under the topic PREPARATION (previously mentioned) are in good order.
Select “IDLE AIR VOL LEARN” in “WORK SUPPORT” mode.

SEF217Z

EC-858

BASIC SERVICE PROCEDURE
[HR (WITH EURO-OBD)]
6.

Touch “START” and wait 20 seconds.
A

EC

C
SEF454Y

D

7.

8.

Make sure that “CMPLT” is displayed on CONSULT-II screen. If
“CMPLT” is not displayed, Idle Air Volume Learning will not be
carried out successfully. In this case, find the cause of the incident by referring to the DIAGNOSTIC PROCEDURE below.
Rev up the engine two or three times and make sure that idle
speed and ignition timing are within the specifications.

ITEM

SPECIFICATION

Idle speed

A/T: 700 ± 50 rpm (in P or N position)
M/T: 650 ± 50 rpm (in Neutral position)

Ignition timing

A/T: 6 ± 5° BTDC (in P or N position)
M/T: 6 ± 5° BTDC (in Neutral position)

E

F

G
MBIB0238E

H

Without CONSULT-II
NOTE:
●
It is better to count the time accurately with a clock.
●
It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit
has a malfunction.
1. Perform EC-857, «Accelerator Pedal Released Position Learning» .
2. Perform EC-857, «Throttle Valve Closed Position Learning» .
3. Start engine and warm it up to normal operating temperature.
4. Check that all items listed under the topic PREPARATION (previously mentioned) are in good order.
5. Turn ignition switch OFF and wait at least 10 seconds.
6. Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds.
7. Repeat the following procedure quickly five times within 5 seconds.
a. Fully depress the accelerator pedal.
b. Fully release the accelerator pedal.
8. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 20 seconds until the MI stops
blinking and turned ON.
9. Fully release the accelerator pedal within 3 seconds after the MI turned ON.
10. Start engine and let it idle.
11. Wait 20 seconds.

PBIB0665E

EC-859

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BASIC SERVICE PROCEDURE
[HR (WITH EURO-OBD)]
12. Rev up the engine two or three times and make sure that idle speed and ignition timing are within the
specifications.
ITEM

SPECIFICATION

Idle speed

A/T: 700 ± 50 rpm (in P or N position)
M/T: 650 ± 50 rpm (in Neutral position)

Ignition timing

A/T: 6 ± 5° BTDC (in P or N position)
M/T: 6 ± 5° BTDC (in Neutral position)

13. If idle speed and ignition timing are not within the specification, Idle Air Volume Learning will not be carried
out successfully. In this case, find the cause of the incident by referring to the Diagnostic Procedure below.

DIAGNOSTIC PROCEDURE
If idle air volume learning cannot be performed successfully, proceed as follows:
1. Check that throttle valve is fully closed.
2. Check PCV valve operation.
3. Check that downstream of throttle valve is free from air leakage.
4. When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the incident.
It is useful to perform EC-1237, «SERVICE DATA AND SPECIFICATIONS (SDS)» .
5. If any of the following conditions occur after the engine has started, eliminate the cause of the
incident and perform Idle Air Volume Learning all over again:
●
Engine stalls.
●
Erroneous idle.

Fuel Pressure Check

BBS0049K

FUEL PRESSURE RELEASE
With CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON.
Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT”
mode with CONSULT-II.
Start engine.
After engine stalls, crank it two or three times to release all fuel
pressure.
Turn ignition switch OFF.

SEF214Y

Without CONSULT-II
1.
2.
3.
4.
5.

Remove fuel pump fuse located in IPDM E/R.
Start engine.
After engine stalls, crank it 2 or 3 times to release all fuel pressure.
Turn ignition switch OFF.
Reinstall fuel pump fuse after servicing fuel system.

MBIB0277E

FUEL PRESSURE CHECK
CAUTION:
●
Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger.
●
The fuel hose connection method used when taking fuel pressure check must not be used for
other purposes.

EC-860

BASIC SERVICE PROCEDURE
[HR (WITH EURO-OBD)]
Be careful not to scratch or put debris around connection area when servicing, so that the quick
connector maintains sealability with O-rings inside.
A
●
Do not perform fuel pressure check with electrical systems operating (i.e. lights, rear defogger, A/
C, etc.) Fuel pressure gauge may indicate false readings due to varying engine load and changes
in manifold vacuum.
EC
NOTE:
Prepare pans or saucers under the disconnected fuel line because the fuel may spill out. The fuel pressure cannot be completely released because E11 models do not have fuel return system.
C
1. Release fuel pressure to zero. Refer to EC-860, «FUEL PRESSURE RELEASE» .
2. Prepare fuel hose for fuel pressure check B and fuel tube
adapter (KV10118400) D, then connect fuel pressure gauge A.
D
●
: To quick connector
●

: To fuel tube (engine side)
C: Clamp
● Use suitable fuel hose for fuel pressure check (genuine NISSAN fuel hose without quick connector).
● To avoid unnecessary force or tension to hose, use moderately long fuel hose for fuel pressure check.
● Do not use the fuel hose for checking fuel pressure with damage or cracks on it.
● Use Pressure Gauge to check fuel pressure.
Remove fuel hose. Refer to EM-120, «INTAKE MANIFOLD» .
● Do not twist or kink fuel hose because it is plastic hose.
Connect fuel hose for fuel pressure check (1) to fuel tube
(engine side) with clamp (2) as shown in the figure.
● No.2 spool (5)
● Wipe off oil or dirt from hose insertion part using cloth moistened with gasoline.
● Apply proper amount of gasoline between top of the fuel tube
(3) and No.1 spool (4).
● Insert fuel hose for fuel pressure check until it touches the
No.1 spool on fuel tube.
● Use NISSAN genuine hose clamp (part number: 16439
N4710 or 16439 40U00).
● When reconnecting fuel line, always use new clamps.
● Use a torque driver to tighten clamps.
● Install hose clamp to the position within 1 — 2 mm (0.04 — 0.08 in).
●

E

●

3.
4.

Tightening torque:
5.

6.

7.
8.
9.

F
PBIB2982E

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PBIB2983E

L

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1 — 1.5 N·m (0.1 — 0.15 kg-m, 9 — 13 in-lb)

● Make sure that clamp screw does not contact adjacent parts.
Connect fuel tube adapter to quick connector.
● A: Fuel pressure gauge
● B: Fuel hose for fuel pressure check
After connecting fuel hose for fuel pressure check, pull the hose
with a force of approximately 98 N (10 kg, 22 lb) to confirm fuel
tube does not come off.
Turn ignition switch ON and check for fuel leakage.
Start engine and check for fuel leakage.
Read the indication of fuel pressure gauge.
● Do not perform fuel pressure check with system operating.
Fuel pressure gauge may indicate false readings.
● During fuel pressure check, confirm for fuel leakage from fuel connection every 3 minutes.

EC-861

PBIB2984E

BASIC SERVICE PROCEDURE
[HR (WITH EURO-OBD)]
At idling:

Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi)

10. If result is unsatisfactory, go to next step.
11. Check the following.
● Fuel hoses and fuel tubes for clogging
● Fuel filter for clogging
● Fuel pump
● Fuel pressure regulator for clogging
If OK, replace fuel pressure regulator.
If NG, repair or replace.

EC-862

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

TROUBLE DIAGNOSIS
Trouble Diagnosis Introduction

PFP:00004

A
BBS0049L

INTRODUCTION
The engine has an ECM to control major systems such as fuel control, ignition control, idle air control system, etc. The ECM accepts
input signals from sensors and instantly drives actuators. It is essential that both input and output signals are proper and stable. At the
same time, it is important that there are no malfunctions such as vacuum leaks, fouled spark plugs, or other malfunctions with the engine.

EC

C

D

MEF036D

It is much more difficult to diagnose an incident that occurs intermittently rather than continuously. Most intermittent incidents are
caused by poor electric connections or improper wiring. In this case,
careful checking of suspected circuits may help prevent the replacement of good parts.

E

F

G

H
SEF233G

I

A visual check only may not find the cause of the incidents. A road
test with CONSULT-II (or GST) or a circuit tester connected should
be performed. Follow the Work Flow on EC-864, «WORK FLOW» .
Before undertaking actual checks, take a few minutes to talk with a
customer who approaches with a driveability complaint. The customer can supply good information about such incidents, especially
intermittent ones. Find out what symptoms are present and under
what conditions they occur. A Diagnostic Worksheet like the example
on EC-868, «Worksheet Sample» should be used.
Start your diagnosis by looking for conventional malfunctions first.
This will help troubleshoot driveability malfunctions on an electronically controlled engine vehicle.

J

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SEF234G

M

EC-863

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
WORK FLOW
Overall Sequence

PBIB2267E

EC-864

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
Detailed Flow
A

1. GET INFORMATION FOR SYMPTOM

Get the detailed information from the customer about the symptom (the condition and the environment when
EC
the incident/malfunction occurred) using the EC-867, «DIAGNOSTIC WORKSHEET» .
>> GO TO 2.
C

2. CHECK DTC*1
1.

Check DTC*1 .

2.

Perform the following procedure if DTC*1 is displayed.

–

Record DTC*1 and freeze frame data*2 . (Print them out with CONSULT-II or GST.)

–

D

Erase DTC*1 . (Refer to EC-841, «HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .)

Study the relationship between the cause detected by DTC*1 and the symptom described by the customer. (Symptom Matrix Chart is useful. Refer to EC-871, «Symptom Matrix Chart» .)
3. Check related service bulletins for information.
Is any symptom described and any DTC detected?
–

Symptom is described, DTC*1 is displayed>>GO TO 3.
Symptom is described, DTC*1 is not displayed>>GO TO 4.
Symptom is not described, DTC*1 is displayed>>GO TO 5.

E

F

G

H

3. CONFIRM THE SYMPTOM
I

Try to confirm the symptom described by the customer (except MI ON).
DIAGNOSIS WORK SHEET is useful to verify the incident.
Connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis
results.
Verify relation between the symptom and the condition when the symptom is detected.

J

K

>> GO TO 5.

4. CONFIRM THE SYMPTOM

L

Try to confirm the symptom described by the customer.
DIAGNOSIS WORK SHEET is useful to verify the incident.
Connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis
results.
Verify relation between the symptom and the condition when the symptom is detected.
>> GO TO 6.

EC-865

M

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

5. PERFORM DTC CONFIRMATION PROCEDURE
Perform DTC Confirmation Procedure for the displayed DTC*1 , and then make sure that DTC*1 is detected
again.
At this time, always connect CONSULT-II to the vehicle, and check diagnostic results in real time on “DATA
MONITOR (AUTO TRIG)”.
If two or more DTCs*1 are detected, refer to EC-869, «DTC Inspection Priority Chart» and determine trouble
diagnosis order.
NOTE:
●
Freeze frame data*2 is useful if the DTC*1 is not detected.
●
Perform Overall Function Check if DTC Confirmation Procedure is not included on Service Manual. This
simplified check procedure is an effective alternative though DTC*1 cannot be detected during this
check.
If the result of Overall Function Check is NG, it is the same as the detection of DTC*1 by DTC Confirmation Procedure.
Is DTC*1 detected?
Yes
>> GO TO 10.
No
>> Check according to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

6. PERFORM BASIC INSPECTION
Perform EC-851, «Basic Inspection» .
With CONSULT-II>>GO TO 7.
Without CONSULT-II>>GO TO 9.

7. PERFORM DATA MONITOR (SPEC) MODE
With CONSULT-II
Make sure that “MAS A/F SE-B1”, “B/FUEL SCHDL”, and “A/F
ALPHA-B1” are within the SP value using CONSULT-II “DATA MONITOR (SPEC)” mode. Refer to EC-907, «Inspection Procedure» .
Are they within the SP value?
Yes
>> GO TO 9.
No
>> GO TO 8.

SEF601Z

8. DETECT MALFUNCTIONING PART BY TROUBLE DIAGNOSIS — SPECIFICATION VALUE
Detect malfunctioning part according to EC-908, «Diagnostic Procedure» .
Is malfunctioning part detected?
Yes
>> GO TO 11.
No
>> GO TO 9.

9. DETECT MALFUNCTIONING SYSTEM BY SYMPTOM MATRIX CHART
Detect malfunctioning system according to EC-871, «Symptom Matrix Chart» based on the confirmed symptom in step 4, and determine the trouble diagnosis order based on possible causes and symptom.
>> GO TO 10.

EC-866

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

10. DETECT MALFUNCTIONING PART BY DIAGNOSTIC PROCEDURE

A
Inspect according to Diagnostic Procedure of the system.
NOTE:
The Diagnostic Procedure in EC section described based on open circuit inspection. A short circuit inspection EC
is also required for the circuit check in the Diagnostic Procedure. For details, refer to Circuit Inspection in GI25, «How to Perform Efficient Diagnosis for an Electrical Incident» .
Is malfunctioning part detected?
C
Yes
>> GO TO 11.
No
>> Monitor input data from related sensors or check voltage of related ECM terminals using CONSULT-II. Refer to EC-883, «ECM Terminals and Reference Value» , EC-902, «CONSULT-II Refer- D
ence Value in Data Monitor» .

11. REPAIR OR REPLACE THE MALFUNCTIONING PART
1.
2.
3.

E

Repair or replace the malfunctioning part.
Reconnect parts or connectors disconnected during Diagnostic Procedure again after repair and replacement.
Check DTC. If DTC is displayed, erase it, refer to EC-841, «HOW TO ERASE EMISSION-RELATED
DIAGNOSTIC INFORMATION» .

F

G

>> GO TO 12.

12. FINAL CHECK

H

When DTC was detected in step 2, perform DTC Confirmation Procedure or Overall Function Check again,
and then make sure that the malfunction have been repaired securely.
When symptom was described from the customer, refer to confirmed symptom in step 3 or 4, and make sure
that the symptom is not detected.
OK or NG

I

NG (DTC*1 is detected)>>GO TO 10.
NG (Symptom remains)>>GO TO 6.
OK
>> 1. Before returning the vehicle to the customer, make sure to erase unnecessary DTC*1 in ECM
and TCM (Transmission Control Module). (Refer to EC-841, «HOW TO ERASE EMISSIONRELATED DIAGNOSTIC INFORMATION» and AT-98, «OBD Diagnostic Trouble Code (DTC)»
.)
2. If the completion of SRT is needed, drive vehicle under the specific driving pattern. Refer to EC839, «Driving Pattern» .
3. INSPECTION END
*1: Include 1st trip DTC.
*2: Include 1st trip freeze frame data.

DIAGNOSTIC WORKSHEET
Description
There are many operating conditions that lead to the malfunction of
engine components. A good grasp of such conditions can make troubleshooting faster and more accurate.
In general, each customer feels differently about a incident. It is
important to fully understand the symptoms or conditions for a customer complaint.
Utilize a diagnostic worksheet like the one on the next page in order
to organize all the information for troubleshooting.
Some conditions may cause the MI to come on steady or blink and
DTC to be detected. Examples:
●
Vehicle ran out of fuel, which caused the engine to misfire.

EC-867

SEF907L

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TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
Worksheet Sample

MTBL0017

EC-868

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

DTC Inspection Priority Chart

BBS0049M

A
If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
chart.
NOTE:
●
If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC EC
U1000, U1001. Refer to EC-925, «DTC U1000, U1001 CAN COMMUNICATION LINE» .
●
If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer
C
to EC-928, «DTC U1010 CAN COMMUNICATION» .
Priority
1

2

3

Detected items (DTC)
●

U1000 U1001 CAN communication line

●

U1010 CAN communication

●

P0102 P0103 Mass air flow sensor

●

P0112 P0113 Intake air temperature sensor

●

P0117 P0118 Engine coolant temperature sensor

●

P0122 P0123 P0222 P0223 P1225 P1226 P2135 Throttle position sensor

●

P0327 P0328 Knock sensor

●

P0335 Crankshaft position sensor (POS)

●

P0340 Camshaft position sensor (PHASE)

●

P0500 Vehicle speed sensor

●

P0605 ECM

●

P0705 Park/Neutral position (PNP) switch

●

P1229 Sensor power supply

●

P1610 — P1615 NATS

●

P1706 Park/Neutral position (PNP) switch

●

P2122 P2123 P2127 P2128 P2138 Accelerator pedal position sensor

●

P0132 P0133 P0134 P1143 P1144 Heated oxygen sensor 1

●

P0135 Heated oxygen sensor 1 heater

●

P0138 P0139 P1146 P1147 Heated oxygen sensor 2

●

P0141 Heated oxygen sensor 2 heater

●

P0444 EVAP canister purge volume control solenoid valve

●

P0710 P0720 P0725 P0731 P0732 P0733 P0734 P0740 P0744 P0745 P0750 P0755 P1705 P1760 A/T related sensors, solenoid valves and switches

●

P1065 ECM

●

P1111 Intake valve timing control solenoid valve

●

P1122 Electric throttle control function

●

P1124 P1126 Throttle control motor relay

●

P1128 Throttle control motor

●

P1217 Engine over temperature (OVERHEAT)

●

P1805 Brake switch

●

P0011 Intake valve timing control

●

P0171 P0172 Fuel injection system function

●

P0300 — P0304 Misfire

●

P0420 Three way catalyst function

●

P1121 Electric throttle control actuator

●

P1212 ESP communication line

D

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EC-869

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

Fail-Safe Chart

BBS0049N

When the DTC listed below is detected, the ECM enters fail-safe mode and the MI lights up.
DTC No.

Detected items

Engine operating condition in fail-safe mode

P0102
P0103

Mass air flow sensor circuit

Engine speed will not rise more than 2,400 rpm due to the fuel cut.

P0117
P0118

Engine coolant temperature sensor circuit

Engine coolant temperature will be determined by ECM based on the time after turning
ignition switch ON or START.
CONSULT-II displays the engine coolant temperature decided by ECM.
Condition

Engine coolant temperature decided (CONSULTII display)

Just as ignition switch is turned
ON or START

40°C (104°F)

More than approx. 4 minutes after
ignition ON or START

80°C (176°F)

Except as shown above

40 — 80°C (104 — 176°F)
(Depends on the time)

When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates while engine is running.
P0122
P0123
P0222
P0223
P2135

Throttle position sensor

The ECM controls the electric throttle control actuator in regulating the throttle opening
in order for the idle position to be within +10 degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

P1121

Electric throttle control actuator

(When electric throttle control actuator does not function properly due to the return
spring malfunction:)
ECM controls the electric throttle actuator by regulating the throttle opening around the
idle position. The engine speed will not rise more than 2,000 rpm.
(When throttle valve opening angle in fail-safe mode is not in specified range:)
ECM controls the electric throttle control actuator by regulating the throttle opening to
20 degrees or less.
(When ECM detects the throttle valve is stuck open:)
While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops,
the engine stalls.
The engine can restart in N or P (A/T), Neutral (M/T) position, and engine speed will
not exceed 1,000 rpm or more.

●

P1122

Electric throttle control function

ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.

P1124
P1126

Throttle control relay

ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.

P1128

Throttle control motor

ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.

P1229

Sensor power supply

ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.

P2122
P2123
P2127
P2128
P2138

Accelerator pedal position
sensor

The ECM controls the electric throttle control actuator in regulating the throttle opening
in order for the idle position to be within +10 degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

When there is an open circuit on MI circuit, the ECM cannot warn the driver by lighting up MI when there
is malfunction on engine control system.
Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected
as NG for 5 trips, ECM warns the driver that engine control system malfunctions and MI circuit is open by
means of operating fail-safe function.
The fail-safe function also operates when above diagnoses except MI circuit are detected and demands
the driver to repair the malfunction.
Engine operating condition in fail-safe mode

Engine speed will not rise more than 2,500 rpm due to the fuel cut

EC-870

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

Symptom Matrix Chart

BBS0049O

A

SYSTEM — BASIC ENGINE CONTROL SYSTEM

1

1

2

3

2

Fuel pressure regulator system

3

3

4

4

4

Fuel injector circuit

1

1

2

3

2

Evaporative emission system

3

3

4

4

4

Air

Positive crankcase ventilation system

4

4

4

3

3

Incorrect idle speed adjustment

Ignition

BATTERY DEAD (UNDER CHARGE)

Fuel pump circuit

EXCESSIVE OIL CONSUMPTION

Fuel

EXCESSIVE FUEL CONSUMPTION

AE

OVERHEATS/WATER TEMPERATURE HIGH

LACK OF POWER/POOR ACCELERATION

AD

SLOW/NO RETURN TO IDLE

SPARK KNOCK/DETONATION

AC

IDLING VIBRATION

HESITATION/SURGING/FLAT SPOT

AB

ROUGH IDLE/HUNTING

ENGINE STALL

AA

Warranty symptom code

HIGH IDLE/LOW IDLE

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

AF

AG

AH

AJ

AK

AL

AM

HA

2

2

4

4

2

2

4

4

4

4

4

1
2

4

EC

3
4

2

C
Reference
page

E

F
EC-1215

4

EC-860

2

EC-1209

4

4

EC-823

4

4

4

1

1

1

1

2

2

2

2

1

EC-851

1

2

3

3

Incorrect ignition timing adjustment

3

3

1

1

1

1

1

1

EC-851

Ignition circuit

1

1

2

2

2

2

2

2

EC-1221

2

2

3

3

3

3

3

3

EC-918

Engine coolant temperature sensor circuit

2

2
3

3

Heated oxygen sensor 1 circuit
2

2

2

2

2
3

Knock sensor circuit

2

EC-959,
EC-967 ,
EC-977 ,
EC-1101 ,
EC-1107
EC-953,
EC-1026 ,
EC-1146 ,
EC-1148 ,
EC-1191

Throttle position sensor circuit

Accelerator pedal position sensor circuit

2

EC-1150,
EC-1172 ,
EC-1181 ,
EC-1197

1

2

3

EC-1038

Crankshaft position sensor (POS) circuit

2

2

EC-1042

Camshaft position sensor (PHASE) circuit

3

2

EC-1049

Vehicle speed signal circuit
ECM

2

2

3

2

3

3
3

J

K

EC-947

3
2

2

I

EC-935

1

1

H

EC-1082,
EC-1084

1

Mass air flow sensor circuit

G

EC-828

Electric throttle control actuator

Main power supply and ground circuit

D

3

EC-871

3

3

3

3

3

3

EC-1070

3

EC-1072,
EC-1075

L

M

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

AF

AG

AH

AJ

AK

AL

AM

HA

2

1

3

2

2

3

3

3

3

3

HESITATION/SURGING/FLAT SPOT

AE

ENGINE STALL

AD

HARD/NO START/RESTART (EXCP. HA)
Warranty symptom code

SPARK KNOCK/DETONATION

SYMPTOM

AA

AB

AC

3

Intake valve timing control solenoid valve circuit
PNP switch circuit
Refrigerant pressure sensor circuit

2

3

Electrical load signal circuit

3

3

EC-1077

3

EC-1158

4

EC-1231

3

Air conditioner circuit

2

2

ABS actuator and electric unit (control unit)

3

3

3

3

3

Reference
page

EC-1207
3

3

3

2

ATC-20,
MTC-20
BRC-8 or
BRC-49

4

1 — 6: The numbers refer to the order of inspection.
(continued on next page)

SYSTEM — ENGINE MECHANICAL & OTHER

Fuel

ENGINE STALL

HESITATION/SURGING/FLAT SPOT

SPARK KNOCK/DETONATION

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

Warranty symptom code

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

AA

AB

AC

AD

AE

AF

AG

AH

AJ

AK

AL

AM

HA

Fuel tank
Fuel piping

FL-19
5

Vapor lock

5

5

5

5

5

5

FL-14
—

5

Valve deposit
Poor fuel (Heavy weight gasoline, Low octane)

Reference
page

—
5

5

5

5

5

5

5
—

EC-872

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
SYMPTOM

Air

HARD/NO START/RESTART (EXCP. HA)

ENGINE STALL

HESITATION/SURGING/FLAT SPOT

SPARK KNOCK/DETONATION

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

Warranty symptom code

A

AA

AB

AC

AD

AE

AF

AG

AH

AJ

AK

AL

AM

HA

E

Air cleaner

EM-118

5

5

5

5
5

5

5

5

EM-118

5
5

EM-120

Air leakage from intake manifold/
Collector/Gasket

SC-5
1

Starter circuit

3

Signal plate

6

PNP switch

4

Cylinder head

5

1

1

1

1

1

1

5

5

5

5

5

5

5
4

EM-189

J

AT-105,
MT-16 ,
MT-46

K

EM-173

L
4
6

6

6

6

6

6

6

6

EM-189

Connecting rod
Bearing
Crankshaft
Timing chain

EM-142

Camshaft

EM-151
5

5

5

5

5

5

5

EM-142

5

Intake valve

3

EM-173

Exhaust valve
Exhaust

Exhaust manifold/Tube/Muffler/
Gasket

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

Three way catalyst
Lubrication

Oil pan/Oil strainer/Oil pump/Oil
filter/Oil gallery

I

3

Piston

Intake valve timing control

H

SC-15

Cylinder block

Valve
mechanism

G

SC-45
1

Cylinder head gasket

Piston ring

F

EM-120

Battery
Generator circuit

C

D

EM-118

Electric throttle control actuator

Engine

Reference
page

Air duct

Air leakage from air duct
(Mass air flow sensor — electric
throttle control actuator)

Cranking

EC

Oil level (Low)/Filthy oil

EM-124,
EX-3
EM-127,
LU-19
LU-16

EC-873

M

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

Cooling

ENGINE STALL

HESITATION/SURGING/FLAT SPOT

SPARK KNOCK/DETONATION

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

Warranty symptom code

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

AA

AB

AC

AD

AE

AF

AG

AH

AJ

AK

AL

AM

HA

Radiator/Hose/Radiator filler cap

CO-31

Thermostat

5

CO-38

Water pump
Water gallery

CO-36
5

5

5

5

5

5

5

4

Cooling fan

5

CO-26
CO-33

5

Coolant level (Low)/Contaminated coolant
NATS (Nissan Anti-Theft System)

Reference
page

CO-27
1

1

BL-215

1 — 6: The numbers refer to the order of inspection.

EC-874

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

Engine Control Component Parts Location

BBS0049P

A

EC

C

D

E

F

G

H

I

J
MBIB1542E

1.

Ignition coil (with power transistor)
and spark plug

2.

Intake valve timing control solenoid
valve

3.

Refrigerant pressure sensor

4.

Knock sensor

5.

Fuel injector

6.

Cooling fan motor

7.

Camshaft position sensor (PHASE)

ECM

10. Mass air flow sensor
(with intake air temperature sensor)

K

8.

IPDM E/R

9.

11.

Engine coolant temperature sensor

12. Electric throttle control actuator
(with built-in throttle position sensor,
throttle control motor)

13. EVAP canister purge volume control
solenoid valve

L

M

EC-875

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

PBIB2940E

: Vehicle front
1.

Mass air flow sensor
(with intake air temperature sensor)

2.

Engine coolant temperature sensor

3.

Electric throttle control actuator

4.

Camshaft position sensor (PHASE)

5.

Ignition coil (with power transistor)

6.

Fuel injector

7.

EVAP canister purge volume control
solenoid valve

EC-876

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
A

EC

C

D

E

F

G

H

I

J

K

L

M
MBIB1543E

: Vehicle front
1.

ECM harness connectors

2.

ECM

3.

IPDM E/R

4.

Fuel pump fuse (15A)

5.

Intake valve timing control solenoid
valve

6.

Knock sensor

7.

Refrigerant pressure sensor

8.

PCV valve

EC-877

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

PBIB2942E

PBIB2943E

: Vehicle front
1.

Exhaust manifold

4.

Heated oxygen sensor 2 harness
connector

2.

Heated oxygen sensor 1

EC-878

3.

Heated oxygen sensor 2

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
A

EC

C

D

E

F

G

H

I

J

K

L

M
MBIB1544E

1.

Cooling fan motor

2.

Crankshaft position sensor (POS)

3.

Stop lamp switch

4.

Brake pedal

5.

Accelerator pedal position sensor
harness connector

6.

Accelerator pedal position sensor

7.

Accelerator pedal

8.

Fuel level sensor unit and fuel pump
harness connector

9.

Fuel pump and fuel filter

10. Fuel pressure regulator

11. Fuel level sensor unit

EC-879

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

Vacuum Hose Drawing

BBS0049Q

PBIB2946E

: Vehicle front
1.

Intake manifold

: To EVAP canister
2.

EVAP canister purge volume control
solenoid valve

3.

EVAP purge resonator

NOTE:
Do not use soapy water or any type of solvent while installing vacuum hoses or purge hoses.

Refer to EC-816, «System Diagram» for Vacuum Control System.

EC-880

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

Circuit Diagram

BBS0049R

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1453E

EC-881

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

MBWA1454E

EC-882

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

ECM Harness Connector Terminal Layout

BBS0049S

A

EC

C

PBIA9221J

ECM Terminals and Reference Value

BBS0049T

PREPARATION
1.

E

ECM (1) is located in the engine room left side near battery.
●

D

: Vehicle front
F

G

H
PBIB2959E

2.

3.

Disconnect ECM harness connector.
● When disconnecting ECM harness connector, loosen (A) it
with levers (1) as far as they will go as shown in the figure.
– ECM (2)
– Fasten (B)
Connect a break-out box (SST) and Y-cable adapter (SST)
between the ECM and ECM harness connector.
● Use extreme care not to touch 2 pins at one time.
● Data is for comparison and may not be exact.

I

J

K

PBIB2947E

L

ECM INSPECTION TABLE
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECMs transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Approximately 3.2V
[Ignition switch: ON]
1

P

Throttle control motor
(Open)

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed
PBIA8150J

2

LG

Throttle control motor power
supply

[Ignition switch: ON]

EC-883

BATTERY VOLTAGE
(11 — 14V)

M

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Approximately 10V
[Engine is running]

3

Y

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

Heated oxygen sensor 1
heater
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

[Engine is running]
●

BATTERY VOLTAGE
(11 — 14V)

Engine speed: Above 3,600 rpm
Approximately 1.8V

[Ignition switch: ON]
4

L

Throttle control motor
(Close)

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released
PBIA8149J

[Engine is running]

5

GR

●

Engine speed: Below 3,600 rpm after the
following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between
3,500 and 4,000 rpm for 1 minute and at
idle for 1 minute under no load.

Heated oxygen sensor 2
heater

Approximately 10V

PBIA8148J

[Ignition switch: ON]
●

Engine stopped

[Engine is running]
●

BATTERY VOLTAGE
(11 — 14V)

Engine speed: Above 3,600 rpm
BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
●

9

LG

Idle speed

EVAP canister purge volume control solenoid valve

PBIB0050E

Approximately 10V
[Engine is running]
●

Engine speed: About 2,000 rpm (More
than 100 seconds after starting engine)

PBIB0520E

10
11

B
B/W

ECM ground

[Engine is running]
●

Idle speed

EC-884

Body ground

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

[Engine is running]
●

Warm-up condition

●

Idle speed

DATA (DC Voltage)

A

3 — 5V

EC

NOTE:
The pulse cycle changes depending on
rpm at idle.

C
PBIA8164J

13

L

Tachometer signal

D

3 — 5V
[Engine is running]
●
●

E

Warm-up condition
Engine speed: 2,000 rpm

F
PBIA8165J

15

G

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 1.0V

Throttle control motor relay

[Engine is running]

17
18
21
22

V
BR
G
Y

●

Warm-up condition

●

Idle speed

G

0 — 0.3V

H

NOTE:
The pulse cycle changes depending on
rpm at idle.

Ignition signal No. 1
Ignition signal No. 2
Ignition signal No. 4
Ignition signal No. 3

I
PBIA9265J

J

0.2 — 0.5V
[Engine is running]
●
●

K

Warm-up condition
Engine speed: 2,500 rpm

L
PBIA9266J

[Ignition switch: ON]
●

23

R

Fuel pump relay

For 1 second after turning ignition switch
ON

0 — 1.0V

[Engine is running]
[Ignition switch: ON]
●

More than 1 second after turning ignition
switch ON

EC-885

BATTERY VOLTAGE
(11 — 14V)

M

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)
BATTERY VOLTAGE

[Engine is running]

25
29
30
31

R
O
GR
L

●

Warm-up condition

●

Idle speed

(11 — 14V)

NOTE:
The pulse cycle changes depending on
rpm at idle.

Fuel injector No. 4
Fuel injector No. 3
Fuel injector No. 2
Fuel injector No. 1

PBIB0529E

BATTERY VOLTAGE
(11 — 14V)
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

PBIA4943J

[Engine is running]
[Ignition switch: OFF]
●

32

P

ECM relay
(Self shut-off)

For a few seconds after turning ignition
switch OFF

[Ignition switch: OFF]
●

More than a few seconds after turning
ignition switch OFF

0 — 1.0V

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

33

Y

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

More than 0.36V

Throttle position sensor 1
[Ignition switch: ON]
●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

Less than 4.75V

[Ignition switch: ON]

34

R

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

Throttle position sensor 2

Less than 4.75V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

More than 0.36V

[Engine is running]
36

37

BR

W

Sensor ground
(Throttle position sensor)

Knock sensor

●

Warm-up condition

●

Idle speed

[Engine is running]
●

38

P

Engine coolant temperature
sensor

Idle speed

[Engine is running]

EC-886

Approximately 0V

Approximately 2.5V
Approximately 0 — 4.8V
Output voltage varies with engine
coolant temperature.

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

A

[Engine is running]
40

—

Sensor ground
(Knock sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

EC

[Engine is running]
●

41

44

BR

B

Refrigerant pressure sensor

Sensor ground
(Engine coolant temperature
sensor)

●

C

Warm-up condition
Both A/C switch and blower fan switch:
ON
(Compressor operates.)

1.0 — 4.0V

D

[Engine is running]
●

Warm-up condition

●

Idle speed

[Ignition switch: ON]
●

Engine stopped

Approximately 0V

E
Approximately 0.4V

F

[Engine is running]
45

G

Mass air flow sensor

●

Warm-up condition

●

Idle speed

[Engine is running]

46

V

Intake air temperature
sensor

48

Y

Sensor ground
(Refrigerant pressure sensor)

●

Warm-up condition

●

Engine is revving from idle to about 4,000
rpm

[Engine is running]

1.0 — 1.3V

G
1.0 — 1.3 to Approximately 2.4V
(Check for linear voltage rise in
response to engine being
increased to about 4,000 rpm.)

H

Approximately 0 — 4.8V
Output voltage varies with intake
air temperature.

I

Approximately 0V

J

0 — Approximately 1.0V
(Periodically change)

K

[Engine is running]
●

Warm-up condition

●

Idle speed

[Engine is running]
49

BR

Heated oxygen sensor 1

●

Warm-up condition

●

Engine speed: 2,000 rpm

[Engine is running]

50

B

Heated oxygen sensor 2

●

Revving engine from idle to 3,000 rpm
quickly after the following conditions are
met.

–

Engine: After warming up

–

Keeping the engine speed between
3,500 and 4,000 rpm for 1 minute and at
idle for 1 minute under no load.

L
0 — Approximately 1.0V

[Engine is running]
52

55

LG

O

Sensor ground
(Mass air flow sensor)
Sensor ground
(Intake air temperature sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
56

R

Sensor ground
(Heated oxygen sensor 1)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
59

LG

Sensor ground
(Heated oxygen sensor 2)

●

Warm-up condition

●

Idle speed

EC-887

Approximately 0V

M

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

[Engine is running]
●

Warm-up condition

●

Idle speed

DATA (DC Voltage)

0 — 1.0V

NOTE:
The pulse cycle changes depending on
rpm at idle.
61

Y

MBIB1453E

Crankshaft position sensor
(POS)

0 — 1.0V

[Engine is running]
●

Engine speed: 2,000 rpm

MBIB1454E

62

63

W

B

Sensor ground
[Crankshaft position sensor
(POS)]

[Engine is running]

Sensor ground
[Camshaft position sensor
(PHASE)]

[Engine is running]

●

Warm-up condition

●

Idle speed

●

Warm-up condition

●

Idle speed

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0V

Approximately 0V

0 — 1.0V

NOTE:
The pulse cycle changes depending on
rpm at idle.
65

R

MBIB1455E

Camshaft position sensor
(PHASE)

0 — 1.0V

[Engine is running]
●

Engine speed: 2,000 rpm

MBIB1456E

[Ignition switch: ON]
70

GR

Park/Neutral position (PNP)
switch

●

Shift lever: P or N (A/T models)

●

Shift lever: Neutral (M/T models)

[Ignition switch: ON]
●

72

L

Sensor power supply
(Throttle position sensor)

Except above position

[Ignition switch: ON]

EC-888

Approximately 0V

BATTERY VOLTAGE
(11 — 14V)
Approximately 5V

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

A

[Engine is running]
●

Warm-up condition

●

Idle speed

BATTERY VOLTAGE
(11 — 14V)

EC

7 — 10V
73

LG

Intake valve timing control
solenoid valve

C

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

D

PBIA4937J

74

W

Sensor power supply
(Refrigerant pressure
sensor)

75

G

Sensor power supply
[Crankshaft position sensor
(POS)]

[Ignition switch: ON]

Approximately 5V

78

O

Sensor power supply
[Camshaft position sensor
(PHASE)]

[Ignition switch: ON]

Approximately 5V

83

Y

CAN communication line

[Ignition switch: ON]

Approximately 1.7 — 2.3V

84

L

CAN communication line

[Ignition switch: ON]

Approximately 2.6 — 3.2V

88

LG

DATA link connector

[Ignition switch: ON]

Approximately 5V

F

G

[Ignition switch: ON]
●

93

O

CONSULT-II or GST: Disconnected.

0V

[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)

●

R

Stop lamp switch

Brake pedal: Fully released

[Ignition switch: OFF]
●

102

BR

Sensor power supply
(Accelerator pedal position
sensor 2)

Approximately 2.7V

[Ignition switch: OFF]
Ignition switch
[Ignition switch: OFF]
99

Brake pedal: Slightly depressed

104

G

B

Accelerator pedal position
sensor 2

H

I

J

Approximately 0V

K
BATTERY VOLTAGE
(11 — 14V)

L
[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

103

E

●

Engine stopped

●

Accelerator pedal: Fully released

M
0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

Sensor ground
(Accelerator pedal position
sensor 2)

[Engine is running]
●

Warm-up condition

●

Idle speed

1.95 — 2.4V

Approximately 0V

105

G

Power supply for ECM

[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)

106

O

Sensor power supply
(Accelerator pedal position
sensor 1)

[Ignition switch: ON]

Approximately 5V

108

B

ECM ground

[Engine is running]
●

Idle speed

EC-889

Body ground

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch: ON]

110

111

W

B

Accelerator pedal position
sensor 1

Sensor ground
(Accelerator pedal position
sensor 1)

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

[Engine is running]
●

Warm-up condition

●

Idle speed

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-890

Approximately 0V

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

CONSULT-II Function (ENGINE)

BBS0049U

A

FUNCTION
Diagnostic test mode

Function

Work support

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

Self-diagnostic results

Self-diagnostic results such as 1st trip DTC, DTCs and 1st trip freeze frame data or freeze frame data
can be read and erased quickly.*

Data monitor

Input/Output data in the ECM can be read.

Data monitor (SPEC)

Input/Output of the specification for Basic fuel schedule, AFM, A/F feedback control value and the
other data monitor items can be read.

CAN diagnostic support
monitor

The results of transmit/receive diagnosis of CAN communication can be read.

Active test

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

Function test

This mode is used to inform customers when their vehicle condition requires periodic maintenance.

DTC & SRT confirmation

The status of system monitoring tests and the self-diagnosis status/result can be confirmed.

ECM part number

ECM part number can be read.

EC

C

D

E

F

*: The following emission-related diagnostic information is cleared when the ECM memory is erased.
●

Diagnostic trouble codes

●

1st trip diagnostic trouble codes

●

Freeze frame data

●

1st trip freeze frame data

●

System readiness test (SRT) codes

●

Test values

G

H

I

J

K

L

M

EC-891

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
DIAGNOSTIC TEST MODE
SELF-DIAGNOSTIC RESULTS
Item

WORK
SUPPORT

DTC*1

FREEZE
FRAME

DATA
MONITOR

DATA
MONITOR
(SPEC)

INPUT
OUTPUT

ENGINE CONTROL COMPONENT PARTS

ENGINE CONTROL COMPONENT PARTS

DATA*2

DTC & SRT
CONFIRMATION
ACTIVE
TEST

SRT
STATUS

DTC
WORK
SUPPORT

Crankshaft position sensor (POS)

×

×

×

×

Camshaft position sensor
(PHASE)

×

×

×

×

Mass air flow sensor

×

×

×

Engine coolant temperature sensor

×

×

×

Heated oxygen sensor 1

×

×

×

×

×

Heated oxygen sensor 2

×

×

×

×

×

Wheel sensor

×

×

×

Accelerator pedal position sensor

×

×

×

Throttle position sensor

×

×

×

Intake air temperature sensor

×

×

×

Knock sensor

×

EPS control unit

×

×

Refrigerant pressure sensor

×

×

Closed throttle position switch
(accelerator pedal position sensor
signal)

×

×

Air conditioner switch

×

×

×

×

×

×

Park/neutral position (PNP) switch

×

×

×

Stop lamp switch

×

×

×

Battery voltage

×

×

Load signal

×

×

Fuel injector

×

×

×

Power transistor (Ignition timing)

×

×

×

×

×

×

×

×

×

×

×

×
×

Throttle control motor relay

×

Throttle control motor

×

EVAP canister purge volume control solenoid valve

×

Air conditioner relay
Fuel pump relay

×

×

×

Cooling fan relay

×

×

×

Heated oxygen sensor 1 heater

×

×

×

×

Heated oxygen sensor 2 heater

×

×

×

×

Intake valve timing control solenoid
valve

×

×

×

×

×

×

Calculated load value

×

X: Applicable
*1: This item includes 1st trip DTCs.
*2: This mode includes 1st trip freeze frame data or freeze frame data. The items appear on CONSULT-II screen in freeze frame data
mode only if a 1st trip DTC or DTC is detected. For details, refer to EC-834, «FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME
DATA» .

EC-892

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
INSPECTION PROCEDURE
A

Refer to GI-36, «CONSULT-II Start Procedure» .

WORK SUPPORT MODE
Work Item

EC

WORK ITEM

CONDITION

FUEL PRESSURE RELEASE

IDLE AIR VOL LEARN

●

●

SELF-LEARNING CONT

●

USAGE

FUEL PUMP WILL STOP BY TOUCHING “START” DURING IDLING.
CRANK A FEW TIMES AFTER ENGINE STALLS.

When releasing fuel pressure
from fuel line

THE IDLE AIR VOLUME THAT KEEPS THE ENGINE
WITHIN THE SPECIFIED RANGE IS MEMORIZED IN
ECM.

When learning the idle air volume

THE COEFFICIENT OF SELF-LEARNING CONTROL
MIXTURE RATIO RETURNS TO THE ORIGINAL COEFFICIENT.

When clearing the coefficient of
self-learning control value

C

D

TARGET IDLE RPM ADJ*

●

IDLE CONDITION

When setting target idle speed

TARGET IGN TIM ADJ*

●

IDLE CONDITION

When adjusting target ignition timing

E

F

*: This function is not necessary in the usual service procedure.

G

SELF-DIAG RESULTS MODE
Self Diagnostic Item
Regarding items of DTC and 1st trip DTC, refer to EC-831, «EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS» .

H

Freeze Frame Data and 1st Trip Freeze Frame Data
Freeze frame data
item*
DIAG TROUBLE
CODE
[PXXXX]

Description
●

The engine control component part/control system has a trouble code, it is displayed as PXXXX. (Refer to
EC-803, «INDEX FOR DTC» .)

●

“Fuel injection system status” at the moment a malfunction is detected is displayed.

●

One mode in the following is displayed.
Mode2: Open loop due to detected system malfunction
Mode3: Open loop due to driving conditions (power enrichment, deceleration enleanment)
Mode4: Closed loop — using oxygen sensor(s) as feedback for fuel control
Mode5: Open loop — has not yet satisfied condition to go to closed loop

FUEL SYS-B1

CAL/LD VALUE [%]

●

The calculated load value at the moment a malfunction is detected is displayed.

COOLANT TEMP
[°C] or [°F]

●

The engine coolant temperature at the moment a malfunction is detected is displayed.

●

“Long-term fuel trim” at the moment a malfunction is detected is displayed.

●

The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule
than short-term fuel trim.

L-FUEL TRM-B1 [%]

●

“Short-term fuel trim” at the moment a malfunction is detected is displayed.

S-FUEL TRM-B1 [%]

●

The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel
schedule.

ENGINE SPEED
[rpm]

●

The engine speed at the moment a malfunction is detected is displayed.

VEHICL SPEED
[km/h] or [mph]

●

The vehicle speed at the moment a malfunction is detected is displayed.

B/FUEL SCHDL
[msec]

●

The base fuel schedule at the moment a malfunction is detected is displayed.

INT/A TEMP SE
[°C] or [°F]

●

The intake air temperature at the moment a malfunction is detected is displayed.

*: The items are the same as those of 1st trip freeze frame data.

EC-893

I

J

K

L

M

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
DATA MONITOR MODE
Monitored Item
Monitored item
[Unit]

ECM
INPUT
SIGNALS

×: Applicable
MAIN
SIGNALS

Description

●

ENG SPEED [rpm]

×

×

MAS A/F SE-B1 [V]

×

×

B/FUEL SCHDL
[msec]

×

COOLAN TEMP/S
[°C] or [°F]

×

×

HO2S1 (B1) [V]

×

×

HO2S2 (B1) [V]

×

HO2S1 MNTR (B1)
[RICH/LEAN]

●

The signal voltage of the mass air flow sensor
is displayed.

●

“Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior
to any learned on board correction.

×

A/F ALPHA-B1 [%]

×

Indicates the engine speed computed from the
signals of the crankshaft position sensor
(POS) and camshaft position sensor (PHASE).

●

The mean value of the air-fuel ratio feedback
correction factor per cycle is indicated.

●

The engine coolant temperature (determined
by the signal voltage of the engine coolant
temperature sensor) is displayed.

●

The signal voltage of the heated oxygen sensor 1 is displayed.

●

The signal voltage of the heated oxygen sensor 2 is displayed.

●

Display of heated oxygen sensor 1 signal during air-fuel ratio feedback control:
RICH: means the mixture became “rich”, and
control is being affected toward a leaner mixture.
LEAN: means the mixture became “lean”, and
control is being affected toward a rich mixture.

×

●

Display of heated oxygen sensor 2 signal:
RICH: means the amount of oxygen after three
way catalyst is relatively small.
LEAN: means the amount of oxygen after
three way catalyst is relatively large.

HO2S2 MNTR (B1)
[RICH/LEAN]

×

VHCL SPEED SE
[km/h] or [mph]

×

×

●

The vehicle speed computed from the vehicle
speed signal is displayed.

BATTERY VOLT [V]

×

×

●

The power supply voltage of ECM is displayed.

ACCEL SEN 1 [V]

×

×
●

The accelerator pedal position sensor signal
voltage is displayed.

●

The throttle position sensor signal voltage is
displayed.

ACCEL SEN 2 [V]

×

THRTL SEN 1 [V]

×

THRTL SEN 2 [V]

×

×

EC-894

Remarks
●

Accuracy becomes poor if engine
speed drops below the idle rpm.

●

If the signal is interrupted while
the engine is running, an abnormal value may be indicated.

●

When the engine is stopped, a
certain value is indicated.

●

When the engine is stopped, a
certain value is indicated.

●

This data also includes the data
for the air-fuel ratio learning control.

●

When the engine coolant temperature sensor is open or shortcircuited, ECM enters fail-safe
mode. The engine coolant temperature determined by the ECM
is displayed.

●

After turning ON the ignition
switch, “RICH” is displayed until
air-fuel mixture ratio feedback
control begins.

●

When the air-fuel ratio feedback
is clamped, the value just before
the clamping is displayed continuously.

●

When the engine is stopped, a
certain value is indicated.

●

ACCEL SEN 2 signal is converted by ECM internally. Thus, it
differs from ECM terminal voltage
signal.

●

THRTL SEN 2 signal is converted by ECM internally. Thus, it
differs from ECM terminal voltage
signal.

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
ECM
INPUT
SIGNALS

MAIN
SIGNALS

INT/A TEMP SE
[°C] or [°F]

×

×

START SIGNAL
[ON/OFF]

×

×

CLSD THL POS
[ON/OFF]

×

×

AIR COND SIG
[ON/OFF]

×

×

P/N POSI SW
[ON/OFF]

×

×

PW/ST SIGNAL
[ON/OFF]

×

×

Monitored item
[Unit]

Description
●

●

●

●

Remarks

The intake air temperature (determined by the
signal voltage of the intake air temperature
sensor) is indicated.
Indicates start signal status [ON/OFF] computed by the ECM according to the signals of
engine speed and battery voltage.

EC
●

After starting the engine, [OFF] is
displayed regardless of the
starter signal.

D

Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioner signal.

E

Indicates [ON/OFF] condition from the park/
neutral position (PNP) switch signal.

●

[ON/OFF] condition of the power steering system (determined by the signal sent from EPS
control unit) is indicated.

●

Indicates [ON/OFF] condition from the electrical load signal.
ON: Rear window defogger switch is ON and/
or lighting switch is in 2nd position.
OFF: Both rear window defogger switch and
lighting switch are OFF.

F

G

LOAD SIGNAL
[ON/OFF]

×

IGNITION SW
[ON/OFF]

×

●

Indicates [ON/OFF] condition from ignition
switch.

HEATER FAN SW
[ON/OFF]

×

●

Indicates [ON/OFF] condition from the heater
fan switch signal.

BRAKE SW
[ON/OFF]

×

●

Indicates [ON/OFF] condition from the stop
lamp switch signal.

●

Indicates the actual fuel injection pulse width
compensated by ECM according to the input
signals.

●

When the engine is stopped, a
certain computed value is indicated.

●

Indicates the ignition timing computed by ECM
according to the input signals.

●

When the engine is stopped, a
certain value is indicated.

INJ PULSE-B1
[msec]

×

IGN TIMING [BTDC]

×

CAL/LD VALUE [%]
MASS AIRFLOW
[g·m/s]

●

“Calculated load value” indicates the value of
the current airflow divided by peak airflow.

●

Indicates the mass airflow computed by ECM
according to the signal voltage of the mass air
flow sensor.

●

Indicates the EVAP canister purge volume
control solenoid valve control value computed
by the ECM according to the input signals.

●

The opening becomes larger as the value
increases.

●

Indicates [°CA] of intake camshaft advanced
angle.

●

The control value of the intake valve timing
control solenoid valve (determined by ECM
according to the input signal) is indicated.

●

The advance angle becomes larger as the
value increases

PURG VOL C/V [%]

INT/V TIM (B1)
[°CA]

INT/V SOL (B1) [%]

C

Indicates idle position [ON/OFF] computed by
the ECM according to the accelerator pedal
position sensor signal.

●

×

A

EC-895

H

I

J

K

L

M

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
Monitored item
[Unit]

ECM
INPUT
SIGNALS

MAIN
SIGNALS

AIR COND RLY
[ON/OFF]

×

FUEL PUMP RLY
[ON/OFF]

×

THRTL RELAY
[ON/OFF]

×

Description
●

The air conditioner relay control condition
(determined by ECM according to the input
signals) is indicated.

●

Indicates the fuel pump relay control condition
determined by ECM according to the input signals.

●

Indicates the throttle control motor relay control condition determined by the ECM according to the input signals.

●

Indicates the condition of the cooling fan
(determined by ECM according to the input
signals).
HI: High speed operation
LOW: Low speed operation
OFF: Stop

●

Indicates [ON/OFF] condition of heated oxygen sensor 1 heater determined by ECM
according to the input signals.

●

Indicates [ON/OFF] condition of heated oxygen sensor 2 heater determined by ECM
according to the input signals.

●

Display the condition of idle air volume learning
YET: Idle Air Volume Learning has not been
performed yet.
CMPLT: Idle Air Volume Learning has already
been performed successfully.

●

Distance traveled while MIL is activated.

●

Indicates the heated oxygen sensor 1 heater
control value computed by the ECM according
to the input signals.

COOLING FAN
[HI/LOW/OFF]

HO2S1 HTR (B1)
[ON/OFF]
HO2S2 HTR (B1)
[ON/OFF]

IDL A/V LEARN
[YET/CMPLT]

TRVL AFTER MIL
[km] or [mile]
O2SEN HTR DTY
[%]
I/P PULLY SPD
[km/h] or [MPH]

×

●

Indicates the engine speed computed from the
turbine revolution sensor signal.

AC PRESS SEN [V]

×

●

The signal voltage from the refrigerant pressure sensor is displayed.

Remarks

Voltage [V]
Frequency
[msec], [Hz] or [%]
DUTY-HI
DUTY-LOW

●

Voltage, frequency, duty cycle or pulse width
measured by the probe.

PLS WIDTH-HI

●

Only “#” is displayed if item is
unable to be measured.

●

Figures with “#”s are temporary
ones. They are the same figures
as an actual piece of data which
was just previously measured.

PLS WIDTH-LOW
NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

EC-896

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
DATA MONITOR (SPEC) MODE
Monitored Item
Monitored item [Unit]

ECM
input
signals

A

Main
signals

Description

EC
●

ENG SPEED [rpm]

×

×

MAS A/F SE-B1 [V]

×

×

B/FUEL SCHDL
[msec]

The signal voltage of the mass air flow
sensor specification is displayed.

●

“Base fuel schedule” indicates the fuel
injection pulse width programmed into
ECM, prior to any learned on board correction.

●

×

Indicates the engine speed computed
from the signal of the crankshaft position
sensor (POS) and camshaft position
sensor (PHASE).

●

×

A/F ALPHA-B1 [%]

Remarks

The mean value of the air-fuel ratio feedback correction factor per cycle is indicated.

C
●

●

When engine is running specification
range is indicated.
When engine is running specification
range is indicated.

●

When engine is running specification
range is indicated.

●

This data also includes the data for the
air-fuel ratio learning control.

D

E

F

NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

G

ACTIVE TEST MODE
Test Item

H

TEST ITEM

CONDITION
●

FUEL INJECTION

IGNITION TIMING

POWER BALANCE

COOLING FAN*1,

●

FUEL PUMP
RELAY

Change the amount of fuel injection using CONSULT-II.

●

Engine: Return to the original
trouble condition

●

Timing light: Set

●

Retard the ignition timing using
CONSULT-II.

●

Engine: After warming up, idle
the engine.

●

A/C switch OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

Cut off each fuel injector signal
one at a time using CONSULT-II.

●

Ignition switch: ON

●

Turn the cooling fan “LOW”,
“MID”, “HI” and “OFF” with CONSULT-II.

*2, *3

ENG COOLANT
TEMP

Engine: Return to the original
trouble condition

●

Engine: Return to the original
trouble condition

●

Change the engine coolant temperature using CONSULT-II.

●

Ignition switch: ON (Engine
stopped)

●

Turn the fuel pump relay ON and
OFF using CONSULT-II and listen to operating sound.

JUDGEMENT
If trouble symptom disappears, see
CHECK ITEM.

CHECK ITEM (REMEDY)
●

Harness and connectors

●

Fuel injector

●

Air fuel ratio (A/F) sensor 1

I

J
If trouble symptom disappears, see
CHECK ITEM.

●

K
●

Harness and connectors

●

Compression

●

Fuel injector

●

Power transistor

●

Spark plug

●

Ignition coil

●

Harness and connectors

●

Cooling fan relay

●

Cooling fan motor

●

Harness and connectors

●

Engine coolant temperature sensor

●

Fuel injector

●

Harness and connectors

●

Fuel pump relay

Engine runs rough or dies.

Cooling fan moves and stops.

If trouble symptom disappears, see
CHECK ITEM.

Fuel pump relay makes the operating sound.

EC-897

Perform Idle Air Volume Learning.

L

M

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
TEST ITEM

PURG VOL
CONT/V

CONDITION
●

Engine: After warming up, run
engine at 1,500 rpm.

●

Change the EVAP canister purge
volume control solenoid valve
opening percent using CONSULT-II.

●

V/T ASSIGN
ANGLE

●

Engine: Return to the original
trouble condition
Change intake valve timing using
CONSULT-II.

JUDGEMENT

Engine speed changes according to
the opening percent.

If trouble symptom disappears, see
CHECK ITEM.

CHECK ITEM (REMEDY)

●

Harness and connectors

●

Solenoid valve

●

Harness and connectors

●

Intake valve timing control solenoid valve

*1: Leaving cooling fan OFF with CONSULT-II while engine is running may cause the engine to overheat.
*2: With A/C: “OFF”, “LOW”, “MID” or “HI” is displayed on CONSULT-II screen. But cooling fan operates at the same speed when “MID”
or “HI” is displayed.
*3:Without A/C: “OFF”, “LOW”, “MID” or “HI” is displayed on CONSULT-II screen. But cooling fan operates at the same speed when an
item other than “OFF” is displayed.

DTC & SRT CONFIRMATION MODE
SRT STATUS Mode
For details, refer to EC-834, «SYSTEM READINESS TEST (SRT) CODE» .

SRT WORK SUPPORT Mode
This mode enables a technician to drive a vehicle to set the SRT while monitoring the SRT status.

DTC WORK SUPPORT Mode
Test mode

HO2S1

Test item

Reference page

HO2S1 (B1) P0133

EC-967, «DTC P0133 HO2S1»

HO2S1 (B1) P0134

EC-977, «DTC P0134 HO2S1»

HO2S1 (B1) P1143
HO2S1 (B1) P1144
HO2S2 (B1) P0139
HO2S2

Condition

Refer to corresponding
trouble diagnosis for
DTC.

EC-1101, «DTC P1143 HO2S1»
EC-1107, «DTC P1144 HO2S1»
EC-998, «DTC P0139 HO2S2»

HO2S2 (B1) P1146

EC-1113, «DTC P1146 HO2S2»

HO2S2 (B1) P1147

EC-1121, «DTC P1147 HO2S2»

REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA)
Description
CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR”
mode.
1. “AUTO TRIG” (Automatic trigger):
● The malfunction will be identified on the CONSULT-II screen
in real time.
In other words, DTC/1st trip DTC and malfunction item will be
displayed if the malfunction is detected by ECM.
At the moment a malfunction is detected by ECM, “MONITOR” in “DATA MONITOR” screen is changed to “Recording
Data … xx%” as shown at right, and the data after the malfunction detection is recorded. Then when the percentage
reached 100%, “REAL-TIME DIAG” screen is displayed. If
“STOP” is touched on the screen during “Recording Data …
PBIB1593E
xx%”, “REAL-TIME DIAG” screen is also displayed.

EC-898

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

2.

The recording time after the malfunction detection and the
recording speed can be changed by “TRIGGER POINT” and
“Recording Speed”. Refer to CONSULT-II OPERATION MANUAL.
“MANU TRIG” (Manual trigger):
● DTC/1st trip DTC and malfunction item will not be displayed
automatically on CONSULT-II screen even though a malfunction is detected by ECM.
DATA MONITOR can be performed continuously even though
a malfunction is detected.

A

EC

C
SEF707X

D

Operation
1.

2.

“AUTO TRIG”
● While trying to detect the DTC/1st trip DTC by performing the “DTC Confirmation Procedure”, be sure
to select to “DATA MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is
detected.
● While narrowing down the possible causes, CONSULT-II should be set in “DATA MONITOR (AUTO
TRIG)” mode, especially in case the incident is intermittent.
When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components and harness in the “DTC Confirmation Procedure”, the moment a malfunction is found the DTC/
1st trip DTC will be displayed. (Refer to “INCIDENT SIMULATION TESTS” in GI-25, «How to Perform
Efficient Diagnosis for an Electrical Incident» .)
“MANU TRIG”
● If the malfunction is displayed as soon as “DATA MONITOR” is selected, reset CONSULT-II to “MANU
TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The data can be utilized for further diagnosis, such as a comparison with the value for the normal operating condition.

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PBIB0197E

EC-899

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

Generic Scan Tool (GST) Function

BBS0049V

DESCRIPTION
Generic Scan Tool (OBDII scan tool) complying with ISO 15031-4
has 8 different functions explained below.
ISO9141 is used as the protocol.
The name “GST” or “Generic Scan Tool” is used in this service manual.

SEF139P

FUNCTION
Diagnostic service

Function

Service $01

READINESS TESTS

This diagnostic service gains access to current emission-related data values, including
analog inputs and outputs, digital inputs and outputs, and system status information.

Service $02

(FREEZE DATA)

This diagnostic service gains access to emission-related data value which were stored by
ECM during the freeze frame. For details, refer to EC-834, «FREEZE FRAME DATA AND
1ST TRIP FREEZE FRAME DATA» .

Service $03

DTCs

This diagnostic service gains access to emission-related power train trouble codes which
were stored by ECM.
This diagnostic service can clear all emission-related diagnostic information. This
includes:

Service $04

CLEAR DIAG INFO

●

Clear number of diagnostic trouble codes (Service $01)

●

Clear diagnostic trouble codes (Service $03)

●

Clear trouble code for freeze frame data (Service $01)

●

Clear freeze frame data (Service $02)

●

Reset status of system monitoring test (Service $01)

●

Clear on board monitoring test results (Service $06 and $07)

Service $06

(ON BOARD TESTS)

This diagnostic service accesses the results of on board diagnostic monitoring tests of
specific components/systems that are not continuously monitored.

Service $07

(ON BOARD TESTS)

This diagnostic service enables the off board test drive to obtain test results for emissionrelated powertrain components/systems that are continuously monitored during normal
driving conditions.

Service $08
Service $09

—
(CALIBRATION ID)

This diagnostic service is not applicable on this vehicle.
This diagnostic service enables the off-board test device to request specific vehicle information such as Vehicle Identification Number (VIN) and Calibration IDs.

INSPECTION PROCEDURE
1.
2.

Turn ignition switch OFF.
Connect GST to data link connector (1), which is located under
LH dash panel.

PBIB2951E

EC-900

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
3.
4.

Turn ignition switch ON.
Enter the program according to instruction on the screen or in
the operation manual.
(*: Regarding GST screens in this section, sample screens are
shown.)

A

EC

C
SEF398S

D

5.

Perform each diagnostic service according to each service procedure.
For further information, see the GST Operation Manual of
the tool maker.

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SEF416S

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EC-901

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

CONSULT-II Reference Value in Data Monitor

BBS0049W

Remarks:
● Specification data are reference values.
● Specification data are output/input values which are detected or supplied by the ECM at the connector.
* Specification data may not be directly related to their components signals/values/operations.
i.e. Adjust ignition timing with a timing light before monitoring IGN TIMING, because the monitor may show the specification data in
spite of the ignition timing not being adjusted to the specification data. This IGN TIMING monitors the data calculated by the ECM
according to the signals input from the camshaft position sensor and other ignition timing related sensors.
MONITOR ITEM
CONDITION
SPECIFICATION
●

ENG SPEED

Run engine and compare CONSULT-II value with the tachometer indication.

Almost the same speed as
the tachometer indication.

MAS A/F SE-B1

See EC-907, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .

B/FUEL SCHDL

See EC-907, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .

A/F ALPHA-B1

See EC-907, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .

COOLAN TEMP/S

●

Engine: After warming up

HO2S1 (B1)

●

Engine: After warming up

●

Revving engine from idle to 3,000 rpm quickly after the following conditions
are met.

–

Engine: After warming up

–

Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute
and idle for 1 minute under no load

●

Engine: After warming up

●

Revving engine from idle to 3,000 rpm quickly after the following conditions
are met.

–

Engine: After warming up

–

Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute
and idle for 1 minute under no load

●

Turn drive wheels and compare CONSULT-II value with the speedometer
indication.

Almost the same speed as
the speedometer indication.

●

Ignition switch: ON (Engine stopped)

11 — 14V

●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

4.0 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

3.9 — 4.8V

HO2S2 (B1)

HO2S1 MNTR (B1)

HO2S2 MNTR (B1)

VHCL SPEED SE
BATTERY VOLT
ACCEL SEN 1

ACCEL SEN 2*1

●

More than 70°C (158°F)
Maintaining engine speed at 2,000 rpm

Maintaining engine speed at 2,000 rpm

0 — 0.3V ←→ Approx. 0.6 1.0V

0 — 0.3V ←→ Approx. 0.6 1.0V

LEAN ←→ RICH
Changes more than 5 times
during 10 seconds.

LEAN ←→ RICH

●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

More than 0.36V

●

Shift lever: D (A/T), 1st (M/T)

Accelerator pedal: Fully depressed

Less than 4.75V

START SIGNAL

●

Ignition switch: ON → START → ON

CLSD THL POS

●

Ignition switch: ON

THRTL SEN 1
THRTL SEN 2*

1

AIR COND SIG

P/N POSI SW

PW/ST SIGNAL

●

●

●

Engine: After warming up, idle
the engine

Ignition switch: ON
Engine: After warming up, idle
the engine

OFF → ON → OFF

Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates.)

ON

Shift lever: P or N (A/T), Neutral (M/T)

ON

Shift lever: Except above

OFF

Steering wheel: Not being turned.

OFF

Steering wheel: Being turned.

ON

EC-902

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
MONITOR ITEM

LOAD SIGNAL

CONDITION

●

Ignition switch: ON

IGNITION SW

●

Ignition switch: ON → OFF → ON

HEATER FAN SW

●

Ignition switch: ON

BRAKE SW

INJ PULSE-B1

IGN TIMING

CAL/LD VALUE

MASS AIRFLOW

PURG VOL C/V

INT/V TIM (B1)

INT/V SOL (B1)

AIR COND RLY

●

Ignition switch: ON

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

●

Engine: After warming up, idle
the engine

SPECIFICATION

A

Rear window defogger switch: ON
and/or
Lighting switch: 2nd

ON

Rear window defogger switch and
lighting switch: OFF

OFF

EC

ON → OFF → ON
Heater fan: Operating.

ON

Heater fan: Not operating

OFF

Brake pedal: Fully released

OFF

Brake pedal: Slightly depressed

ON

Idle

2.0 — 3.0 msec

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D

E
2,000 rpm

1.9 — 2.9 msec

Idle

1° — 11° BTDC

2,000 rpm

25° — 45° BTDC

Idle

10% — 35%

2,500 rpm

10% — 35%

Idle

1.0 — 4.0 g·m/s

2,500 rpm

2.0 — 10.0 g·m/s

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Idle

0%

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2,000 rpm

0 — 50%

Idle

−5° — 5°CA

2,500 rpm

Approx. 0° — 40°CA

Idle

0% — 2%

2,500 rpm

Approx. 0% — 90%

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates)

ON

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EC-903

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]
MONITOR ITEM

FUEL PUMP RLY

THRTL RELAY

CONDITION

SPECIFICATION

●

For 1 second after turning ignition switch ON

●

Engine running or cranking

●

Except above conditions

OFF

●

Ignition switch: ON

ON

●

COOLING FAN
●

Engine: After warming up, idle
the engine
Air conditioner switch: OFF

ON

Engine coolant temperature is 94°C
(201°F) or less

OFF

Engine coolant temperature is between
95°C (203°F) and 99°C (210°F)

LOW*2

Engine coolant temperature is 100°C
(212°F) or more

HIGH*2

●

Engine: After warming up

●

Engine speed: Below 3,600 rpm

●

Engine speed: Above 3,600 rpm

●

Below 3,600 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and
at idle for 1 minute under no load

●

Engine speed: Above 3,600 rpm

OFF

I/P PULLY SPD

●

Vehicle speed: More than 20 km/h (12 MPH)

Almost the same speed as
the tachometer indication

TRVL AFTER MIL

●

Ignition switch: ON

●

Engine coolant temperature when engine started: More than 80°C (176°F)

●

Engine speed: below 3,600 rpm

●

Engine: Idle

●

Air conditioner switch: ON (Compressor operates)

HO2S1 HTR (B1)

HO2S2 HTR (B1)

O2SEN HTR DTY

AC PRESS SEN

ON
OFF

ON

Vehicle has traveled after MI has
turned ON.

0 — 65,535 km
(0 — 40,723 mile)
Approx. 30%

1.0 — 4.0V

*1: Accelerator pedal position sensor 2 signal and throttle position sensor 2 signal are converted by ECM internally. Thus, they differ
from ECM terminals voltage signal.
*2: Models without air conditioner, cooling fan operates only ON and OFF operation, but CONSULT-II display will change OFF, LOW and
HI depends on engine coolant temperature.

EC-904

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

Major Sensor Reference Graph in Data Monitor Mode

BBS0049X

A

The following are the major sensor reference graphs in “DATA MONITOR” mode.

CLSD THL POS, ACCEL SEN 1, THRTL SEN 1
Below is the data for “CLSD THL POS”, “ACCEL SEN 1” and “THRTL SEN 1” when depressing the accelera- EC
tor pedal with the ignition switch ON and with shift lever in D position (A/T), 1st position (M/T).
The signal of “ACCEL SEN 1” and “THRTL SEN 1” should rise gradually without any intermittent drop or rise
after “CLSD THL POS” is changed from “ON” to “OFF”.
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D

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PBIB0198E

ENG SPEED, MAS A/F SE-B1, THRTL SEN 1, HO2S2 (B1), INJ PULSE-B1
Below is the data for “ENG SPEED”, “MAS A/F SE-B1”, “THRTL SEN 1”, “HO2S2 (B1)” and “INJ PULSE-B1”
when revving engine quickly up to 4,800 rpm under no load after warming up engine sufficiently.
Each value is for reference, the exact value may vary.

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PBIB2445E

EC-905

TROUBLE DIAGNOSIS
[HR (WITH EURO-OBD)]

PBIB0668E

EC-906

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITH EURO-OBD)]

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
Description

PFP:00031

A
BBS0049Y

The specification (SP) value indicates the tolerance of the value that is displayed in “DATA MONITOR (SPEC)”
mode of CONSULT-II during normal operation of the Engine Control System. When the value in “DATA MONI- EC
TOR (SPEC)” mode is within the SP value, the Engine Control System is confirmed OK. When the value in
“DATA MONITOR (SPEC)” mode is NOT within the SP value, the Engine Control System may have one or
more malfunctions.
The SP value is used to detect malfunctions that may affect the Engine Control System, but will not light the C
MI.
The SP value will be displayed for the following three items:
●
B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board cor- D
rection)
●
A/F ALPHA-B1 (The mean value of air-fuel ratio feedback correction factor per cycle)
E
●
MAS A/F SE-B1 (The signal voltage of the mass air flow sensor)

Testing Condition
●
●
●
●
●
●
–

–
●
–

BBS0049Z

Vehicle driven distance: More than 5,000 km (3,107 miles)

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2

Barometric pressure: 98.3 — 104.3 kPa (0.983 — 1.043 bar, 1.003 — 1.064 kg/cm , 14.25 — 15.12 psi)
Atmospheric temperature: 20 — 30°C (68 — 86°F)
Engine coolant temperature: 75 — 95°C (167 — 203°F)
Engine speed: Idle
Transmission: Warmed-up
A/T models: After the engine is warmed up to normal operating temperature, drive vehicle until “FLUID
TEMP SE” (A/T fluid temperature sensor signal) indicates more than 60°C (140°F).
M/T models: After the engine is warmed up to normal operating temperature, drive vehicle for 5 minutes.
Electrical load: Not applied
Rear window defogger switch, air conditioner switch, lighting switch are OFF. Steering wheel is straight
ahead.

Inspection Procedure

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BBS004A0

NOTE:
Perform “DATA MONITOR (SPEC)” mode in maximum scale display.
1. Perform EC-851, «Basic Inspection» .
2. Confirm that the testing conditions indicated above are met.
3. Select “B/FUEL SCHDL”, “A/F ALPHA-B1” and “MAS A/F SEB1” in “DATA MONITOR (SPEC)” mode with CONSULT-II.
4. Make sure that monitor items are within the SP value.
5. If NG, go to EC-908, «Diagnostic Procedure» .

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SEF601Z

EC-907

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004A1

OVERALL SEQUENCE

PBIB2384E

EC-908

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITH EURO-OBD)]
A

EC

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PBIB3213E

EC-909

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITH EURO-OBD)]
DETAILED PROCEDURE

1. CHECK “A/F ALPHA-B1”
1.
2.
3.

Start engine.
Confirm that the testing conditions are met. Refer to EC-907, «Testing Condition» .
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode,
and make sure that the each indication is within the SP value.
NOTE:
Check “A/F ALPHA-B1” for approximately 1 minute because
they may fluctuate. It is NG if the indication is out of the SP value
even a little.
OK or NG
OK
>> GO TO 17.
NG (Less than the SP value)>>GO TO 2.
NG (More than the SP value)>>GO TO 3.
PBIB2369E

2. CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and
make sure that the indication is within the SP value.
OK or NG
OK
>> GO TO 4.
NG (More than the SP value)>>GO TO 19.

PBIB2332E

3. CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and
make sure that the indication is within the SP value.
OK or NG
OK
>> GO TO 6.
NG (More than the SP value)>>GO TO 6.
NG (Less than the SP value)>>GO TO 25.

PBIB2332E

4. CHECK “A/F ALPHA-B1”
1.
2.
3.
4.

Stop the engine.
Disconnect PCV hose, and then plug it.
Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is
within the SP value.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 6.

EC-910

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITH EURO-OBD)]

5. CHANGE ENGINE OIL
1.
2.

A
Stop the engine.
Change engine oil.
EC
NOTE:
This symptom may occur when a large amount of gasoline is mixed with engine oil because of driving
conditions (such as when engine oil temperature does not rise enough since a journey distance is too
short during winter). The symptom will not be detected after changing engine oil or changing driving con- C
dition.

>> INSPECTION END

D

6. CHECK FUEL PRESSURE
Check fuel pressure. (Refer to EC-860, «FUEL PRESSURE CHECK» .)
OK or NG
OK
>> GO TO 9.
NG (Fuel pressure is too high)>>Replace fuel pressure regulator, refer to EC-860, «FUEL PRESSURE
CHECK» . GO TO 8.
NG (Fuel pressure is too low)>>GO TO 7.

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7. DETECT MALFUNCTIONING PART

G

1.
–
–
–

2.

Check the following.
Clogged and bent fuel hose and fuel tube
Clogged fuel filter
Fuel pump and its circuit (Refer to EC-1215, «FUEL PUMP» .)
If NG, repair or replace the malfunctioning part. (Refer to EC-860, «FUEL PRESSURE CHECK» .)
If OK, replace fuel pressure regulator.

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>> GO TO 8.

8. CHECK “A/F ALPHA-B1”

K

1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is
within the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 9.

9. PERFORM POWER BALANCE TEST
1.
2.

Perform “POWER BALANCE” in “ACTIVE TEST” mode.
Make sure that the each cylinder produces a momentary engine
speed drop.
OK or NG
OK
>> GO TO 12.
NG
>> GO TO 10.

PBIB0133E

EC-911

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TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITH EURO-OBD)]

10. DETECT MALFUNCTIONING PART
1.
–
–
–
–

2.

Check the following.
Ignition coil and its circuit (Refer to EC-1221, «IGNITION SIGNAL» .)
Fuel injector and its circuit (Refer to EC-1209, «FUEL INJECTOR» .)
Intake air leakage
Low compression pressure (Refer to EM-173, «CHECKING COMPRESSION PRESSURE» .)
If NG, repair or replace the malfunctioning part.
If OK, replace fuel injector. (It may be caused by leakage from fuel injector or clogging.)
>> GO TO 11.

11. CHECK “A/F ALPHA-B1”
1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is
within the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 12.

12. CHECK HEATED OXYGEN SENSOR 1 FUNCTION
1.
2.
3.

Run engine at about 2,000 rpm for about 2 minutes under no load.
Select “HO2S1 MNTR (B1)”, in “DATA MONITOR” mode.
Running engine at 2,000 rpm under no load (The engine is
warmed up to normal operating temperature.), check that the
monitor fluctuates between LEAN and RICH more than 5 times
during 10 seconds.
1 time
2 times

: RICH → LEAN → RICH
: RICH → LEAN → RICH → LEAN → RICH

OK or NG
OK
>> GO TO 15.
NG
>> GO TO 13.
SEF820Y

13. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT
Check heated oxygen sensor 1 and its circuit. Refer to EC-977, «DTC P0134 HO2S1» .
>> GO TO 14.

14. CHECK “A/F ALPHA-B1”
1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is
within the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 15.

EC-912

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITH EURO-OBD)]

15. DISCONNECT AND RECONNECT ECM HARNESS CONNECTOR
1.
2.

A

Stop the engine.
Disconnect ECM harness connector. Check pin terminal and connector for damage, and then reconnect it.
EC

>> GO TO 16.

16. CHECK “A/F ALPHA-B1”

C

1.
2.

D

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is
within the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> Detect malfunctioning part according to EC-871, «Symptom Matrix Chart» .

17. CHECK “B/FUEL SCHDL”

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F

Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and
make sure that the indication is within the SP value.
OK or NG
OK
>> INSPECTION END
NG (More than the SP value)>>GO TO 18.
NG (Less than the SP value)>>GO TO 25.

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PBIB2332E

18. DETECT MALFUNCTIONING PART
1.
–
–
–
–
–

2.
–
–
–

J

Check for the cause of large engine friction. Refer to the following.
Engine oil level is too high
Engine oil viscosity
Belt tension of power steering, alternator, A/C compressor, etc. is excessive
Noise from engine
Noise from transmission, etc.
Check for the cause of insufficient combustion. Refer to the following.
Valve clearance malfunction
Intake valve timing control function malfunction
Camshaft sprocket installation malfunction, etc.
>> Repair or replace malfunctioning part, and then GO TO 30.

19. CHECK INTAKE SYSTEM
Check for the cause of uneven air flow through mass air flow sensor. Refer to the following.
●
Crushed air ducts
●
Malfunctioning seal of air cleaner element
●
Uneven dirt of air cleaner element
●
Improper specification of intake air system
OK or NG
OK
>> GO TO 21.
NG
>> Repair or replace malfunctioning part, and then GO TO 20.

EC-913

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TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITH EURO-OBD)]

20. CHECK “A/F ALPHA-B1” AND “B/FUEL SCHDL”
Select “A/F ALPHA-B1” and “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the
each indication is within the SP value.
OK or NG
OK
>> INSPECTION END
NG (“B/FUEL SCHDL” is more, “A/F ALPHA-B1” is less than the SP value)>>GO TO 21.

21. DISCONNECT AND RECONNECT MASS AIR FLOW SENSOR HARNESS CONNECTOR
1.
2.

Stop the engine.
Disconnect mass air flow sensor harness connector. Check pin terminal and connector for damage and
then reconnect it again.
>> GO TO 22.

22. CHECK “A/F ALPHA-B1”
1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is
within the SP value.
OK or NG
OK
>> 1. Detect malfunctioning part of mass air flow sensor circuit and repair it. Refer to EC-935, «DTC
P0102, P0103 MAF SENSOR» .
2. GO TO 29.
NG
>> GO TO 23.

23. CHECK “MAS A/F SE-B1”
Select “MAS A/F SE-B1” in “DATA MONITOR (SPEC)” mode, and
make sure that the indication is within the SP value.
OK or NG
OK
>> GO TO 24.
NG (More than the SP value)>>Replace mass air flow sensor, and
then GO TO 29.

PBIB2370E

24. REPLACE ECM
1.
2.
3.
4.
5.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-215,
«NATS (Nissan Anti-Theft System)» .
Perform EC-857, «Accelerator Pedal Released Position Learning» .
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .
>> GO TO 29.

EC-914

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITH EURO-OBD)]

25. CHECK INTAKE SYSTEM

A

Check for the cause of uneven air flow through mass air flow sensor. Refer to the following.
●
Crushed air ducts
●
Malfunctioning seal of air cleaner element
●
Uneven dirt of air cleaner element
●
Improper specification of intake air system
OK or NG
OK
>> GO TO 27.
NG
>> Repair or replace malfunctioning part, and then GO TO 26.

EC

C

D

26. CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the
SP value.
OK or NG
OK
>> INSPECTION END
NG (Less than the SP value)>>GO TO 27.

27. CHECK “MAS A/F SE-B1”

E

F

G

Select “MAS A/F SE-B1” in “DATA MONITOR (SPEC)” mode, and
make sure that the indication is within the SP value.
OK or NG
OK
>> GO TO 28.
NG (Less than the SP value)>>Replace mass air flow sensor, and
then GO TO 30.

H

I

J
PBIB2370E

28. CHECK INTAKE SYSTEM

K

Check for the cause of air leak after the mass air flow sensor. Refer to the following.
●
Disconnection, looseness, and cracks in air duct
●
Looseness of oil filler cap
●
Disconnection of oil level gauge
●
Open stuck, breakage, hose disconnection, or cracks of PCV valve
●
Disconnection or cracks of EVAP purge hose, open stuck of EVAP canister purge volume control solenoid
valve
●
Malfunctioning seal of rocker cover gasket
●
Disconnection, looseness, or cracks of hoses, such as vacuum hose, connecting to intake air system
parts
●
Malfunctioning seal of intake air system, etc.
>> GO TO 30.

29. CHECK “A/F ALPHA-B1” AND “B/FUEL SCHDL”
Select “A/F ALPHA-B1” and “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the
each indication is within the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> Detect malfunctioning part according to EC-871, «Symptom Matrix Chart» .

EC-915

L

M

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITH EURO-OBD)]

30. CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and then make sure that the indication is within
the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> Detect malfunctioning part according to EC-871, «Symptom Matrix Chart» .

EC-916

TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT
[HR (WITH EURO-OBD)]

TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT
Description

PFP:00006

A
BBS004A2

Intermittent incidents may occur. In many cases, the malfunction resolves itself (the part or circuit function
returns to normal without intervention). It is important to realize that the symptoms described in the customer’s EC
complaint often do not recur on (1st trip) DTC visits. Realize also that the most frequent cause of intermittent
incidents occurrences is poor electrical connections. Because of this, the conditions under which the incident
occurred may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may
C
not indicate the specific malfunctioning area.
Common Intermittent Incidents Report Situations
STEP in Work Flow
2
3 or 4

Situation

D

The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than [0] or [1t].
The symptom described by the customer does not recur.

5

(1st trip) DTC does not appear during the DTC Confirmation Procedure.

10

The Diagnostic Procedure for PXXXX does not indicate the malfunctioning area.

Diagnostic Procedure

E

BBS004A3

F

1. INSPECTION START
Erase (1st trip) DTCs. Refer to EC-841, «HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .

G

H

>> GO TO 2.

2. CHECK GROUND TERMINALS
Check ground terminals for corroding or loose connection.
Refer to EC-924, «Ground Inspection» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

3. SEARCH FOR ELECTRICAL INCIDENT

I

J

K

Perform GI-25, «How to Perform Efficient Diagnosis for an Electrical Incident» , “INCIDENT SIMULATION
TESTS”.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace.

EC-917

L

M

POWER SUPPLY AND GROUND CIRCUIT
[HR (WITH EURO-OBD)]

POWER SUPPLY AND GROUND CIRCUIT
Wiring Diagram

PFP:24110
BBS004A4

MBWA1455E

EC-918

POWER SUPPLY AND GROUND CIRCUIT
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
10
11

EC

WIRE
COLOR
B
B/W

ITEM

ECM ground

CONDITION
[Engine is running]
●

Idle speed

[Engine is running]
[Ignition switch: OFF]
●

32

P

ECM relay
(Self shut-off)

For a few seconds after turning ignition switch
OFF

[Ignition switch: OFF]
●

93

O

Ignition switch

105

G

Power supply for
ECM

108

B

ECM ground

More than a few seconds after turning ignition
switch OFF

DATA (DC Voltage)

[Ignition switch: ON]
[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)

Diagnostic Procedure

E

BATTERY VOLTAGE
(11 — 14V)

BATTERY VOLTAGE
(11 — 14V)

Idle speed

D

0 — 1.0V

0V

[Engine is running]

C

Body ground

[Ignition switch: OFF]

●

F

G

Body ground

H
BBS004A5

1. INSPECTION START

I

Start engine.
Is engine running?
Yes or No
Yes
>> GO TO 8.
No
>> GO TO 2.

J

K

2. CHECK ECM POWER SUPPLY CIRCUIT-I
1.
2.

A

Turn ignition switch OFF and then ON.
Check voltage between ECM terminal 93 and ground with CONSULT-II or tester.

L

M

Voltage: Battery voltage
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

PBIA9561J

EC-919

POWER SUPPLY AND GROUND CIRCUIT
[HR (WITH EURO-OBD)]

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M1, E101
●
Fuse block (J/B) connector M1.
●
10A fuse
●
Harness for open or short between ECM and fuse
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK GROUND CONNECTIONS-1
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

Body ground

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace ground connections.

5. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-I
1.
2.

Disconnect ECM harness connector.
Check harness continuity between ECM terminals 10, 11, 108 and ground.
Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

6. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors F1, E59
●
Harness for open or short between ECM and ground
●

>> Repair open circuit or short to power in harness or connectors.

EC-920

POWER SUPPLY AND GROUND CIRCUIT
[HR (WITH EURO-OBD)]

7. CHECK ECM POWER SUPPLY CIRCUIT-II
1.
2.
3.

A

Reconnect ECM harness connector.
Turn ignition switch ON.
Check voltage between IPDM E/R terminal 33 and ground with
CONSULT-II or tester.

EC

Voltage: Battery voltage

C

OK or NG
OK
>> Go to EC-1221, «IGNITION SIGNAL» .
NG
>> GO TO 8.

D

MBIB1353E

E

8. CHECK ECM POWER SUPPLY CIRCUIT-III
1.
2.
3.

F

Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON and then OFF.
Check voltage between ECM terminal 105 and ground with
CONSULT-II or tester.
Voltage:

G

After turning ignition switch OFF, battery
voltage will exist for a few seconds, then
drop approximately 0V.

OK or NG
OK
>> GO TO 14.
NG (Battery voltage does not exist.)>>GO TO 9.
NG (Battery voltage exists for more than a few seconds.)>>GO TO
11.

H

I

PBIB3037E

J

9. CHECK ECM POWER SUPPLY CIRCUIT-IV
1.
2.

K

Turn ignition switch OFF and wait at least 10 seconds.
Check voltage between ECM terminal 32 and ground with CONSULT-II or tester.

L

Voltage: Battery voltage
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 11.

M

PBIA9562J

EC-921

POWER SUPPLY AND GROUND CIRCUIT
[HR (WITH EURO-OBD)]

10. CHECK ECM POWER SUPPLY CIRCUIT-V
1.
2.
3.

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between ECM terminal 105 and IPDM E/R terminal 32.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 17.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

11. CHECK ECM POWER SUPPLY CIRCUIT-VI
1.
2.
3.

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between ECM terminal 32 and IPDM E/R terminal 29.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 13.
NG
>> GO TO 12.

12. DETECT MALFUNCTIONING PART
Check the following.
●
Harness or connectors E59, F1
●
Harness for open or short between ECM and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

13. CHECK 20A FUSE
1. Disconnect 20A fuse from IPDM E/R.
2. Check 20A fuse.
OK or NG
OK
>> GO TO 17.
NG
>> Replace 20A fuse.

EC-922

POWER SUPPLY AND GROUND CIRCUIT
[HR (WITH EURO-OBD)]

14. CHECK GROUND CONNECTIONS-II
1.

A

Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .
EC

C

D

MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

E

Body ground

OK or NG
OK
>> GO TO 15.
NG
>> Repair or replace ground connections.

F

15. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-II

G

1.
2.

H

Disconnect ECM harness connector.
Check harness continuity between ECM terminals 10, 11, 108 and ground.
Refer to Wiring Diagram.
Continuity should exist.

I

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 17.
NG
>> GO TO 16.

J

16. DETECT MALFUNCTIONING PART

K

Check the following.
●
Harness or connectors F1, E59
●
Harness for open or short between ECM and ground
>> Repair open circuit or short to power in harness or connectors.

17. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)»
NG
>> Repair open circuit or short to power in harness or connectors.

EC-923

L

M

POWER SUPPLY AND GROUND CIRCUIT
[HR (WITH EURO-OBD)]

Ground Inspection

BBS004A6

Ground connections are very important to the proper operation of electrical and electronic circuits. Ground
connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can
become an unwanted resistance. This unwanted resistance can change the way a circuit works.
Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even
when the ground connection looks clean, there can be a thin film of rust on the surface.
When inspecting a ground connection follow these rules:
●
Remove the ground bolt or screw.
●
Inspect all mating surfaces for tarnish, dirt, rust, etc.
●
Clean as required to assure good contact.
●
Reinstall bolt or screw securely.
●
Inspect for “add-on” accessories which may be interfering with the ground circuit.
●
If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the
wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one
eyelet make sure no ground wires have excess wire insulation.
For detailed ground distribution information, refer to PG-38, «Ground Distribution» .

PBIB1870E

EC-924

DTC U1000, U1001 CAN COMMUNICATION LINE
[HR (WITH EURO-OBD)]

DTC U1000, U1001 CAN COMMUNICATION LINE
Description

PFP:23710

A
BBS004A7

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- EC
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
C
Each control unit transmits/receives data but selectively reads required data only.

On Board Diagnosis Logic
DTC No.

1000*1
U1001*2
1001*2

D

Trouble diagnosis
name

U1000*1

DTC detecting condition
●

CAN communication
line

BBS004A8

●

ECM cannot communicate to other control
units.
ECM cannot communicate for more than the
specified time.

Possible cause

●

Harness or connectors
(CAN communication line is open or
shorted.)

E

F

*1: This self-diagnosis has the one trip detection logic.
*2: The MI will not light up for this self-diagnosis.

G

DTC Confirmation Procedure
1.
2.
3.

BBS004A9

Turn ignition switch ON and wait at least 3 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
If 1st trip DTC is detected, go to EC-927, «Diagnostic Procedure» .

H

I

J

K

L

M

EC-925

DTC U1000, U1001 CAN COMMUNICATION LINE
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004AA

MBWA1456E

EC-926

DTC U1000, U1001 CAN COMMUNICATION LINE
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004AB

Go to LAN-3, «Precautions When Using CONSULT-II» .

A

EC

C

D

E

F

G

H

I

J

K

L

M

EC-927

DTC U1010 CAN COMMUNICATION
[HR (WITH EURO-OBD)]

DTC U1010 CAN COMMUNICATION
Description

PFP:23710
BBS004AC

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

On Board Diagnosis Logic

BBS004AD

This self-diagnosis has the one trip detection logic (A/T).
The MI will not light up for this self-diagnosis (M/T).
DTC No.
U1010
1010

Trouble diagnosis name
CAN communication bus

DTC detecting condition
Initializing CAN communication bus is malfunctioning.

DTC Confirmation Procedure

Possible cause
●

ECM

BBS004AE

WITH CONSULT-II
1.
2.
3.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
If 1st trip DTC is detected, go to EC-929, «Diagnostic Procedure»
.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-928

DTC U1010 CAN COMMUNICATION
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004AF

1. INSPECTION START
1.
2.
3.
4.
5.

A

With CONSULT-II
Turn ignition switch ON.
Select “SELF-DIAG RESULTS” mode with CONSULT-II.
Touch “ERASE”.
Perform DTC Confirmation Procedure.
See EC-928, «DTC Confirmation Procedure» .
Is the 1st trip DTC U1010 displayed again?

With GST
1. Turn ignition switch ON.
2. Select Service $04 with GST.
3. Perform DTC Confirmation Procedure.
See EC-928, «DTC Confirmation Procedure» .
4. Is the 1st trip DTC U1010 displayed again?
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END

EC

C

D

E

F

G

2. REPLACE ECM
1.
2.
3.
4.
5.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
Perform EC-857, «Accelerator Pedal Released Position Learning» .
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .

H

I

J

>> INSPECTION END
K

L

M

EC-929

DTC P0011 IVT CONTROL
[HR (WITH EURO-OBD)]

DTC P0011 IVT CONTROL
Description

PFP:23796
BBS004AG

SYSTEM DESCRIPTION
Sensor

Input signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed and piston position

Engine coolant temperature sensor

Engine coolant temperature

Wheel sensor

Vehicle speed*

ECM function

Intake valve
timing control

Actuator

Intake valve timing control
solenoid valve

*: This signal is sent to the ECM through CAN communication line.

MBIB1560E

This mechanism hydraulically controls cam phases continuously with the fixed operating angle of the intake
valve.
The ECM receives signals such as crankshaft position, camshaft position, engine speed, and engine coolant
temperature. Then, the ECM sends ON/OFF pulse duty signals to the intake valve timing control solenoid
valve depending on driving status. This makes it possible to control the shut/open timing of the intake valve to
increase engine torque in low/mid speed range and output in high-speed range.

CONSULT-II Reference Value in Data Monitor Mode

BBS004AH

Specification data are reference values.
MONITOR ITEM

INT/V TIM (B1)

INT/V SOL (B1)

CONDITION
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

SPECIFICATION

Idle

−5° — 5°CA

2,500 rpm

Approx. 0° — 40°CA

Idle

0% — 2%

2,500 rpm

Approx. 0% — 90%

EC-930

DTC P0011 IVT CONTROL
[HR (WITH EURO-OBD)]

On Board Diagnosis Logic

BBS004AI

A

The MI will not light up for these self-diagnoses.
DTC No.

P0011
0011

Trouble diagnosis name

Intake valve timing control
performance

Detecting condition

There is a gap between angle of target and
phase-control angle degree.

Possible cause

EC

●

Crankshaft position sensor (POS)

●

Camshaft position sensor (PHASE)

●

Intake valve timing control solenoid valve

●

Accumulation of debris to the signal pick-up
portion of the camshaft

●

Timing chain installation

●

Foreign matter caught in the oil groove for
intake valve timing control

C

D

E

FAIL-SAFE MODE
ECM enters in fail-safe mode when the malfunction is detected.
Detected items
Intake valve timing control

Engine operating condition in fail-safe mode
The signal is not energized to the solenoid valve and the valve control does not function

DTC Confirmation Procedure

F

BBS004AJ

CAUTION:
Always drive at a safe speed.
NOTE:
●
If DTC P0011 is displayed with DTC P1111, first perform trouble diagnosis for DTC P1111. See EC1077, «DTC P1111 IVT CONTROL SOLENOID VALVE» .
●
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
at least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is between 10V and 16V at
idle.

G

H

I

J

WITH CONSULT-II
1.
2.
3.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and warm it up to the normal operating temperature.
Maintain the following conditions for at least 6 consecutive seconds.
Hold the accelerator pedal as steady as possible.

ENG SPEED

1,200 — 2,000 rpm (A constant rotation is maintained.)

COOLAN TEMP/S

60 — 120°C (140 — 248°F)

B/FUEL SCHDL

More than 3.5 msec

Shift lever

A/T: P or N position
M/T: Neutral position

4.
5.
6.

K

L

M

SEF174Y

Let engine idle for 10 seconds.
If the 1st trip DTC is detected, go to EC-932, «Diagnostic Procedure» .
If the 1st trip DTC is not detected, go to next step.
Maintain the following conditions for at least 20 consecutive seconds.

ENG SPEED

1,700 — 3,175 rpm (A constant rotation is maintained.)

COOLAN TEMP/S

70 — 105°C (158 — 221°F)

EC-931

DTC P0011 IVT CONTROL
[HR (WITH EURO-OBD)]
Shift lever

1st or 2nd position

Driving location uphill

Driving vehicle uphill
(Increased engine load will help maintain the driving
conditions required for this test.)

7.

If 1st trip DTC is detected, go to EC-932, «Diagnostic Procedure» .

WITH GST
Follow the procedure “WITH CONSULT-II” above.

Diagnostic Procedure

BBS004AK

1. CHECK OIL PRESSURE WARNING LAMP
1.
2.

Start engine.
Check oil pressure warning lamp and confirm it is not illuminated.
OK or NG
OK
>> GO TO 2.
KG
>> Go to LU-16, «OIL PRESSURE CHECK» .

PBIA8559J

2. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE
Refer to EC-933, «Component Inspection» .
OK or NG
OK
>> GO TO 3.
NG
>> Replace intake valve timing control solenoid valve.

3. CHECK CRANKSHAFT POSITION SENSOR (POS)
Refer to EC-1048, «Component Inspection» .
OK or NG
OK
>> GO TO 4.
NG
>> Replace crankshaft position sensor (POS).

4. CHECK CAMSHAFT POSITION SENSOR (PHASE)
Refer to EC-1054, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace camshaft position sensor (PHASE).

EC-932

DTC P0011 IVT CONTROL
[HR (WITH EURO-OBD)]

5. CHECK CAMSHAFT (INTAKE)

A

Check the following.
●
Accumulation of debris to the signal plate of camshaft (1) rear
end
●
Chipping signal plate of camshaft rear end
OK or NG
OK
>> GO TO 6.
NG
>> Remove debris and clean the signal plate of camshaft
rear end or replace camshaft.

EC

C

D
PBIA9557J

6. CHECK TIMING CHAIN INSTALLATION

E

Check service records for any recent repairs that may cause timing chain misaligned.
Are there any service records that may cause timing chain misaligned?
Yes or No
Yes
>> Check timing chain installation. Refer to EM-142, «TIMING CHAIN» .
No
>> GO TO 7.

F

G

7. CHECK LUBRICATION CIRCUIT
Refer to EM-166, «Inspection of Camshaft Sprocket (INT) Oil Groove» .
OK or NG
OK
>> GO TO 8.
NG
>> Clean lubrication line.

H

I

8. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
For Wiring Diagram, refer to EC-1044, «Wiring Diagram» for CKP sensor (POS) and EC-1051, «Wiring Diagram» for CMP sensor (PHASE).

J

K

>> INSPECTION END

Component Inspection

BBS004AL

INTAKE VALVE TIMING CONTROL SOLENOID VALVE
1.
2.

3.

Disconnect intake valve timing control solenoid valve harness connector.
Check resistance between intake valve timing control solenoid
valve as follows.
Terminal

Resistance

1 and 2

6.7 — 7.7Ω [at 20°C (68°F)]

1 or 2 and ground

∞Ω
(Continuity should not exist.)

If NG, replace intake valve timing control solenoid valve.
If OK, go to next step.
Remove intake valve timing control solenoid valve.

EC-933

L

M

PBIB0193E

DTC P0011 IVT CONTROL
[HR (WITH EURO-OBD)]
4.

Provide 12V DC between intake valve timing control solenoid
valve terminals and then interrupt it. Make sure that the plunger
moves as shown in the figure.
CAUTION:
Do not apply 12V DC continuously for 5 seconds or more.
Doing so may result in damage to the coil in intake valve
timing control solenoid valve.
If NG, replace intake valve timing control solenoid valve.
NOTE:
Always replace O-ring when intake valve timing control
solenoid valve is removed.

Removal and Installation

PBIB2275E

BBS004AM

INTAKE VALVE TIMING CONTROL SOLENOID VALVE
Refer to EM-142, «TIMING CHAIN» .

EC-934

DTC P0102, P0103 MAF SENSOR
[HR (WITH EURO-OBD)]

DTC P0102, P0103 MAF SENSOR
Component Description

PFP:22680

A
BBS004AN

The mass air flow sensor (1) is placed in the stream of intake air. It
measures the intake flow rate by measuring a part of the entire
intake flow. The mass air flow sensor controls the temperature of the
hot wire to a certain amount. The heat generated by the hot wire is
reduced as the intake air flows around it. The more air, the greater
the heat loss.
Therefore, the electric current supplied to hot wire is changed to
maintain the temperature of the hot wire as air flow increases. The
ECM detects the air flow by means of this current change.

EC

C

D
PBIA9559J

E

CONSULT-II Reference Value in Data Monitor Mode

BBS004AO

Specification data are reference values.
MONITOR ITEM
MAS A/F SE-B1

CONDITION

SPECIFICATION

●

Engine: After warming up

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

Air conditioner switch: OFF

●

No load

●

Engine: After warming up

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

Air conditioner switch: OFF

●

No load

CAL/LD VALUE

MASS AIRFLOW

Idle

10% — 35%

2,500 rpm

10% — 35%

G

H
Idle

1.0 — 4.0 g·m/s

I
2,500 rpm

2.0 — 10.0 g·m/s

J

On Board Diagnosis Logic

BBS004AP

These self-diagnoses have the one trip detection logic.
DTC No.

P0102
0102

P0103
0103

F

See EC-907, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .

Trouble diagnosis
name

Mass air flow sensor
circuit low input

Mass air flow sensor
circuit high input

K

DTC detecting condition

Possible cause

An excessively low voltage from the sensor is
sent to ECM.

●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Intake air leaks

●

Mass air flow sensor

●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Mass air flow sensor

An excessively high voltage from the sensor is
sent to ECM.

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Detected items
Mass air flow sensor circuit

Engine operating condition in fail-safe mode
Engine speed will not rise more than 2,400 rpm due to the fuel cut.

EC-935

L

M

DTC P0102, P0103 MAF SENSOR
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004AQ

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

PROCEDURE FOR DTC P0102
With CONSULT-II
1.
2.
3.
4.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and wait at least 5 seconds.
If DTC is detected, go to EC-938, «Diagnostic Procedure» .

SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

PROCEDURE FOR DTC P0103
With CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 5 seconds.
If DTC is detected, go to EC-938, «Diagnostic Procedure» .
If DTC is not detected, go to next step.
Start engine and wait at least 5 seconds.
If DTC is detected, go to EC-938, «Diagnostic Procedure» .

SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

EC-936

DTC P0102, P0103 MAF SENSOR
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004AR

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1457E

EC-937

DTC P0102, P0103 MAF SENSOR
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION
[Engine is running]
[Ignition switch: OFF]
●

32

P

ECM relay
(Self shut-off)

For a few seconds after turning ignition
switch OFF

[Ignition switch: OFF]
●

More than a few seconds after turning ignition switch OFF

[Ignition switch: ON]
●

Engine stopped

DATA (DC Voltage)

0 — 1.0V

BATTERY VOLTAGE
(11 — 14V)

Approximately 0.4V

[Engine is running]
45

G

Mass air flow sensor

●

Warm-up condition

●

Idle speed

[Engine is running]
●

Warm-up condition

●

Engine is revving from idle to about 4,000
rpm

1.0 — 1.3V

1.0 — 1.3 to Approximately 2.4V
(Check for linear voltage rise in
response to engine being
increased to about 4,000 rpm.)

[Engine is running]
52

105

LG

G

Sensor ground
(Mass air flow sensor)

Power supply for ECM

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]

Diagnostic Procedure

Approximately 0V

BATTERY VOLTAGE
(11 — 14V)
BBS004AS

1. INSPECTION START
Which malfunction (P0102 or P0103) is duplicated?
P0102 or P0103
P0102 >> GO TO 2.
P0103 >> GO TO 3.

2. CHECK INTAKE SYSTEM
Check the following for connection.
Air duct
●
Vacuum hoses
●
Intake air passage between air duct to intake manifold
OK or NG
OK
>> GO TO 3.
NG
>> Reconnect the parts.
●

EC-938

DTC P0102, P0103 MAF SENSOR
[HR (WITH EURO-OBD)]

3. CHECK GROUND CONNECTIONS
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

EC

C

D

E
MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

Body ground

F

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace ground connections.

G

4. CHECK MAF SENSOR POWER SUPPLY CIRCUIT
1.
2.

H

Disconnect mass air flow (MAF) sensor (1) harness connector.
Turn ignition switch ON.

I

J

PBIB2948E

3.

Check voltage between MAF sensor terminal 2 and ground with
CONSULT-II or tester.

K

L

Voltage: Battery voltage
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

M

PBIB1168E

5. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between mass air flow sensor and ECM
●
Harness for open or short between mass air flow sensor and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-939

DTC P0102, P0103 MAF SENSOR
[HR (WITH EURO-OBD)]

6. CHECK MAF SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between MAF sensor terminal 3 and ECM terminal 52.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

7. CHECK MAF SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between MAF sensor terminal 4 and ECM terminal 45.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK MASS AIR FLOW SENSOR
Refer to EC-940, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace mass air flow sensor.

9. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004AT

MASS AIR FLOW SENSOR
With CONSULT-II
1.
2.
3.
4.

Reconnect all harness connectors disconnected.
Start engine and warm it up to normal operating temperature.
Connect CONSULT-II and select “DATA MONITOR” mode.
Select “MAS A/F SE-B1” and check indication under the following conditions.
Condition

MAS A/F SE-B1 (V)

Ignition switch ON (Engine stopped.)

Approx. 0.4

Idle (Engine is warmed-up to normal
operating temperature.)

1.0 — 1.3

Idle to about 4,000 rpm

1.0 — 1.3 to Approx. 2.4*

*: Check for linear voltage rise in response to engine being increased to about
4,000 rpm.
PBIB2371E

5.
a.

If the voltage is out of specification, proceed the following.
Check for the cause of uneven air flow through mass air flow sensor. Refer to following.

EC-940

DTC P0102, P0103 MAF SENSOR
[HR (WITH EURO-OBD)]
Crushed air ducts
Malfunctioning seal of air cleaner element
● Uneven dirt of air cleaner element
● Improper specification of intake air system parts
If NG, repair or replace malfunctioning part and perform step 2 to 4 again.
If OK, go to next step.
Turn ignition switch OFF.
Disconnect mass air flow sensor harness connector and reconnect it again.
Perform step 2 to 4 again.
If NG, clean or replace mass air flow sensor.
●

A

●

b.
6.
7.
8.
9.

EC

C

D

Without CONSULT-II
1.
2.
3.

Reconnect all harness connectors disconnected.
Start engine and warm it up to normal operating temperature.
Check voltage between ECM terminal 45 (Mass air flow sensor
signal) and ground.

E

F
Condition

Voltage V

Ignition switch ON (Engine stopped.)

Approx. 0.4

Idle (Engine is warmed-up to normal
operating temperature.)

1.0 — 1.3

Idle to about 4,000 rpm

G

1.0 — 1.3 to Approx. 2.4*

H

*: Check for linear voltage rise in response to engine being increased to about
4,000 rpm.
PBIA9564J

4.
a.

b.
5.
6.
7.
8.

If the voltage is out of specification, proceed the following.
Check for the cause of uneven air flow through mass air flow sensor. Refer to following.
● Crushed air ducts
● Malfunctioning seal of air cleaner element
● Uneven dirt of air cleaner element
● Improper specification of intake air system parts
If NG, repair or replace malfunctioning part and perform step 2 to 3 again.
If OK, go to next step.
Turn ignition switch OFF.
Disconnect mass air flow sensor harness connector and reconnect it again.
Perform step 2 and 3 again.
If NG, clean or replace mass air flow sensor.

Removal and Installation

I

J

K

L

BBS004AU

MASS AIR FLOW SENSOR
Refer to EM-118, «AIR CLEANER AND AIR DUCT» .

EC-941

M

DTC P0112, P0113 IAT SENSOR
[HR (WITH EURO-OBD)]

DTC P0112, P0113 IAT SENSOR
Component Description

PFP:22630
BBS004AV

The intake air temperature sensor is built-into mass air flow sensor
(1). The sensor detects intake air temperature and transmits a signal
to the ECM.
The temperature sensing unit uses a thermistor which is sensitive to
the change in temperature. Electrical resistance of the thermistor
decreases in response to the temperature rise.

PBIA9559J

Intake air temperature
°C (°F)

Voltage*

V

Resistance

kΩ

25 (77)

3.3

1.800 — 2.200

80 (176)

1.2

0.283 — 0.359

*: This data is reference value and is measured between ECM terminal 46 (Intake air
temperature sensor) and ground.

CAUTION:
Do not use ECM ground terminals when measuring input/output
voltage. Doing so may result in damage to the ECM’s transistor.
Use a ground other than ECM terminals, such as the ground.

SEF012P

On Board Diagnosis Logic
DTC No.

Trouble diagnosis
name

BBS004AW

DTC detecting condition

P0112
0112

Intake air temperature sensor circuit
low input

An excessively low voltage from the sensor is
sent to ECM.

P0113
0113

Intake air temperature sensor circuit
high input

An excessively high voltage from the sensor is
sent to ECM.

DTC Confirmation Procedure

Possible cause

●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Intake air temperature sensor

BBS004AX

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 5 seconds.
If 1st trip DTC is detected, go to EC-945, «Diagnostic Procedure»
.

SEF058Y

EC-942

DTC P0112, P0113 IAT SENSOR
[HR (WITH EURO-OBD)]
WITH GST
A

Follow the procedure “WITH CONSULT-II” above.

EC

C

D

E

F

G

H

I

J

K

L

M

EC-943

DTC P0112, P0113 IAT SENSOR
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004AY

MBWA1458E

EC-944

DTC P0112, P0113 IAT SENSOR
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004AZ

1. CHECK GROUND CONNECTIONS
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

EC

C

D

E
MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

F

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

G

2. CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT
1.
2.

H

Disconnect mass air flow sensor (intake air temperature sensor
is built-into) (1) harness connector.
Turn ignition switch ON.

I

J

K
PBIB2948E

3.

Check voltage between mass air flow sensor terminal 5 and
ground with CONSULT-II or tester.

L

Voltage: Approximately 5V
M

OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

PBIB1169E

EC-945

DTC P0112, P0113 IAT SENSOR
[HR (WITH EURO-OBD)]

3. CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between mass air flow sensor terminal 6 and ECM terminal 55.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK INTAKE AIR TEMPERATURE SENSOR
Refer to EC-946, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace mass air flow sensor (with intake air temperature sensor).

5. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004B0

INTAKE AIR TEMPERATURE SENSOR
1.

2.

Check resistance between mass air flow sensor (1) terminals 5
and 6 under the following conditions.
Intake air temperature °C (°F)

Resistance kΩ

25 (77)

1.800 — 2.200

If NG, replace mass air flow sensor (with intake air temperature
sensor).

PBIA9559J

SEF012P

Removal and Installation

BBS004B1

MASS AIR FLOW SENSOR
Refer to EM-118, «AIR CLEANER AND AIR DUCT» .

EC-946

DTC P0117, P0118 ECT SENSOR
[HR (WITH EURO-OBD)]

DTC P0117, P0118 ECT SENSOR
Component Description

PFP:22630

A
BBS004B2

The engine coolant temperature sensor is used to detect the engine
coolant temperature. The sensor modifies a voltage signal from the
ECM. The modified signal returns to the ECM as the engine coolant
temperature input. The sensor uses a thermistor which is sensitive to
the change in temperature. The electrical resistance of the thermistor decreases as temperature increases.

EC

C

D
SEF594K

E

Engine coolant temperature
°C (°F)
–10 (14)

Voltage*

V

Resistance

4.4

F

kΩ

7.0 — 11.4

20 (68)

3.5

2.1 — 2.9

50 (122)

2.2

0.68 — 1.00

90 (194)

0.9

0.236 — 0.260

G

H

*: This data is reference value and is measured between ECM terminal 38 (Engine
coolant temperature sensor) and ground.

SEF012P

CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.

On Board Diagnosis Logic

BBS004B3

I

J

These self-diagnoses have the one trip detection logic.
DTC No.

Trouble Diagnosis
Name

DTC Detecting Condition

P0117
0117

Engine coolant temperature sensor circuit low input

An excessively low voltage from the sensor is
sent to ECM.

P0118
0118

Engine coolant temperature sensor circuit high input

An excessively high voltage from the sensor is
sent to ECM.

Possible Cause

●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Engine coolant temperature sensor

When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
Engine coolant temperature will be determined by ECM based on the time after turning ignition switch ON
or START.
CONSULT-II displays the engine coolant temperature decided by ECM.
Condition
Engine coolant temperature sensor circuit

L

M

FAIL-SAFE MODE
Detected items

K

Engine coolant temperature decided
(CONSULT-II display)

Just as ignition switch is turned ON or START

40°C (104°F)

More than approx. 4 minutes after ignition ON or START

80°C (176°F)
40 — 80°C (104 — 176°F)
(Depends on the time)

Except as shown above

When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates
while engine is running.

EC-947

DTC P0117, P0118 ECT SENSOR
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004B4

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 5 seconds.
If DTC is detected, go to EC-950, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-948

DTC P0117, P0118 ECT SENSOR
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004B5

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1459E

EC-949

DTC P0117, P0118 ECT SENSOR
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004B6

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

2. CHECK ECT SENSOR POWER SUPPLY CIRCUIT
1.

Disconnect engine coolant temperature (ECT) sensor (1) harness connector.

–

: Vehicle front
Turn ignition switch ON.

2.

PBIB2964E

3.

Check voltage between ECT sensor terminal 1 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

PBIB0080E

EC-950

DTC P0117, P0118 ECT SENSOR
[HR (WITH EURO-OBD)]

3. CHECK ECT SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.
4.

A

Turn ignition switch OFF.
Disconnect ECM harness connector.
Disconnect TCM harness connector.
Check harness continuity between ECM terminal 44, TCM terminal 42 and ECT sensor terminal 2.
Refer to Wiring Diagram.

EC

C

Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

D

E

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between ECM and ECT sensor
●
Harness for open or short between TCM and ECT sensor

F

G

>> Repair open circuit or short to ground or short to power in harness or connectors.
H

5. CHECK ENGINE COOLANT TEMPERATURE SENSOR
Refer to EC-951, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace engine coolant temperature sensor.

I

J

6. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

K

>> INSPECTION END

Component Inspection

BBS004B7

L

ENGINE COOLANT TEMPERATURE SENSOR
1.

Check resistance between engine coolant temperature sensor
terminals 1 and 2 as shown in the figure.

M

PBIB2005E

EC-951

DTC P0117, P0118 ECT SENSOR
[HR (WITH EURO-OBD)]

Temperature

2.

°C (°F)

Resistance

kΩ

20 (68)

2.1 — 2.9

50 (122)

0.68 — 1.00

90 (194)

0.236 — 0.260

If NG, replace engine coolant temperature sensor.

SEF012P

Removal and Installation

BBS004B8

ENGINE COOLANT TEMPERATURE SENSOR
Refer to EM-173, «CYLINDER HEAD» .

EC-952

DTC P0122, P0123 TP SENSOR
[HR (WITH EURO-OBD)]

DTC P0122, P0123 TP SENSOR
Component Description

PFP:16119

A
BBS004B9

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

EC

C

D
PBIB0145E

E

CONSULT-II Reference Value in Data Monitor Mode

BBS004BA

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Ignition switch: ON
(Engine stopped)

●

Shift lever: D (A/T), 1st (M/T)

THRTL SEN 1
THRTL SEN 2*

SPECIFICATION

Accelerator pedal: Fully released

More than 0.36V

Accelerator pedal: Fully depressed

Less than 4.75V

F

G

*: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic

BBS004BB

These self-diagnoses have the one trip detection logic.
NOTE:
If DTC P0122 or P0123 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229.
Refer to EC-1150, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

Trouble diagnosis name

DTC detecting condition

Possible cause

P0122
0122

Throttle position sensor
2 circuit low input

An excessively low voltage from the TP sensor
2 is sent to ECM.

●

Harness or connectors
(TP sensor 2 circuit is open or shorted.)

P0123
0123

Throttle position sensor
2 circuit high input

An excessively high voltage from the TP sensor 2 is sent to ECM.

●

Electric throttle control actuator
(TP sensor 2)

FAIL-SAFE MODE

H

I

J

K

L

When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-953

M

DTC P0122, P0123 TP SENSOR
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004BC

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-956, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-954

DTC P0122, P0123 TP SENSOR
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004BD

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1460E

EC-955

DTC P0122, P0123 TP SENSOR
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch: ON]

33

Y

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

Throttle position sensor 1

More than 0.36V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

Less than 4.75V

[Ignition switch: ON]

34

R

Throttle position sensor 2

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

Less than 4.75V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

More than 0.36V

[Engine is running]
36

72

BR

L

Sensor ground
(Throttle position sensor)
Sensor power supply
(Throttle position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Ignition switch: ON]

Approximately 5V

Diagnostic Procedure

BBS004BE

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-956

3.

Body ground

DTC P0122, P0123 TP SENSOR
[HR (WITH EURO-OBD)]

2. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT
1.

Disconnect electric throttle control actuator (1) harness connector.

–

: Vehicle front
Turn ignition switch ON.

2.

A

EC

C

D
PBIB2965E

3.

Check voltage between electric throttle control actuator terminal
1 and ground with CONSULT-II or tester.

E

Voltage: Approximately 5V
F

OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

G

PBIA9580J

H

3. CHECK THROTTLE POSITION SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 36.
Refer to Wiring Diagram.

I

J

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

K

L

4. CHECK THROTTLE POSITION SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 34 and electric throttle control actuator terminal 3.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK THROTTLE POSITION SENSOR
Refer to EC-958, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

EC-957

M

DTC P0122, P0123 TP SENSOR
[HR (WITH EURO-OBD)]

6. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .
>> INSPECTION END

7. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004BF

THROTTLE POSITION SENSOR
1.
2.
3.
4.
5.

Reconnect all harness connectors disconnected.
Perform EC-857, «Throttle Valve Closed Position Learning» .
Turn ignition switch ON.
Set shift lever to D position (A/T) or 1st position (M/T).
Check voltage between ECM terminals 33 (TP sensor 1 signal),
34 (TP sensor 2 signal) and ground under the following conditions.
Terminal

Accelerator pedal

Voltage

33
(Throttle position sensor 1)

Fully released

More than 0.36V

Fully depressed

Less than 4.75V

Fully released

Less than 4.75V

Fully depressed

More than 0.36V

34
(Throttle position sensor 2)

6.
7.
8.

If NG, replace electric throttle control actuator and go to the next
step.
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .

Removal and Installation

PBIB3038E

BBS004BG

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-120, «INTAKE MANIFOLD» .

EC-958

DTC P0132 HO2S1
[HR (WITH EURO-OBD)]

DTC P0132 HO2S1
Component Description

PFP:22690

A
BBS004BH

The heated oxygen sensor 1 is placed into the exhaust manifold. It
detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.

EC

C

D
SEF463R

E

F

G

H
SEF288D

CONSULT-II Reference Value in Data Monitor Mode

BBS004BI

I

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

J

0 — 0.3V ←→ Approx. 0.6 — 1.0V

HO2S1 (B1)
●

HO2S1 MNTR (B1)

Engine: After warming up

Maintaining engine speed at 2,000 rpm.

LEAN ←→ RICH
Changes more than 5 times during
10 seconds.

On Board Diagnosis Logic

K

BBS004BJ

L

To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 output is not inordinately high.

M

PBIB1848E

DTC No.
P0132
0132

Trouble diagnosis name
Heated oxygen sensor 1
circuit high voltage

DTC detecting condition

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 1

An excessively high voltage from the sensor
is sent to ECM.

EC-959

DTC P0132 HO2S1
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004BK

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Restart engine and let it idle for 2 minutes.
If 1st trip DTC is detected, go to EC-962, «Diagnostic Procedure»
.

SEF174Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-960

DTC P0132 HO2S1
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004BL

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1461E

EC-961

DTC P0132 HO2S1
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Approximately 10V
[Engine is running]

3

Y

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

Heated oxygen sensor 1
heater
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
●

Engine speed: Above 3,600 rpm

[Engine is running]
49

56

BR

R

Heated oxygen sensor 1

Sensor ground
(Heated oxygen sensor 1)

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

[Engine is running]
●

Approximately 0V

Idle speed

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004BM

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-962

3.

Body ground

DTC P0132 HO2S1
[HR (WITH EURO-OBD)]

2. RETIGHTEN HEATED OXYGEN SENSOR 1

A

Loosen and retighten heated oxygen sensor 1 (1).
●
●

: Vehicle front
Exhaust manifold (2)

EC

Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb)
C

>> GO TO 3.
D
PBIB2966E

3. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT
1.

Disconnect heated oxygen sensor 1 harness connector (1).

–

: Vehicle front
Disconnect ECM harness connector.
Check harness continuity between HO2S1 terminal 1 and ECM
terminal 56.
Refer to Wiring Diagram.

2.
3.

E

F

G

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

PBIB2967E

I

J

Check harness continuity between HO2S1 terminal 4 and ECM terminal 49.
Refer to Wiring Diagram.
K

Continuity should exist.
2.

H

Check harness continuity between ECM terminal 49 or HO2S1 terminal 4 and ground.
Refer to Wiring Diagram.

L

Continuity should not exist.
3. Also check harness for short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK HO2S1 CONNECTOR FOR WATER
Check heated oxygen sensor 1 connector for water.
Water should not exist.
OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace harness or connectors.

EC-963

M

DTC P0132 HO2S1
[HR (WITH EURO-OBD)]

6. CHECK HEATED OXYGEN SENSOR 1
Refer to EC-965, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace heated oxygen sensor 1.

7. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-964

DTC P0132 HO2S1
[HR (WITH EURO-OBD)]

Component Inspection

BBS004BN

A

HEATED OXYGEN SENSOR 1
With CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC
II.
Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
C
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch “RECORD” on CONSULT-II screen.
D

E

SEF646Y

F

6.

Check the following.
● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes
from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds.
5 times (cycles) are counted as shown in the figure.
● “HO2S1 (B1)” voltage goes above 0.6V at least once.
● “HO2S1 (B1)” voltage goes below 0.3V at least once.
● “HO2S1 (B1)” voltage never exceeds 1.0V.

G

H

I
SEF217YA

J

K

L

SEF648Y

CAUTION:
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.
●

Without CONSULT-II
1.
2.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground.

EC-965

M

DTC P0132 HO2S1
[HR (WITH EURO-OBD)]
3.

Check the following with engine speed held at 2,000 rpm constant under no load.
● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
● The maximum voltage is over 0.6V at least 1 time.
● The minimum voltage is below 0.3V at least 1 time.
● The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V
→ 0 — 0.3V
PBIA9566J
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Removal and Installation

BBS004BO

HEATED OXYGEN SENSOR 1
Refer to EM-124, «EXHAUST MANIFOLD» .

EC-966

DTC P0133 HO2S1
[HR (WITH EURO-OBD)]

DTC P0133 HO2S1
Component Description

PFP:22690

A
BBS004BP

The heated oxygen sensor 1 is placed into the exhaust manifold. It
detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.

EC

C

D
SEF463R

E

F

G

H
SEF288D

CONSULT-II Reference Value in Data Monitor Mode

BBS004BQ

I

Specification data are reference values.
MONITOR ITEM

CONDITION

J

0 — 0.3V ←→ Approx. 0.6 — 1.0V

HO2S1 (B1)
●

HO2S1 MNTR (B1)

SPECIFICATION

Engine: After warming up

Maintaining engine speed at 2,000
rpm.

On Board Diagnosis Logic

LEAN ←→ RICH
Changes more than 5 times during 10 seconds.

K

BBS004BR

L

To judge the malfunction of heated oxygen sensor 1, this diagnosis
measures response time of heated oxygen sensor 1 signal. The time
is compensated by engine operating (speed and load), fuel feedback
control constant, and heated oxygen sensor 1 temperature index.
Judgment is based on whether the compensated time (heated oxygen sensor 1 cycling time index) is inordinately long or not.

M

PBIB2991E

EC-967

DTC P0133 HO2S1
[HR (WITH EURO-OBD)]
DTC No.

P0133
0133

Trouble diagnosis name

Heated oxygen sensor 1
circuit slow response

DTC detecting condition

The response of the voltage signal from the
sensor takes more than the specified time.

DTC Confirmation Procedure

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 1

●

Fuel pressure

●

Fuel injector

●

Intake air leaks

●

Exhaust gas leaks

●

PCV valve

●

Mass air flow sensor
BBS004BS

CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
●
Always perform at a temperature above −10°C (14°F).
●
Before performing the following procedure, confirm that battery voltage is more than 11V at idle.

WITH CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Stop engine and wait at least 10 seconds.
Turn ignition switch ON and select “HO2S1 (B1) P0133” of “HO2S1” in “DTC WORK SUPPORT” mode
with CONSULT-II.
Touch “START”.
Start engine and let it idle for at least 3 minutes.
NOTE:
Never raise engine speed above 3,600 rpm after this step. If
the engine speed limit is exceeded, return to step 5.

SEF338Z

6.

When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will
take approximately 40 to 50 seconds.)

ENG SPEED

A/T: 1,900 — 3,300 rpm
M/T: 2,400 — 3,950 rpm

VHCL SPEED SE

More than 80 km/h (50 MPH)

B/FUEL SCHDL

A/T: 3.5 — 11.2 msec
M/T: 2.8 — 10.2 msec

Shift lever

Suitable position

SEF339Z

If “TESTING” is not displayed after 5 minutes, retry from step 2.

EC-968

DTC P0133 HO2S1
[HR (WITH EURO-OBD)]
7.

Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”. If “NG” is displayed, refer to EC-971, «Diagnostic
Procedure» .

A

EC

C
SEF658Y

D

Overall Function Check

BBS004BT

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st
trip DTC might not be confirmed.

E

WITH GST
1.
2.
3.
●

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground.
Check the following with engine speed held at 2,000 rpm constant under no load.
The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more
than 5 times within 10 seconds.
1 time:
2 times:

4.

F

G

0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V
→ 0 — 0.3V

H

I

If NG, go to EC-971, «Diagnostic Procedure» .
PBIA9566J

J

K

L

M

EC-969

DTC P0133 HO2S1
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004BU

MBWA1461E

EC-970

DTC P0133 HO2S1
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
Approximately 10V
[Engine is running]

3

Y

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

D

Heated oxygen sensor 1
heater

E
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

●

F

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
Engine speed: Above 3,600 rpm

G

[Engine is running]
49

BR

Heated oxygen sensor 1

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

H

[Engine is running]
56

R

Sensor ground
(Heated oxygen sensor 1)

●

Warm-up condition

●

Idle speed

Approximately 0V

I

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004BV

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

J

K

L

M

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-971

3.

Body ground

DTC P0133 HO2S1
[HR (WITH EURO-OBD)]

2. RETIGHTEN HEATED OXYGEN SENSOR 1
Loosen and retighten heated oxygen sensor 1 (1).
●
●

: Vehicle front
Exhaust manifold (2)
Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb)
>> GO TO 3.

PBIB2966E

3. CHECK FOR EXHAUST GAS LEAK
1.
2.

Start engine and run it at idle.
Listen for an exhaust gas leak before three way catalyst (manifold).

SEC502D

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace.

4. CHECK FOR INTAKE AIR LEAK
Listen for an intake air leak after the mass air flow sensor.
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace.

EC-972

DTC P0133 HO2S1
[HR (WITH EURO-OBD)]

5. CLEAR THE SELF-LEARNING DATA
1.
2.
3.
4.

A

With CONSULT-II
Start engine and warm it up to normal operating temperature.
Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II.
Clear the self-learning control coefficient by touching “CLEAR”.
Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 or P0172 detected?
Is it difficult to start engine?

EC

C

D

E
SEF215Z

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF.
3. Disconnect mass air flow sensor (1) harness connector, and
restart and run engine for at least 5 seconds at idle speed.
4. Stop engine and reconnect mass air flow sensor harness connector.
5. Make sure that DTC P0102 is displayed.
6. Erase the DTC memory. Refer to EC-841, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .
7. Make sure that DTC P0000 is displayed.
8. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 or P0172 detected?
PBIB2948E
Is it difficult to start engine?
Yes or No
Yes
>> Perform trouble diagnosis for DTC P0171 or DTC P0172 (Refer to EC-1012, «DTC P0171 FUEL
INJECTION SYSTEM FUNCTION»
or EC-1019, «DTC P0172 FUEL INJECTION SYSTEM
FUNCTION» ).
No
>> GO TO 6.

F

G

H

I

J

K

L

6. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.

Turn ignition switch OFF.
Disconnect heated oxygen sensor 1 harness connector (1).

–

: Vehicle front
Disconnect ECM harness connector.
Check harness continuity between HO2S1 terminal 1 and ECM
terminal 56. Refer to Wiring Diagram.

3.
4.

M

Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

EC-973

PBIB2967E

DTC P0133 HO2S1
[HR (WITH EURO-OBD)]

7. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between HO2S1 terminal 4 and ECM terminal 49.
Refer to Wiring Diagram.
Continuity should exist.

2.

Check harness continuity between ECM terminal 49 or HO2S1 terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 8.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK MASS AIR FLOW SENSOR
Refer to EC-940, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace mass air flow sensor.

9. CHECK PCV VALVE
Refer to EC-828, «Component Inspection» .
OK or NG
OK
>> GO TO 10.
NG
>> Replace PCV valve.

10. CHECK HEATED OXYGEN SENSOR 1
Refer to EC-975, «Component Inspection» .
OK or NG
OK
>> GO TO 11.
NG
>> Replace heated oxygen sensor 1.

11. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-974

DTC P0133 HO2S1
[HR (WITH EURO-OBD)]

Component Inspection

BBS004BW

A

HEATED OXYGEN SENSOR 1
With CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC
II.
Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
C
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch “RECORD” on CONSULT-II screen.
D

E

SEF646Y

F

6.

Check the following.
● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes
from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds.
5 times (cycles) are counted as shown in the figure.
● “HO2S1 (B1)” voltage goes above 0.6V at least once.
● “HO2S1 (B1)” voltage goes below 0.3V at least once.
● “HO2S1 (B1)” voltage never exceeds 1.0V.

G

H

I
SEF217YA

J

K

L

SEF648Y

CAUTION:
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.
●

EC-975

M

DTC P0133 HO2S1
[HR (WITH EURO-OBD)]
Without CONSULT-II
1.
2.
3.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground.
Check the following with engine speed held at 2,000 rpm constant under no load.
● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
● The maximum voltage is over 0.6V at least 1 time.
● The minimum voltage is below 0.3V at least 1 time.
● The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V
→ 0 — 0.3V
PBIA9566J
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Removal and Installation

BBS004BX

HEATED OXYGEN SENSOR 1
Refer to EM-124, «EXHAUST MANIFOLD» .

EC-976

DTC P0134 HO2S1
[HR (WITH EURO-OBD)]

DTC P0134 HO2S1
Component Description

PFP:22690

A
BBS004BY

The heated oxygen sensor 1 is placed into the exhaust manifold. It
detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.

EC

C

D
SEF463R

E

F

G

H
SEF288D

CONSULT-II Reference Value in Data Monitor Mode

BBS004BZ

I

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

J

0 — 0.3V ←→ Approx. 0.6 — 1.0V

HO2S1 (B1)
●

HO2S1 MNTR (B1)

Engine: After warming up

Maintaining engine speed at 2,000
rpm.

LEAN ←→ RICH
Changes more than 5 times during 10 seconds.

On Board Diagnosis Logic

BBS004C0

L

Under the condition in which the heated oxygen sensor 1 signal is
not input, the ECM circuits will read a continuous approximately
0.3V. Therefore, for this diagnosis, the time that output voltage is
within 200 to 400 mV range is monitored, and the diagnosis checks
that this time is not inordinately long.

M

SEF237U

DTC No.
P0134
0134

Trouble diagnosis name
Heated oxygen sensor 1
circuit no activity detected

K

DTC detecting condition

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 1

The voltage from the sensor is constantly
approx. 0.3V.

EC-977

DTC P0134 HO2S1
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004C1

CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 11V at idle.

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

Start engine and warm it up to normal operating temperature.
Select “HO2S1 (B1) P0134” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II.
Touch “START”.
Let it idle for at least 3 minutes.
NOTE:
Never raise engine speed above 3,600 rpm after this step. If
the engine speed limit is exceeded, return to step 4.

PBIB0544E

5.

When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will
take approximately 10 to 60 seconds.)

ENG SPEED

A/T: 1,300 — 3,500 rpm
M/T: 1,800 — 4,250 rpm

VHCL SPEED SE

More than 64 km/h (40 MPH)

B/FUEL SCHDL

A/T: 2.8 — 11.2 msec
M/T: 2.0 — 10.2 msec

Shift lever

Suitable position

6.

PBIB0545E

If “TESTING” is not displayed after 5 minutes, retry from step 2.
Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”. If “NG” is displayed, refer to EC-981, «Diagnostic
Procedure» .

SEC750C

EC-978

DTC P0134 HO2S1
[HR (WITH EURO-OBD)]

Overall Function Check

BBS004C2

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st
trip DTC might not be confirmed.

WITH GST
1.
2.
3.
●

4.

A

EC

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground.
Check the following with engine speed held at 2,000 rpm constant under no load.
The voltage does not remain in the range of 0.2 to 0.4V.
If NG, go to EC-981, «Diagnostic Procedure» .

C

D

E

PBIA9566J

F

G

H

I

J

K

L

M

EC-979

DTC P0134 HO2S1
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004C3

MBWA1461E

EC-980

DTC P0134 HO2S1
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
Approximately 10V
[Engine is running]

3

Y

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

D

Heated oxygen sensor 1
heater

E
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

●

F

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
Engine speed: Above 3,600 rpm

G

[Engine is running]
49

BR

Heated oxygen sensor 1

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

H

[Engine is running]
56

R

Sensor ground
(Heated oxygen sensor 1)

●

Warm-up condition

●

Idle speed

Approximately 0V

I

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004C4

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

J

K

L

M

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-981

3.

Body ground

DTC P0134 HO2S1
[HR (WITH EURO-OBD)]

2. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT
1.

Disconnect heated oxygen sensor 1 harness connector (1).

–

: Vehicle front
Disconnect ECM harness connector.
Check harness continuity between HO2S1 terminal 1 and ECM
terminal 56.
Refer to Wiring Diagram.

2.
3.

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between HO2S1 terminal 4 and ECM terminal 49.
Refer to Wiring Diagram.
Continuity should exist.

2.

Check harness continuity between ECM terminal 49 or HO2S1 terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK HEATED OXYGEN SENSOR 1
Refer to EC-983, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace heated oxygen sensor 1.

5. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-982

PBIB2967E

DTC P0134 HO2S1
[HR (WITH EURO-OBD)]

Component Inspection

BBS004C5

A

HEATED OXYGEN SENSOR 1
With CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC
II.
Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
C
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch “RECORD” on CONSULT-II screen.
D

E

SEF646Y

F

6.

Check the following.
● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes
from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds.
5 times (cycles) are counted as shown in the figure.
● “HO2S1 (B1)” voltage goes above 0.6V at least once.
● “HO2S1 (B1)” voltage goes below 0.3V at least once.
● “HO2S1 (B1)” voltage never exceeds 1.0V.

G

H

I
SEF217YA

J

K

L

SEF648Y

CAUTION:
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.
●

Without CONSULT-II
1.
2.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground.

EC-983

M

DTC P0134 HO2S1
[HR (WITH EURO-OBD)]
3.

Check the following with engine speed held at 2,000 rpm constant under no load.
● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
● The maximum voltage is over 0.6V at least 1 time.
● The minimum voltage is below 0.3V at least 1 time.
● The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V
→ 0 — 0.3V
PBIA9566J
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Removal and Installation

BBS004C6

HEATED OXYGEN SENSOR 1
Refer to EM-124, «EXHAUST MANIFOLD» .

EC-984

DTC P0135 HO2S1 HEATER
[HR (WITH EURO-OBD)]

DTC P0135 HO2S1 HEATER
Description

PFP:23710

A
BBS004C7

SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Camshaft position sensor (PHASE)
Crankshaft position sensor (POS)

Engine speed

Engine coolant temperature sensor

Engine coolant temperature

ECM function

Actuator

Heated oxygen sensor 1
heater control

EC

Heated oxygen sensor 1 heater

The ECM performs ON/OFF duty control of the heated oxygen sensor 1 heater corresponding to the engine
speed and engine coolant temperature. The duty percent varies with engine coolant temperature when engine
is started.

OPERATION
Heated oxygen sensor 1 heater

Above 3,600 rpm

OFF

Below 3,600 rpm after warming up

ON

F

CONSULT-II Reference Value in Data Monitor Mode

BBS004C8

Specification data are reference values.

G

MONITOR ITEM

CONDITION

SPECIFICATION

●

Engine: After warming up

●

Engine speed: Below 3,600 rpm

●

Engine speed: Above 3,600 rpm

●

Engine coolant temperature when engine started: More than 80°C (176°F)

●

Engine speed: Below 3,600 rpm

O2SEN HTR DTY

ON

P0135
0135

Trouble diagnosis
name
Heated oxygen
sensor 1 heater
control circuit

H

OFF

I

Approx. 30%

On Board Diagnosis Logic
DTC No.

D

E
Engine speed

HO2S1 HTR (B1)

C

BBS004C9

J
DTC detecting condition

The current amperage in the heated oxygen sensor
1 heater circuit is out of the normal range.
(An excessively low voltage signal is sent to ECM
through the heated oxygen sensor 1 heater.)

Possible cause
●

Harness or connectors
(The heated oxygen sensor 1 heater circuit
is open or shorted.)

●

Heated oxygen sensor 1 heater

K

L

M

EC-985

DTC P0135 HO2S1 HEATER
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004CA

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is between 11V and 16V at
idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 5 seconds.
If 1st trip DTC is detected, go to EC-988, «Diagnostic Procedure»
.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-986

DTC P0135 HO2S1 HEATER
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004CB

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1462E

EC-987

DTC P0135 HO2S1 HEATER
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Approximately 10V
[Engine is running]

3

Y

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

Heated oxygen sensor 1
heater
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
●

Engine speed: Above 3,600 rpm

[Engine is running]
49

56

BR

R

Heated oxygen sensor 1

Sensor ground
(Heated oxygen sensor 1)

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

[Engine is running]
●

Approximately 0V

Idle speed

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004CC

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-988

3.

Body ground

DTC P0135 HO2S1 HEATER
[HR (WITH EURO-OBD)]

2. CHECK HO2S1 POWER SUPPLY CIRCUIT

A

1.

Disconnect heated oxygen sensor 1 harness connector (1).

–

: Vehicle front
Turn ignition switch ON.

2.

EC

C

D
PBIB2967E

3.

E

Check voltage between HO2S1 terminal 2 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

F

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

G

PBIA9576J

H

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
IPDM E/R connector E10
●
10A fuse
●
Harness for open or short between heated oxygen sensor 1 and fuse

I

J

K

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK HO2S1 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

L

1.
2.
3.

M

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 3 and HO2S1 terminal 3.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK HEATED OXYGEN SENSOR 1 HEATER
Refer to EC-990, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 1.

EC-989

DTC P0135 HO2S1 HEATER
[HR (WITH EURO-OBD)]

6. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004CD

HEATED OXYGEN SENSOR 1 HEATER
1.

Check resistance between HO2S1 terminals as follows.
Terminal No.

Resistance

2 and 3

3.4 — 4.4 Ω [at 25°C (77°F)]

1 and 2, 3, 4

∞Ω
(Continuity should not exist)

4 and 1, 2, 3

2. If NG, replace heated oxygen sensor 1.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped
from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system
threads using Oxygen Sensor Thread Cleaner tool and
approved anti-seize lubricant.

PBIA9577J

Removal and Installation

BBS004CE

HEATED OXYGEN SENSOR 1
Refer to EM-124, «EXHAUST MANIFOLD» .

EC-990

DTC P0138 HO2S2
[HR (WITH EURO-OBD)]

DTC P0138 HO2S2
Component Description

PFP:226A0

A
BBS004CF

The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.

EC

C

D
SEF327R

E

CONSULT-II Reference Value in Data Monitor Mode

BBS004CG

Specification data are reference values.
MONITOR ITEM
HO2S2 (B1)

HO2S2 MNTR (B1)

F

CONDITION

SPECIFICATION

●

Revving engine from idle to 3,000 rpm quickly after the following conditions are met.

0 — 0.3V ←→ Approx. 0.6 — 1.0V

–

Engine: After warming up

–

Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute
and idle for 1 minute under no load

G

LEAN ←→ RICH

H

On Board Diagnosis Logic

BBS004CH

The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity before the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the voltage is unusually high during
the various driving condition such as fuel-cut.

I

J

K
PBIB1848E

L
DTC No.
P0138
0138

Trouble diagnosis name
Heated oxygen sensor 2
circuit high voltage

DTC detecting condition

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 2

An excessively high voltage from the sensor
is sent to ECM.

EC-991

M

DTC P0138 HO2S2
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004CI

CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II.
Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least 1 minute under no load.
Let engine idle for 2 minutes.
If 1st trip DTC is detected, go to EC-994, «Diagnostic Procedure»
.

SEF174Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-992

DTC P0138 HO2S2
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004CJ

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1463E

EC-993

DTC P0138 HO2S2
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Approximately 10V

[Engine is running]

5

GR

●

Below 3,600 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load

Heated oxygen sensor 2
heater

PBIA8148J

[Ignition switch: ON]
●

Engine stopped

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
●

Engine speed: Above 3,600 rpm

[Engine is running]

50

B

Heated oxygen sensor 2

●

Revving engine from idle to 3,000 rpm quickly
after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load.

0 — Approximately 1.0V

[Engine is running]
59

LG

Sensor ground
(Heated oxygen sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004CK

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-994

3.

Body ground

DTC P0138 HO2S2
[HR (WITH EURO-OBD)]

2. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT
1.
–

2.
3.

A

Disconnect heated oxygen sensor 2 harness connector (2).
Heated oxygen sensor 2 (1)
Disconnect ECM harness connector.
Check harness continuity between HO2S2 terminal 1 and ECM
terminal 59.
Refer to Wiring Diagram.

EC

C

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D
PBIB2949E

E

3. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

F

Check harness continuity between HO2S2 terminal 4 ECM terminal 50.
Refer to Wiring Diagram.
Continuity should exist.

2.

G

Check harness continuity between ECM terminal 50 or HO2S2 terminal 4 and ground.
Refer to Wiring Diagram.
H

Continuity should not exist.
3. Also check harness for short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

I

4. CHECK HEATED OXYGEN SENSOR 2

J

Refer to EC-995, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace heated oxygen sensor 2.

K

L

5. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

M

>> INSPECTION END

Component Inspection

BBS004CL

HEATED OXYGEN SENSOR 2
With CONSULT-II
1.
2.
3.
4.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.

EC-995

DTC P0138 HO2S2
[HR (WITH EURO-OBD)]
5.

Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select
“HO2S2 (B1)” as the monitor item with CONSULT-II.

SEF662Y

6.

Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%.

PBIB0551E

“HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%.
“HO2S2 (B1)” should be below 0.50V at least once when the “FUEL INJECTION” is −25%.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Without CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground.
Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.68V at least once during this
procedure.
If the voltage is above 0.68V at step 6, step 7 is not necessary.
7. Keep vehicle idling for 10 minutes, then check voltage. Or check
the voltage when coasting from 80 km/h (50 MPH) in D position
with “OD” OFF (A/T), 3rd gear position (M/T).
The voltage should be below 0.50V at least once during this
PBIB2996E
procedure.
8. If NG, replace heated oxygen sensor 2.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

EC-996

DTC P0138 HO2S2
[HR (WITH EURO-OBD)]

Removal and Installation

BBS004CM

A

HEATED OXYGEN SENSOR 2
Refer to EX-3, «EXHAUST SYSTEM» .

EC

C

D

E

F

G

H

I

J

K

L

M

EC-997

DTC P0139 HO2S2
[HR (WITH EURO-OBD)]

DTC P0139 HO2S2
Component Description

PFP:226A0
BBS004CN

The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
SEF327R

CONSULT-II Reference Value in Data Monitor Mode

BBS004CO

Specification data are reference values.
MONITOR ITEM
HO2S2 (B1)

HO2S2 MNTR (B1)

CONDITION

SPECIFICATION

●

Revving engine from idle to 3,000 rpm quickly after the following conditions are met.

0 — 0.3V ←→ Approx. 0.6 — 1.0V

–

Engine: After warming up

–

Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute
and idle for 1 minute under no load

LEAN ←→ RICH

On Board Diagnosis Logic

BBS004CP

The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity before the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the switching response of the sensor’s voltage is faster than specified during the various driving condition such as fuel-cut.

SEF302U

DTC No.

P0139
0139

Trouble diagnosis name

Heated oxygen sensor 2
circuit slow response

DTC detecting condition

It takes more time for the sensor to respond
between rich and lean than the specified time.

EC-998

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 2

●

Fuel pressure

●

Fuel injector

●

Intake air leaks

DTC P0139 HO2S2
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004CQ

A
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
●
“COMPLETED” will appear on CONSULT-II screen when all tests “COND1”, “COND2” and EC
“COND3” are completed.
●
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
C
at least 10 seconds before conducting the next test.
TESTING CONDITION:
Never stop engine during this procedure. If the engine is stopped, retry this procedure from step 2 in
D
Procedure for COND1.

WITH CONSULT-II
Procedure for COND1
For the best results, perform DTC WORK SUPPORT at a temperature of 0 to 30°(32 to 86°F).
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
4. Let engine idle 1 minute.
5. Select “HO2S2 (B1) P0139” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II.
6. Touch “START”.
7. Start engine and let it idle for at least 30 seconds.
8. Rev engine up to 2,000 rpm two or three times quickly under no load.
If “COMPLETED” appears on CONSULT-II screen, go to step 2 in Procedure for COND3.
If “COMPLETED” does not appear on CONSULT-II screen, go to the following step.
9. When the following conditions are met, “TESTING” will be displayed at “COND1” on the CONSULT-II
screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take
approximately 60 seconds.)
ENG SPEED

More than 1.0 msec

COOLAN TEMP/S

70 — 119 °C (158 — 246°F)

Shift level

Suitable position

F

G

H

I

J

1,000 — 3,600 rpm

B/FUEL SCHDL

E

K

L

M

PBIB0552E

NOTE:
If “TESTING” is not displayed after 5 minutes, retry from step 2 in Procedure for COND1.
● If “COMPLETED” already appears at “COND2” on CONSULT-II screen before Procedure for
COND2 is conducted, it is unnecessary to conduct step 1 in Procedure for COND2.
●

EC-999

DTC P0139 HO2S2
[HR (WITH EURO-OBD)]
Procedure for COND2
1.

While driving, release accelerator pedal completely with “OD”
OFF (A/T) from the above condition [step 9] until “INCOMPLETE” at “COND2” on CONSULT-II screen has turned to
“COMPLETED”. (It will take approximately 4 seconds.)
NOTE:
If “COMPLETED” already appears at “COND3” on CONSULT-II
screen before Procedure for COND3 is conducted, it is unnecessary to conduct step 1 in Procedure for COND3.

PBIB0553E

Procedure for COND3
1.

2.

a.
b.
c.
d.

Stop vehicle and let it idle until “INCOMPLETE” of “COND3” on
CONSULT-II screen has turned to “COMPLETED”. (It will take a
maximum of approximately 6 minutes.)
Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”.
If “NG” is displayed, refer to EC-1002, «Diagnostic Procedure» .
If “CAN NOT BE DIAGNOSED” is displayed, perform the following.
Turn ignition switch OFF and leave the vehicle in a cool place
(soak the vehicle).
Turn ignition switch ON and select “COOLAN TEMP/S” in “DATA
MONITOR” mode with CONSULT-II.
Start engine and warm it up while monitoring “COOLAN TEMP/S” indication on CONSULT-II.
When “COOLAN TEMP/S” indication reaches to 70°(158°F), go to Procedure for COND1 step 3.

Overall Function Check

SEF668Y

BBS004CR

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st
trip DTC might not be confirmed.

WITH GST
1.
2.
3.
4.
5.
6.

7.

8.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground.
Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
A change of voltage should be more than 0.06V for 1 second during this procedure.
If the voltage can be confirmed in step 6, step 7 is not necessary.
Keep vehicle at idling for 10 minutes, then check the voltage. Or
check the voltage when coasting from 80 km/h (50 MPH) in D
position with “OD” OFF (A/T), 3rd gear position (M/T).
A change of voltage should be more than 0.06V for 1 secPBIB2996E
ond during this procedure.
If NG, go to EC-1002, «Diagnostic Procedure» .

EC-1000

DTC P0139 HO2S2
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004CS

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1463E

EC-1001

DTC P0139 HO2S2
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Approximately 10V

[Engine is running]

5

GR

●

Below 3,600 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load

Heated oxygen sensor 2
heater

PBIA8148J

[Ignition switch: ON]
●

Engine stopped

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
●

Engine speed: Above 3,600 rpm

[Engine is running]

50

B

Heated oxygen sensor 2

●

Revving engine from idle to 3,000 rpm quickly
after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load.

0 — Approximately 1.0V

[Engine is running]
59

LG

Sensor ground
(Heated oxygen sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004CT

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1002

3.

Body ground

DTC P0139 HO2S2
[HR (WITH EURO-OBD)]

2. CLEAR THE SELF-LEARNING DATA

A

With CONSULT-II
Start engine and warm it up to normal operating temperature.
Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode
with CONSULT-II.
3. Clear the self-learning control coefficient by touching “CLEAR”.
4. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 or P0172 detected?
Is it difficult to start engine?
1.
2.

EC

C

D

E
SEF215Z

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF.
3. Disconnect mass air flow sensor (1) harness connector, and
restart and run engine for at least 5 seconds at idle speed.
4. Stop engine and reconnect mass air flow sensor harness connector.
5. Make sure that DTC P0102 is displayed.
6. Erase the DTC memory. Refer to EC-841, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .
7. Make sure that DTC P0000 is displayed.
8. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 or P0172 detected?
PBIB2948E
Is it difficult to start engine?
Yes or No
Yes
>> Perform trouble diagnosis for DTC P0171 or P0172. Refer to EC-1012, «DTC P0171 FUEL
INJECTION SYSTEM FUNCTION»
or EC-1019, «DTC P0172 FUEL INJECTION SYSTEM
FUNCTION» .
No
>> GO TO 3.

–

3.
4.

Turn ignition switch OFF.
Disconnect heated oxygen sensor 2 harness connector (2).
Heated oxygen sensor 2 (1)
Disconnect ECM harness connector.
Check harness continuity between and HO2S2 terminal 1 and
ECM terminal 59.
Refer to Wiring Diagram.

EC-1003

H

I

J

K

M

Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

G

L

3. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.

F

PBIB2949E

DTC P0139 HO2S2
[HR (WITH EURO-OBD)]

4. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between HO2S2 terminal 4 and ECM terminal 50.
Refer to Wiring Diagram.
Continuity should exist.

2.

Check harness continuity between ECM terminal 50 or HO2S2 terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK HEATED OXYGEN SENSOR 2
Refer to EC-1004, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 2.

6. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004CU

HEATED OXYGEN SENSOR 2
With CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select
“HO2S2 (B1)” as the monitor item with CONSULT-II.

SEF662Y

EC-1004

DTC P0139 HO2S2
[HR (WITH EURO-OBD)]
6.

Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%.
A

EC

C

PBIB0551E

“HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%.
“HO2S2 (B1)” should be below 0.50V at least once when the “FUEL INJECTION” is −25%.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

D

E

F

Without CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground.
Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.68V at least once during this
procedure.
If the voltage is above 0.68V at step 6, step 7 is not necessary.
7. Keep vehicle idling for 10 minutes, then check voltage. Or check
the voltage when coasting from 80 km/h (50 MPH) in D position
with “OD” OFF (A/T), 3rd gear position (M/T).
The voltage should be below 0.50V at least once during this
PBIB2996E
procedure.
8. If NG, replace heated oxygen sensor 2.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Removal and Installation

BBS004CV

HEATED OXYGEN SENSOR 2
Refer to EX-3, «EXHAUST SYSTEM»

EC-1005

G

H

I

J

K

L

M

DTC P0141 HO2S2 HEATER
[HR (WITH EURO-OBD)]

DTC P0141 HO2S2 HEATER
Description

PFP:23710
BBS004CW

SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Camshaft position sensor (PHASE)

ECM Function

Actuator

Heated oxygen sensor 2
heater control

Heated oxygen sensor 2 heater

Engine speed

Crankshaft position sensor (POS)
Engine coolant temperature sensor

Engine coolant temperature

Mass air flow sensor

Amount of intake air

The ECM performs ON/OFF control of the heated oxygen sensor 2 heater corresponding to the engine speed,
amount of intake air and engine coolant temperature.

OPERATION
Engine speed

Heated oxygen sensor 2 heater

Above 3,600 rpm

OFF

●

Below 3,600 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1
minute and at idle for 1 minute under no load

ON

CONSULT-II Reference Value in Data Monitor Mode

BBS004CX

Specification data are reference values.
MONITOR ITEM

HO2S2 HTR (B1)

CONDITION

SPECIFICATION

●

Engine speed: Above 3,600 rpm

●

Below 3,600 rpm after the following conditions are met.

OFF

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute
and at idle for 1 minute under no load

ON

On Board Diagnosis Logic
DTC No.

P0141
0141

Trouble diagnosis
name
Heated oxygen
sensor 2 heater
control circuit

BBS004CY

DTC detecting condition
The current amperage in the heated oxygen sensor
2 heater circuit is out of the normal range.
(An excessively low voltage signal is sent to ECM
through the heated oxygen sensor 2 heater.)

EC-1006

Possible cause
●

Harness or connectors
(The heated oxygen sensor 2 heater circuit
is open or shorted.)

●

Heated oxygen sensor 2 heater

DTC P0141 HO2S2 HEATER
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004CZ

A
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
EC
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is between 11V and 16V at
idle.
C
WITH CONSULT-II

1.
2.
3.
4.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 5 seconds.
If 1st trip DTC is detected, go to EC-1009, «Diagnostic Procedure» .

D

E

F

SEF058Y

WITH GST

G

Follow the procedure “WITH CONSULT-II” above.
H

I

J

K

L

M

EC-1007

DTC P0141 HO2S2 HEATER
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004D0

MBWA1464E

EC-1008

DTC P0141 HO2S2 HEATER
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
Approximately 10V

[Engine is running]

5

GR

●

Below 3,600 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load

Heated oxygen sensor 2
heater

D

E
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

●

F

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
Engine speed: Above 3,600 rpm

G

[Engine is running]

50

B

Heated oxygen sensor 2

●

Revving engine from idle to 3,000 rpm quickly
after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load.

H

0 — Approximately 1.0V

I

[Engine is running]
59

LG

Sensor ground
(Heated oxygen sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

J

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004D1

K

1. CHECK GROUND CONNECTIONS
1.
2.

L

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

M

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1009

3.

Body ground

DTC P0141 HO2S2 HEATER
[HR (WITH EURO-OBD)]

2. CHECK HO2S2 POWER SUPPLY CIRCUIT
1.
–

2.

Disconnect heated oxygen sensor 2 harness connector (2).
Heated oxygen sensor 2 (1)
Turn ignition switch ON.

PBIB2949E

3.

Check voltage between HO2S2 terminal 2 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

PBIA9576J

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
IPDM E/R connector E10
●
10A fuse
●
Harness for open or short between heated oxygen sensor 2 and fuse
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK HO2S2 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 5 and HO2S2 terminal 3.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK HEATED OXYGEN SENSOR 2 HEATER
Refer to EC-1011, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 2.

EC-1010

DTC P0141 HO2S2 HEATER
[HR (WITH EURO-OBD)]

6. CHECK INTERMITTENT INCIDENT

A

Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
EC

>> INSPECTION END

Component Inspection

BBS004D2

HEATED OXYGEN SENSOR 2 HEATER
1.

C

Check resistance between HO2S2 terminals as follows.
Terminal No.

Resistance

2 and 3

3.4 — 4.4 Ω [at 25°C (77°F)]

1 and 2, 3, 4

∞Ω
(Continuity should not exist)

4 and 1, 2, 3

D

E

2. If NG, replace heated oxygen sensor 2.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped
from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system
threads using Oxygen Sensor Thread Cleaner tool and
approved anti-seize lubricant.

F

G

H

I
PBIA9577J

J

Removal and Installation

BBS004D3

HEATED OXYGEN SENSOR 2
Refer to EX-3, «EXHAUST SYSTEM» .

K

L

M

EC-1011

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
[HR (WITH EURO-OBD)]

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
On Board Diagnosis Logic

PFP:16600
BBS004D4

With the Air-Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the
theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensor 1. The
ECM calculates the necessary compensation to correct the offset between the actual and the theoretical
ratios.
In case the amount of the compensation value is extremely large (The actual mixture ratio is too lean.), the
ECM judges the condition as the fuel injection system malfunction and lights up the MI (2 trip detection logic).
Sensor
Heated oxygen sensor 1

Input Signal to ECM
Density of oxygen in exhaust gas
(Mixture ratio feedback signal)

Trouble diagnosis
name

DTC No.

Fuel injection system
too lean

Fuel injection control

Actuator
Fuel injector

DTC detecting condition

●

P0171
0171

ECM function

●

Possible cause
●

Intake air leaks

●

Heated oxygen sensor 1

Fuel injection system does not operate properly.

●

Fuel injector

The amount of mixture ratio compensation is too
large.
(The mixture ratio is too lean.)

●

Exhaust gas leaks

●

Incorrect fuel pressure

●

Lack of fuel

●

Mass air flow sensor

●

Incorrect PCV hose connection

DTC Confirmation Procedure

BBS004D5

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

a.
b.

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON and select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II.
Clear the self-learning control coefficient by touching “CLEAR”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine again and let it idle for at least 10 minutes.
The 1st trip DTC P0171 should be detected at this stage, if a
malfunction exists. If so, go to EC-1016, «Diagnostic Procedure»
.
NOTE:
If 1st trip DTC is not detected during above procedure, performing the following procedure is advised.
Turn ignition switch OFF and wait at least 10 seconds.
SEF215Z
Start engine and drive the vehicle under the similar conditions to
(1st trip) Freeze Frame Data for 10 minutes. Refer to the table below.
Hold the accelerator pedal as steady as possible.
The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time.

Engine speed

Engine speed in the freeze frame data ± 400 rpm

Vehicle speed

Vehicle speed in the freeze frame data ± 10 km/h (6 MPH)

EC-1012

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
[HR (WITH EURO-OBD)]
Engine coolant temperature
(T) condition

7.
8.

When the freeze frame data shows lower than 70 °C (158 °F),
T should be lower than 70 °C (158 °F).

A

When the freeze frame data shows higher than or equal to 70 °C (158 °F),
T should be higher than or equal to 70 °C (158 °F).

EC
If it is difficult to start engine at step 6, the fuel injection system has a malfunction, too.
Crank engine while depressing accelerator pedal. If engine starts, go to EC-1016, «Diagnostic Procedure»
. If engine does not start, check exhaust and intake air leak visually.
C

WITH GST
1.
2.
3.
4.
5.
6.
7.
8.
9.

a.
b.

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Disconnect mass air flow sensor (1) harness connector.
Restart engine and let idle for at least 5 seconds.
Stop engine and reconnect mass air flow sensor harness connector.
Select Service $03 with GST. Make sure DTC P0102 is
detected.
Select Service $04 with GST and erase the DTC P0102.
Start engine again and let it idle for at least 10 minutes.
Select Service $07 with GST. The 1st trip DTC P0171 should be
PBIB2948E
detected at this stage, if a malfunction exists. If so, go to EC1016, «Diagnostic Procedure» .
NOTE:
If 1st trip DTC is not detected during above procedure, performing the following procedure is advised.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for 10 minutes. Refer to the table below.
Hold the accelerator pedal as steady as possible.

D

E

F

G

H

I

J

The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time.
Engine speed

Engine speed in the freeze frame data ± 400 rpm

Vehicle speed

Vehicle speed in the freeze frame data ± 10 km/h (6 MPH)

Engine coolant temperature
(T) condition

When the freeze frame data shows lower than 70 °C (158 °F),
T should be lower than 70 °C (158 °F).
When the freeze frame data shows higher than or equal to 70 °C (158 °F),
T should be higher than or equal to 70 °C (158 °F).

10. If it is difficult to start engine at step 8, the fuel injection system has a malfunction.
11. Crank engine while depressing accelerator pedal. If engine starts, go to EC-1016, «Diagnostic Procedure»
.
If engine does not start, check exhaust and intake air leak visually.

EC-1013

K

L

M

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004D6

MBWA1465E

EC-1014

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
Approximately 10V
[Engine is running]

3

Y

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

D

Heated oxygen sensor 1
heater

E
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

[Engine is running]
●

F

BATTERY VOLTAGE
(11 — 14V)

Engine speed: Above 3,600 rpm

G

BATTERY VOLTAGE
[Engine is running]

25
29
30
31

R
O
GR
L

●

Warm-up condition

●

Idle speed

(11 — 14V)

H

NOTE:
The pulse cycle changes depending on rpm
at idle

Fuel injector No. 4
Fuel injector No. 3
Fuel injector No. 2
Fuel injector No. 1

I
PBIB0529E

BATTERY VOLTAGE

J

(11 — 14V)
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

K

L
PBIA4943J

[Engine is running]
49

56

BR

R

Heated oxygen sensor 1

Sensor ground
(Heated oxygen sensor 1)

●

Warm-up condition

●

Engine speed: 2,000 rpm

[Engine is running]
●

Idle speed

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-1015

0 — Approximately 1.0V
(Periodically change)

Approximately 0V

M

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004D7

1. CHECK EXHAUST GAS LEAK
1.
2.

Start engine and run it at idle.
Listen for an exhaust gas leak before three way catalyst (manifold).

SEC502D

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace.

2. CHECK FOR INTAKE AIR LEAK AND PCV HOSE
1. Listen for an intake air leak after the mass air flow sensor.
2. Check PCV hose connection.
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

3. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT
1.
2.

Turn ignition switch OFF.
Disconnect heated oxygen sensor 1 harness connector (1).

–

: Vehicle front
Disconnect ECM harness connector.
Check harness continuity between HO2S1 terminal 4 and ECM
terminal 49.
Refer to Wiring Diagram.

3.
4.

Continuity should exist.
5.

Check harness continuity between ECM terminal 49 or HO2S1
terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

6. Also check harness for short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1016

PBIB2967E

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
[HR (WITH EURO-OBD)]

4. CHECK FUEL PRESSURE
1.
2.

A

Release fuel pressure to zero. Refer to EC-860, «FUEL PRESSURE RELEASE» .
Install fuel pressure gauge and check fuel pressure. Refer to EC-860, «FUEL PRESSURE CHECK» .
At idling: Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi)

EC

OK or NG
OK
>> GO TO 5.
NG
>> Follow the construction of EC-860, «FUEL PRESSURE CHECK» .

C

5. CHECK MASS AIR FLOW SENSOR

D

With CONSULT-II
1. Install all removed parts.
2. Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II.

E

1.0 — 4.0 g·m/sec:
2.0 — 10.0 g·m/sec:
1.
2.

at idling
at 2,500 rpm

F

With GST
Install all removed parts.
Check mass air flow sensor signal in Service $01 with GST.
1.0 — 4.0 g·m/sec:
2.0 — 10.0 g·m/sec:

at idling
at 2,500 rpm

G

H

OK or NG
OK
>> GO TO 6.
NG
>> Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or
ground. Refer to EC-935, «DTC P0102, P0103 MAF SENSOR» .

I

J

K

L

M

EC-1017

DTC P0171 FUEL INJECTION SYSTEM FUNCTION
[HR (WITH EURO-OBD)]

6. CHECK FUNCTION OF FUEL INJECTORS
With CONSULT-II
Start engine.
Perform “POWER BALANCE” in “ACTIVE TEST” mode with
CONSULT-II.
3. Make sure that each circuit produces a momentary engine
speed drop.
1.
2.

PBIB0133E

Without CONSULT-II
1. Start engine.
2. Listen to each fuel injector operating sound.
Clicking noise should be heard.
OK or NG
OK
>> GO TO 7.
NG
>> Perform trouble diagnosis for EC-1209, «FUEL INJECTOR» .

PBIB1986E

7. CHECK FUEL INJECTOR
1.
2.
3.

4.
5.
6.

Confirm that the engine is cooled down and there are no fire hazards near the vehicle.
Turn ignition switch OFF.
Remove fuel tube assembly. Refer to EM-135, «FUEL INJECTOR AND FUEL TUBE» .
Keep fuel hose and all fuel injectors connected to fuel tube.
The fuel injector harness connectors should remain connected.
Disconnect all ignition coil harness connectors.
Prepare pans or saucers under each fuel injector.
Crank engine for about 3 seconds. Make sure that fuel sprays
out from fuel injectors.
Fuel should be sprayed evenly for each fuel injector.

OK or NG
OK
>> GO TO 8.
NG
>> Replace fuel injectors from which fuel does not spray
out. Always replace O-ring with new ones.

PBIB1726E

8. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1018

DTC P0172 FUEL INJECTION SYSTEM FUNCTION
[HR (WITH EURO-OBD)]

DTC P0172 FUEL INJECTION SYSTEM FUNCTION
On Board Diagnosis Logic

PFP:16600

A
BBS004D8

With the Air-Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the
theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensors 1. The EC
ECM calculates the necessary compensation to correct the offset between the actual and the theoretical
ratios.
In case the amount of the compensation value is extremely large (The actual mixture ratio is too rich.), the
C
ECM judges the condition as the fuel injection system malfunction and lights up the MI (2 trip detection logic).
Sensor
Heated oxygen sensor 1

Density of oxygen in exhaust gas
(Mixture ratio feedback signal)

Trouble diagnosis
name

DTC No.

P0172
0172

Input Signal to ECM

Fuel injection system
too rich

ECM function
Fuel injection control

DTC detecting condition

●

Fuel injection system does not operate properly.

●

The amount of mixture ratio compensation is too
large.
(The mixture ratio is too rich.)

Actuator

D

Fuel injector

E

Possible cause
●

Heated oxygen sensor 1

●

Fuel injector

●

Exhaust gas leaks

●

Incorrect fuel pressure

●

Mass air flow sensor

DTC Confirmation Procedure

F

G
BBS004D9

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

a.
b.

I

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON and select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II.
Clear the self-learning control coefficient by touching “CLEAR”.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine again and let it idle for at least 10 minutes.
The 1st trip DTC P0172 should be detected at this stage, if a
malfunction exists. If so, go to EC-1023, «Diagnostic Procedure»
.
NOTE:
If 1st trip DTC is not detected during above procedure, performing the following procedure is advised.
Turn ignition switch OFF and wait at least 10 seconds.
SEF215Z
Start engine and drive the vehicle under the similar conditions to
(1st trip) Freeze Frame Data for 10 minutes. Refer to the table below.
Hold the accelerator pedal as steady as possible.
The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time.

Engine speed

Engine speed in the freeze frame data ± 400 rpm

Vehicle speed

Vehicle speed in the freeze frame data ± 10 km/h (6 MPH)

Engine coolant temperature
(T) condition

7.

H

When the freeze frame data shows lower than 70 °C (158 °F),
T should be lower than 70 °C (158 °F).
When the freeze frame data shows higher than or equal to 70 °C (158 °F),
T should be higher than or equal to 70 °C (158 °F).

If it is difficult to start engine at step 6, the fuel injection system has a malfunction, too.

EC-1019

J

K

L

M

DTC P0172 FUEL INJECTION SYSTEM FUNCTION
[HR (WITH EURO-OBD)]
8.

Crank engine while depressing accelerator pedal.
If engine starts, go to EC-1023, «Diagnostic Procedure» . If engine does not start, remove ignition plugs
and check for fouling, etc.

WITH GST
1.
2.
3.
4.
5.
6.
7.
8.
9.

a.
b.

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Disconnect mass air flow sensor (1) harness connector.
Restart engine and let idle for at least 5 seconds.
Stop engine and reconnect mass air flow sensor harness connector.
Select Service $03 with GST. Make sure DTC P0102 is
detected.
Select Service $04 with GST and erase the DTC P0102.
Start engine again and let it idle for at least 10 minutes.
Select Service $07 with GST. The 1st trip DTC P0172 should be
PBIB2948E
detected at this stage, if a malfunction exists. If so, go to EC1023, «Diagnostic Procedure» .
NOTE:
If 1st trip DTC is not detected during above procedure, performing the following procedure is advised.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for 10 minutes. Refer to the table below.
Hold the accelerator pedal as steady as possible.
The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time.

Engine speed

Engine speed in the freeze frame data ± 400 rpm

Vehicle speed

Vehicle speed in the freeze frame data ± 10 km/h (6 MPH)

Engine coolant temperature
(T) condition

When the freeze frame data shows lower than 70 °C (158 °F),
T should be lower than 70 °C (158 °F).
When the freeze frame data shows higher than or equal to 70 °C (158 °F),
T should be higher than or equal to 70 °C (158 °F).

10. If it is difficult to start engine at step 8, the fuel injection system has a malfunction.
11. Crank engine while depressing accelerator pedal.
If engine starts, go to EC-1023, «Diagnostic Procedure» . If engine does not start, remove ignition plugs
and check for fouling, etc.

EC-1020

DTC P0172 FUEL INJECTION SYSTEM FUNCTION
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004DA

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1465E

EC-1021

DTC P0172 FUEL INJECTION SYSTEM FUNCTION
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Approximately 10V
[Engine is running]

3

Y

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

Heated oxygen sensor 1
heater
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

[Engine is running]
●

BATTERY VOLTAGE
(11 — 14V)

Engine speed: Above 3,600 rpm
BATTERY VOLTAGE

[Engine is running]

25
29
30
31

R
O
GR
L

●

Warm-up condition

●

Idle speed

(11 — 14V)

NOTE:
The pulse cycle changes depending on rpm
at idle

Fuel injector No. 4
Fuel injector No. 3
Fuel injector No. 2
Fuel injector No. 1

PBIB0529E

BATTERY VOLTAGE
(11 — 14V)
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

PBIA4943J

[Engine is running]
49

56

BR

R

Heated oxygen sensor 1

●

Warm-up condition

●

Engine speed: 2,000 rpm

Sensor ground
(Heated oxygen sensor 1)

[Engine is running]
●

Idle speed

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-1022

0 — Approximately 1.0V
(Periodically change)

Approximately 0V

DTC P0172 FUEL INJECTION SYSTEM FUNCTION
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004DB

1. CHECK EXHAUST GAS LEAK
1.
2.

A

Start engine and run it at idle.
Listen for an exhaust gas leak before three way catalyst (manifold).

EC

C

D

E
SEC502D

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace.

F

2. CHECK FOR INTAKE AIR LEAK

G

Listen for an intake air leak after the mass air flow sensor.
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

H

3. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT

I

1.
2.

Turn ignition switch OFF.
Disconnect heated oxygen sensor 1 harness connector (1).

J

–

: Vehicle front
Disconnect ECM harness connector.
Check harness continuity between HO2S1 terminal 4 and ECM
terminal 49.
Refer to Wiring Diagram.

K

3.
4.

L

Continuity should exist.
5.

Check harness continuity between ECM terminal 49 or HO2S1
terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

6. Also check harness for short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1023

PBIB2967E

M

DTC P0172 FUEL INJECTION SYSTEM FUNCTION
[HR (WITH EURO-OBD)]

4. CHECK FUEL PRESSURE
1.
2.

Release fuel pressure to zero. Refer to EC-860, «FUEL PRESSURE RELEASE» .
Install fuel pressure gauge and check fuel pressure. Refer to EC-860, «FUEL PRESSURE CHECK» .
At idling: 350 kPa (3.5 bar, 3.57 kg/cm2, 51 psi)

OK or NG
OK
>> GO TO 5.
NG
>> Follow the construction of EC-860, «FUEL PRESSURE CHECK» .

5. CHECK MASS AIR FLOW SENSOR
With CONSULT-II
1. Install all removed parts.
2. Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II.
1.0 — 4.0 g·m/sec:
2.0 — 10.0 g·m/sec:

at idling
at 2,500 rpm

With GST
1. Install all removed parts.
2. Check mass air flow sensor signal in Service $01 with GST.
1.0 — 4.0 g·m/sec:
2.0 — 10.0 g·m/sec:

at idling
at 2,500 rpm

OK or NG
OK
>> GO TO 6.
NG
>> Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or
ground. Refer to EC-935, «DTC P0102, P0103 MAF SENSOR» .

EC-1024

DTC P0172 FUEL INJECTION SYSTEM FUNCTION
[HR (WITH EURO-OBD)]

6. CHECK FUNCTION OF FUEL INJECTORS

A

With CONSULT-II
Start engine.
Perform “POWER BALANCE” in “ACTIVE TEST” mode with
CONSULT-II.
3. Make sure that each circuit produces a momentary engine
speed drop.
1.
2.

EC

C

D

E
PBIB0133E

Without CONSULT-II
1. Start engine.
2. Listen to each fuel injector operating sound.

F

Clicking noise should be heard.

G

OK or NG
OK
>> GO TO 7.
NG
>> Perform trouble diagnosis for EC-1209, «FUEL INJECTOR» .

H

I
PBIB1986E

7. CHECK FUEL INJECTOR

J

Remove fuel injector assembly. Refer to EM-135, «FUEL INJECTOR AND FUEL TUBE» .
Keep fuel hose and all fuel injectors connected to fuel tube.
2. Confirm that the engine is cooled down and there are no fire hazards near the vehicle.
3. Disconnect fuel injector harness connectors.
4. Disconnect all ignition coil harness connectors.
5. Prepare pans or saucers under each fuel injectors.
6. Crank engine for about 3 seconds.
Make sure fuel does not drip from fuel injector.
OK or NG
OK (Does not drip.)>>GO TO 8.
NG (Drips.)>>Replace the fuel injectors from which fuel is dripping. Always replace O-ring with new one.

1.

8. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1025

K

L

M

DTC P0222, P0223 TP SENSOR
[HR (WITH EURO-OBD)]

DTC P0222, P0223 TP SENSOR
Component Description

PFP:16119
BBS004DC

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

PBIB0145E

CONSULT-II Reference Value in Data Monitor Mode

BBS004DD

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Ignition switch: ON
(Engine stopped)

●

Shift lever: D (A/T), 1st (M/T)

THRTL SEN 1
THRTL SEN 2*

SPECIFICATION

Accelerator pedal: Fully released

More than 0.36V

Accelerator pedal: Fully depressed

Less than 4.75V

*: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic

BBS004DE

These self-diagnoses have the one trip detection logic.
NOTE:
If DTC P0222 or P0223 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229.
Refer to EC-1150, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

Trouble diagnosis name

DTC detecting condition

Possible cause

P0222
0222

Throttle position sensor
1 circuit low input

An excessively low voltage from the TP sensor 1
is sent to ECM.

●

Harness or connectors
(TP sensor 1 circuit is open or shorted.)

P0223
0223

Throttle position sensor
1 circuit high input

An excessively high voltage from the TP sensor
1 is sent to ECM.

●

Electric throttle control actuator
(TP sensor 1)

FAIL-SAFE MODE
When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-1026

DTC P0222, P0223 TP SENSOR
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004DF

A
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
EC
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

C

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-1029, «Diagnostic Procedure» .

D

E

F
SEF058Y

WITH GST

G

Follow the procedure “WITH CONSULT-II” above.
H

I

J

K

L

M

EC-1027

DTC P0222, P0223 TP SENSOR
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004DG

MBWA1466E

EC-1028

DTC P0222, P0223 TP SENSOR
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

EC
ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch: ON]

33

Y

A

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

Throttle position sensor 1

C
More than 0.36V

D

[Ignition switch: ON]
●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

Less than 4.75V

E

[Ignition switch: ON]
●

34

R

Throttle position sensor 2

F

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

Less than 4.75V

G

[Ignition switch: ON]
●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

More than 0.36V

H

[Engine is running]
36

72

BR

L

Sensor ground
(Throttle position sensor)
Sensor power supply
(Throttle position sensor)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]

Approximately 0V

I

Approximately 5V

J

Diagnostic Procedure

BBS004DH

1. CHECK GROUND CONNECTIONS

K

1.
2.

L

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

M

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1029

3.

Body ground

DTC P0222, P0223 TP SENSOR
[HR (WITH EURO-OBD)]

2. CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT
1.

Disconnect electric throttle control actuator (1) harness connector.

–

: Vehicle front
Turn ignition switch ON.

2.

PBIB2965E

3.

Check voltage between electric throttle control actuator terminal
1 and ground with CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

PBIA9580J

3. CHECK THROTTLE POSITION SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 36.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK THROTTLE POSITION SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 33 and electric throttle control actuator terminal 2.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK THROTTLE POSITION SENSOR
Refer to EC-1031, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

EC-1030

DTC P0222, P0223 TP SENSOR
[HR (WITH EURO-OBD)]

6. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

A

Replace the electric throttle control actuator.
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .

EC

>> INSPECTION END

C

7. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

D

>> INSPECTION END
E

Component Inspection

BBS004DI

THROTTLE POSITION SENSOR
1.
2.
3.
4.
5.

Reconnect all harness connectors disconnected.
Perform EC-857, «Throttle Valve Closed Position Learning» .
Turn ignition switch ON.
Set shift lever to D (A/T), 1st (M/T) position.
Check voltage between ECM terminals 33 (TP sensor 1 signal),
34 (TP sensor 2 signal) and ground under the following conditions.
Terminal

Accelerator pedal

Voltage

33
(Throttle position sensor 1)

Fully released

More than 0.36V

Fully depressed

Less than 4.75V

Fully released

Less than 4.75V

Fully depressed

More than 0.36V

34
(Throttle position sensor 2)

6.
7.
8.

If NG, replace electric throttle control actuator and go to the next
step.
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .

Removal and Installation

F

G

H

I

J
PBIB3038E

K

BBS004DJ

ELECTRIC THROTTLE CONTROL ACTUATOR

L

Refer to EM-120, «INTAKE MANIFOLD» .
M

EC-1031

DTC P0300 — P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 — 4 CYLINDER MISFIRE
[HR (WITH EURO-OBD)]

DTC P0300 — P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 — 4 CYLINDER MISFIRE
PFP:00000
On Board Diagnosis Logic

BBS004DK

When a misfire occurs, engine speed will fluctuate. If the engine speed fluctuates enough to cause the crankshaft position (CKP) sensor (POS) signal to vary, ECM can determine that a misfire is occurring.
Sensor
Crankshaft position sensor (POS)

Input Signal to ECM

ECM function

Engine speed

On board diagnosis of misfire

The misfire detection logic consists of the following two conditions.
1. One Trip Detection Logic (Three Way Catalyst Damage)
On the first trip that a misfire condition occurs that can damage the three way catalyst (TWC) due to overheating, the MI will blink.
When a misfire condition occurs, the ECM monitors the CKP sensor (POS) signal every 200 engine revolutions for a change.
When the misfire condition decreases to a level that will not damage the TWC, the MI will turn off.
If another misfire condition occurs that can damage the TWC on a second trip, the MI will blink.
When the misfire condition decreases to a level that will not damage the TWC, the MI will remain on.
If another misfire condition occurs that can damage the TWC, the MI will begin to blink again.
2. Two Trip Detection Logic (Exhaust quality deterioration)
For misfire conditions that will not damage the TWC (but will affect vehicle emissions), the MI will only light
when the misfire is detected on a second trip. During this condition, the ECM monitors the CKP sensor
signal every 1,000 engine revolutions.
A misfire malfunction can be detected on any one cylinder or on multiple cylinders.
DTC No.

Trouble diagnosis name

DTC detecting condition

P0300
0300

Multiple cylinder misfire
detected

Multiple cylinder misfire.

P0301
0301

No.1 cylinder misfire
detected

No. 1 cylinder misfires.

P0302
0302

No. 2 cylinder misfire
detected

No. 2 cylinder misfires.

P0303
0303

No. 3 cylinder misfire
detected

P0304
0304

No. 4 cylinder misfire
detected

No. 3 cylinder misfires.

No. 4 cylinder misfires.

EC-1032

Possible cause
●

Improper spark plug

●

Insufficient compression

●

Incorrect fuel pressure

●

Fuel injector circuit is open or shorted

●

Fuel injector

●

Intake air leak

●

The ignition signal circuit is open or
shorted

●

Lack of fuel

●

Drive plate or flywheel

●

Heated oxygen sensor 1

●

Incorrect PCV hose connection

DTC P0300 — P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 — 4 CYLINDER MISFIRE
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004DL

A
CAUTION:
Always drive vehicle in safe manner according to traffic conditions and obey all traffic laws when driving.
EC
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
C

WITH CONSULT-II

1.
2.
3.
4.
5.

a.
b.

Turn ignition switch ON, and select “DATA MONITOR” mode
with CONSULT-II.
Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Restart engine and let it idle for about 15 minutes.
If 1st trip DTC is detected, go to EC-1033, «Diagnostic Procedure» .
NOTE:
If 1st trip DTC is not detected during above procedure, performing the following procedure is advised.
PBIB0164E
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for a certain
time. Refer to table below.
Hold the accelerator pedal as steady as possible.

D

E

F

G

H

The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following condition should be satisfied at the same time:
Engine speed

Engine speed in the freeze frame data ± 400 rpm

Vehicle speed

Vehicle speed in the freeze frame data ± 10 km/h (6 MPH)

I

When the freeze frame data shows lower than 70°C (158°F), T should be lower than 70°C (158°F)
Engine coolant temperature
(T) condition

J

When the freeze frame data shows higher than or equal to 70°C (158°F), T should be higher than or
equal to 70°C (158°F)

K

The time to driving varies according to the engine speed in the freeze frame data.
Refer to the following table.
Engine speed

Time

Around 1,000 rpm

Approximately 10 minutes

Around 2,000 rpm

Approximately 5 minutes

More than 3,000 rpm

Approximately 3.5 minutes

L

M

WITH GST
Follow the procedure “WITH CONSULT-II” above.

Diagnostic Procedure

BBS004DM

1. CHECK FOR INTAKE AIR LEAK AND PCV HOSE
1. Start engine and run it at idle speed.
2. Listen for the sound of the intake air leak.
3. Check PCV hose connection.
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace.

EC-1033

DTC P0300 — P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 — 4 CYLINDER MISFIRE
[HR (WITH EURO-OBD)]

2. CHECK FOR EXHAUST SYSTEM CLOGGING
Stop engine and visually check exhaust tube, three way catalyst and muffler for dents.
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

3. PERFORM POWER BALANCE TEST
With CONSULT-II
1. Perform “POWER BALANCE” in “ACTIVE TEST” mode.
2. Is there any cylinder which does not produce a momentary
engine speed drop?

PBIB0133E

Without CONSULT-II
When disconnecting each fuel injector (2) harness connector one at
a time, is there any cylinder which does not produce a momentary
engine speed drop?
●
Ignition coil (1)

PBIB2968E

Yes or No
Yes
>> GO TO 4.
No
>> GO TO 9.

4. CHECK FUEL INJECTOR
Does each fuel injector make an operating sound at idle?
Yes or No
Yes
>> GO TO 5.
No
>> Check fuel injector(s) and circuit(s). Refer to EC-1209,
«FUEL INJECTOR» .

PBIB1986E

EC-1034

DTC P0300 — P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 — 4 CYLINDER MISFIRE
[HR (WITH EURO-OBD)]

5. CHECK FUNCTION OF IGNITION COIL-I

A

CAUTION:
Do the following procedure in the place where ventilation is good without the combustible.
1. Turn ignition switch OFF.
2. Remove fuel pump fuse in IPDM E/R to release fuel pressure.
NOTE:
Do not use CONSULT-II to release fuel pressure, or fuel pressure applies again during the following procedure.
3. Start engine.
4. After engine stalls, crank it two or three times to release all fuel
pressure.
5. Turn ignition switch OFF.
6. Remove all ignition coil harness connectors to avoid the electrical discharge from the ignition coils.
7. Remove ignition coil and spark plug of the cylinder to be
checked.
8. Crank engine for 5 seconds or more to remove combustion gas in the cylinder.
9. Connect spark plug and harness connector to ignition coil.
10. Fix ignition coil using a rope etc. with gap of 13 — 17 mm
between the edge of the spark plug and grounded metal portion
as shown in the figure.
11. Crank engine for about three seconds, and check whether spark
is generated between the spark plug and the grounded metal
portion.

EC

C

D

E
MBIB0277E

G

H

I

Spark should be generated.
CAUTION:
● Do not approach to the spark plug and the ignition coil
within 50cm. Be careful not to get an electrical shock
PBIB2325E
while checking, because the electrical discharge voltage
becomes 20kV or more.
● It might cause to damage the ignition coil if the gap of more than 17 mm is taken.
NOTE:
When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning.
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 6.

J

K

L

M

6. CHECK FUNCTION OF IGNITION COIL-II
1.
2.
3.

F

Turn ignition switch OFF.
Disconnect spark plug and connect a known-good spark plug.
Crank engine for about three seconds, and recheck whether spark is generated between the spark plug
and the grounded metal portion.
Spark should be generated.

OK or NG
OK
>> GO TO 7.
NG
>> Check ignition coil, power transistor and their circuits. Refer to EC-1221, «IGNITION SIGNAL» .

EC-1035

DTC P0300 — P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 — 4 CYLINDER MISFIRE
[HR (WITH EURO-OBD)]

7. CHECK SPARK PLUG
Check the initial spark plug for fouling, etc.
OK or NG
OK
>> Replace spark plug(s) with standard type one(s). For
spark plug type, refer to EM-133, «SPARK PLUG (PLATINUM-TIPPED TYPE)» .
NG
>> 1. Repair or clean spark plug.
2. GO TO 8.

SEF156I

8. CHECK FUNCTION OF IGNITION COIL-III
1.
2.

Reconnect the initial spark plugs.
Crank engine for about three seconds, and recheck whether spark is generated between the spark plug
and the grounded portion.
Spark should be generated.

OK or NG
OK
>> INSPECTION END
NG
>> Replace spark plug(s) with standard type one(s). For spark plug type, refer to EM-133, «SPARK
PLUG (PLATINUM-TIPPED TYPE)» .

9. CHECK COMPRESSION PRESSURE
Check compression pressure. Refer to EM-173, «CHECKING COMPRESSION PRESSURE» .
OK or NG
OK
>> GO TO 10.
NG
>> Check pistons, piston rings, valves, valve seats and cylinder head gaskets.

10. CHECK FUEL PRESSURE
1.
2.
3.

Install all removed parts.
Release fuel pressure to zero. Refer to EC-860, «FUEL PRESSURE RELEASE» .
Install fuel pressure gauge and check fuel pressure. Refer to EC-860, «FUEL PRESSURE CHECK» .
At idle: Approx. 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi)

OK or NG
OK
>> GO TO 12.
NG
>> GO TO 11.

11. DETECT MALFUNCTIONING PART
Check the following.
Fuel pump and circuit (Refer to EC-1215, «FUEL PUMP» .)
●
Fuel pressure regulator (Refer to EC-860, «FUEL PRESSURE CHECK» .)
●
Fuel lines
●
Fuel filter for clogging
●

>> Repair or replace.

EC-1036

DTC P0300 — P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 — 4 CYLINDER MISFIRE
[HR (WITH EURO-OBD)]

12. CHECK IGNITION TIMING

A

Check the following items. Refer to EC-851, «Basic Inspection» .
Items

Specifications

Target idle speed

Ignition timing

A/T models

700 ± 50 rpm (in P or N position)

M/T models

650 ± 50 rpm (in Neutral position)

A/T models

6 ± 5° BTDC (in P or N position)

M/T models

6 ± 5° BTDC (in Neutral position)

OK or NG
OK
>> GO TO 13.
NG
>> Follow the EC-851, «Basic Inspection» .

EC

C

D

13. CHECK HEATED OXYGEN SENSOR 1

E

Refer to EC-975, «Component Inspection» .
OK or NG
OK
>> GO TO 14.
NG
>> Replace heated oxygen sensor 1.

F

G

14. CHECK MASS AIR FLOW SENSOR
With CONSULT-II
Check mass air flow sensor signal in “DATA MONITOR” mode with CONSULT-II.
1.0 — 4.0 g·m/sec:
2.0 — 10.0 g·m/sec:

at idling
at 2,500 rpm

H

I

With GST
Check mass air flow sensor signal in Service $01 with GST.
1.0 — 4.0 g·m/sec:
2.0 — 10.0 g·m/sec:

J

at idling
at 2,500 rpm

OK or NG
OK
>> GO TO 15.
NG
>> Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or
ground. Refer to EC-935, «DTC P0102, P0103 MAF SENSOR» .

K

L

15. CHECK SYMPTOM MATRIX CHART
Check items on the rough idle symptom in EC-871, «Symptom Matrix Chart» .
OK or NG
OK
>> GO TO 16.
NG
>> Repair or replace.

16. ERASE THE 1ST TRIP DTC
Some tests may cause a 1st trip DTC to be set.
Erase the 1st trip DTC from the ECM memory after performing the tests. Refer to EC-841, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .
>> GO TO 17.

17. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1037

M

DTC P0327, P0328 KS
[HR (WITH EURO-OBD)]

DTC P0327, P0328 KS
Component Description

PFP:22060
BBS004DN

The knock sensor (1) is attached to the cylinder block. It senses
engine knocking using a piezoelectric element. A knocking vibration
from the cylinder block is sensed as vibrational pressure. This pressure is converted into a voltage signal and sent to the ECM.
: Vehicle front

●

PBIB2969E

On Board Diagnosis Logic

BBS004DO

The MI will not light up for these self-diagnoses.
DTC No.

Trouble Diagnosis Name

DTC Detected Condition

Possible Cause

P0327
0327

Knock sensor circuit low
input

An excessively low voltage from the sensor is
sent to ECM.

●

Harness or connectors
(The sensor circuit is open or shorted.)

P0328
0328

Knock sensor circuit high
input

An excessively high voltage from the sensor is
sent to ECM.

●

Knock sensor

DTC Confirmation Procedure

BBS004DP

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

WITH CONSULT-II
1.
2.
3.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and run it for at least 5 seconds at idle speed.
If 1st trip DTC is detected, go to EC-1040, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-1038

DTC P0327, P0328 KS
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004DQ

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1467E

EC-1039

DTC P0327, P0328 KS
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
37

WIRE
COLOR
W

ITEM

Knock sensor

CONDITION
[Engine is running]
●

Idle speed

DATA (DC Voltage)

Approximately 2.5V

[Engine is running]
40

—

Sensor ground
(Knock sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

Diagnostic Procedure

BBS004DR

1. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-I
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check resistance between ECM terminal 37 and ground. Refer to Wiring Diagram.
NOTE:
It is necessary to use an ohmmeter which can measure more than 10 MΩ.
Resistance: Approximately 530 — 590kΩ [at 20°C (68°F)]

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 2.

2. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-II
1.

Disconnect knock sensor (1) harness connector.

–

: Vehicle front
Check harness continuity between ECM terminal 37 and knock
sensor terminal 1.
Refer to Wiring Diagram.

2.

Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

3. CHECK KNOCK SENSOR
Refer to EC-1041, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace knock sensor.

EC-1040

PBIB2969E

DTC P0327, P0328 KS
[HR (WITH EURO-OBD)]

4. CHECK GROUND CONNECTIONS

A

Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .
EC

C

D

MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

E

Body ground

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace ground connections.

F

5. CHECK KNOCK SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT

G

1.
2.

Reconnect knock sensor harness connector.
Check harness continuity between ECM terminal 40 and knock sensor terminal 2.

H

Continuity should exist
I

3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

J

6. CHECK INTERMITTENT INCIDENT
K

Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

L

Component Inspection

BBS004DS

KNOCK SENSOR
M

Check resistance between knock sensor terminal 1 and ground.
NOTE:
It is necessary to use an ohmmeter which can measure more
than 10 MΩ.
Resistance: Approximately 530 — 590kΩ [at 20°C (68°F)]
CAUTION:
Do not use any knock sensors that have been dropped or physically damaged. Use only new ones.
SEF227W

Removal and Installation

BBS004DT

KNOCK SENSOR
Refer to EM-189, «CYLINDER BLOCK» .

EC-1041

DTC P0335 CKP SENSOR (POS)
[HR (WITH EURO-OBD)]

DTC P0335 CKP SENSOR (POS)
Component Description

PFP:23731
BBS004DU

The crankshaft position sensor (POS) is located on the cylinder
block rear housing facing the gear teeth (cogs) of the signal plate at
the end of the crankshaft. It detects the fluctuation of the engine revolution.
The sensor consists of a permanent magnet and Hall IC.
When the engine is running, the high and low parts of the teeth
cause the gap with the sensor to change.
The changing gap causes the magnetic field near the sensor to
change.
Due to the changing magnetic field, the voltage from the sensor
changes.
The ECM receives the voltage signal and detects the fluctuation of
the engine revolution.
ECM receives the signals as shown in the figure.

PBIA9209J

PBIB2382E

CONSULT-II Reference Value in Data Monitor Mode

BBS004DV

Specification data are reference values.
MONITOR ITEM
ENG SPEED

CONDITION
●

SPECIFICATION

Run engine and compare CONSULT-II value with the tachometer indication.

Almost the same speed as the
tachometer indication.

On Board Diagnosis Logic
DTC No.

P0335
0335

Trouble diagnosis name

Crankshaft position
sensor (POS) circuit

BBS004DW

DTC detecting condition

●

The crankshaft position sensor (POS) signal is not
detected by the ECM during the first few seconds of
engine cranking.

●

The proper pulse signal from the crankshaft position
sensor (POS) is not sent to ECM while the engine is
running.

●

The crankshaft position sensor (POS) signal is not in
the normal pattern during engine running.

EC-1042

Possible cause
●

Harness or connectors
[Crankshaft position sensor (POS)
circuit is open or shorted.]
(Accelerator pedal position sensor
circuit is shorted.)
(Refrigerant pressure sensor circuit
is shorted.)

●

Crankshaft position sensor (POS)

●

Accelerator pedal position sensor

●

Refrigerant position sensor

●

Signal plate

DTC P0335 CKP SENSOR (POS)
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004DX

A
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
EC
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON.
C
WITH CONSULT-II

1.
2.
3.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed.
If 1st trip DTC is detected, go to EC-1046, «Diagnostic Procedure» .

D

E

F
SEF058Y

WITH GST

G

Follow the procedure “WITH CONSULT-II” above.
H

I

J

K

L

M

EC-1043

DTC P0335 CKP SENSOR (POS)
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004DY

MBWA1468E

EC-1044

DTC P0335 CKP SENSOR (POS)
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
[Engine is running]
●

Warm-up condition

●

Idle speed

0 — 1.0V

D

NOTE:
The pulse cycle changes depending on rpm
at idle
61

Y

E
MBIB1453E

Crankshaft position
sensor (POS)

0 — 1.0V

F
[Engine is running]
●

Engine speed: 2,000 rpm

G
MBIB1454E

62

W

Sensor ground
[Crankshaft position sensor
(POS)]

H

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0V

I

W

Sensor power supply
(Refrigerant pressure sensor)

[Ignition switch: ON]

75

G

Sensor power supply
[Crankshaft position sensor
(POS)]

[Ignition switch: ON]

Approximately 5V

102

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

74

Approximately 5V

J

K

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

L

M

EC-1045

DTC P0335 CKP SENSOR (POS)
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004DZ

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

2. CHECK CRANKSHAFT POSITION (CKP) SENSOR (POS) POWER SUPPLY CIRCUIT-I
1.
2.

Disconnect crankshaft position (CKP) sensor (POS) (1) harness
connector.
Turn ignition switch ON.

PBIB2970E

3.

Check voltage between CKP sensor (POS) terminal 1 and
ground with CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 3.

PBIB2609E

EC-1046

DTC P0335 CKP SENSOR (POS)
[HR (WITH EURO-OBD)]

3. CHECK CKP SENSOR (POS) POWER SUPPLY CIRCUIT-II
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between CKP sensor (POS) terminal 1 and ECM terminal 75.
Refer to Wiring Diagram.
Continuity should exist.

EC

C

OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit.

D

4. CHECK CKP SENSOR (POS) POWER SUPPLY CIRCUIT-III
Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

E

Reference Wiring Diagram

74

Refrigerant pressure sensor terminal 3

EC-1232, «Wiring Diagram»

75

Crankshaft position sensor (POS) terminal 1

EC-1044, «Wiring Diagram»

102

APP sensor terminal 5

EC-1183, «Wiring Diagram»

OK or NG
OK
>> GO TO 5.
NG
>> Repair short to ground or short to power in harness or connectors.

F

G

H

5. CHECK COMPONENTS
Check the following.
●
Accelerator pedal position sensor (Refer to EC-1190, «Component Inspection» .)
●
Refrigerant pressure sensor (Refer to ATC-85, «Refrigerant Pressure Sensor» .)
OK or NG
OK
>> GO TO 10.
NG
>> Replace malfunctioning component.

6. CHECK CKP SENSOR (POS) GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between CKP sensor (POS) terminal 2 and ECM terminal 62.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

7. CHECK CKP SENSOR (POS) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between CKP sensor (POS) terminal 3 and ECM terminal 61.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1047

I

J

K

L

M

DTC P0335 CKP SENSOR (POS)
[HR (WITH EURO-OBD)]

8. CHECK CRANKSHAFT POSITION SENSOR (POS)
Refer to EC-1048, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace crankshaft position sensor (POS).

9. CHECK GEAR TOOTH
Visually check for chipping signal plate gear tooth.
OK or NG
OK
>> GO TO 10.
NG
>> Replace the signal plate.

10. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004E0

CRANKSHAFT POSITION SENSOR (POS)
1.
2.
3.
4.

Loosen the fixing bolt of the sensor.
Disconnect crankshaft position sensor (POS) harness connector.
Remove the sensor.
Visually check the sensor for chipping.

PBIA9210J

5.

Check resistance as shown in the figure.
Terminal No. (Polarity)

Resistance Ω [at 25°C (77°F)]

1 (+) — 2 (-)
1 (+) — 3 (-)

Except 0 or ∞

2 (+) — 3 (-)

6.

If NG, replace crankshaft position sensor (POS).

PBIA9584J

Removal and Installation

BBS004E1

CRANKSHAFT POSITION SENSOR (POS)
Refer to EM-189, «CYLINDER BLOCK» .

EC-1048

DTC P0340 CMP SENSOR (PHASE)
[HR (WITH EURO-OBD)]

DTC P0340 CMP SENSOR (PHASE)
Component Description

PFP:23731

A
BBS004E2

The camshaft position sensor (PHASE) senses the protrusion of
camshaft (INT) to identify a particular cylinder. The camshaft position
sensor (PHASE) senses the piston position.
When the crankshaft position sensor (POS) system becomes inoperative, the camshaft position sensor (PHASE) provides various controls of engine parts instead, utilizing timing of cylinder identification
signals.
The sensor consists of a permanent magnet and Hall IC.
When engine is running, the high and low parts of the teeth cause
the gap with the sensor to change.
The changing gap causes the magnetic field near the sensor to
change.
Due to the changing magnetic field, the voltage from the sensor changes.
ECM receives the signals as shown in the figure.

EC

C

D
PBIA9209J

E

F

G

H

PBIB2382E

I

On Board Diagnosis Logic

BBS004E3

NOTE:
If DTC P0340 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to
EC-1150, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

Trouble diagnosis name

DTC detecting condition

●

P0340
0340

Camshaft position sensor
(PHASE) circuit

The cylinder No. signal is not sent to ECM
for the first few seconds during engine
cranking.

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Camshaft position sensor (PHASE)

●

Camshaft (Intake)

●

The cylinder No. signal is not set to ECM
during engine running.

●

Starter motor (Refer to SC-45, «STARTING SYSTEM» .)

●

The cylinder No. signal is not in the normal
pattern during engine running.

●

Starting system circuit (Refer to SC-45,
«STARTING SYSTEM» .)

●

Dead (Weak) battery

EC-1049

J

K

L

M

DTC P0340 CMP SENSOR (PHASE)
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004E4

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON.

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

5.
6.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed.
If 1st trip DTC is detected, go to EC-1052, «Diagnostic Procedure» .
If 1st trip DTC is not detected, go to next step.
Maintain engine speed at more than 800 rpm for at least 5 seconds.
If 1st trip DTC is detected, go to EC-1052, «Diagnostic Procedure» .

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-1050

SEF058Y

DTC P0340 CMP SENSOR (PHASE)
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004E5

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1469E

EC-1051

DTC P0340 CMP SENSOR (PHASE)
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

63

WIRE
COLOR

B

ITEM

Sensor ground
[Camshaft position sensor
(PHASE)]

CONDITION

DATA (DC Voltage)

[Engine is running]
●

Warm-up condition

●

Idle speed

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0V

0 — 1.0V

NOTE:
The pulse cycle changes depending on rpm
at idle
65

R

MBIB1455E

Camshaft position sensor
(PHASE)

0 — 1.0V

[Engine is running]
●

Engine speed: 2,000 rpm

MBIB1456E

78

O

Sensor power supply
[Camshaft position sensor
(PHASE)]

[Ignition switch: ON]

Approximately 5V

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004E6

1. CHECK STARTING SYSTEM
Turn ignition switch to START position.
Does the engine turn over?
Does the starter motor operate?
Yes or No
Yes
>> GO TO 2.
No
>> Check starting system. (Refer to SC-45, «STARTING SYSTEM» .)

EC-1052

DTC P0340 CMP SENSOR (PHASE)
[HR (WITH EURO-OBD)]

2. CHECK GROUND CONNECTIONS
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

EC

C

D

E
MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

Body ground

F

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace ground connections.

G

3. CHECK CAMSHAFT POSITION (CMP) SENSOR (PHASE) POWER SUPPLY CIRCUIT
1.

Disconnect camshaft position (CMP) sensor (PHASE) (1) harness connector.

–

: Vehicle front
Turn ignition switch ON.

2.

H

I

J

PBIB2971E

3.

Check voltage between CMP sensor (PHASE) terminal 1 and
ground with CONSULT-II or tester.

K

L

Voltage: Battery voltage
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

M

PBIB2609E

EC-1053

DTC P0340 CMP SENSOR (PHASE)
[HR (WITH EURO-OBD)]

4. CHECK CMP SENSOR (PHASE) GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between CMP sensor (PHASE) terminal 2 and ECM terminal 63.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK CMP SENSOR (PHASE) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between CMP sensor (PHASE) terminal 3 and ECM terminal 65.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK CAMSHAFT POSITION SENSOR (PHASE)
Refer to EC-1054, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace camshaft position sensor (PHASE).

7. CHECK CAMSHAFT (INTAKE)
Check the following.
Accumulation of debris to the signal plate of camshaft (1) rear
end
●
Chipping signal plate of camshaft rear end
OK or NG
OK
>> GO TO 8.
NG
>> Remove debris and clean the signal plate of camshaft
rear end or replace camshaft.
●

PBIA9557J

8. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004E7

CAMSHAFT POSITION SENSOR (PHASE)
1.
2.
3.

Loosen the fixing bolt of the sensor.
Disconnect camshaft position sensor (PHASE) harness connector.
Remove the sensor.

EC-1054

DTC P0340 CMP SENSOR (PHASE)
[HR (WITH EURO-OBD)]
4.

Visually check the sensor for chipping.
A

EC

C
PBIA9210J

D

5.

Check resistance as shown in the figure.
Terminal No. (Polarity)

Resistance Ω [at 25°C (77°F)]

E

1 (+) — 2 (-)
1 (+) — 3 (-)

Except 0 or ∞

2 (+) — 3 (-)

F

G
PBIA9584J

Removal and Installation

BBS004E8

H

CAMSHAFT POSITION SENSOR (PHASE)
Refer to EM-151, «CAMSHAFT» .

I

J

K

L

M

EC-1055

DTC P0420 THREE WAY CATALYST FUNCTION
[HR (WITH EURO-OBD)]

DTC P0420 THREE WAY CATALYST FUNCTION
On Board Diagnosis Logic

PFP:20905
BBS004E9

The ECM monitors the switching frequency ratio of heated oxygen
sensors 1 and 2.
A three way catalyst (manifold) with high oxygen storage capacity
will indicate a low switching frequency of heated oxygen sensor 2.
As oxygen storage capacity decreases, the heated oxygen sensor 2
switching frequency will increase.
When the frequency ratio of heated oxygen sensors 1 and 2
approaches a specified limit value, the three way catalyst (manifold)
malfunction is diagnosed.
SEF484YF

DTC No.

P0420
0420

Trouble diagnosis name

Catalyst system efficiency
below threshold

DTC detecting condition

●

Three way catalyst (manifold) does not operate
properly.

●

Three way catalyst (manifold) does not have
enough oxygen storage capacity.

DTC Confirmation Procedure

Possible cause
●

Three way catalyst (manifold)

●

Exhaust tube

●

Intake air leaks

●

Fuel injector

●

Fuel injector leaks

●

Spark plug

●

Improper ignition timing
BBS004EA

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
TESTING CONDITION:
●
Open engine hood before conducting the following procedure.
●
Do not hold engine speed for more than the specified minutes below.
1. Start engine and warm it up to the normal operating temperature.
2. Turn ignition switch OFF and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
4. Let engine idle for 1 minute.
5. Select “DTC & SRT CONFIRMATION” then “SRT WORK SUPPORT” mode with CONSULT-II.
6. Start engine.
7. Rev engine up to 2,000 to 3,000 rpm and hold it for 3 consecutive minutes then release the accelerator pedal completely.
If “INCMP” of “CATALYST” changed to “COMPLT”, go to step 10
8. Wait 5 seconds at idle.

PBIB0566E

EC-1056

DTC P0420 THREE WAY CATALYST FUNCTION
[HR (WITH EURO-OBD)]
9.

Rev engine up to 2,000 to 3,000 rpm and maintain it until
“INCMP” of “CATALYST” changes to “CMPLT” (It will take
approximately 5 minutes).
If not “CMPLT”, stop engine and cool it down to less than 70°C
(158°F) and then retest from step 1.

A

EC

C
PBIB0567E

D

a.
b.
c.
d.

Turn ignition switch OFF and leave the vehicle in a cool place
(soak the vehicle)
Turn ignition switch ON and select “COOLAN TEMP/S” in “DATA
MONITOR” mode with CONSULT-II.
Start engine and warm it up while monitoring “COOLAN TEMP/
S” indication on CONSULT-II.
When “COOLAN TEMP/S” indication reaches to 70°(158°F), go
to step 3.

E

F

G
SEF013Y

10. Select “SELF-DIAG RESULTS” mode with CONSULT-II.
11. Confirm that the 1st trip DTC is not detected.
If the 1st trip DTC is detected, go to EC-1059, «Diagnostic Procedure» .

H

I

J

SEF535Z

Overall Function Check

K

BBS004EB

Use this procedure to check the overall function of the three way catalyst (manifold). During this check, a 1st
trip DTC might not be confirmed.

L

WITH GST
1.
2.
3.
4.
5.

6.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeters probes between ECM terminal 49 (HO2S1 signal) and ground, and ECM terminal 50 (HO2S2 signal) and
ground.
Keep engine speed at 2,000 rpm constant under no load.

PBIA9566J

EC-1057

M

DTC P0420 THREE WAY CATALYST FUNCTION
[HR (WITH EURO-OBD)]
7.

Make sure that the voltage switching frequency (high & low)
between ECM terminal 50 and ground is very less than that of
ECM terminal 49 and ground.
Switching frequency ratio = A/B
A: Heated oxygen sensor 2 voltage switching frequency
B: Heated oxygen sensor 1 voltage switching frequency
This ratio should be less than 0.75.
If the ratio is greater than above, it means three way catalyst
does not operate properly. Go to EC-1059, «Diagnostic Procedure» .
NOTE:
PBIB3000E
If the voltage at terminal 49 does not switch periodically more than 5
times within 10 seconds at step 7, perform trouble diagnosis for DTC P0133 first. (See EC-967, «DTC P0133
HO2S1» .)

EC-1058

DTC P0420 THREE WAY CATALYST FUNCTION
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004EC

1. CHECK EXHAUST SYSTEM

A

Visually check exhaust tubes and muffler for dent.
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace.

EC

C

2. CHECK EXHAUST GAS LEAK
1.
2.

Start engine and run it at idle.
Listen for an exhaust gas leak before the three way catalyst (manifold).

D

E

F

G
SEC502D

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

H

3. CHECK INTAKE AIR LEAK

I

Listen for an intake air leak after the mass air flow sensor.
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace.

J

K

4. CHECK IGNITION TIMING
Check the following items. Refer to EC-851, «Basic Inspection» .
Items
Target idle speed

Ignition timing

L

Specifications
A/T models

700 ± 50 rpm (in P or N position)

M/T models

650 ± 50 rpm (in Neutral position)

A/T models

6 ± 5° BTDC (in P or N position)

M/T models

6 ± 5° BTDC (in Neutral position)

OK or NG
OK
>> GO TO 5.
NG
>> Follow the EC-851, «Basic Inspection» .

EC-1059

M

DTC P0420 THREE WAY CATALYST FUNCTION
[HR (WITH EURO-OBD)]

5. CHECK FUEL INJECTORS
1.
2.
3.

Refer to Wiring Diagram for fuel injectors, EC-1210, «Wiring Diagram» .
Stop engine and then turn ignition switch ON.
Check voltage between ECM terminals 25, 29, 30, 31 and
ground with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 6.
NG
>> Perform EC-1211, «Diagnostic Procedure» .

PBIB3001E

6. CHECK FUNCTION OF IGNITION COIL-I
CAUTION:
Do the following procedure in the place where ventilation is good without the combustible.
1. Turn ignition switch OFF.
2. Remove fuel pump fuse in IPDM E/R to release fuel pressure.
NOTE:
Do not use CONSULT-II to release fuel pressure, or fuel pressure applies again during the following procedure.
3. Start engine.
4. After engine stalls, crank it two or three times to release all fuel
pressure.
5. Turn ignition switch OFF.
6. Remove all ignition coil harness connectors to avoid the electrical discharge from the ignition coils.
7. Remove ignition coil and spark plug of the cylinder to be
checked.
8. Crank engine for 5 seconds or more to remove combustion gas in the cylinder.
9. Connect spark plug and harness connector to ignition coil.
10. Fix ignition coil using a rope etc. with gap of 13 — 17 mm
between the edge of the spark plug and grounded metal portion
as shown in the figure.
11. Crank engine for about three seconds, and check whether spark
is generated between the spark plug and the grounded metal
portion.

MBIB0277E

Spark should be generated.
CAUTION:
Do not approach to the spark plug and the ignition coil
within 50cm. Be careful not to get an electrical shock
PBIB2325E
while checking, because the electrical discharge voltage
becomes 20kV or more.
● It might cause to damage the ignition coil if the gap of more than 17 mm is taken.
NOTE:
When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning.
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 7.
●

EC-1060

DTC P0420 THREE WAY CATALYST FUNCTION
[HR (WITH EURO-OBD)]

7. CHECK FUNCTION OF IGNITION COIL-II
1.
2.
3.

A
Turn ignition switch OFF.
Disconnect spark plug and connect a known-good spark plug.
Crank engine for about three seconds, and recheck whether spark is generated between the spark plug EC
and the grounded metal portion.

Spark should be generated.

C

OK or NG
OK
>> GO TO 8.
NG
>> Check ignition coil, power transistor and their circuits. Refer to EC-1221, «IGNITION SIGNAL» .

D

8. CHECK SPARK PLUG
E

Check the initial spark plug for fouling, etc.
OK or NG
OK
>> Replace spark plug(s) with standard type one(s). For
spark plug type, refer to EM-133, «SPARK PLUG (PLATINUM-TIPPED TYPE)» .
NG
>> 1. Repair or clean spark plug.
2. GO TO 9.

F

G

SEF156I

H

9. CHECK FUNCTION OF IGNITION COIL-III
1.
2.

Reconnect the initial spark plugs.
Crank engine for about three seconds, and recheck whether spark is generated between the spark plug
and the grounded portion.

I

J

Spark should be generated.
OK or NG
OK
>> INSPECTION END
NG
>> Replace spark plug(s) with standard type one(s). For spark plug type, refer to EM-133, «SPARK
PLUG (PLATINUM-TIPPED TYPE)» .

10. CHECK FUEL INJECTOR
1.
2.

Turn ignition switch OFF.
Remove fuel injector assembly.
Refer to EM-135, «FUEL INJECTOR AND FUEL TUBE» .
Keep fuel hose and all fuel injectors connected to fuel tube.
3. Disconnect all ignition coil harness connectors.
4. Reconnect all fuel injector harness connectors disconnected.
5. Turn ignition switch ON.
Make sure fuel does not drip from fuel injector.
OK or NG
OK (Does not drip.)>>GO TO 11.
NG (Drips.)>>Replace the fuel injector(s) from which fuel is dripping.

EC-1061

K

L

M

DTC P0420 THREE WAY CATALYST FUNCTION
[HR (WITH EURO-OBD)]

11. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
Trouble is fixed.>>INSPECTION END
Trouble is not fixed.>>Replace three way catalyst (manifold).

EC-1062

DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[HR (WITH EURO-OBD)]

DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
PFP:14920

Description

A

BBS004ED

SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*1

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Battery

Battery voltage*1

Throttle position sensor

Throttle position

ECM function

C

EVAP canister
purge flow control

Accelerator pedal position sensor

Accelerator pedal position

Heated oxygen sensor 1

Density of oxygen in exhaust gas
(Mixture ratio feedback signal)

Wheel sensor

Vehicle speed*2

EC

Actuator

EVAP canister purge volume
control solenoid valve

D

E

F

*1: ECM determines the start signal status by the signals of engine speed and battery voltage.
*2: This signal is sent to the ECM through CAN communication line.

This system controls flow rate of fuel vapor from the EVAP canister. The opening of the vapor by-pass passage in the EVAP canister purge volume control solenoid valve changes to control the flow rate. The EVAP
canister purge volume control solenoid valve repeats ON/OFF operation according to the signal sent from the
ECM. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is
determined by considering various engine conditions. When the engine is operating, the flow rate of fuel vapor
from the EVAP canister is regulated as the air flow changes.

G

COMPONENT DESCRIPTION

I

The EVAP canister purge volume control solenoid valve uses a ON/
OFF duty to control the flow rate of fuel vapor from the EVAP canister. The EVAP canister purge volume control solenoid valve is
moved by ON/OFF pulses from the ECM. The longer the ON pulse,
the greater the amount of fuel vapor that will flow through the valve.

J

H

K

L
PBIA9215J

CONSULT-II Reference Value in Data Monitor Mode

BBS004EE

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

Air conditioner switch: OFF

●

No load

PURG VOL C/V

SPECIFICATION

Idle

0%

2,000 rpm

0 — 50%

On Board Diagnosis Logic
DTC No.

P0444
0444

Trouble diagnosis name
EVAP canister purge volume
control solenoid valve circuit
open

BBS004EF

DTC detecting condition

Possible cause
●

Harness or connectors
(The solenoid valve circuit is open or
shorted.)

●

EVAP canister purge volume control
solenoid valve

An excessively low voltage signal is sent
to ECM through the valve

EC-1063

M

DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004EG

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm battery voltage is more than 11V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for at least 13 seconds.
If 1st trip DTC is detected, go to EC-1067, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-1064

DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004EH

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1470E

EC-1065

DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)
BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
●

9

LG

Idle speed

EVAP canister purge volume control solenoid valve

PBIB0050E

Approximately 10V
[Engine is running]
●

Engine speed: About 2,000 rpm (More than
100 seconds after starting engine)

PBIB0520E

[Engine is running]
[Ignition switch: OFF]
●

32

P

ECM relay
(Self shut-off)

[Ignition switch: OFF]
●

105

G

Power supply for ECM

For a few seconds after turning ignition switch
OFF

More than a few seconds after turning ignition
switch OFF

[Ignition switch: ON]

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-1066

0 — 1.0V

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004EI

1. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIR-

A

CUIT
1.
2.

Turn ignition switch OFF.
Disconnect EVAP canister purge volume control solenoid valve
(1) harness connector.

–

: Vehicle front
Turn ignition switch ON.

3.

EC

C

D

E
PBIB2972E

4.

F

Check voltage between EVAP canister purge volume control
solenoid valve terminal 1 and ground with CONSULT-II or tester.
Voltage: Battery voltage

G

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

H

PBIB0148E

I

2. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between EVAP canister purge volume control solenoid valve and IPDM E/R
●
Harness for open or short between EVAP canister purge volume control solenoid valve and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

J

K

L

3. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

M

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 9 and EVAP canister purge volume control solenoid
valve terminal 2. Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK (With CONSULT-II)>>GO TO 4.
OK (Without CONSULT-II)>>GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1067

DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[HR (WITH EURO-OBD)]

4. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION
With CONSULT-II
Reconnect all harness connectors disconnected.
Start engine.
Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with
CONSULT-II. Check that engine speed varies according to the
valve opening.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.
1.
2.
3.

PBIB0569E

5. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
Refer to EC-1068, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace EVAP canister purge volume control solenoid valve.

6. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004EJ

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
With CONSULT-II
Check air passage continuity of EVAP canister purge volume control
solenoid valve under the following conditions.
Condition
(PURG VOL CONT/V value)

Air passage continuity
between A and B

100%

Yes

0%

No

PBIA9668J

Without CONSULT-II
Check air passage continuity of EVAP canister purge volume control
solenoid valve under the following conditions.
Condition

Air passage continuity
between A and B

12V direct current supply between terminals 1 and 2

Yes

No supply

No

PBIA9560J

EC-1068

DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[HR (WITH EURO-OBD)]

Removal and Installation

BBS004EK

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

A

Refer to EM-120, «INTAKE MANIFOLD» .
EC

C

D

E

F

G

H

I

J

K

L

M

EC-1069

DTC P0500 VSS
[HR (WITH EURO-OBD)]

DTC P0500 VSS
Description

PFP:32702
BBS004EL

NOTE:
●
If DTC P0500 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC
U1000, U1001. Refer to EC-925, «DTC U1000, U1001 CAN COMMUNICATION LINE» .
●
If DTC P0500 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010.
Refer to EC-928, «DTC U1010 CAN COMMUNICATION» .
The vehicle speed signal is sent to the combination meter from “ABS actuator and electric unit (control unit)”
through CAN communication line. The combination meter then sends a signal to the ECM through CAN communication line.

On Board Diagnosis Logic
DTC No.

P0500
0500

Trouble diagnosis name

Vehicle speed sensor

BBS004EM

DTC detecting condition

The almost 0 km/h (0 MPH) signal from
vehicle speed sensor is sent to ECM
even when vehicle is being driven.

DTC Confirmation Procedure

Possible cause
●

Harness or connectors
(The CAN communication line is open or
shorted.)

●

Harness or connectors
(Wheel sensor circuit is open or shorted)

●

ABS actuator and electric unit (control unit)

●

Wheel sensor

●

Combination meter
BBS004EN

CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Steps 1 and 2 may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a
road test is expected to be easier, it is unnecessary to lift the vehicle.

WITH CONSULT-II
1.
2.

3.
4.
5.

Start engine.
Read “VHCL SPEED SE” in “DATA MONITOR” mode with CONSULT-II. The vehicle speed on CONSULTII should exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position.
If NG, go to EC-1071, «Diagnostic Procedure» .
If OK, go to following step.
Select “DATA MONITOR” mode with CONSULT-II.
Warm engine up to normal operating temperature.
Maintain the following conditions for at least 60 consecutive seconds.

ENG SPEED

A/T: More than 1,900 rpm
M/T: More than 2,500 rpm

COOLAN TEMP/S

More than 70°C (158°F)

B/FUEL SCHDL

A/T: 4.8 — 31.8 msec
M/T: 3.8 — 31.8 msec

Shift lever

Suitable position

PW/ST SIGNAL

OFF
SEF196Y

6.

If 1st trip DTC is detected, go to EC-1071, «Diagnostic Procedure» .

EC-1070

DTC P0500 VSS
[HR (WITH EURO-OBD)]

Overall Function Check

BBS004EO

Use this procedure to check the overall function of the vehicle speed signal circuit. During this check, a 1st trip
DTC might not be confirmed.

WITH GST
1.
2.
3.

4.

A

EC

Lift up drive wheels.
Start engine.
Read vehicle speed signal in Service $01 with GST.
The vehicle speed signal on GST should be able to exceed 10 km/h (6 MPH) when rotating wheels with
suitable gear position.
If NG, go to EC-1071, «Diagnostic Procedure» .

Diagnostic Procedure

C

D

BBS004EP

1. CHECK DTC WITH “ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)”
Refer to BRC-49, «TROUBLE DIAGNOSIS» (models with ESP) or BRC-8, «TROUBLE DIAGNOSIS» (models
without ESP).
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace.

E

F

G

2. CHECK COMBINATION METER
Check combination meter function.
Refer to DI-4, «COMBINATION METERS» .

H

>> INSPECTION END

I

J

K

L

M

EC-1071

DTC P0605 ECM
[HR (WITH EURO-OBD)]

DTC P0605 ECM
Component Description

PFP:23710
BBS004EQ

The ECM consists of a microcomputer and connectors for signal
input and output and for power supply. The ECM controls the engine.

PBIA9222J

On Board Diagnosis Logic

BBS004ER

This self-diagnosis has one or two trip detection logic.
DTC No.
P0605
0605

Trouble diagnosis name

Engine control module

DTC detecting condition
A)

ECM calculation function is malfunctioning.

B)

ECM EEP-ROM system is malfunctioning.

C)

ECM self shut-off function is malfunctioning.

Possible cause

●

ECM

FAIL-SAFE MODE
ECM enters fail-safe mode when malfunction A is detected.
Detected items
Malfunction A

Engine operation condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5
degrees) by the return spring.

DTC Confirmation Procedure

BBS004ES

Perform PROCEDURE FOR MALFUNCTION A first. If the 1st trip DTC cannot be confirmed, perform
PROCEDURE FOR MALFUNCTION B. If there is no malfunction on PROCEDURE FOR MALFUNCTION
B, perform PROCEDURE FOR MALFUNCTION C.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

PROCEDURE FOR MALFUNCTION A
With CONSULT-II
1.
2.
3.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
If 1st trip DTC is detected, go to EC-1073, «Diagnostic Procedure» .

SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

EC-1072

DTC P0605 ECM
[HR (WITH EURO-OBD)]
PROCEDURE FOR MALFUNCTION B
With CONSULT-II
1.
2.
3.
4.

A

Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch OFF, wait at least 10 seconds and then turn
ON.
If 1st trip DTC is detected, go to EC-1073, «Diagnostic Procedure» .

EC

C

D

SEF058Y

E

With GST
Follow the procedure “With CONSULT-II” above.
F

PROCEDURE FOR MALFUNCTION C
With CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch OFF, wait at least 10 seconds and then turn
ON.
Repeat step 3 for 32 times.
If 1st trip DTC is detected, go to EC-1073, «Diagnostic Procedure» .

G

H

I

J
SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

K

Diagnostic Procedure

BBS004ET

1. INSPECTION START

L

With CONSULT-II
Turn ignition switch ON.
Select “SELF DIAG RESULTS” mode with CONSULT-II.
Touch “ERASE”.
Perform DTC Confirmation Procedure.
See EC-1072, «DTC Confirmation Procedure» .
5. Is the 1st trip DTC P0605 displayed again?
1.
2.
3.
4.

With GST
Turn ignition switch ON.
Select Service $04 with GST.
Perform DTC Confirmation Procedure.
See EC-1072, «DTC Confirmation Procedure» .
4. Is the 1st trip DTC P0605 displayed again?
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END
1.
2.
3.

EC-1073

M

DTC P0605 ECM
[HR (WITH EURO-OBD)]

2. REPLACE ECM
1.
2.
3.
4.
5.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
Perform EC-857, «Accelerator Pedal Released Position Learning» .
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .
>> INSPECTION END

EC-1074

DTC P1065 ECM
[HR (WITH EURO-OBD)]

DTC P1065 ECM
Component Description

PFP:23710

A
BBS004EU

ECM has the memory function of the DTC memory, the air-fuel ratio
feedback compensation value memory, the Idle Air Volume Learning
value memory, etc. even when the ignition switch is turned OFF.

EC

C

D
PBIA9222J

E

On Board Diagnosis Logic
DTC No.
P1065*
1065

Trouble diagnosis name
Engine control module

BBS004EV

DTC detecting condition
ECM back-up RAM system does not function
properly.

Possible cause

F
●

ECM

*: This self-diagnosis is not for ECM power supply circuit, even though “ECM BACK UP/CIRCUIT” is displayed on CONSULT-II screen.

DTC Confirmation Procedure

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

G

BBS004EW

H

I

Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn
ON.
Repeat steps 3 and 4 for 4 times.
If 1st trip DTC is detected, go to EC-1076, «Diagnostic Procedure» .

J

K

L
SEF058Y

WITH GST

M

Follow the procedure “WITH CONSULT-II” above.

EC-1075

DTC P1065 ECM
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004EX

1. INSPECTION START
1.
2.
3.
4.
5.

With CONSULT-II
Turn ignition switch ON.
Select “SELF-DIAG RESULTS” mode with CONSULT-II.
Touch “ERASE”.
Perform DTC Confirmation Procedure.
See EC-1075, «DTC Confirmation Procedure» .
Is the 1st trip DTC P1065 displayed again?

With GST
1. Turn ignition switch ON.
2. Select Service $04 with GST.
3. Perform DTC Confirmation Procedure.
See EC-1075, «DTC Confirmation Procedure» .
4. Is the 1st trip DTC P1065 displayed again?
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END

2. REPLACE ECM
1.
2.
3.
4.
5.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
Perform EC-857, «Accelerator Pedal Released Position Learning» .
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .
>> INSPECTION END

EC-1076

DTC P1111 IVT CONTROL SOLENOID VALVE
[HR (WITH EURO-OBD)]

DTC P1111 IVT CONTROL SOLENOID VALVE
Component Description

PFP:23796

A
BBS004EY

Intake valve timing control solenoid valve is activated by ON/OFF
pulse duty (ratio) signals from the ECM.
The intake valve timing control solenoid valve changes the oil
amount and direction of flow through intake valve timing control unit
or stops oil flow.
The longer pulse width advances valve angle.
The shorter pulse width retards valve angle.
When ON and OFF pulse widths become equal, the solenoid valve
stops oil pressure flow to fix the intake valve angle at the control
position.

EC

C

D
PBIB1842E

E

CONSULT-II Reference Value in Data Monitor Mode

BBS004EZ

Specification data are reference values.
MONITOR ITEM

INT/V SOL (B1)

CONDITION
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

0% — 2%

2,500 rpm

Approx. 0% — 90%

G

H

On Board Diagnosis Logic
DTC No.
P1111
1111

Trouble diagnosis name
Intake valve timing control
solenoid valve circuit

F

SPECIFICATION

Idle

BBS004F0

DTC detecting condition
An improper voltage is sent to the ECM
through intake valve timing control solenoid
valve.

DTC Confirmation Procedure

Possible cause

I

●

Harness or connectors
(Solenoid valve circuit is open or shorted.)

●

Intake valve timing control solenoid valve
BBS004F1

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.

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

J

L

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If 1st trip DTC is detected, go to EC-1080, «Diagnostic Procedure» .

M

SEF058Y

WITH GST
Following the procedure “WITH CONSULT-II” above.

EC-1077

K

DTC P1111 IVT CONTROL SOLENOID VALVE
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004F2

MBWA1471E

EC-1078

DTC P1111 IVT CONTROL SOLENOID VALVE
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

C
[Engine is running]
[Ignition switch: OFF]
●

32

DATA (DC Voltage)

P

ECM relay
(Self shut-off)

For a few seconds after turning ignition switch
OFF

[Ignition switch: OFF]
●

More than a few seconds after turning ignition
switch OFF

0 — 1.0V

D
BATTERY VOLTAGE
(11 — 14V)

E

BATTERY VOLTAGE
(11 — 14V)

F

[Engine is running]
●

Warm-up condition

●

Idle speed
7 — 10V

73

LG

Intake valve timing control
solenoid valve

G
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

H
PBIA4937J

105

G

Power supply for ECM

[Ignition switch: ON]

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

BATTERY VOLTAGE
(11 — 14V)

I

J

K

L

M

EC-1079

DTC P1111 IVT CONTROL SOLENOID VALVE
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004F3

1. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect intake valve timing control solenoid valve (1) harness connector.
Turn ignition switch ON.

MBIB1546E

4.

Check voltage between intake valve timing control solenoid
valve terminal 2 and ground with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

PBIB0192E

2. DETECT MALFUNCTION PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between intake valve timing control solenoid valve and IPDM E/R
>> Repair or replace harness or connectors.

3. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR
OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 73 and intake valve timing control solenoid valve terminal 1. Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE
Refer to EC-1081, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace intake valve timing control solenoid valve.

EC-1080

DTC P1111 IVT CONTROL SOLENOID VALVE
[HR (WITH EURO-OBD)]

5. CHECK INTERMITTENT INCIDENT

A

Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
EC

>> INSPECTION END

Component Inspection

BBS004F4

INTAKE VALVE TIMING CONTROL SOLENOID VALVE
1.
2.

3.
4.

C

Disconnect intake valve timing control solenoid valve harness connector.
Check resistance between intake valve timing control solenoid
valve as follows.
Terminal

Resistance

1 and 2

6.7 — 7.7Ω [at 20°C (68°F)]

1 or 2 and ground

∞Ω
(Continuity should not exist.)

If NG, replace intake valve timing control solenoid valve.
If OK, go to next step.
Remove intake valve timing control solenoid valve.
Provide 12V DC between intake valve timing control solenoid
valve terminals and then interrupt it. Make sure that the plunger
moves as shown in the figure.
CAUTION:
Do not apply 12V DC continuously for 5 seconds or more.
Doing so may result in damage to the coil in intake valve
timing control solenoid valve.
If NG, replace intake valve timing control solenoid valve.
NOTE:
Always replace O-ring when intake valve timing control
solenoid valve is removed.

Removal and Installation

D

E

F
PBIB0193E

G

H

I

J
PBIB2275E

BBS004F5

INTAKE VALVE TIMING CONTROL SOLENOID VALVE

K

Refer to EM-142, «TIMING CHAIN» .
L

M

EC-1081

DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR
[HR (WITH EURO-OBD)]

DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR
Component Description

PFP:16119
BBS004F6

Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc.
The throttle control motor is operated by the ECM and it opens and closes the throttle valve.
The throttle position sensor detects the throttle valve position, and the opening and closing speed of the throttle valve and feeds the voltage signals to the ECM. The ECM judges the current opening angle of the throttle
valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening
angle properly in response to driving condition.

On Board Diagnosis Logic

BBS004F7

This self-diagnosis has the one trip detection logic.
DTC No.

P1121
1121

Trouble diagnosis name

Electric throttle control
actuator

DTC detecting condition
A)

Electric throttle control actuator does not function
properly due to the return spring malfunction.

B)

Throttle valve opening angle in fail-safe mode is
not in specified range.

C)

ECM detect the throttle valve is stuck open.

Possible cause

●

Electric throttle control actuator

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Detected items

Engine operating condition in fail-safe mode

Malfunction A

The ECM controls the electric throttle actuator by regulating the throttle opening around the idle position.
The engine speed will not rise more than 2,000 rpm.

Malfunction B

ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less.

Malfunction C

While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls.
The engine can restart in N or P position (A/T), Neutral position (M/T), and engine speed will not exceed
1,000 rpm or more.

DTC Confirmation Procedure

BBS004F8

NOTE:
●
Perform PROCEDURE FOR MALFUNCTION A AND B first. If the DTC cannot be confirmed, perform
PROCEDURE FOR MALFUNCTION C.
●
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
at least 10 seconds before conducting the next test.

PROCEDURE FOR MALFUNCTION A AND B
With CONSULT-II
1.
2.
3.

Turn ignition witch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Set shift lever to D position (A/T), 1st position (M/T) and wait at
least 3 seconds.
4. Set shift lever to P position (A/T), Neutral position (M/T).
5. Turn ignition switch OFF and wait at least 10 seconds.
6. Turn ignition switch ON and wait at least 1 second.
7. Set shift lever to D position (A/T), 1st position (M/T) and wait at
least 3 seconds.
8. Set shift lever to P position (A/T), Neutral position (M/T).
9. Turn ignition switch OFF, wait at least 10 seconds and then turn
ON.
10. If DTC is detected, go to EC-1083, «Diagnostic Procedure» .

EC-1082

SEF058Y

DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR
[HR (WITH EURO-OBD)]
With GST
A

Follow the procedure “With CONSULT-II” above.

PROCEDURE FOR MALFUNCTION C
With CONSULT-II
1.
2.
3.
4.
5.
6.

EC

Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Set shift lever to D position (A/T), 1st position (M/T) and wait at
least 3 seconds.
Set shift lever to P position (A/T), Neutral position (M/T).
Start engine and let it idle for 3 seconds.
If DTC is detected, go to EC-1083, «Diagnostic Procedure» .

C

D

E
SEF058Y

F

With GST
Follow the procedure “With CONSULT-II” above.

Diagnostic Procedure

BBS004F9

1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY
1.
2.

Remove the intake air duct.
Check if a foreign matter is caught between the throttle valve (1)
and the housing.

G

H

–
: Vehicle front
OK or NG
OK
>> GO TO 2.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.

I

J

K
PBIB2974E

2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

L

Replace the electric throttle control actuator.
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .

M

>> INSPECTION END

Removal and Installation

BBS004FA

Refer to EM-120, «INTAKE MANIFOLD» .

EC-1083

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[HR (WITH EURO-OBD)]

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
Description

PFP:16119
BBS004FB

NOTE:
If DTC P1122 is displayed with DTC P1121 or P1126, first perform the trouble diagnosis for DTC P1121
or P1126. Refer to EC-1082, «DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR» or EC-1090,
«DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY» .
Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc.
The throttle control motor is operated by the ECM and it opens and closes the throttle valve.
The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feedback to the ECM to control the throttle control motor to make the throttle valve opening angle properly in
response to driving condition.

On Board Diagnosis Logic

BBS004FC

This self-diagnosis has the one trip detection logic.
DTC No.
P1122
1122

Trouble diagnosis name
Electric throttle control
performance

DTC detecting condition

Possible cause
●

Harness or connectors
(Throttle control motor circuit is open or
shorted)

●

Electric throttle control actuator

Electric throttle control function does not operate properly.

FAIL-SAFE MODE
When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.

DTC Confirmation Procedure

BBS004FD

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 11V when engine
is running.

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

Turn ignition switch ON and wait at least 2 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If DTC is detected, go to EC-1086, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-1084

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004FE

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1472E

EC-1085

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

0 — 14V
[Ignition switch: ON]
1

P

Throttle control motor
(Open)

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed
PBIB1105E

2

LG

Throttle control motor relay
power supply

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 14V
[Ignition switch: ON]
4

L

Throttle control motor
(Close)

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Released
PBIB1104E

15

G

Throttle control motor relay

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 1.0V

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004FF

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1086

3.

Body ground

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[HR (WITH EURO-OBD)]

2. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-I

A

Check voltage between ECM terminal 2 and ground under the following conditions with CONSULT-II or tester.
Ignition switch

Voltage

OFF

Approximately 0V

ON

Battery voltage
(11 — 14V)

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 3.

EC

C

D
PBIA9568J

3. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-I
1.
2.

E

Turn ignition switch OFF.
Check voltage between ECM terminal 15 and ground with CONSULT-II or tester.

F

Voltage: Battery voltage
G

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 4.

H

PBIA9569J

I

4. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-II
1.
2.
3.

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E5.
Check harness continuity between ECM terminal 15 and IPDM E/R terminal 70.
Refer to Wiring Diagram.

J

K

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between ECM and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK FUSE
1. Disconnect 20A fuse.
2. Check 20A fuse for blown.
OK or NG
OK
>> GO TO 9.
NG
>> Replace 20A fuse.

EC-1087

L

M

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[HR (WITH EURO-OBD)]

7. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-II
1.
2.
3.

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between ECM terminal 2 and IPDM E/R terminal 28.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.

8. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between ECM and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

9. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connectors.

10. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT
1.
2.

Turn ignition switch OFF.
Disconnect electric throttle control actuator (1) harness connector.

–

: Vehicle front
Disconnect ECM harness connector.
Check harness continuity between the following terminals.
Refer to Wiring Diagram.

3.
4.

Electric throttle control
actuator terminal
5

6

ECM terminal

Continuity

1

Should not exist

4

Should exist

1

Should exist

4

Should not exist

PBIB2965E

5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 11.
NG
>> Repair or replace.

EC-1088

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[HR (WITH EURO-OBD)]

11. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY
1.
2.

A

Remove the intake air duct.
Check if foreign matter is caught between the throttle valve (1)
and the housing.

EC

: Vehicle front
–
Illustration shows the view with intake air duct removed.
OK or NG
OK
>> GO TO 12.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.
–

C

D
PBIB2974E

E

12. CHECK THROTTLE CONTROL MOTOR
Refer to EC-1089, «Component Inspection» .
OK or NG
OK
>> GO TO 13.
NG
>> GO TO 14.

F

G

13. CHECK INTERMITTENT INCIDENT
H

Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> GO TO 14.
NG
>> Repair or replace harness or connectors.

I

14. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

J

Replace the electric throttle control actuator.
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .

K

>> INSPECTION END

Component Inspection

BBS004FG

L

THROTTLE CONTROL MOTOR
1.
2.

Disconnect electric throttle control actuator harness connector.
Check resistance between terminals 5 and 6.

M

Resistance: Approximately 1 — 15 Ω [at 25 °C (77°F)]
3.
4.
5.

If NG, replace electric throttle control actuator and go to next
step.
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .

PBIB2909E

Removal and Installation

BBS004FH

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-120, «INTAKE MANIFOLD» .

EC-1089

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[HR (WITH EURO-OBD)]

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
Component Description

PFP:16119
BBS004FI

Power supply for the throttle control motor is provided to the ECM via throttle control motor relay. The throttle
control motor relay is ON/OFF controlled by the ECM. When the ignition switch is turned ON, the ECM sends
an ON signal to throttle control motor relay and battery voltage is provided to the ECM. When the ignition
switch is turned OFF, the ECM sends an OFF signal to throttle control motor relay and battery voltage is not
provided to the ECM.

CONSULT-II Reference Value in Data Monitor Mode

BBS004FJ

Specification data are reference values.
MONITOR ITEM
THRTL RELAY

CONDITION
●

SPECIFICATION

Ignition switch: ON

ON

On Board Diagnosis Logic

BBS004FK

These self-diagnoses have the one trip detection logic.
DTC No.
P1124
1124

P1126
1126

Trouble diagnosis name
Throttle control motor
relay circuit short

Throttle control motor
relay circuit open

DTC detecting condition

Possible cause
●

Harness or connectors
(Throttle control motor relay circuit is
shorted)

●

Throttle control motor relay

●

Harness or connectors
(Throttle control motor relay circuit is
open)

●

Throttle control motor relay

ECM detect the throttle control motor relay is
stuck ON.

ECM detects a voltage of power source for
throttle control motor is excessively low.

FAIL-SAFE MODE
When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.

DTC Confirmation Procedure

BBS004FL

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

PROCEDURE FOR DTC P1124
With CONSULT-II
1.
2.
3.

Turn ignition switch ON and wait at least 1 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
If DTC is detected, go to EC-1093, «Diagnostic Procedure» .

SEF058Y

With GST
Follow the procedure “With CONSULT-II” above.

EC-1090

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[HR (WITH EURO-OBD)]
PROCEDURE FOR DTC P1126
A

TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 8V.

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

EC

Turn ignition switch ON and wait at least 2 second.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If DTC is detected, go to EC-1093, «Diagnostic Procedure» .

C

D

E
SEF058Y

With GST

F

Follow the procedure “With CONSULT-II” above.
G

H

I

J

K

L

M

EC-1091

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004FM

MBWA1473E

EC-1092

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
0 — 14V
[Ignition switch: ON]

1

P

Throttle control motor
(Open)

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

D

E
PBIB1105E

2

LG

Throttle control motor relay
power supply

[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)

F

0 — 14V
[Ignition switch: ON]
4

L

Throttle control motor
(Close)

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Released

G

H
PBIB1104E

15

G

Throttle control motor relay

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 1.0V

I

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

J
BBS004FN

1. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-I
1.
2.

K

Turn ignition switch OFF.
Check voltage between ECM terminal 15 and ground with CONSULT-II or tester.

L

Voltage: Battery voltage
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.

M

PBIA9569J

EC-1093

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[HR (WITH EURO-OBD)]

2. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-II
1.
2.
3.

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E5.
Check continuity between ECM terminal 15 and IPDM E/R terminal 70.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between ECM and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK FUSE
1. Disconnect 20A fuse.
2. Check 20A fuse for blown.
OK or NG
OK
>> GO TO 8.
NG
>> Replace 20A fuse.

5. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-I
1.

Check voltage between ECM terminal 2 and ground under the
following conditions with CONSULT-II or tester.
Ignition switch

Voltage

OFF

Approximately 0V

ON

Battery voltage
(11 — 14V)

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 6.

PBIA9568J

6. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-II
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E7.
Check continuity between ECM terminal 2 and IPDM E/R terminal 28.
Refer to Wiring Diagram.
Continuity should exist.

5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

EC-1094

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[HR (WITH EURO-OBD)]

7. DETECT MALFUNCTIONING PART

A

Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between ECM and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC

C

8. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connectors.

D

E

F

G

H

I

J

K

L

M

EC-1095

DTC P1128 THROTTLE CONTROL MOTOR
[HR (WITH EURO-OBD)]

DTC P1128 THROTTLE CONTROL MOTOR
Component Description

PFP:16119
BBS004FO

The throttle control motor is operated by the ECM and it opens and closes the throttle valve.
The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feedback to the ECM to control the throttle control motor to make the throttle valve opening angle properly in
response to driving condition.

On Board Diagnosis Logic

BBS004FP

This self-diagnosis has the one trip detection logic.
DTC No.
P1128
1128

Trouble diagnosis name
Throttle control motor
circuit short

DTC detecting condition
ECM detects short in both circuits between
ECM and throttle control motor.

Possible cause
●

Harness or connectors
(Throttle control motor circuit is shorted.)

●

Electric throttle control actuator
(Throttle control motor)

FAIL-SAFE MODE
When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.

DTC Confirmation Procedure

BBS004FQ

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

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

Turn ignition switch ON and wait at least 2 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If DTC is detected, go to EC-1098, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-1096

DTC P1128 THROTTLE CONTROL MOTOR
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004FR

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1474E

EC-1097

DTC P1128 THROTTLE CONTROL MOTOR
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

0 — 14V
[Ignition switch: ON]
1

P

Throttle control motor
(Open)

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed
PBIB1105E

2

LG

Throttle control motor relay
power supply

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 14V
[Ignition switch: ON]
4

L

Throttle control motor
(Close)

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Released
PBIB1104E

15

G

Throttle control motor relay

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 1.0V

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004FS

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1098

3.

Body ground

DTC P1128 THROTTLE CONTROL MOTOR
[HR (WITH EURO-OBD)]

2. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Disconnect electric throttle control actuator (1) harness connector.

–

: Vehicle front
Disconnect ECM harness connector.
Check harness continuity between the following terminals.
Refer to Wiring Diagram.

2.
3.

Electric throttle control
actuator terminal
5

6

ECM terminal

A

EC

C

Continuity

D
1

Should not exist

4

Should exist

1

Should exist

4

Should not exist

PBIB2965E

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

E

F

G

3. CHECK THROTTLE CONTROL MOTOR
Refer to EC-1100, «Component Inspection» .
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 5.

H

I

4. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace harness or connectors.

J

K

5. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
L

1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .
>> INSPECTION END

EC-1099

M

DTC P1128 THROTTLE CONTROL MOTOR
[HR (WITH EURO-OBD)]

Component Inspection

BBS004FT

THROTTLE CONTROL MOTOR
1.
2.

Disconnect electric throttle control actuator harness connector.
Check resistance between terminals 5 and 6.
Resistance: Approximately 1 — 15 Ω [at 25 °C (77°F)]

3.
4.
5.

If NG, replace electric throttle control actuator and go to next
step.
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .

PBIB2909E

Removal and Installation

BBS004FU

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-120, «INTAKE MANIFOLD» .

EC-1100

DTC P1143 HO2S1
[HR (WITH EURO-OBD)]

DTC P1143 HO2S1
Component Description

PFP:22690

A
BBS004FV

The heated oxygen sensor 1 is placed into the exhaust manifold. It
detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.

EC

C

D
SEF463R

E

F

G

H
SEF288D

CONSULT-II Reference Value in Data Monitor Mode

BBS004FW

I

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

J

0 — 0.3V ←→ Approx. 0.6 — 1.0V

HO2S1 (B1)
●

HO2S1 MNTR (B1)

Engine: After warming up

Maintaining engine speed at 2,000
rpm

LEAN ←→ RICH
Changes more than 5 times during 10 seconds.

On Board Diagnosis Logic

BBS004FX

L

To judge the malfunction, the output from the heated oxygen sensor
1 is monitored to determine whether the “rich” output is sufficiently
high and whether the “lean” output is sufficiently low. When both the
outputs are shifting to the lean side, the malfunction will be detected.

M

SEF300U

DTC No.

P1143
1143

Trouble diagnosis name

Heated oxygen sensor 1
lean shift monitoring

K

DTC detecting condition

The maximum and minimum voltage from the
sensor are not reached to the specified voltages.

EC-1101

Possible cause
●

Heated oxygen sensor 1

●

Heated oxygen sensor 1 heater

●

Fuel pressure

●

Fuel injector

●

Intake air leaks

DTC P1143 HO2S1
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004FY

CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
●
Always perform at a temperature above −10°C (14°F).
●
Before performing following procedure, confirm that battery voltage is more than 11V at idle.

WITH CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Stop engine and wait at least 10 seconds.
Turn ignition switch ON and select “HO2S1 (B1) P1143” of “HO2S1” in “DTC WORK SUPPORT” mode
with CONSULT-II.
Touch “START”.
Start engine and let it idle for at least 3 minutes.
NOTE:
Never raise engine speed above 3,600 rpm after this step. If
the engine speed limit is exceeded, return to step 5.

PBIB0546E

6.

When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will
take approximately 50 seconds or more.)

ENG SPEED

A/T: 1,300 — 2,800 rpm
M/T: 1,500 — 3,600 rpm

VHCL SPEED SE

Less than 100 km/h (62 MPH)

B/FUEL SCHDL

A/T: 2.8 — 11.2 msec
M/T: 2.0 — 11.2 msec

Shift lever

Suitable position

7.

PBIB0547E

If “TESTING” is not displayed after 5 minutes, retry from step 2.
Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”. If “NG” is displayed, refer to EC-1103, «Diagnostic
Procedure» .

SEC769C

EC-1102

DTC P1143 HO2S1
[HR (WITH EURO-OBD)]

Overall Function Check

BBS004FZ

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st
trip DTC might not be confirmed.

WITH GST
1.
2.
3.
●
●

4.

A

EC

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground.
Check one of the following with engine speed held at 2,000 rpm
constant under no load.
The maximum voltage is over 0.6V at least 1 time.
The minimum voltage is over 0.1V at least 1 time.
If NG, go to EC-1103, «Diagnostic Procedure» .

C

D

E

PBIA9566J

Diagnostic Procedure

BBS004G0

1. CHECK GROUND CONNECTIONS
1.
2.

F

G

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

H

I

J

K
MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

Body ground

L

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

M

2. RETIGHTEN HEATED OXYGEN SENSOR 1
Loosen and retighten heated oxygen sensor 1 (1).
●
●

: Vehicle front
Exhaust manifold (2)
Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb)
>> GO TO 3.

PBIB2966E

EC-1103

DTC P1143 HO2S1
[HR (WITH EURO-OBD)]

3. CLEAR THE SELF-LEARNING DATA
1.
2.
3.
4.

With CONSULT-II
Start engine and warm it up to normal operating temperature.
Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II.
Clear the self-learning control coefficient by touching “CLEAR”.
Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 detected?
Is it difficult to start engine?

SEF215Z

Without CONSULT-II
Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF.
Disconnect mass air flow sensor (1) harness connector, and
restart and run engine for at least 5 seconds at idle speed.
4. Stop engine and reconnect mass air flow sensor harness connector.
5. Make sure that DTC P0102 is displayed.
6. Erase the DTC memory. Refer to EC-841, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .
7. Make sure that DTC P0000 is displayed.
8. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 detected?
PBIB2948E
Is it difficult to start engine?
Yes or No
Yes
>> Perform trouble diagnosis for DTC P0171. Refer to EC-1012, «DTC P0171 FUEL INJECTION
SYSTEM FUNCTION» .
No
>> GO TO 4.
1.
2.
3.

4. CHECK HEATED OXYGEN SENSOR 1 HEATER
Refer to EC-990, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace heated oxygen sensor 1.

5. CHECK HEATED OXYGEN SENSOR 1
Refer to EC-975, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 1.

6. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
For circuit, refer to EC-970, «Wiring Diagram» .
>> INSPECTION END

EC-1104

DTC P1143 HO2S1
[HR (WITH EURO-OBD)]

Component Inspection

BBS004G1

A

HEATED OXYGEN SENSOR 1
With CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC
II.
Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
C
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch “RECORD” on CONSULT-II screen.
D

E

SEF646Y

F

6.

Check the following.
● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes
from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds.
5 times (cycles) are counted as shown in the figure.
● “HO2S1 (B1)” voltage goes above 0.6V at least once.
● “HO2S1 (B1)” voltage goes below 0.3V at least once.
● “HO2S1 (B1)” voltage never exceeds 1.0V.

G

H

I
SEF217YA

J

K

L

SEF648Y

CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Without CONSULT-II
1.
2.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground.

EC-1105

M

DTC P1143 HO2S1
[HR (WITH EURO-OBD)]
3.

Check the following with engine speed held at 2,000 rpm constant under no load.
● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
● The maximum voltage is over 0.6V at least 1 time.
● The minimum voltage is below 0.3V at least 1 time.
● The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V
→ 0 — 0.3V
PBIA9566J
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Removal and Installation

BBS004G2

HEATED OXYGEN SENSOR 1
Refer to EM-124, «EXHAUST MANIFOLD» .

EC-1106

DTC P1144 HO2S1
[HR (WITH EURO-OBD)]

DTC P1144 HO2S1
Component Description

PFP:22690

A
BBS004G3

The heated oxygen sensor 1 is placed into the exhaust manifold. It
detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.

EC

C

D
SEF463R

E

F

G

H
SEF288D

CONSULT-II Reference Value in Data Monitor Mode

BBS004G4

I

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

J

0 — 0.3V ←→ Approx. 0.6 — 1.0V

HO2S1 (B1)
●

HO2S1 MNTR (B1)

Engine: After warming up

Maintaining engine speed at 2,000
rpm

LEAN ←→ RICH
Changes more than 5 times during 10 seconds.

On Board Diagnosis Logic

BBS004G5

L

To judge the malfunction, the output from the heated oxygen sensor
1 is monitored to determine whether the “rich” output is sufficiently
high and “lean” output is sufficiently low. When both the outputs are
shifting to the rich side, the malfunction will be detected.

M

SEF299U

DTC No.

P1144
1144

K

Trouble diagnosis name

DTC detecting condition

Heated oxygen sensor 1
rich shift monitoring

The maximum and minimum voltages from the
sensor are beyond the specified voltages.

EC-1107

Possible cause
●

Heated oxygen sensor 1

●

Heated oxygen sensor 1 heater

●

Fuel pressure

●

Fuel injector

DTC P1144 HO2S1
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004G6

CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
●
Always perform at a temperature above −10°C (14°F).
●
Before performing the following procedure, confirm that battery voltage is more than 11V at idle.

WITH CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Stop engine and wait at least 5 seconds.
Turn ignition switch ON and select “HO2S1 (B1) P1144” of “HO2S1” in “DTC WORK SUPPORT” mode
with CONSULT-II.
Touch “START”.
Start engine and let it idle for at least 3 minutes.
NOTE:
Never raise engine speed above 3,600 rpm after this step. If
the engine speed limit is exceeded, return to step 5.

PBIB0548E

6.

When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will
take approximately 50 seconds or more.)

ENG SPEED

A/T: 1,300 — 2,800 rpm
M/T: 1,500 — 3,600 rpm

VHCL SPEED SE

Less than 100 km/h (62 MPH)

B/FUEL SCHDL

A/T: 2.8 — 11.2 msec
M/T: 2.0 — 11.2 msec

Shift lever

Suitable position

7.

PBIB0549E

If “TESTING” is not displayed after 5 minutes, retry from step 2.
Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”. If “NG” is displayed, refer to EC-1109, «Diagnostic
Procedure» .

SEC772C

EC-1108

DTC P1144 HO2S1
[HR (WITH EURO-OBD)]

Overall Function Check

BBS004G7

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st
trip DTC might not be confirmed.

WITH GST
1.
2.
3.
●
●

4.

A

EC

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground.
Check one of the following with engine speed held at 2,000 rpm
constant under no load.
The maximum voltage is below 0.8V at least 1 time.
The minimum voltage is below 0.35V at least 1 time.
If NG, go to EC-1109, «Diagnostic Procedure» .

C

D

E

PBIA9566J

Diagnostic Procedure

BBS004G8

1. CHECK GROUND CONNECTIONS
1.
2.

F

G

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

H

I

J

K
MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

Body ground

L

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

M

2. RETIGHTEN HEATED OXYGEN SENSOR 1
Loosen and retighten heated oxygen sensor 1 (1).
●
●

: Vehicle front
Exhaust manifold (2)
Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb)
>> GO TO 3.

PBIB2966E

EC-1109

DTC P1144 HO2S1
[HR (WITH EURO-OBD)]

3. CLEAR THE SELF-LEARNING DATA
1.
2.
3.
4.

With CONSULT-II
Start engine and warm it up to normal operating temperature.
Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II.
Clear the self-learning control coefficient by touching “CLEAR”.
Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0172 detected?
Is it difficult to start engine?

SEF215Z

Without CONSULT-II
Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF.
Disconnect mass air flow sensor (1) harness connector, and
restart and run engine for at least 5 seconds at idle speed.
4. Stop engine and reconnect mass air flow sensor harness connector.
5. Make sure that DTC P0102 is displayed.
6. Erase the DTC memory. Refer to EC-841, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .
7. Make sure that DTC P0000 is displayed.
8. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0172 detected?
PBIB2948E
Is it difficult to start engine?
Yes or No
Yes
>> Perform trouble diagnosis for DTC P0172. Refer to EC-1019, «DTC P0172 FUEL INJECTION
SYSTEM FUNCTION» .
No
>> GO TO 4.
1.
2.
3.

4. CHECK HO2S1 CONNECTOR FOR WATER
1.
2.

Turn ignition switch OFF.
Disconnect heated oxygen sensor 1 harness connector (1).

–

: Vehicle front
Check connectors for water.

3.

Water should not exist.
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace harness or connectors.
PBIB2967E

EC-1110

DTC P1144 HO2S1
[HR (WITH EURO-OBD)]

5. CHECK HEATED OXYGEN SENSOR 1 HEATER

A

Refer to EC-990, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 1.

EC

6. CHECK HEATED OXYGEN SENSOR 1

C

Refer to EC-975, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace heated oxygen sensor 1.

D

7. CHECK INTERMITTENT INCIDENT

E

Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
For circuit, refer to EC-970, «Wiring Diagram» .

F

>> INSPECTION END

Component Inspection

BBS004G9

HEATED OXYGEN SENSOR 1
With CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULTII.
Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch “RECORD” on CONSULT-II screen.

G

H

I

J

K

L
SEF646Y

6.

Check the following.
● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes
from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds.
5 times (cycles) are counted as shown in the figure.
● “HO2S1 (B1)” voltage goes above 0.6V at least once.
● “HO2S1 (B1)” voltage goes below 0.3V at least once.
● “HO2S1 (B1)” voltage never exceeds 1.0V.

M

SEF217YA

EC-1111

DTC P1144 HO2S1
[HR (WITH EURO-OBD)]

SEF648Y

CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Without CONSULT-II
1.
2.
3.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground.
Check the following with engine speed held at 2,000 rpm constant under no load.
● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
● The maximum voltage is over 0.6V at least 1 time.
● The minimum voltage is below 0.3V at least 1 time.
● The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V
→ 0 — 0.3V
PBIA9566J
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Removal and Installation

BBS004GA

HEATED OXYGEN SENSOR 1
Refer to EM-124, «EXHAUST MANIFOLD» .

EC-1112

DTC P1146 HO2S2
[HR (WITH EURO-OBD)]

DTC P1146 HO2S2
Component Description

PFP:226A0

A
BBS004GB

The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.

EC

C

D
SEF327R

E

CONSULT-II Reference Value in Data Monitor Mode

BBS004GC

Specification data are reference values.
MONITOR ITEM
HO2S2 (B1)

HO2S2 MNTR (B1)

F

CONDITION

SPECIFICATION

●

Revving engine from idle to 3,000 rpm quickly after the following conditions are met.

0 — 0.3V ←→ Approx. 0.6 — 1.0V

–

Engine: After warming up

–

Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute
and idle for 1 minute under no load

G

LEAN ←→ RICH

H

On Board Diagnosis Logic

BBS004GD

The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity of the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the minimum voltage of sensor is
sufficiently low during the various driving condition such as fuel-cut.

I

J

K
PBIB0554E

L
DTC No.

P1146
1146

Trouble diagnosis name

Heated oxygen sensor 2
minimum voltage monitoring

DTC detecting condition

The minimum voltage from the sensor is not
reached to the specified voltage.

EC-1113

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 2

●

Fuel pressure

●

Fuel injector

M

DTC P1146 HO2S2
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004GE

CAUTION:
Always drive vehicle at a safe speed.
NOTE:
●
“COMPLETED” will appear on CONSULT-II screen when all tests “COND1”, “COND2” and
“COND3” are completed.
●
If DTC confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
at least 10 seconds before conducting the next test.
TESTING CONDITION:
Never stop engine during this procedure. If the engine is stopped, retry procedure from step 2 in Procedure for COND1

WITH CONSULT-II
Procedure for COND1
For the best results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30°C(32 to 86°F).
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
4. Let engine idle 1 minute.
5. Select “HO2S2 (B1) P1146” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II.
6. Touch “START”.
7. Start engine and let it idle for at least 30 seconds.
8. Rev engine up to 2,000 rpm two or three times quickly under no load.
If “COMPLETED” appears on CONSULT-II screen, go to step 2 in Procedure for COND3”.
If “COMPLETED” does not appear on CONSULT-II screen, go to the following step.
9. When the following conditions are met, “TESTING” will be displayed at “COND1” on the CONSULT-II
screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take
approximately 60 seconds.)
ENG SPEED

1,000 — 3,600 rpm

B/FUEL SCHDL

More than 1.0 msec

COOLAN TEMP/S

70 — 119°C (158 — 246°F)

Shift lever

Suitable position

PBIB0555E

NOTE:
If “TESTING” is not displayed after 5 minutes, retry from step 2 in Procedure for COND1.
● If “COMPLETED” already appears at “COND2” on CONSULT-II screen before Procedure for
COND2 is conducted, it is unnecessary to conduct step 1 in Procedure for COND2.
●

EC-1114

DTC P1146 HO2S2
[HR (WITH EURO-OBD)]
Procedure for COND2
1.

A

While driving, release accelerator pedal completed with “OD”
OFF (A/T) from the above condition [step 9] until “INCOMPLETE” at “COND2” on CONSULT-II screen has turned to
“COMPLETED” (It will take approximately 4 seconds.)
NOTE:
If “COMPLETE” already appears at “COND3” on CONSULTII screen before Procedure for COND3 is conducted, it is
unnecessary to conduct step 1 in Procedure for COND3.

EC

C

PBIB0556E

D

Procedure for COND3
1.

2.

a.
b.
c.
d.

Stop vehicle and let it idle until “INCOMPLETE” of “COND3” on
CONSULT-II screen has turned to “COMPLETED”. (It will take a
maximum of approximately 6 minutes.)
Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”.
If “NG” is displayed, refer to EC-1117, «Diagnostic Procedure» .
If “CAN NOT BE DIAGNOSED” is displayed, performed the following.
Turn ignition switch OFF and leave the vehicle in a cool place
(soak the vehicle).
SEC775C
Turn ignition switch ON and select “COOLAN TEMP/S” in “DATA
MONITOR” mode with CONSULT-II.
Start engine and warm it up while monitoring “COOLAN TEMP/S” indication on CONSULT-II.
When “COOLAN TEMP/S” indication reaches to 70°C(158°F), go to Procedure for COND1 step 3.

Overall Function Check

E

F

G

H

I

BBS004GF

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st
trip DTC might not be confirmed.

J

WITH GST
1.
2.
3.
4.
5.
6.

7.

8.

Start engine and warm it up to the operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground.
Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be below 0.50V at least once during this
procedure.
If the voltage can be confirmed in step 6, step 7 is not necessary.
Keep vehicle at idling for 10 minutes, then check the voltage. Or
check the voltage when coasting from 80 km/h (50 MPH) in D
position with “OD” OFF (A/T), 3rd gear position (M/T).
The voltage should be below 0.50V at least once during this
PBIB2996E
procedure.
If NG, go to EC-1117, «Diagnostic Procedure» .

EC-1115

K

L

M

DTC P1146 HO2S2
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004GG

MBWA1463E

EC-1116

DTC P1146 HO2S2
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
Approximately 10V

[Engine is running]

5

GR

●

Below 3,600 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load

Heated oxygen sensor 2
heater

D

E
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

●

F

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
Engine speed: Above 3,600 rpm

G

[Engine is running]

50

B

Heated oxygen sensor 2

●

Revving engine from idle to 3,000 rpm quickly
after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load.

H

0 — Approximately 1.0V

I

[Engine is running]
59

LG

Sensor ground
(Heated oxygen sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

J

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004GH

K

1. CHECK GROUND CONNECTIONS
1.
2.

L

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

M

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1117

3.

Body ground

DTC P1146 HO2S2
[HR (WITH EURO-OBD)]

2. CLEAR THE SELF-LEARNING DATA
With CONSULT-II
Start engine and warm it up to normal operating temperature.
Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode
with CONSULT-II.
3. Clear the self-learning control coefficient by touching “CLEAR”.
4. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0172 detected?
Is it difficult to start engine?
1.
2.

SEF215Z

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF.
3. Disconnect mass air flow sensor (1) harness connector, and
restart and run engine for at least 5 seconds at idle speed.
4. Stop engine and reconnect mass air flow sensor harness connector.
5. Make sure that DTC P0102 is displayed.
6. Erase the DTC memory. Refer to EC-841, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .
7. Make sure that DTC P0000 is displayed.
8. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0172 detected?
PBIB2948E
Is it difficult to start engine?
Yes or No
Yes
>> Perform trouble diagnosis for DTC P0172. Refer to EC-1019, «DTC P0172 FUEL INJECTION
SYSTEM FUNCTION» .
No
>> GO TO 3.

3. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
–

3.
4.

Turn ignition switch OFF.
Disconnect heated oxygen sensor 2 harness connector (2).
Heated oxygen sensor 2 (1)
Disconnect ECM harness connector.
Check harness continuity between HO2S2 terminal 1 and ECM
terminal 59.
Refer to Wiring Diagram.
Continuity should exist.

5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1118

PBIB2949E

DTC P1146 HO2S2
[HR (WITH EURO-OBD)]

4. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

A

Check harness continuity between HO2S2 terminal 4 and ECM terminal 50.
Refer to Wiring Diagram.
EC

Continuity should exist.
2.

Check harness continuity between ECM terminal 50 or HO2S2 terminal 4 and ground.
Refer to Wiring Diagram.

C

Continuity should not exist.
3. Also check harness for short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D

E

5. CHECK HEATED OXYGEN SENSOR 2
Refer to EC-1119, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 2.

F

G

6. CHECK INTERMITTENT INCIDENT
H

Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

I

Component Inspection

BBS004GI

HEATED OXYGEN SENSOR 2
With CONSULT-II
1.
2.
3.
4.
5.

J

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select
“HO2S2 (B1)” as the monitor item with CONSULT-II.

K

L

M

SEF662Y

EC-1119

DTC P1146 HO2S2
[HR (WITH EURO-OBD)]
6.

Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%.

PBIB0551E

“HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%.
“HO2S2 (B1)” should be below 0.50V at least once when the “FUEL INJECTION” is −25%.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Without CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground.
Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.68V at least once during this
procedure.
If the voltage is above 0.68V at step 6, step 7 is not necessary.
7. Keep vehicle at idling for 10 minutes, then check voltage. Or
check the voltage when coasting from 80 km/h (50 MPH) in D
position with “OD” OFF (A/T), 3rd gear position (M/T).
The voltage should be below 0.50V at least once during this
PBIB2996E
procedure.
8. If NG, replace heated oxygen sensor 2.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Removal and Installation

BBS004GJ

HEATED OXYGEN SENSOR 2
Refer to EX-3, «EXHAUST SYSTEM» .

EC-1120

DTC P1147 HO2S2
[HR (WITH EURO-OBD)]

DTC P1147 HO2S2
Component Description

PFP:226A0

A
BBS004GK

The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.

EC

C

D
SEF327R

E

CONSULT-II Reference Value in Data Monitor Mode

BBS004GL

Specification data are reference values.
MONITOR ITEM
HO2S2 (B1)

HO2S2 MNTR (B1)

F

CONDITION

SPECIFICATION

●

Revving engine from idle to 3,000 rpm quickly after the following conditions are met.

0 — 0.3V ←→ Approx. 0.6 — 1.0V

–

Engine: After warming up

–

Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute
and idle for 1 minute under no load

G

LEAN ←→ RICH

H

On Board Diagnosis Logic

BBS004GM

The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity before the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the maximum voltage of the sensor
is sufficiently high during the various driving condition such as fuelcut.

I

J

K
SEF259VA

L
DTC No.

P1147
1147

Trouble diagnosis name

Heated oxygen sensor 2
maximum voltage monitoring

DTC detecting condition

The maximum voltage from the sensor is
not reached to the specified voltage.

EC-1121

Possible cause
●

Harness or connectors
(The sensor circuit open or shorted.)

●

Heated oxygen sensor 2

●

Fuel pressure

●

Fuel injector

●

Intake air leaks

M

DTC P1147 HO2S2
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004GN

CAUTION:
Always drive vehicle at a safe speed.
NOTE:
●
“COMPLETED” will appear on CONSULT-II screen when all tests “COND1”, “COND2” and
“COND3” are completed.
●
If DTC confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
at least 10 seconds before conducting the next test.
TESTING CONDITION:
Never stop engine during this procedure. If the engine is stopped, retry procedure from step 2 in “Procedure for COND1”

WITH CONSULT-II
Procedure for COND1
For the best results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30°C(32 to 86°F).
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
4. Let engine idle 1 minute.
5. Select “HO2S2 (B1) P1147” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II.
6. Touch “START”.
7. Start engine and let it idle for at least 30 seconds.
8. Rev engine up to 2,000 rpm two or three times quickly under no load.
If “COMPLETED” appears on CONSULT-II screen, go to step 2 in “Procedure for COND3”.
If “COMPLETED” does not appear on CONSULT-II screen, go to the following step.
9. When the following conditions are met, “TESTING” will be displayed at COND1” on the CONSULT-II
screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take
approximately 60 seconds.)
ENG SPEED

1,000 — 3,600 rpm

B/FUEL SCHDL

More than 1.0 msec

COOLAN TEMP/S

70 — 119°C (158 — 246°F)

Shift lever

Suitable position

PBIB0557E

NOTE:
If “TESTING” is not displayed after 5 minutes, retry from step 2 in Procedure for COND1.
● If “COMPLETED” already appears at “COND2” on CONSULT-II screen before Procedure for
COND2 is conducted, it is unnecessary to conduct step 1 in Procedure for COND2.
●

EC-1122

DTC P1147 HO2S2
[HR (WITH EURO-OBD)]
Procedure for COND2
1.

A

While driving, release accelerator pedal completed with “OD”
OFF (A/T) from the above condition [step 9] until “INCOMPLETE” at “COND2” on CONSULT-II screen has turned to
“COMPLETED” (It will take approximately 4 seconds.)
NOTE:
If “COMPLETE” already appears at “COND3” on CONSULTII screen before Procedure for COND3 is conducted, it is
unnecessary to conduct step 1 in “Procedure for COND3”.

EC

C

PBIB0558E

D

Procedure for COND3
1.

2.

a.
b.
c.
d.

Stop vehicle and let it idle until “INCOMPLETE” of “COND3” on
CONSULT-II screen has turned to “COMPLETED”. (It will take a
maximum of approximately 6 minutes.)
Make sure that “OK” is displayed after touching “SELF-DIAG
RESULTS”.
If “NG” is displayed, refer to EC-1125, «Diagnostic Procedure» .
If “CAN NOT BE DIAGNOSED” is displayed, perform the following.
Turn ignition switch OFF and leave the vehicle in a cool place
(soak the vehicle).
SEC778C
Turn ignition switch ON and select “COOLAN TEMP/S” in “DATA
MONITOR” mode with CONSULT-II.
Start engine and warm it up while monitoring “COOLAN TEMP/S” indication on CONSULT-II.
When “COOLAN TEMP/S” indication reaches to 70°C(158°F), go to Procedure for COND1 step 3.

Overall Function Check

E

F

G

H

I

BBS004GO

Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st
trip DTC might not be confirmed.

J

WITH GST
1.
2.
3.
4.
5.
6.

7.

8.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground.
Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.68V at least once during this
procedure.
If the voltage can be confirmed in step 6, step 7 is not necessary.
Keep vehicle idling for 10 minutes, then check the voltage. Or
check the voltage when coasting from 80 km/h (50 MPH) in D
position with “OD” OFF (A/T), 3rd gear position (M/T).
The voltage should be above 0.68V at least once during this
PBIB2996E
procedure.
If NG, go to EC-1125, «Diagnostic Procedure» .

EC-1123

K

L

M

DTC P1147 HO2S2
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004GP

MBWA1463E

EC-1124

DTC P1147 HO2S2
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
Approximately 10V

[Engine is running]

5

GR

●

Below 3,600 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load

Heated oxygen sensor 2
heater

D

E
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

●

F

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
Engine speed: Above 3,600 rpm

G

[Engine is running]

50

B

Heated oxygen sensor 2

●

Revving engine from idle to 3,000 rpm quickly
after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load.

H

0 — Approximately 1.0V

I

[Engine is running]
59

LG

Sensor ground
(Heated oxygen sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

J

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004GQ

K

1. CHECK GROUND CONNECTIONS
1.
2.

L

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

M

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1125

3.

Body ground

DTC P1147 HO2S2
[HR (WITH EURO-OBD)]

2. CLEAR THE SELF-LEARNING DATA
With CONSULT-II
Start engine and warm it up to normal operating temperature.
Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode
with CONSULT-II.
3. Clear the self-learning control coefficient by touching “CLEAR”.
4. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 detected?
Is it difficult to start engine?
1.
2.

SEF215Z

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF.
3. Disconnect mass air flow sensor (1) harness connector, and
restart and run engine for at least 5 seconds at idle speed.
4. Stop engine and reconnect mass air flow sensor harness connector.
5. Make sure that DTC P0102 is displayed.
6. Erase the DTC memory. Refer to EC-841, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .
7. Make sure that DTC P0000 is displayed.
8. Run engine for at least 10 minutes at idle speed.
Is the 1st trip DTC P0171 detected?
PBIB2948E
Is it difficult to start engine?
Yes or No
Yes
>> Perform trouble diagnosis for DTC P0171. Refer to EC-1012, «DTC P0171 FUEL INJECTION
SYSTEM FUNCTION» .
No
>> GO TO 3.

3. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
–

3.
4.

Turn ignition switch OFF.
Disconnect heated oxygen sensor 2 harness connector (2).
Heated oxygen sensor 2 (1)
Disconnect ECM harness connector.
Check harness continuity between HO2S2 terminal 1 and ECM
terminal 59.
Refer to Wiring Diagram.
Continuity should exist.

5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1126

PBIB2949E

DTC P1147 HO2S2
[HR (WITH EURO-OBD)]

4. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

A

Check harness continuity between HO2S2 terminal 4 and ECM terminal 50.
Refer to Wiring Diagram.
EC

Continuity should exist.
2.

Check harness continuity between ECM terminal 50 or HO2S2 terminal 4 and ground.
Refer to Wiring Diagram.

C

Continuity should not exist.
3. Also check harness for short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D

E

5. CHECK HEATED OXYGEN SENSOR 2
Refer to EC-1127, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace heated oxygen sensor 2.

F

G

6. CHECK INTERMITTENT INCIDENT
H

Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

I

Component Inspection

BBS004GR

HEATED OXYGEN SENSOR 2
With CONSULT-II
1.
2.
3.
4.
5.

J

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select
“HO2S2 (B1)” as the monitor item with CONSULT-II.

K

L

M

SEF662Y

EC-1127

DTC P1147 HO2S2
[HR (WITH EURO-OBD)]
6.

Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%.

PBIB0551E

“HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%.
“HO2S2 (B1)” should be below 0.50V at least once when the “FUEL INJECTION” is −25%.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Without CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground.
Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.68V at least once during this
procedure.
If the voltage is above 0.68V at step 6, step 7 is not necessary.
7. Keep vehicle idling for 10 minutes, then check voltage. Or check
the voltage when coasting from 80 km/h (50 MPH) in D position
with “OD” OFF (A/T), 3rd gear position (M/T).
The voltage should be below 0.50V at least once during this
PBIB2996E
procedure.
8. If NG, replace heated oxygen sensor 2.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Removal and Installation

BBS004GS

HEATED OXYGEN SENSOR 2
Refer to EX-3, «EXHAUST SYSTEM» .

EC-1128

DTC P1212 TCS COMMUNICATION LINE
[HR (WITH EURO-OBD)]

DTC P1212 TCS COMMUNICATION LINE
Description

PFP:47850

A
BBS004GX

NOTE:
●
If DTC P1212 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC EC
U1000, U1001. Refer to EC-925, «DTC U1000, U1001 CAN COMMUNICATION LINE» .
●
If DTC P1212 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010.
Refer to EC-928, «DTC U1010 CAN COMMUNICATION» .
C
This CAN communication line is used to control the smooth engine operation during the TCS operation. Pulse
signals are exchanged between ECM and “ABS actuator and electric unit (control unit)”.
Be sure to erase the malfunction information such as DTC not only for “ABS actuator and electric unit
D
(control unit)” but also for ECM after TCS related repair.

On Board Diagnosis Logic

BBS004GY

E

The MI will not light up for this self-diagnosis.
Freeze frame data is not stored in the ECM for this self-diagnosis.
DTC No.

P1212
1212

Trouble diagnosis name

TCS communication
line

DTC detecting condition

ECM can not receive the information
from “ABS actuator and electric unit (control unit)” continuously.

DTC Confirmation Procedure

Possible cause

F

●

Harness or connectors
(The CAN communication line is open or
shorted.)

●

ABS actuator and electric unit (control unit)

●

Dead (Weak) battery
BBS004GZ

G

H

TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle.
I

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for at least 10 seconds.
If 1st trip DTC is detected, go to EC-1129, «Diagnostic Procedure» .

J

K

L

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

Diagnostic Procedure

BBS004H0

BRC-49, «TROUBLE DIAGNOSIS»

EC-1129

M

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITH EURO-OBD)]

DTC P1217 ENGINE OVER TEMPERATURE
System Description

PFP:00000
BBS004V3

SYSTEM DESCRIPTION
NOTE:
●
If DTC P1217 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC
U1000, U1001. Refer to EC-925, «DTC U1000, U1001 CAN COMMUNICATION LINE» .
●
If DTC P1217 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010.
Refer to EC-928, «DTC U1010 CAN COMMUNICATION» .

Cooling Fan Control
Sensor

Input Signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*1

Battery

Battery voltage*1

Wheel sensor

Vehicle speed*2

Engine coolant temperature sensor
Air conditioner switch*

3

Refrigerant pressure sensor*3

ECM function

Cooling fan
control

Actuator

IPDM E/R
(Cooling fan relays)

Engine coolant temperature
Air conditioner ON signal*2
Refrigerant pressure

*1: The ECM determines the start signal status by the signals of engine speed and battery voltage.
*2: This signal is sent to ECM through CAN communication line.
*3: Models with air conditioner

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, refrigerant
pressure, and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF] (Models with
A/C) or 2-step control [ON/OFF] (Models without A/C).

Cooling Fan Operation
Models with A/C

MBIB1451E

EC-1130

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITH EURO-OBD)]
Models without A/C
A

EC

C

MBIB1393E

D

Cooling Fan Relay Operation
The ECM controls cooling fan relays in the IPDM E/R through CAN communication line.

E

Cooling fan relay

Cooling fan speed
LO

HI

Stop (OFF)

OFF

OFF

Low (LOW)

ON

OFF

High (HI)

OFF

ON

F

G

CONSULT-II Reference Value in Data Monitor Mode

BBS004V4

Specification data are reference values.
MONITOR ITEM
AIR COND SIG

H
CONDITION

●

Engine: After warming up, idle
the engine

●

Engine: After warming up, idle
the engine

●

Air conditioner switch: OFF

COOLING FAN

SPECIFICATION

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates.)

ON

Engine coolant temperature is 97°C
(207°F) or less

OFF

Engine coolant temperature is
between 98°C (208°F) and 99°C
(210°F) or more

LOW*

Engine coolant temperature is 100°C
(212°F) or more

HIGH*

I

J

K

*: Models without air conditioner, cooling fan operates only ON and OFF operation, but CONSULT-II display will change OFF, LOW and
HI depends on engine coolant temperature.

On Board Diagnosis Logic

L

BBS004V5

If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise. When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction
is indicated.
This self-diagnosis has the one trip detection logic.

EC-1131

M

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITH EURO-OBD)]
DTC No.

Trouble diagnosis name

DTC detecting condition

●

P1217
1217

Engine over temperature
(Overheat)

Cooling fan does not operate properly (Overheat).

Possible cause
●

Harness or connectors
(The cooling fan circuit is open or
shorted.)

●

Cooling fan

●

IPDM E/R (Cooling fan relays)

●

Radiator hose
Radiator

●

Cooling fan system does not operate properly
(Overheat).

●
●

Reservoir tank (M/T models with A/C)

●

Engine coolant was not added to the system
using the proper filling method.

●

Reservoir tank cap (M/T models with
A/C)

●

Engine coolant is not within the specified
range.

●

Radiator cap (M/T models without A/C
and A/T models)

●

Water pump

●

Thermostat

For more information, refer to EC-1144,
«Main 12 Causes of Overheating» .

CAUTION:
When a malfunction is indicated, be sure to replace the coolant. Refer to MA-39, «Changing Engine
Coolant» . Also, replace the engine oil. Refer to MA-45, «Changing Engine Oil» .
1. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to
use coolant with the proper mixture ratio. Refer to MA-26, «Engine Coolant Mixture Ratio» .
2. After refilling coolant, run engine to ensure that no water-flow noise is emitted.

Overall Function Check

BBS004V6

Use this procedure to check the overall function of the cooling fan. During this check, a DTC might not be confirmed.
WARNING:
Never remove the reservoir tank cap (M/T models with A/C) or the radiator cap (M/T models without A/
C and A/T models) when the engine is hot. Serious burns could be caused by high pressure fluid
escaping from the reservoir tank or the radiator.
Wrap a thick cloth around cap. Carefully remove the cap by turning it a quarter turn to allow built-up
pressure to escape. Then turn the cap all the way off.

WITH CONSULT-II
1.

2.

3.

Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to EC-1137,
«PROCEDURE FOR MODELS WITH AIR CONDITIONER» or
EC-1141, «PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER» .
Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to EC-1137,
«PROCEDURE FOR MODELS WITH AIR CONDITIONER» or
EC-1141, «PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER» .
Turn ignition switch ON.

EC-1132

SEF621W

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITH EURO-OBD)]
4.
5.

Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II.
If the results are NG, go to EC-1137, «PROCEDURE FOR MODELS WITH AIR CONDITIONER» or EC-1141, «PROCEDURE
FOR MODELS WITHOUT AIR CONDITIONER» .

A

EC

C
SEF646X

D

WITH GST
Models with Air Conditioner
1.

Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to EC-1137,
«PROCEDURE FOR MODELS WITH AIR CONDITIONER» .
2. Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to EC-1137,
«PROCEDURE FOR MODELS WITH AIR CONDITIONER» .
3. Start engine.
CAUTION:
Be careful not to overheat engine.
4. Set temperature control switch to full cold position.
5. Turn air conditioner switch ON.
6. Turn blower fan switch ON.
7. Run engine at idle for a few minutes with air conditioner operating.
CAUTION:
Be careful not to overheat engine.
8. Make sure that cooling fans operates at low speed.
If NG, go to EC-1137, «PROCEDURE FOR MODELS WITH AIR
CONDITIONER» or .
If OK, go to the following step.
9. Turn ignition switch OFF.
10. Turn air conditioner switch and blower fan switch OFF.
11. Disconnect engine coolant temperature sensor harness connector.
12. Connect 150Ω resistor to engine coolant temperature sensor
harness connector.

E

F

G

SEF621W

I

J

K

L

M
MBIB0651E

13. Restart engine and make sure that cooling fan operates at
higher speed than low speed.
CAUTION:
Be careful not to overheat engine.
14. If NG, go to EC-1137, «PROCEDURE FOR MODELS WITH AIR
CONDITIONER» .

SEF023R

EC-1133

H

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITH EURO-OBD)]
Models without Air Conditioner
1.

2.

3.
4.
5.
6.

Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to EC-1141,
«PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER»
.
Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to EC-1141,
«PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER»
.
Disconnect engine coolant temperature sensor harness connector.
Connect 150Ω resistor to engine coolant temperature sensor harness connector.
Start engine and make that cooling fan operates. Be careful not
to overheat engine.
If NG, go to EC-1141, «PROCEDURE FOR MODELS WITHOUT
AIR CONDITIONER» .

SEF621W

SEF023R

EC-1134

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004V7

A

MODELS WITH AIR CONDITIONER

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1475E

EC-1135

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITH EURO-OBD)]
MODELS WITHOUT AIR CONDITIONER

MBWA1476E

EC-1136

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004V8

A

PROCEDURE FOR MODELS WITH AIR CONDITIONER

1. INSPECTION START
EC

Do you have CONSULT-II?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 4.

C

2. CHECK COOLING FAN LOW SPEED OPERATION
D

With CONSULT-II
1. Turn ignition switch ON.
2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II and touch “LOW” on the CONSULT-II screen.
3. Make sure that cooling fan operates at low speed.
OK or NG
OK
>> GO TO 3.
NG
>> Check cooling fan control circuit. (Go to EC-1139,
«PROCEDURE A» .)

E

F

G

SEF784Z

H

3. CHECK COOLING FAN HIGH SPEED OPERATION
I

With CONSULT-II
1. Touch “HIGH” on the CONSULT-II screen.
2. Make sure that cooling fan operates at higher speed than low
speed.
OK or NG
OK
>> GO TO 6.
NG
>> Check cooling fan control circuit. (Go to EC-1139,
«PROCEDURE A» .)

J

K

L
SEF785Z

M

EC-1137

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITH EURO-OBD)]

4. CHECK COOLING FAN LOW SPEED OPERATION
Without CONSULT-II
1. Start engine and let it idle.
2. Turn air conditioner switch ON.
3. Turn blower fan switch ON.
4. Make sure that cooling fan operates at low speed.
OK or NG
OK
>> GO TO 5.
NG
>> Check cooling fan low speed control circuit. (Go to EC1139, «PROCEDURE A» .)

MBIB0651E

5. CHECK COOLING FAN HIGH SPEED OPERATION
Without CONSULT-II
Turn ignition switch OFF.
Turn air conditioner switch and blower fan switch OFF.
Disconnect engine coolant temperature sensor harness connector.
Connect 150Ω resistor to engine coolant temperature sensor harness connector.
Restart engine and make sure that cooling fan operates at
higher speed than low speed.
OK or NG
OK
>> GO TO 6.
NG
>> Check cooling fan high speed control circuit. (Go to EC1139, «PROCEDURE A» .)

1.
2.
3.
4.
5.

SEF023R

6. CHECK COOLING SYSTEM FOR LEAK
Refer to CO-27, «ENGINE COOLANT» .
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

7. DETECT MALFUNCTIONING PART
Check the following for leak.
●
Hose
●
Radiator
●
Water pump (Refer to CO-36, «WATER PUMP» .)
●
Reservoir tank
>> Repair or replace.

EC-1138

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITH EURO-OBD)]

8. CHECK RESERVOIR TANK CAP (M/T MODELS) OR RADIATOR CAP (A/T MODELS)

A
Refer to CO-35, «Checking Reservoir Tank Cap (M/T with A/C Models)» or CO-34, «Checking Radiator Cap
(All Models Except M/T with A/C)» .
EC
OK or NG
OK
>> GO TO 9.
NG
>> Replace reservoir tank cap (M/T models) or radiator cap (A/T models).
C
CHECK THERMOSTAT

9.

Refer to CO-38, «THERMOSTAT» .
OK or NG
OK
>> GO TO 10.
NG
>> Replace thermostat.

D

E

10. CHECK ENGINE COOLANT TEMPERATURE SENSOR
Refer to EC-951, «Component Inspection» .
OK or NG
OK
>> GO TO 11.
NG
>> Replace engine coolant temperature sensor.

F

G

11. CHECK MAIN 12 CAUSES
H

If the cause cannot be isolated, go to EC-1144, «Main 12 Causes of Overheating» .
>> INSPECTION END

I

PROCEDURE A

1. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

J

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E6.
Check voltage between IPDM E/R terminal 14 and ground with
CONSULT-II or tester.

K

Voltage: Battery voltage

L

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

M

MBIB1307E

2. DETECT MALFUNCTIONING PART
Check the following.
●
40A fusible link
●
Harness for open or short between IPDM E/R and battery
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1139

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITH EURO-OBD)]

3. CHECK COOLING FAN MOTOR CIRCUIT
1.

Disconnect cooling fan motor harness connector (1).

–

: Vehicle front
Disconnect IPDM E/R harness connectors E11 and E12.
Check harness continuity between cooling fan motor terminal 1
and IPDM E/R terminal 10, cooling fan motor terminal 2 and
ground.
Refer to wiring diagram.

2.
3.

Continuity should exist.
4.
5.

Also check harness for short to ground and short to power.
Check harness continuity between IPDM E/R terminal 12 and
cooling fan motor terminal 1.
Refer to wiring diagram.

MBIB1549E

Continuity should exist.
6.
7.

Also check harness for short to ground and short to power.
Check harness continuity between IPDM E/R terminals 3, 53 and ground.
Refer to Wiring Diagram.
Continuity should exist.

8. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness for open or short between cooling fan motor and IPDM E/R
●
Harness for open or short between cooling fan motor and ground
●
Harness for open or short between resistor and IPDM E/R
●
Harness for open or short between resistor and cooling fan motor
●
Resistor E62
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK COOLING FAN MOTOR
Refer to EC-1145, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace cooling fan motor.

6. CHECK INTERMITTENT INCIDENT
Perform EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connector.

EC-1140

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITH EURO-OBD)]
PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER
A

1. INSPECTION START
Do you have CONSULT-II?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.

EC

C

2. CHECK COOLING FAN OPERATION
With CONSULT-II
1. Turn ignition switch ON.
2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II and touch “LOW” on the CONSULT-II screen.
3. Make sure that cooling fan operates.
OK or NG
OK
>> GO TO4.
NG
>> Check cooling fan control circuit. (Go to EC-1142,
«PROCEDURE B» .)

D

E

F

G
SEF784Z

H

3. CHECK COOLING FAN OPERATION
Without CONSULT-II
1. Turn ignition switch OFF.
2. Disconnect engine coolant temperature sensor harness connector.
3. Connect 150Ω resistor to engine coolant temperature sensor harness connector.
4. Restart engine and make sure that cooling fan operates.
OK or NG
OK
>> GO TO 4.
NG
>> Check cooling fan speed control circuit. (Go to EC-1142,
«PROCEDURE B» .)

I

J

K

L

M
SEF023R

4. CHECK COOLING SYSTEM FOR LEAK
Refer to CO-27, «ENGINE COOLANT» .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

EC-1141

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITH EURO-OBD)]

5. DETECT MALFUNCTIONING PART
Check the following for leak.
●
Hose
●
Radiator
●
Water pump (Refer to CO-36, «WATER PUMP» .)
>> Repair or replace.

6. CHECK RADIATOR CAP
Refer to CO-34, «Checking Radiator Cap (All Models Except M/T with A/C)» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace radiator cap.

7. CHECK THERMOSTAT
Refer to CO-38, «THERMOSTAT» .
OK or NG
OK
>> GO TO 8.
NG
>> Replace thermostat.

8. CHECK ENGINE COOLANT TEMPERATURE SENSOR
Refer to EC-170, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace engine coolant temperature sensor.

9. CHECK MAIN 12 CAUSES
If the cause cannot be isolated, go to EC-1144, «Main 12 Causes of Overheating» .
>> INSPECTION END

PROCEDURE B

1. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E6.
Check voltage between IPDM E/R terminal 14 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

MBIB1307E

EC-1142

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITH EURO-OBD)]

2. DETECT MALFUNCTIONING PART

A

Check the following.
●
40A fusible link
●
Harness for open or short between IPDM E/R and battery

EC

>> Repair open circuit or short to ground or short to power in harness or connectors.

C

3. CHECK COOLING FAN MOTORS CIRCUIT
1.

Disconnect cooling fan motor harness connector (1).

–

: Vehicle front
Disconnect IPDM E/R harness connectors E11 and E12.
Check harness continuity between cooling fan motor terminal 1
and IPDM E/R terminal 10, cooling fan motor terminal 2 and
ground.
Refer to wiring diagram.

2.
3.

D

E

F

Continuity should exist.
4.
5.

Also check harness for short to ground and short to power.
Check harness continuity between IPDM E/R terminals 3, 53
and ground.
Refer to Wiring Diagram.

MBIB1549E

G

H

Continuity should exist.
6. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness for open or short between cooling fan motor and IPDM E/R
●
Harness for open or short between cooling fan motor and ground

I

J

K

L

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK COOLING FAN MOTOR

M

Refer to EC-1145, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace cooling fan motor.

6. CHECK INTERMITTENT INCIDENT
Perform EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connector.

EC-1143

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITH EURO-OBD)]

Main 12 Causes of Overheating
Engine

Step

OFF

1

Inspection item
●

Blocked radiator

●

Blocked condenser

●

Blocked radiator grille

●

Blocked bumper

2

●

3

4*5

BBS004V9

Equipment

Standard

Reference page

●

Visual

No blocking

Coolant mixture

●

Coolant tester

50 — 50% coolant mixture

See MA-26, «Engine
Coolant Mixture Ratio» .

●

Coolant level

●

Visual

Coolant up to MAX level
in reservoir tank and radiator filler neck

See CO-27, «LEVEL
CHECK» .

●

Radiator cap

●

Pressure tester

59 — 98 kPa
(0.59 — 0.98 bar, 0.6 — 1.0

See CO-34, «Checking
Radiator Cap (All Models
Except M/T with A/C)» .

kg/cm2 , 9 — 14 psi) (Limit)
88 kPa (0.88 bar, 0.90 kg/

—

See CO-35, «Checking
Reservoir Tank Cap (M/T
with A/C Models)» .

4*6

●

Reservoir tank cap

●

Pressure tester

ON*2

5

●

Coolant leaks

●

Visual

No leaks

See CO-27, «LEAK
CHECK» .

ON*2

6

●

Thermostat

●

Touch the upper and
lower radiator hoses

Both hoses should be hot

See CO-38, «THERMOSTAT» , and CO-31,
«RADIATOR» .

ON*1

7

●

Cooling fan

●

CONSULT-II

Operating

See trouble diagnosis for
DTC P1217 (EC-1137,
«Diagnostic Procedure» ).

OFF

8

●

Combustion gas leak

●

Color checker chemical
tester 4 Gas analyzer

Negative

—

ON*3

9

●

Coolant temperature
gauge

●

Visual

Gauge less than 3/4
when driving

—

●

Coolant overflow to
reservoir tank

●

Visual

No overflow during driving
and idling

See MA-39, «Changing
Engine Coolant» .

cm2 , 12.8psi)

OFF*4

10

●

Coolant return from
reservoir tank to radiator

●

Visual

Should be initial level in
reservoir tank

See CO-27, «LEVEL
CHECK» .

OFF

11

●

Cylinder head

●

Straight gauge feeler
gauge

0.1 mm (0.004 in) Maximum distortion (warping)

See EM-173, «CYLINDER HEAD» .

12

●

Cylinder block and pistons

●

Visual

No scuffing on cylinder
walls or piston

See EM-189, «CYLINDER BLOCK» .

*1: Turn the ignition switch ON.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
*5: M/T models without A/C and A/T models.
*6: M/T models with A/C.
For more information, refer to CO-24, «OVERHEATING CAUSE ANALYSIS» .

EC-1144

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITH EURO-OBD)]

Component Inspection

BBS004VA

A

COOLING FAN MOTOR
1.
2.

Disconnect cooling fan motor harness connectors.
Supply cooling fan motor terminals with battery voltage and
check operation.

EC

Terminals

Cooling fan motor

(+)

(-)

1

2

C

D
MBIB0607E

E

F

G

H

I

J

K

L

M

EC-1145

DTC P1225 TP SENSOR
[HR (WITH EURO-OBD)]

DTC P1225 TP SENSOR
Component Description

PFP:16119
BBS004H9

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

PBIB0145E

On Board Diagnosis Logic

BBS004HA

The MI will not light up for this diagnosis.
DTC No.
P1225
1225

Trouble diagnosis name

DTC detecting condition

Closed throttle position
learning performance

Closed throttle position learning value is excessively low.

DTC Confirmation Procedure

Possible cause
●

Electric throttle control actuator
(TP sensor 1 and 2)
BBS004HB

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON.
If 1st trip DTC is detected, go to EC-1147, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-1146

DTC P1225 TP SENSOR
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004HC

1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY
1.
2.
3.

A

Turn ignition switch OFF.
Remove the intake air duct.
Check if foreign matter is caught between the throttle valve (1)
and the housing.

EC

C

: Vehicle front
–
Illustration shows the view with intake air duct removed.
OK or NG
OK
>> GO TO 2.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.
–

D

E
PBIB2974E

2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR

F

1.
2.
3.

G

Replace the electric throttle control actuator.
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .

H

>> INSPECTION END

Removal and Installation

BBS004HD

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-120, «INTAKE MANIFOLD» .

I

J

K

L

M

EC-1147

DTC P1226 TP SENSOR
[HR (WITH EURO-OBD)]

DTC P1226 TP SENSOR
Component Description

PFP:16119
BBS004HE

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

PBIB0145E

On Board Diagnosis Logic

BBS004HF

The MI will not light up for this diagnosis.
DTC No.
P1226
1226

Trouble diagnosis name
Closed throttle position
learning performance

DTC detecting condition
Closed throttle position learning is not performed successfully, repeatedly.

DTC Confirmation Procedure

Possible cause
●

Electric throttle control actuator
(TP sensor 1 and 2)
BBS004HG

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON.
Repeat steps 3 and 4 for 32 times.
If 1st trip DTC is detected, go to EC-1149, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-1148

DTC P1226 TP SENSOR
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004HH

1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY
1.
2.
3.

A

Turn ignition switch OFF.
Remove the intake air duct.
Check if foreign matter is caught between the throttle valve (1)
and the housing.

EC

C

: Vehicle front
–
Illustration shows the view with intake air duct removed.
OK or NG
OK
>> GO TO 2.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.
–

D

E
PBIB2974E

2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR

F

1.
2.
3.

G

Replace the electric throttle control actuator.
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .

H

>> INSPECTION END

Removal and Installation

BBS004HI

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-120, «INTAKE MANIFOLD» .

I

J

K

L

M

EC-1149

DTC P1229 SENSOR POWER SUPPLY
[HR (WITH EURO-OBD)]

DTC P1229 SENSOR POWER SUPPLY
On Board Diagnosis Logic

PFP:16119
BBS004HJ

This self-diagnosis has the one trip detection logic.
DTC No.

P1229
1229

Trouble diagnosis
name

Sensor power supply
circuit short

DTC detecting condition

Possible cause
●

Harness or connectors
(APP sensor 1 circuit is shorted.)
(Throttle position sensor circuit is shorted.)
[Camshaft position sensor (PHASE) circuit is
shorted.]

●

Accelerator pedal position sensor

●

Throttle position sensor

●

Camshaft position sensor (PHASE)

ECM detects a voltage of power source for
sensor is excessively low or high.

FAIL-SAFE MODE
When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.

DTC Confirmation Procedure

BBS004HK

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-1155, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-1150

DTC P1229 SENSOR POWER SUPPLY
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004HL

A

LHD MODELS

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1477E

EC-1151

DTC P1229 SENSOR POWER SUPPLY
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

72

L

Sensor power supply
(Throttle position sensor)

[Ignition switch: ON]

Approximately 5V

78

O

Sensor power supply
[Camshaft position sensor
(PHASE)]

[Ignition switch: ON]

Approximately 5V

102

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

103

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Engine is running]
104

106

B

Sensor ground
(APP sensor 2)

O

Sensor power supply
(APP sensor 1)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]

Approximately 0V

Approximately 5V

[Ignition switch: ON]

110

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

[Engine is running]
111

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

EC-1152

Approximately 0V

DTC P1229 SENSOR POWER SUPPLY
[HR (WITH EURO-OBD)]
RHD MODELS
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1478E

EC-1153

DTC P1229 SENSOR POWER SUPPLY
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

72

L

Sensor power supply
(Throttle position sensor)

[Ignition switch: ON]

Approximately 5V

78

O

Sensor power supply
[Camshaft position sensor
(PHASE)]

[Ignition switch: ON]

Approximately 5V

102

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

103

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Engine is running]
104

106

B

Sensor ground
(APP sensor 2)

O

Sensor power supply
(APP sensor 1)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]

Approximately 0V

Approximately 5V

[Ignition switch: ON]

110

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

[Engine is running]
111

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

EC-1154

Approximately 0V

DTC P1229 SENSOR POWER SUPPLY
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004HM

1. CHECK GROUND CONNECTIONS
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

EC

C

D

E
MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

F

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

G

2. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT
1.
–
–

2.

H

Disconnect accelerator pedal position (APP) sensor harness
connector (1).
Accelerator pedal position sensor (2)
Accelerator pedal (3)
Turn ignition switch ON.

I

J

K
PBIB2975E

3.

L

Check voltage between APP sensor terminal 4 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

M

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.

PBIA9606J

EC-1155

DTC P1229 SENSOR POWER SUPPLY
[HR (WITH EURO-OBD)]

3. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between APP sensor terminal 4 and ECM terminal 106.
Refer to Wiring Diagram.
Continuity should exist.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
>> Repair open circuit.

5. CHECK SENSOR POWER SUPPLY CIRCUITS
Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

72

Throttle position sensor terminal 1

EC-1193, «Wiring Diagram»

78

Camshaft position sensor (PHASE) terminal 1

EC-1051, «Wiring Diagram»

106

APP sensor terminal 4

EC-1151, «Wiring Diagram»

OK or NG
OK
>> GO TO 6.
NG
>> Repair short to ground or short to power in harness or connectors.

6. CHECK COMPONENTS
Check the following.
●
Throttle position sensor (Refer to EC-1196, «Component Inspection» .)
●
Camshaft position sensor (PHASE) (Refer to EC-1054, «Component Inspection» .)
OK or NG
OK
>> GO TO 7.
NG
>> Replace malfunctioning component.

7. CHECK APP SENSOR
Refer to EC-1206, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.

EC-1156

DTC P1229 SENSOR POWER SUPPLY
[HR (WITH EURO-OBD)]

8. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace accelerator pedal assembly.
Perform EC-857, «Accelerator Pedal Released Position Learning» .
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .

A

EC

C

>> INSPECTION END

9. CHECK INTERMITTENT INCIDENT

D

Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
E

>> INSPECTION END

F

G

H

I

J

K

L

M

EC-1157

DTC P1706 PNP SWITCH
[HR (WITH EURO-OBD)]

DTC P1706 PNP SWITCH
Component Description

PFP:32006
BBS004HN

When the shift lever position is P or N (A/T), Neutral (M/T), park/neutral position (PNP) switch is ON.
ECM detects the position because the continuity of the line (the ON signal) exists.

CONSULT-II Reference Value in Data Monitor Mode

BBS004HO

Specification data are reference values.
MONITOR ITEM
P/N POSI SW

CONDITION
●

Ignition switch: ON

SPECIFICATION

Shift lever: P or N (A/T), Neutral (M/T)

ON

Shift lever: Except above

OFF

On Board Diagnosis Logic
DTC No.
P1706
1706

BBS004HP

Trouble diagnosis name

DTC detecting condition

Park/neutral position switch

The signal of the park/neutral position (PNP)
switch is not changed in the process of
engine starting and driving.

DTC Confirmation Procedure

Possible cause
●

Harness or connectors
(PNP switch circuit is open or shorted.)

●

Park/neutral position (PNP) switch
BBS004HQ

CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.

Turn ignition switch ON.
Select “P/N POSI SW” in “DATA MONITOR” mode with CONSULT-II. Then check the “P/N POSI SW” signal under the following conditions.
Position (Shift lever)

Known-good signal

N or P position (A/T)
Neutral position (M/T)

ON

Except above position

OFF

3.
4.
5.

If NG, go to EC-1163, «Diagnostic Procedure» .
If OK, go to following step.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and warm it up to normal operating temperature.
Maintain the following conditions for at least 60 consecutive seconds.

ENG SPEED

A/T: 1,650 — 6,375 rpm
M/T: 1,925 — 6,375 rpm

COOLAN TEMP/S

More than 70°C (158°F)

B/FUEL SCHDL

A/T: 3.5 — 31.8 msec
M/T: 2.5 — 31.8 msec

VHCL SPEED SE

More than 64km/h (29 MPH)

Shift lever

Suitable position

SEF212Y

SEF213Y

6.

If 1st trip DTC is detected, go to EC-1163, «Diagnostic Procedure» .

EC-1158

DTC P1706 PNP SWITCH
[HR (WITH EURO-OBD)]

Overall Function Check

BBS004HR

Use this procedure to check the overall function of the park/neutral position (PNP) switch circuit. During this
check, a 1st trip DTC might not be confirmed.

WITH GST
1.
2.

EC

Turn ignition switch ON.
Check voltage between ECM terminal 70 (PNP switch signal)
and ground under the following conditions.
Condition (Shift lever)

C

Voltage V (Known-good data)

P or N position (A/T)
Neutral position (M/T)

Approx. 0

Except above position

BATTERY VOLTAGE
(11 — 14V)

3.

A

D

E

If NG, go to EC-1163, «Diagnostic Procedure» .
MBIB1397E

F

G

H

I

J

K

L

M

EC-1159

DTC P1706 PNP SWITCH
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004HS

A/T MODELS

MBWA1479E

EC-1160

DTC P1706 PNP SWITCH
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

EC
ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch: ON]
70

GR

A

Park/Neutral position
(PNP) switch

●

Shift lever: P or N (A/T models)

●

Shift lever: Neutral (M/T models)

[Ignition switch: ON]
●

Except above position

C
Approximately 0V

BATTERY VOLTAGE
(11 — 14V)

D

E

F

G

H

I

J

K

L

M

EC-1161

DTC P1706 PNP SWITCH
[HR (WITH EURO-OBD)]
M/T MODELS

MBWA1480E

EC-1162

DTC P1706 PNP SWITCH
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

EC

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch: ON]
70

GR

Park/Neutral position
(PNP) switch

●

Shift lever: P or N (A/T models)

●

Shift lever: Neutral (M/T models)

[Ignition switch: ON]
●

Except above position

Diagnostic Procedure

C
Approximately 0V

D

BATTERY VOLTAGE
(11 — 14V)
BBS004HT

1. CHECK PNP SWITCH CIRCUIT
1.
2.

A

Turn ignition switch ON.
Check voltage between IPDM E/R terminal 31 and ground under
following condition.
Shift lever position

F

G

Voltage

P or N (A/T models)
Neutral (M/T models)

Battery voltage (11- 14V)

Except above position

Approximately 0V

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 2.

E

H

I
MBIB0652E

J

K

L

M

EC-1163

DTC P1706 PNP SWITCH
[HR (WITH EURO-OBD)]

2. CHECK PNP SWITCH POWER SUPPLY CIRCUIT
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect PNP switch harness connector.
Turn ignition switch ON.
Check voltage between PNP switch terminal 1 (A/T models), 2
(M/T models) and ground with CONSULT-II or tester.

MBIB0654E

MBIB0653E

Voltage: Battery voltage
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

3. DETECT MALFUNCTIONING PARTS
Check the following.
●
10A fuse
●
Harness connectors E59, F1
●
IPDM E/R connector E7
●
Harness for short or open between PNP switch and fuse
>> Repair or replace harness or connectors.

EC-1164

DTC P1706 PNP SWITCH
[HR (WITH EURO-OBD)]

4. CHECK HARNESS CONTINUTY BETWEEN PNP SWITCH AND IPDM E/R
1.
2.
3.

A
Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between IPDM E/R terminal 31 and PNP switch terminal 2 (A/T models), 3 (M/T EC
models).Refer to Wiring Diagram.

Continuity should exist.

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. DETECT MALFUNCTIONING PART

D

E

Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between IPDM E/R and PNP switch
>> Repair open circuit or short to ground or short to power in harness or connectors.

F

G

6. CHECK PNP SWITCH
Refer to AT-109, «Component Inspection» (A/T models) or MT-16, «Park/Neutral Position Switch» (M/T models).
OK or NG
OK
>> GO TO 7.
NG
>> Replace PNP switch.

7. CHECK INTERMITTENT INCIDENT

H

I

J

Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
K

>> INSPECTION END

8. CHECK PNP SWITCH GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connectors E11 and E12.
Check harness continuity between IPDM E/R terminal 3, 54 and ground.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to power.
OK or NG
OK
>> GO TO 9.
NG
>> Repair open circuit or short to power in harness or connectors.

EC-1165

L

M

DTC P1706 PNP SWITCH
[HR (WITH EURO-OBD)]

9. CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Disconnect IPDM E/R harness connector E5
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 70 and IPDM E/R terminal 64.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 10.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

10. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace.

EC-1166

DTC P1805 BRAKE SWITCH
[HR (WITH EURO-OBD)]

DTC P1805 BRAKE SWITCH
Description

PFP:25320

A
BBS004HU

Brake switch signal is applied to the ECM through the stop lamp switch when the brake pedal is depressed.
This signal is used mainly to decrease the engine speed when the vehicle is driving.
EC

CONSULT-II Reference Value in Data Monitor Mode

BBS004HV

Specification data are reference values.

C

MONITOR ITEM
BRAKE SW

CONDITION
●

Ignition switch: ON

SPECIFICATION

Brake pedal: Fully released

OFF

Brake pedal: Slightly depressed

ON

On Board Diagnosis Logic

D
BBS004HW

E

The MI will not light up for this self-diagnosis.
DTC No.

Trouble diagnosis name

P1805
1805

Brake switch

DTC detecting condition
A brake switch signal is not sent to ECM for
extremely long time while the vehicle is driving.

Possible cause
●

Harness or connectors
(Stop lamp switch circuit is open or shorted.)

●

Stop lamp switch

FAIL-SAFE MODE

BBS004HX

F

G

When the malfunction is detected, the ECM enters in fail-safe mode.
H

Engine operation condition in fail-fail safe mode
ECM controls the electric throttle control actuator by regulating the throttle opening to a small range.
Therefore, acceleration will be poor.
Vehicle condition

Driving condition

When engine is idling

Normal

When accelerating

Poor acceleration

DTC Confirmation Procedure

I

J
BBS004HY

WITH CONSULT-II
1.
2.
3.
4.
5.

K

Turn ignition switch ON.
Fully depress the brake pedal for at least 5 seconds.
Erase the DTC with CONSULT-II.
Select “DATA MONITOR” mode with CONSULT-II.
If 1st trip DTC is detected, go to EC-1169, «Diagnostic Procedure» .

L

M

PBIB1952E

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-1167

DTC P1805 BRAKE SWITCH
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004HZ

MBWA1481E

EC-1168

DTC P1805 BRAKE SWITCH
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

EC

WIRE
COLOR

ITEM

CONDITION
[Ignition switch: OFF]
●

99

R

Stop lamp switch

Brake pedal: Fully released

[Ignition switch: OFF]
●

Brake pedal: Slightly depressed

DATA (DC Voltage)

C

Approximately 0V
BATTERY VOLTAGE
(11 — 14V)

Diagnostic Procedure

D
BBS004I0

1. CHECK STOP LAMP SWITCH CIRCUIT
1.
2.

E

Turn ignition switch OFF.
Check the stop lamp when depressing and releasing the brake pedal.
Brake pedal

Stop lamp

Fully released

Not illuminated

Slightly depressed

Illuminated

F

G

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 2.

H

2. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT
1.
–

A

I

Disconnect stop lamp switch (1) harness connector.
Brake pedal (2)
J

K

L
PBIB2976E

2.

M

Check voltage between stop lamp switch terminal 1 and ground with CONSULT-II or tester.

PBIB2284E

Voltage: Battery voltage
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

EC-1169

DTC P1805 BRAKE SWITCH
[HR (WITH EURO-OBD)]

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M1, E101 (LHD models)
●
Harness connectors M8, M201 (RHD models)
●
10A fuse
●
Harness for open and short between stop lamp switch and battery
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
–

2.
3.

Disconnect stop lamp switch (1) harness connector.
Brake pedal (2)
Disconnect ECM harness connector.
Check harness continuity between stop lamp switch terminal 2
and ECM terminal 99.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M8, M201 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open and short between stop lamp switch and ECM
>> Repair open circuit or short to ground or short to power in harness connectors.

6. CHECK STOP LAMP SWITCH
Refer to EC-1171, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace stop lamp switch.

7. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1170

PBIB2976E

DTC P1805 BRAKE SWITCH
[HR (WITH EURO-OBD)]

Component Inspection

BBS004I1

A

STOP LAMP SWITCH
1.
2.
3.

Turn ignition switch OFF.
Disconnect stop lamp switch harness connector.
Check continuity between stop lamp switch terminals 1 and 2 under the following conditions.

EC

C

D

E
PBIB2285E

Condition
Brake pedal: Fully released.
Brake pedal: Slightly depressed.

Continuity

F

Should not exist.
Should exist.

G

If NG, adjust stop lamp switch installation, refer to BR-6, «BRAKE PEDAL» , and perform step 3 again.
H

I

J

K

L

M

EC-1171

DTC P2122, P2123 APP SENSOR
[HR (WITH EURO-OBD)]

DTC P2122, P2123 APP SENSOR
Component Description

PFP:18002
BBS004I2

The accelerator pedal position sensor is installed on the upper end
of the accelerator pedal assembly. The sensor detects the accelerator position and sends a signal to the ECM.
Accelerator pedal position sensor has two sensors. These sensors
are a kind of potentiometers which transform the accelerator pedal
position into output voltage, and emit the voltage signal to the ECM.
In addition, these sensors detect the opening and closing speed of
the accelerator pedal and feed the voltage signals to the ECM. The
ECM judges the current opening angle of the accelerator pedal from
these signals and controls the throttle control motor based on these
signals.
PBIB1741E
Idle position of the accelerator pedal is determined by the ECM
receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut.

CONSULT-II Reference Value in Data Monitor Mode

BBS004I3

Specification data are reference values.
MONITOR ITEM
ACCEL SEN 1

ACCEL SEN 2*

CLSD THL POS

CONDITION
●

●

●

SPECIFICATION

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

4.0 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

3.9 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage.

On Board Diagnosis Logic

BBS004I4

These self-diagnoses have the one trip detection logic.
NOTE:
If DTC P2122 or P2123 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229.
Refer to EC-1150, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

Trouble diagnosis name

DTC detecting condition

P2122
2122

Accelerator pedal position
sensor 1 circuit low input

An excessively low voltage from the APP
sensor 1 is sent to ECM.

P2123
2123

Accelerator pedal position
sensor 1 circuit high input

An excessively high voltage from the APP
sensor 1 is sent to ECM.

Possible cause
●

Harness or connectors
(APP sensor 1 circuit is open or
shorted.)

●

Accelerator pedal position sensor
(APP sensor 1)

FAIL-SAFE MODE
When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-1172

DTC P2122, P2123 APP SENSOR
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004I5

A
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
EC
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

C

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-1177, «Diagnostic Procedure» .

D

E

F
SEF058Y

WITH GST

G

Follow the procedure “WITH CONSULT-II” above.
H

I

J

K

L

M

EC-1173

DTC P2122, P2123 APP SENSOR
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004I6

LHD MODELS

MBWA1482E

EC-1174

DTC P2122, P2123 APP SENSOR
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
102

WIRE
COLOR
BR

A

EC
ITEM
Sensor power supply
(APP sensor 2)

CONDITION

[Ignition switch: ON]

DATA (DC Voltage)

Approximately 5V

C

0.3 — 0.6V

D

1.95 — 2.4V

E

Approximately 0V

F

Approximately 5V

G

[Ignition switch: ON]

103

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

[Engine is running]
104

106

B

O

Sensor ground
(APP sensor 2)
Sensor power supply
(APP sensor 1)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]
[Ignition switch: ON]

110

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

H

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

I

Approximately 0V

J

[Engine is running]
111

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

K

L

M

EC-1175

DTC P2122, P2123 APP SENSOR
[HR (WITH EURO-OBD)]
RHD MODELS

MBWA1483E

EC-1176

DTC P2122, P2123 APP SENSOR
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
102

WIRE
COLOR
BR

A

EC
ITEM

CONDITION

Sensor power supply
(APP sensor 2)

DATA (DC Voltage)

[Ignition switch: ON]

Approximately 5V

C

0.3 — 0.6V

D

1.95 — 2.4V

E

Approximately 0V

F

Approximately 5V

G

[Ignition switch: ON]

103

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

[Engine is running]
104

106

B

O

Sensor ground
(APP sensor 2)
Sensor power supply
(APP sensor 1)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]
[Ignition switch: ON]

110

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

H

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

I

Approximately 0V

J

[Engine is running]
111

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

Diagnostic Procedure

BBS004I7

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

K

L

M

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1177

3.

Body ground

DTC P2122, P2123 APP SENSOR
[HR (WITH EURO-OBD)]

2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT
1.
–
–

2.

Disconnect accelerator pedal position (APP) sensor harness
connector (1).
Accelerator pedal position sensor (2)
Accelerator pedal (3)
Turn ignition switch ON.

PBIB2975E

3.

Check voltage between APP sensor terminal 4 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

PBIA9606J

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK APP SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 111 and APP sensor terminal 2.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1178

DTC P2122, P2123 APP SENSOR
[HR (WITH EURO-OBD)]

6. CHECK APP SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

A

Check harness continuity between ECM terminal 110 and APP sensor terminal 3.
Refer to Wiring Diagram.
EC

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

C

7. DETECT MALFUNCTIONING PART

D

Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM

E

F

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK APP SENSOR

G

Refer to EC-1180, «Component Inspection» .
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 9.

H

9. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace accelerator pedal assembly.
Perform EC-857, «Accelerator Pedal Released Position Learning» .
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .

I

J

K

>> INSPECTION END
L

10. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

M

>> INSPECTION END

EC-1179

DTC P2122, P2123 APP SENSOR
[HR (WITH EURO-OBD)]

Component Inspection

BBS004I8

ACCELERATOR PEDAL POSITION SENSOR
1.
2.
3.

Reconnect all harness connectors disconnected.
Turn ignition switch ON.
Check voltage between ECM terminals 110 (APP sensor 1 signal), 103 (APP sensor 2 signal) and ground under the following
conditions.
Terminal

Accelerator pedal

Voltage

110
(Accelerator pedal position
sensor 1)

Fully released

0.6 — 0.9V

Fully depressed

3.9 — 4.7V

Fully released

0.3 — 0.6V

Fully depressed

1.95 — 2.4V

103
(Accelerator pedal position
sensor 2)

4.
5.
6.
7.

PBIA9572J

If NG, replace accelerator pedal assembly and go to next step.
Perform EC-857, «Accelerator Pedal Released Position Learning» .
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .

Removal and Installation

BBS004I9

ACCELERATOR PEDAL
Refer to ACC-2, «ACCELERATOR CONTROL SYSTEM» .

EC-1180

DTC P2127, P2128 APP SENSOR
[HR (WITH EURO-OBD)]

DTC P2127, P2128 APP SENSOR
Component Description

PFP:18002

A
BBS004IA

The accelerator pedal position sensor is installed on the upper end
of the accelerator pedal assembly. The sensor detects the acceleraEC
tor position and sends a signal to the ECM.
Accelerator pedal position sensor has two sensors. These sensors
are a kind of potentiometers which transform the accelerator pedal
C
position into output voltage, and emit the voltage signal to the ECM.
In addition, these sensors detect the opening and closing speed of
the accelerator pedal and feed the voltage signals to the ECM. The
ECM judges the current opening angle of the accelerator pedal from
D
these signals and controls the throttle control motor based on these
signals.
PBIB1741E
Idle position of the accelerator pedal is determined by the ECM
E
receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut.

CONSULT-II Reference Value in Data Monitor Mode

BBS004IB

F

Specification data are reference values.
MONITOR ITEM
ACCEL SEN 1

ACCEL SEN 2*

CLSD THL POS

CONDITION
●

●

●

SPECIFICATION

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

4.0 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

3.9 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

G

H

I

*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage.

On Board Diagnosis Logic

BBS004IC

J

These self-diagnoses have the one trip detection logic.
DTC No.
P2127
2127

P2128
2128

Trouble diagnosis name
Accelerator pedal position
sensor 2 circuit low input

Accelerator pedal position
sensor 2 circuit high input

DTC detecting condition
An excessively low voltage from the APP
sensor 2 is sent to ECM.

An excessively high voltage from the APP
sensor 2 is sent to ECM.

Possible cause
●

Harness or connectors
(APP sensor 2 circuit is open or shorted.)
[Crankshaft position sensor (POS) circuit
is shorted.]
(Refrigerant pressure sensor circuit is
shorted.)

●

Accelerator pedal position sensor
(APP sensor 2)

●

Crankshaft position sensor (POS)

●

Refrigerant pressure sensor

FAIL-SAFE MODE
When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-1181

K

L

M

DTC P2127, P2128 APP SENSOR
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004ID

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-1187, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-1182

DTC P2127, P2128 APP SENSOR
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004IE

A

LHD MODELS

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1484E

EC-1183

DTC P2127, P2128 APP SENSOR
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

74

W

Sensor power supply
(Refrigerant pressure sensor)

[Ignition switch: ON]

Approximately 5V

75

G

Sensor power supply
[Crankshaft position sensor
(POS)]

[Ignition switch: ON]

Approximately 5V

102

B

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

103

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Engine is running]
104

106

B

O

Sensor ground
(APP sensor 2)
Sensor power supply
(APP sensor 1)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]

Approximately 0V

Approximately 5V

[Ignition switch: ON]

110

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

[Engine is running]
111

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

EC-1184

Approximately 0V

DTC P2127, P2128 APP SENSOR
[HR (WITH EURO-OBD)]
RHD MODELS
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1485E

EC-1185

DTC P2127, P2128 APP SENSOR
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

74

W

Sensor power supply
(Refrigerant pressure sensor)

[Ignition switch: ON]

Approximately 5V

75

G

Sensor power supply
[Crankshaft position sensor
(POS)]

[Ignition switch: ON]

Approximately 5V

102

B

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

103

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Engine is running]
104

106

B

O

Sensor ground
(APP sensor 2)
Sensor power supply
(APP sensor 1)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]

Approximately 0V

Approximately 5V

[Ignition switch: ON]

110

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

[Engine is running]
111

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

EC-1186

Approximately 0V

DTC P2127, P2128 APP SENSOR
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004IF

1. CHECK GROUND CONNECTIONS
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

EC

C

D

E
MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

F

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

G

2. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I
1.
–
–

2.

H

Disconnect accelerator pedal position (APP) sensor harness
connector (1).
Accelerator pedal position sensor (2)
Accelerator pedal (3)
Turn ignition switch ON.

I

J

K
PBIB2975E

3.

Check voltage between APP sensor terminal 5 and ground with
CONSULT-II or tester.

L

Voltage: Approximately 5V
M

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.

PBIA9607J

EC-1187

DTC P2127, P2128 APP SENSOR
[HR (WITH EURO-OBD)]

3. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between APP sensor terminal 5 and ECM terminal 102.
Refer to Wiring Diagram.
Continuity should exist.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
>> Repair open circuit in harness or connectors.

5. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III
Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

74

Refrigerant pressure sensor terminal 3

EC-1232, «Wiring Diagram»

75

Crankshaft position sensor (POS) terminal 1

EC-1044, «Wiring Diagram»

102

APP sensor terminal 5

EC-1183, «Wiring Diagram»

OK or NG
OK
>> GO TO 6.
NG
>> Repair short to ground or short to power in harness or connectors.

6. CHECK COMPONENTS
Check the following.
●
Crankshaft position sensor (POS) (Refer to EC-1048, «Component Inspection» .)
●
Refrigerant pressure sensor (Refer to ATC-85, «Refrigerant Pressure Sensor» .)
OK or NG
OK
>> GO TO 13.
NG
>> Replace malfunctioning component.

7. CHECK APP SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 104 and APP sensor terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.

EC-1188

DTC P2127, P2128 APP SENSOR
[HR (WITH EURO-OBD)]

8. DETECT MALFUNCTIONING PART

A

Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

9. CHECK APP SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

EC

C

D

Check harness continuity between ECM terminal 103 and APP sensor terminal 6.
Refer to Wiring Diagram.
E

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

F

10. DETECT MALFUNCTIONING PART

G

Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM

H

I

>> Repair open circuit or short to ground or short to power in harness or connectors.

11. CHECK APP SENSOR

J

Refer to EC-1190, «Component Inspection» .
OK or NG
OK
>> GO TO 13.
NG
>> GO TO 12.

K

12. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace accelerator pedal assembly.
Perform EC-857, «Accelerator Pedal Released Position Learning» .
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .
>> INSPECTION END

13. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1189

L

M

DTC P2127, P2128 APP SENSOR
[HR (WITH EURO-OBD)]

Component Inspection

BBS004IG

ACCELERATOR PEDAL POSITION SENSOR
1.
2.
3.

Reconnect all harness connectors disconnected.
Turn ignition switch ON.
Check voltage between ECM terminals 110 (APP sensor 1 signal), 103 (APP sensor 2 signal) and ground under the following
conditions.
Terminal

Accelerator pedal

Voltage

110
(Accelerator pedal position
sensor 1)

Fully released

0.6 — 0.9V

Fully depressed

3.9 — 4.7V

Fully released

0.3 — 0.6V

Fully depressed

1.95 — 2.4V

103
(Accelerator pedal position
sensor 2)

4.
5.
6.
7.

PBIA9572J

If NG, replace accelerator pedal assembly and go to next step.
Perform EC-857, «Accelerator Pedal Released Position Learning» .
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .

Removal and Installation

BBS004IH

ACCELERATOR PEDAL
Refer to ACC-2, «ACCELERATOR CONTROL SYSTEM» .

EC-1190

DTC P2135 TP SENSOR
[HR (WITH EURO-OBD)]

DTC P2135 TP SENSOR
Component Description

PFP:16119

A
BBS004II

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

EC

C

D
PBIB0145E

E

CONSULT-II Reference Value in Data Monitor Mode

BBS004IJ

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

More than 0.36V

●

Shift lever: D (A/T), 1st (M/T)

Accelerator pedal: Fully depressed

Less than 4.75V

THRTL SEN 1
THRTL SEN 2*

F

SPECIFICATION

G

*: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic

BBS004IK

This self-diagnosis has the one trip detection logic.
NOTE:
If DTC P2135 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to
EC-1150, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

P2135
2135

Trouble diagnosis name

DTC detecting condition

Throttle position sensor
circuit range/performance

Rationally incorrect voltage is sent to ECM
compared with the signals from TP sensor 1
and TP sensor 2.

Possible cause
●

Harness or connector
(TP sensor 1 and 2 circuit is open or
shorted.)

●

Electric throttle control actuator
(TP sensor 1 and 2)

H

I

J

K

L

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-1191

M

DTC P2135 TP SENSOR
[HR (WITH EURO-OBD)]

DTC Confirmation Procedure

BBS004IL

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-1194, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-1192

DTC P2135 TP SENSOR
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004IM

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1486E

EC-1193

DTC P2135 TP SENSOR
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch: ON]

33

Y

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

Throttle position sensor 1

More than 0.36V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

Less than 4.75V

[Ignition switch: ON]

34

R

Throttle position sensor 2

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

Less than 4.75V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

More than 0.36V

[Engine is running]
36

72

BR

L

Sensor ground
(Throttle position sensor)
Sensor power supply
(Throttle position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Ignition switch: ON]

Approximately 5V

Diagnostic Procedure

BBS004IN

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1194

3.

Body ground

DTC P2135 TP SENSOR
[HR (WITH EURO-OBD)]

2. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT
1.

2.

A

Disconnect electric throttle control actuator (1) harness connector.
: Vehicle front
Turn ignition switch ON.

EC

C

D
PBIB2965E

3.

Check voltage between electric throttle control actuator terminal
1 and ground with CONSULT-II or tester.

E

Voltage: Approximately 5V
F

OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

G

PBIA9580J

H

3. CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 36.
Refer to Wiring Diagram.

I

J

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

K

L

4. CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between electric throttle control actuator terminal 2 and ECM terminal 33, electric throttle control actuator terminal 3 and ECM terminal 34.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK THROTTLE POSITION SENSOR
Refer to EC-1196, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

EC-1195

M

DTC P2135 TP SENSOR
[HR (WITH EURO-OBD)]

6. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .
>> INSPECTION END

7. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004IO

THROTTLE POSITION SENSOR
1.
2.
3.
4.
5.

Reconnect all harness connectors disconnected.
Perform EC-857, «Throttle Valve Closed Position Learning» .
Turn ignition switch ON.
Set shift lever to D position (A/T) or 1st position (M/T).
Check voltage between ECM terminals 33 (TP sensor 1 signal),
34 (TP sensor 2 signal) and ground under the following conditions.
Terminal

Accelerator pedal

Voltage

33
(Throttle position sensor 1)

Fully released

More than 0.36V

Fully depressed

Less than 4.75V

Fully released

Less than 4.75V

Fully depressed

More than 0.36V

34
(Throttle position sensor 2)

6.
7.
8.

If NG, replace electric throttle control actuator and go to the next
step.
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .

Removal and Installation

PBIB3038E

BBS004IP

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-120, «INTAKE MANIFOLD» .

EC-1196

DTC P2138 APP SENSOR
[HR (WITH EURO-OBD)]

DTC P2138 APP SENSOR
Component Description

PFP:18002

A
BBS004IQ

The accelerator pedal position sensor is installed on the upper end
of the accelerator pedal assembly. The sensor detects the acceleraEC
tor position and sends a signal to the ECM.
Accelerator pedal position sensor has two sensors. These sensors
are a kind of potentiometers which transform the accelerator pedal
C
position into output voltage, and emit the voltage signal to the ECM.
In addition, these sensors detect the opening and closing speed of
the accelerator pedal and feed the voltage signals to the ECM. The
ECM judges the current opening angle of the accelerator pedal from
D
these signals and controls the throttle control motor based on these
signals.
PBIB1741E
Idle position of the accelerator pedal is determined by the ECM
E
receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut.

CONSULT-II Reference Value in Data Monitor Mode

BBS004IR

F

Specification data are reference values.
MONITOR ITEM
ACCEL SEN 1

ACCEL SEN 2*

CLSD THL POS

CONDITION
●

●

●

SPECIFICATION

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

4.0 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

3.9 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

G

H

I

*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage.

On Board Diagnosis Logic

BBS004IS

This self-diagnosis has the one trip detection logic.
NOTE:
If DTC P2138 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to
EC-1150, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

Trouble diagnosis name

DTC detecting condition

Possible cause
●

P2138
2138

Accelerator pedal position sensor circuit
range/performance

Rationally incorrect voltage is sent to ECM
compared with the signals from APP sensor 1
and APP sensor 2.

EC-1197

Harness or connector
(APP sensor 1 and 2 circuit is open or
shorted.)
[Crankshaft position sensor (POS) circuit
is shorted.]
(Refrigerant pressure sensor circuit is
shorted.)

●

Accelerator pedal position sensor
(APP sensor 1 and 2)

●

Crankshaft position sensor (POS)

●

Refrigerant pressure sensor

J

K

L

M

DTC P2138 APP SENSOR
[HR (WITH EURO-OBD)]
FAIL-SAFE MODE
When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

DTC Confirmation Procedure

BBS004IT

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-1203, «Diagnostic Procedure» .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-1198

DTC P2138 APP SENSOR
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004IU

A

LHD MODELS

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1487E

EC-1199

DTC P2138 APP SENSOR
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

74

W

Sensor power supply
(Refrigerant pressure sensor)

[Ignition switch: ON]

Approximately 5V

75

G

Sensor power supply
[Crankshaft position sensor
(POS)]

[Ignition switch: ON]

Approximately 5V

102

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

103

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Engine is running]
104

106

B

O

Sensor ground
(APP sensor 2)
Sensor power supply
(APP sensor 1)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]

Approximately 0V

Approximately 5V

[Ignition switch: ON]

110

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

[Engine is running]
111

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

EC-1200

Approximately 0V

DTC P2138 APP SENSOR
[HR (WITH EURO-OBD)]
RHD MODELS
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1488E

EC-1201

DTC P2138 APP SENSOR
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

74

W

Sensor power supply
(Refrigerant pressure sensor)

[Ignition switch: ON]

Approximately 5V

75

G

Sensor power supply
[Crankshaft position sensor
(POS)]

[Ignition switch: ON]

Approximately 5V

102

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

103

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Engine is running]
104

106

B

O

Sensor ground
(APP sensor 2)
Sensor power supply
(APP sensor 1)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]

Approximately 0V

Approximately 5V

[Ignition switch: ON]

110

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

[Engine is running]
111

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

EC-1202

Approximately 0V

DTC P2138 APP SENSOR
[HR (WITH EURO-OBD)]

Diagnostic Procedure

BBS004IV

1. CHECK GROUND CONNECTIONS
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

EC

C

D

E
MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

F

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

G

2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT
1.
–
–

2.

H

Disconnect accelerator pedal position (APP) sensor harness
connector (1).
Accelerator pedal position sensor (2)
Accelerator pedal (3)
Turn ignition switch ON.

I

J

K
PBIB2975E

3.

Check voltage between APP sensor terminal 4 and ground with
CONSULT-II or tester.

L

Voltage: Approximately 5V
M

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

PBIA9606J

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1203

DTC P2138 APP SENSOR
[HR (WITH EURO-OBD)]

4. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I
1.
2.

Turn ignition switch ON.
Check voltage between APP sensor terminal 5 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 5.

PBIA9607J

5. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between APP sensor terminal 5 and ECM terminal 102.
Refer to Wiring Diagram.
Continuity should exist.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

6. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open between APP sensor and ECM
>> Repair open circuit in harness or connectors.

7. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III
Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

74

Refrigerant pressure sensor terminal 3

EC-1232, «Wiring Diagram»

75

Crankshaft position sensor (POS) terminal 1

EC-1044, «Wiring Diagram»

102

APP sensor terminal 5

EC-1199, «Wiring Diagram»

OK or NG
OK
>> GO TO 8.
NG
>> Repair short to ground or short to power in harness or connectors.

8. CHECK COMPONENTS
Check the following.
Crankshaft position sensor (POS) (Refer to EC-1048, «Component Inspection» .)
●
Refrigerant pressure sensor (Refer to ATC-85, «Refrigerant Pressure Sensor» .)
OK or NG
OK
>> GO TO 15.
NG
>> Replace malfunctioning component.
●

EC-1204

DTC P2138 APP SENSOR
[HR (WITH EURO-OBD)]

9. CHECK APP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

A
Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 111 and APP sensor terminal 2, ECM terminal 104 and EC
APP sensor terminal 1.
Refer to Wiring Diagram.
C
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

D

E

10. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open between APP sensor and ECM
●

F

G

>> Repair open circuit in harness or connectors.

11. CHECK APP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 110 and APP sensor terminal 3, ECM terminal 103 and
APP sensor terminal 6.
Refer to Wiring Diagram.

H

I

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 13.
NG
>> GO TO 12.

12. DETECT MALFUNCTIONING PART

J

K

L

Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open between APP sensor and ECM
>> Repair open circuit in harness or connectors.

13. CHECK APP SENSOR
Refer to EC-1206, «Component Inspection» .
OK or NG
OK
>> GO TO 15.
NG
>> GO TO 14.

EC-1205

M

DTC P2138 APP SENSOR
[HR (WITH EURO-OBD)]

14. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace accelerator pedal assembly.
Perform EC-857, «Accelerator Pedal Released Position Learning» .
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .
>> INSPECTION END

15. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004IW

ACCELERATOR PEDAL POSITION SENSOR
1.
2.
3.

Reconnect all harness connectors disconnected.
Turn ignition switch ON.
Check voltage between ECM terminals 110 (APP sensor 1 signal), 103 (APP sensor 2 signal) and ground under the following
conditions.
Terminal

Accelerator pedal

Voltage

110
(Accelerator pedal position
sensor 1)

Fully released

0.6 — 0.9V

Fully depressed

3.9 — 4.7V

Fully released

0.3 — 0.6V

Fully depressed

1.95 — 2.4V

103
(Accelerator pedal position
sensor 2)

4.
5.
6.
7.

PBIA9572J

If NG, replace accelerator pedal assembly and go to next step.
Perform EC-857, «Accelerator Pedal Released Position Learning» .
Perform EC-857, «Throttle Valve Closed Position Learning» .
Perform EC-858, «Idle Air Volume Learning» .

Removal and Installation

BBS004IX

ACCELERATOR PEDAL
Refer to ACC-2, «ACCELERATOR CONTROL SYSTEM» .

EC-1206

ELECTRICAL LOAD SIGNAL
[HR (WITH EURO-OBD)]

ELECTRICAL LOAD SIGNAL
CONSULT-II Reference Value in Data Monitor Mode

PFP:25350

A
BBS004J1

Specification data are reference values.
MONITOR ITEM

LOAD SIGNAL

CONDITION

●

HEATER FAN SW

●

Ignition switch: ON

Ignition switch: ON

SPECIFICATION

Rear window defogger switch is ON and/or lighting
switch is in 2nd position.

ON

Rear window defogger switch is OFF and lighting switch
is OFF.

OFF

Heater fan is operating.

ON

Heater fan is not operating.

OFF

Diagnostic Procedure

C

D
BBS004J2

1. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCITION-I
1.
2.

E

Turn ignition switch ON.
Check “LOAD SIGNAL” in “DATA MONITOR” mode with CONSULT-II under the following conditions.
Condition

EC

F

LOAD SIGNAL

Lighting switch: ON at 2nd position

ON

Lighting switch: OFF

OFF

G

OK or NG
OK
>> GO TO 2.
NG
>> GO TO 4.

H

PBIB0103E

I

2. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-II
J

Check “LOAD SIGNAL” in “DATA MONITOR” mode with CONSULTII under the following conditions.
Condition

LOAD SIGNAL

Rear window defogger switch: ON

ON

Rear window defogger switch: OFF

OFF

K

L

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 5.

M
PBIB0103E

3. CHECK HEATER FAN SIGNAL CIRCUIT OVERALL FUNCTION
Check “HEATER FAN SW” in “DATA MONITOR” mode with CONSULT-II under the following conditions.
Condition

HEATER FAN SW

Heater fan control switch: ON

ON

Heater fan control switch: OFF

OFF

OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 6.
PBIB1995E

EC-1207

ELECTRICAL LOAD SIGNAL
[HR (WITH EURO-OBD)]

4. CHECK HEADLAMP SYSTEM
Refer to LT-7, «HEADLAMP -CONVENTIONAL TYPE-» or LT-35, «HEADLAMP — DAYTIME LIGHT SYSTEM «.
>> INSPECTION END

5. CHECK REAR WINDOW DEFOGGER SYSTEM
Refer to GW-12, «REAR WINDOW DEFOGGER» .
>> INSPECTION END

6. CHECK HEATER FAN CONTROL SYSTEM
Refer to ATC-26, «TROUBLE DIAGNOSIS» (models with automatic air conditioner), MTC-23, «TROUBLE
DIAGNOSIS» (models with manual air conditioner).
>> INSPECTION END

EC-1208

FUEL INJECTOR
[HR (WITH EURO-OBD)]

FUEL INJECTOR
Component Description

PFP:16600

A
BBS004J3

The fuel injector is a small, precise solenoid valve. When the ECM
supplies a ground to the fuel injector circuit, the coil in the fuel injector is energized. The energized coil pulls the ball valve back and
allows fuel to flow through the fuel injector into the intake manifold.
The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the fuel injector remains
open. The ECM controls the injection pulse duration based on
engine fuel needs.

EC

C

D
SEF375Z

E

CONSULT-II Reference Value in Data Monitor Mode

BBS004J4

Specification data are reference values.
MONITOR ITEM
B/FUEL SCHDL

INJ PULSE-B1

CONDITION

SPECIFICATION

F

See EC-907, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

Idle

2.0 — 3.0 msec

2,000 rpm

1.9 — 2.9 msec

G

H

I

J

K

L

M

EC-1209

FUEL INJECTOR
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004J5

MBWA1489E

EC-1210

FUEL INJECTOR
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
BATTERY VOLTAGE
[Engine is running]

25
29
30
31

R
O
GR
L

●

Warm-up condition

●

Idle speed

(11 — 14V)

D

NOTE:
The pulse cycle changes depending on rpm
at idle

Fuel injector No. 4
Fuel injector No. 3
Fuel injector No. 2
Fuel injector No. 1

E
PBIB0529E

BATTERY VOLTAGE

F

(11 — 14V)
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

G

H
PBIA4943J

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

I

Diagnostic Procedure

BBS004J6

1. INSPECTION START
J

Turn ignition switch to START.
Is any cylinder ignited?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.

K

L

M

EC-1211

FUEL INJECTOR
[HR (WITH EURO-OBD)]

2. CHECK OVERALL FUNCTION
With CONSULT-II
Start engine.
Perform “POWER BALANCE” in “ACTIVE TEST” mode with
CONSULT-II.
3. Make sure that each circuit produces a momentary engine
speed drop.
1.
2.

PBIB0133E

Without CONSULT-II
1. Start engine.
2. Listen to each fuel injector operating sound.
Clicking noise should be heard.

PBIB1986E

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 3.

EC-1212

FUEL INJECTOR
[HR (WITH EURO-OBD)]

3. CHECK FUEL INJECTOR POWER SUPPLY CIRCUIT
1.
2.
–

3.

A

Turn ignition switch OFF.
Disconnect fuel injector (2) harness connector.
Ignition coil (1)
Turn ignition switch ON.

EC

C

D
PBIB2968E

E

4.

Check voltage between fuel injector terminal 1 and ground with
CONSULT-II or tester.
F

Voltage: Battery voltage
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

G

H
PBIB0582E

4. DETECT MALFUNCTIONING PART

I

Check the following.
●
Harness connectors E59, F1
●
IPDM E/R harness connector E10
●
10A fuse
●
Harness for open or short between fuel injector and fuse

J

K

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK FUEL INJECTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between fuel injector terminal 2 and ECM terminals 25, 29, 30, 31.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK FUEL INJECTOR
Refer to EC-1214, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace fuel injector.

EC-1213

L

M

FUEL INJECTOR
[HR (WITH EURO-OBD)]

7. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004J7

FUEL INJECTOR
1.
2.

Disconnect fuel injector harness connector.
Check resistance between terminals as shown in the figure.
Resistance: 11.1 — 14.5Ω [at 10 — 60°C (50 — 140°F)]

PBIB1727E

Removal and Installation

BBS004J8

FUEL INJECTOR
Refer to EM-135, «FUEL INJECTOR AND FUEL TUBE» .

EC-1214

FUEL PUMP
[HR (WITH EURO-OBD)]

FUEL PUMP
Description

PFP:17042

A
BBS004J9

SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*

Battery

Battery voltage*

ECM Function

Actuator

Fuel pump control

EC

Fuel pump relay

C

*: ECM determines the start signal status by the signals of engine speed and battery voltage.

The ECM activates the fuel pump for several seconds after the ignition switch is turned ON to improve engine
startability. If the ECM receives a engine speed signal from the crankshaft position sensor (POS) and camshaft position sensor (PHASE), it knows that the engine is rotating, and causes the pump to operate. If the
engine speed signal is not received when the ignition switch is ON, the engine stalls. The ECM stops pump
operation and prevents battery discharging, thereby improving safety. The ECM does not directly drive the fuel
pump. It controls the ON/OFF fuel pump relay, which in turn controls the fuel pump.
Condition

D

E

Fuel pump operation

Ignition switch is turned to ON

Operates for 1 second

Engine running and cranking

Operates

When engine is stopped

Stops in 1.5 seconds

Except as shown above

Stops

F

G

COMPONENT DESCRIPTION

H

A turbine type design fuel pump is used in the fuel tank.

I

J

K
MBIB0291E

CONSULT-II Reference Value in Data Monitor Mode

BBS004JA

L

Specification data are reference values.
MONITOR ITEM

FUEL PUMP RLY

CONDITION
●

For 1 second after turning ignition switch ON

●

Engine running or cranking

●

Except above conditions

SPECIFICATION
ON
OFF

EC-1215

M

FUEL PUMP
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004JB

MBWA1490E

EC-1216

FUEL PUMP
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

EC

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch: ON]
●

23

R

A

Fuel pump relay

For 1 second after turning ignition switch ON

C
0 — 1.0V

[Engine is running]
[Ignition switch: ON]
●

More than 1 second after turning ignition
switch ON

D
BATTERY VOLTAGE
(11 — 14V)

E

Diagnostic Procedure

BBS004JC

1. CHECK OVERALL FUNCTION
1.
2.
–

F

Turn ignition switch ON.
Pinch fuel feed hose (1) with two fingers.
Illustration shows the view with intake air duct removed.

G

Fuel pressure pulsation should be felt on the fuel
feed hose for 1 second after ignition switch is turned
ON.

H

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

I
PBIB2978E

2. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-I
1.
2.
3.
4.

J

Turn ignition switch OFF.
Disconnect ECM harness connector.
Turn ignition switch ON.
Check voltage between ECM terminal 23 and ground with CONSULT-II or tester.

K

L

Voltage: Battery voltage
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.

M

PBIA9573J

EC-1217

FUEL PUMP
[HR (WITH EURO-OBD)]

3. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E5.
Check harness continuity between ECM terminal 23 and IPDM E/R terminal 69.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 4.

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness or connectors E59, F1
●
Harness for open or short between IPDM E/R and ECM
>> Repair harness or connectors.

5. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-III
1.
2.
3.
4.

Turn ignition switch OFF.
Reconnect all harness connectors disconnected.
Disconnect “fuel level sensor unit and fuel pump” harness connector.
Turn ignition switch ON.

MBIB0288E

5.

Check voltage between “fuel level sensor unit and fuel pump”
terminal 1 and ground with CONSULT-II or tester.
Voltage:

Battery voltage should exist for 1 second
after ignition switch is turned ON.

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 6.

PBIB3004E

EC-1218

FUEL PUMP
[HR (WITH EURO-OBD)]

6. CHECK 15A FUSE

A

1. Turn ignition switch OFF.
2. Disconnect 15A fuse.
3. Check 15A fuse.
OK or NG
OK
>> GO TO 7.
NG
>> Replace fuse.

EC

C

7. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-IV
1.
2.

Disconnect IPDM E/R harness connector E10.
Check harness continuity between IPDM E/R terminal 20 and “fuel level sensor unit and fuel pump” terminal 1.
Refer to Wiring Diagram.

D

E

Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 8.

F

G

8. DETECT MALFUNCTIONING PART
H

Check the following.
●
Harness or connectors M1, E101
●
Harness or connectors M72, B21
●
Harness for open or short between IPDM E/R and “fuel level sensor unit and fuel pump”

I

J

>> Repair harness or connectors.

9. CHECK FUEL PUMP GROUND CIRCUIT
1.

Check harness continuity between “fuel level sensor unit and fuel pump” terminal 3 and ground.
Refer to Wiring Diagram.
Continuity should exist.

K

L

2. Also check harness for short to power.
OK or NG
OK
>> GO TO 10.
NG
>> Repair or replace harness or connectors.

10. CHECK FUEL PUMP
Refer to EC-1220, «Component Inspection» .
OK or NG
OK
>> GO TO 11.
NG
>> Replace “fuel level sensor unit and fuel pump”.

11. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)»
NG
>> Repair or replace harness or connectors.

EC-1219

M

FUEL PUMP
[HR (WITH EURO-OBD)]

Component Inspection

BBS004JD

FUEL PUMP
1.
2.

Disconnect “fuel level sensor unit and fuel pump” harness connector.
Check resistance between “fuel level sensor unit and fuel pump”
terminals 1 and 3.
Resistance: Approximately 0.2 — 5.0Ω [at 25°C (77°F)]

MBIB0311E

Removal and Installation

BBS004JE

FUEL PUMP
Refer to FL-15, «FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY» .

EC-1220

IGNITION SIGNAL
[HR (WITH EURO-OBD)]

IGNITION SIGNAL
Component Description

PFP:22448

A
BBS004JF

IGNITION COIL & POWER TRANSISTOR
The ignition signal from the ECM is sent to and amplified by the
power transistor. The power transistor turns ON and OFF the ignition
coil (1) primary circuit. This ON/OFF operation induces the proper
high voltage in the coil secondary circuit.
●
Fuel injector (2)

EC

C

D

PBIB2968E

E

F

G

H

I

J

K

L

M

EC-1221

IGNITION SIGNAL
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004JG

MBWA1491E

EC-1222

IGNITION SIGNAL
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

EC
ITEM

CONDITION
[Engine is running]
[Ignition switch: OFF]
●

32

P

ECM relay
(Self shut-off)

G

Power supply for ECM

For a few seconds after turning ignition
switch OFF

[Ignition switch: OFF]
●

105

A

More than a few seconds after turning ignition switch OFF

[Ignition switch: ON]

DATA (DC Voltage)

C
0 — 1.0V

D
BATTERY VOLTAGE
(11 — 14V)

E
BATTERY VOLTAGE
(11 — 14V)

F

G

H

I

J

K

L

M

EC-1223

IGNITION SIGNAL
[HR (WITH EURO-OBD)]

MBWA1492E

EC-1224

IGNITION SIGNAL
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

C
[Engine is running]

17
18
21
22

DATA (DC Voltage)

V
BR
G
Y

●

Warm-up condition

●

Idle speed

0 — 0.3V

D

NOTE:
The pulse cycle changes depending on rpm
at idle

Ignition signal No. 1
Ignition signal No. 2
Ignition signal No. 4
Ignition signal No. 3

E
PBIA9265J

0.2 — 0.5V

F
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

G
PBIA9266J

H
: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004JH

I

1. CHECK ENGINE START
Turn ignition switch OFF, and restart engine.
Is engine running?
Yes or No
Yes (With CONSULT-II)>>GO TO 2.
Yes (Without CONSULT-II)>>GO TO 3.
No
>> GO TO 4.

J

K

2. CHECK OVERALL FUNCTION

L

With CONSULT-II
Perform “POWER BALANCE” in “ACTIVE TEST” mode with
CONSULT-II.
2. Make sure that each circuit produces a momentary engine
speed drop.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 10.
1.

M

PBIB0133E

EC-1225

IGNITION SIGNAL
[HR (WITH EURO-OBD)]

3. CHECK OVERALL FUNCTION
Without CONSULT-II
Let engine idle.
Read the voltage signal between ECM terminals 17, 18, 21, 22
and ground with an oscilloscope.
3. Verify that the oscilloscope screen shows the signal wave as
shown below.
NOTE:
The pulse cycle changes depending on rpm at idle.
1.
2.

PBIA9567J

PBIA9265J

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 10.

4. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-I
1.
2.

Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Check voltage between ECM terminal 105 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 5.
NG
>> Go to EC-918, «POWER SUPPLY AND GROUND CIRCUIT» .

PBIA9575J

EC-1226

IGNITION SIGNAL
[HR (WITH EURO-OBD)]

5. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-II
1.
2.

Turn ignition switch OFF.
Disconnect condenser (1) harness connector.

–

: Vehicle front
Turn ignition switch ON.

3.

A

EC

C

D
MBIB1548E

E

4.

Check voltage between condenser terminal 1 and ground with
CONSULT-II or tester.
F

Voltage: Battery voltage
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 6.

G

H
PBIB0624E

6. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-III
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between IPDM E/R terminal 33 and condenser terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

I

J

K

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> Go to EC-918, «POWER SUPPLY AND GROUND CIRCUIT» .
NG
>> GO TO 7.

L

7. DETECT MALFUNCTIONING PART

M

Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between IPDM E/R and condenser
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1227

IGNITION SIGNAL
[HR (WITH EURO-OBD)]

8. CHECK CONDENSER GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.

Turn ignition switch OFF.
Check harness continuity between condenser terminal 2 and ground.
Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 9.
NG
>> Repair open circuit or short to power in harness or connectors.

9. CHECK CONDENSER
Refer to EC-1229, «Component Inspection»
OK or NG
OK
>> GO TO 10.
NG
>> Replace condenser.

10. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-IV
1.
2.
3.
–

4.

Turn ignition switch OFF.
Reconnect all harness connectors disconnected.
Disconnect ignition coil (1) harness connector.
Fuel injector (2)
Turn ignition switch ON.

PBIB2968E

5.

Check voltage between ignition coil terminal 1 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 12.
NG
>> GO TO 11.

SEF107S

11. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connector F1
●
Harness for open or short between ignition coil and harness connector F1
>> Repair or replace harness or connectors.

EC-1228

IGNITION SIGNAL
[HR (WITH EURO-OBD)]

12. CHECK IGNITION COIL GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.

A

Turn ignition switch OFF.
Check harness continuity between ignition coil terminal 2 and ground.
Refer to Wiring Diagram.

EC

Continuity should exist.
3. Also check harness for short to power.
OK or NG
OK
>> GO TO 13.
NG
>> Repair open circuit or short to power in harness or connectors.

C

D

13. CHECK IGNITION COIL OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

E

Disconnect ECM harness connector.
Check harness continuity between ECM terminals 17, 18, 21, 22 and ignition coil terminal 3.
Refer to Wiring Diagram.

F

Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 14.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

G

H

14. CHECK IGNITION COIL WITH POWER TRANSISTOR
Refer to EC-1229, «Component Inspection» .
OK or NG
OK
>> GO TO 15.
NG
>> Replace ignition coil with power transistor.

I

J

15. CHECK INTERMITTENT INCIDENT
Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

K

>> INSPECTION END
L

Component Inspection

BBS004JI

IGNITION COIL WITH POWER TRANSISTOR
CAUTION:
Do the following procedure in the place where ventilation is good without the combustible.
1. Turn ignition switch OFF.
2. Disconnect ignition coil harness connector.
3. Check resistance between ignition coil terminals as follows.
Terminal No. (Polarity)

Resistance Ω [at 25°C (77°F)]

1 and 2

Except 0 or ∞

M

1 and 3
2 and 3

4.
5.
6.

Except 0

If NG, replace ignition coil with power transistor.
If OK, go to next step.
Turn ignition switch OFF.
Reconnect all harness connectors disconnected.

EC-1229

MBIB0032E

IGNITION SIGNAL
[HR (WITH EURO-OBD)]
7.

8.
9.
10.
11.
12.
13.
14.
15.

16.

Remove fuel pump fuse in IPDM E/R to release fuel pressure.
NOTE:
Do not use CONSULT-II to release fuel pressure, or fuel pressure applies again during the following procedure.
Start engine.
After engine stalls, crank it two or three times to release all fuel
pressure.
Turn ignition switch OFF.
Remove all ignition coil harness connectors to avoid the electrical discharge from the ignition coils.
Remove ignition coil and spark plug of the cylinder to be
checked.
Crank engine for 5 seconds or more to remove combustion gas in the cylinder.
Connect spark plug and harness connector to ignition coil.
Fix ignition coil using a rope etc. with gap of 13 — 17 mm
between the edge of the spark plug and grounded metal portion
as shown in the figure.
Crank engine for about three seconds, and check whether spark
is generated between the spark plug and the grounded metal
portion.

MBIB0277E

Spark should be generated.
CAUTION:
Do not approach to the spark plug and the ignition coil
within 50cm. Be careful not to get an electrical shock
PBIB2325E
while checking, because the electrical discharge voltage
becomes 20kV or more.
● It might cause to damage the ignition coil if the gap of more than 17 mm is taken.
NOTE:
When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning.
17. If NG, replace ignition coil with power transistor.
●

CONDENSER
1.
2.
3.

Turn ignition switch OFF.
Disconnect condenser harness connector.
Check resistance between condenser terminals 1 and 2.
Resistance:

Above 1 MΩ at 25°C (77°F)

PBIB0794E

Removal and Installation

BBS004JJ

IGNITION COIL WITH POWER TRANSISTOR
Refer to EM-132, «IGNITION COIL» .

EC-1230

REFRIGERANT PRESSURE SENSOR
[HR (WITH EURO-OBD)]

REFRIGERANT PRESSURE SENSOR
Component Description

PFP:92136

A
BBS004JK

The refrigerant pressure sensor (1) is installed at the condenser of
the air conditioner system. The sensor uses an electrostatic volume
pressure transducer to convert refrigerant pressure to voltage. The
voltage signal is sent to ECM, and ECM controls cooling fan system.
●

EC

: Vehicle front

C

D
PBIB2980E

E

F

G

H
PBIB2657E

I

J

K

L

M

EC-1231

REFRIGERANT PRESSURE SENSOR
[HR (WITH EURO-OBD)]

Wiring Diagram

BBS004JL

MBWA1493E

EC-1232

REFRIGERANT PRESSURE SENSOR
[HR (WITH EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

EC

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]
41

BR

A

C

●

Warm-up condition

●

Both A/C switch and blower fan switch: ON

Refrigerant pressure sensor

1.0 — 4.0V

D

(Compressor operates)
[Engine is running]
48

74

Y

W

Sensor ground
(Refrigerant pressure sensor)
Sensor power supply
(Refrigerant pressure sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

E

[Ignition switch: ON]

Approximately 5V

F

Diagnostic Procedure

BBS004JM

1. CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION
1.
2.
3.

G

Start engine and warm it up to normal operating temperature.
Turn A/C switch and blower fan switch ON.
Check voltage between ECM terminal 41 and ground with CONSULT-II or tester.

H

Voltage: 1.0 — 4.0V
I

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

J

PBIA9574J

K

2. CHECK GROUND CONNECTIONS
1.
2.
3.

L

Turn A/C switch and blower fan switch OFF.
Stop engine.
Loosen and retighten ground screws on the body.
Refer to EC-924, «Ground Inspection» .

M

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace ground connections.

EC-1233

3.

Body ground

REFRIGERANT PRESSURE SENSOR
[HR (WITH EURO-OBD)]

3. CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT
1.

Disconnect refrigerant pressure sensor (1) harness connector.

–

: Vehicle front
Turn ignition switch ON.

2.

PBIB2980E

3.

Check voltage between refrigerant pressure sensor terminal 3
and ground with CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

SEF479Y

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between refrigerant pressure sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between refrigerant pressure sensor terminal 1 and ECM terminal 48.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

6. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between refrigerant pressure sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1234

REFRIGERANT PRESSURE SENSOR
[HR (WITH EURO-OBD)]

7. CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

A

Check harness continuity between refrigerant pressure sensor terminal 2 and ECM terminal 41.
Refer to Wiring Diagram.
EC

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.

C

8. DETECT MALFUNCTIONING PART

D

Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between refrigerant pressure sensor and ECM

E

F

>> Repair open circuit or short to ground or short to power in harness or connectors.

9. CHECK INTERMITTENT INCIDENT

G

Refer to EC-917, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace refrigerant pressure sensor.
NG
>> Repair or replace.

Removal and Installation

H

BBS004JN

REFRIGERANT PRESSURE SENSOR

I

Refer to ATC-135, «REFRIGERANT LINES» or MTC-81, «REFRIGERANT LINES» .
J

K

L

M

EC-1235

MI & DATA LINK CONNECTORS
[HR (WITH EURO-OBD)]

MI & DATA LINK CONNECTORS
Wiring Diagram

PFP:24814
BBS004JO

MBWA1494E

EC-1236

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR (WITH EURO-OBD)]

SERVICE DATA AND SPECIFICATIONS (SDS)
Fuel Pressure

PFP:00030

A
BBS004JP

Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi)

Fuel pressure at idle

EC

Idle Speed and Ignition Timing
Target idle speed

Air conditioner: ON

Ignition timing

BBS004JQ

A/T

No load* (in P or N position)

700 ± 50 rpm

M/T

No load* (in Neutral position)

650 ± 50 rpm

A/T

In P or N position

700 rpm or more

M/T

In Neutral position

750 rpm or more

A/T

In P or N position

M/T

In Neutral position

C

D

6 ± 5° BTDC

E

*: Under the following conditions:
●

Air conditioner switch: OFF

●

Electric load: OFF (Lights, heater fan & rear window defogger)

●

Steering wheel: Kept in straight-ahead position

F

Calculated Load Value

BBS004JR

G

Calculated load value% (Using CONSULT-II or GST)
At idle

10 — 35

At 2,500 rpm

10 — 35

Mass Air Flow Sensor

H
BBS004JS

Supply voltage

Battery voltage (11 — 14V)

Output voltage at idle

I

1.0 — 1.3*V
1.0 — 4.0 g·m/sec at idle*
2.0 — 10.0 g·m/sec at 2,500 rpm*

Mass air flow (Using CONSULT-II or GST)

J

*: Engine is warmed up to normal operating temperature and running under no load.

Intake Air Temperature Sensor

BBS004JT

Temperature °C (°F)

K

Resistance kΩ

25 (77)

1.800 — 2.200

80 (176)

0.283 — 0.359

Engine Coolant Temperature Sensor
Temperature °C (°F)

L
BBS004JU

M

Resistance kΩ

20 (68)

2.1 — 2.9

50 (122)

0.68 — 1.00

90 (194)

0.236 — 0.260

Knock Sensor

BBS00584

Resistance [at 20°C (68°F)]

Approximately 530 – 590kΩ

Heated Oxygen Sensor 1 Heater

BBS004JV

Resistance [at 25°C (77°F)]

3.4 — 4.4Ω

Heated Oxygen sensor 2 Heater

BBS004JW

Resistance [at 25°C (77°F)]

3.4 — 4.4Ω

EC-1237

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR (WITH EURO-OBD)]

Crankshaft Position Sensor (POS)

BBS004JX

Refer to EC-1048, «Component Inspection» .

Camshaft Position Sensor (PHASE)

BBS004JY

Refer to EC-1054, «Component Inspection» .

Intake Valve Timing Control Solenoid Valve
Resistance [at 20°C (68°F)]

BBS00585

6.7 – 7.7Ω

Throttle Control Motor

BBS004JZ

Resistance [at 25°C (77°F)]

Approximately 1 — 15Ω

Fuel Injector

BBS004K0

Resistance [at 10 — 60°C (50 — 140°F)]

11.1 — 14.5Ω

Fuel Pump

BBS004K1

Resistance [at 25°C (77°F)]

Approximately 0.2 — 5.0Ω

EC-1238

INDEX FOR DTC
[HR (WITHOUT EURO-OBD)]

INDEX FOR DTC
DTC No. Index

[HR (WITHOUT EURO-OBD)]

PFP:00024

A
BBS004K2

NOTE:
●
If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC EC
U1000, U1001. Refer to EC-1344, «DTC U1000, U1001 CAN COMMUNICATION LINE» .
●
If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer
to EC-1347, «DTC U1010 CAN COMMUNICATION» .
C
DTC*1

Items
(CONSULT-II screen terms)

Reference page

CONSULT-II

ECM*2

U1000

1000*3

CAN COMM CIRCUIT

EC-1344

U1001

1001*3

CAN COMM CIRCUIT

EC-1344

U1010

1010

CONTROL UNIT(CAN)

EC-1347

P0000

Flashing*4

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

EC-1269

P0000

0000

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

—

D

F

G

P0011

0011

INT/V TIM CONT-B1

EC-1349

P0102

0102

MAF SEN/CIRCUIT

EC-1354

P0103

0103

MAF SEN/CIRCUIT

EC-1354

P0117

0117

ECT SEN/CIRC

EC-1361

P0118

0118

ECT SEN/CIRC

EC-1361

P0122

0122

TP SEN 2/CIRC

EC-1367

P0123

0123

TP SEN 2/CIRC

EC-1367

P0132

0132

HO2S1 (B1)

EC-1373

P0134

0134

HO2S1 (B1)

EC-1381

P0138

0138

HO2S2 (B1)

EC-1388

P0222

0222

TP SEN 1/CIRC

EC-1395

P0223

0223

TP SEN 1/CIRC

EC-1395

P0327

0327

KNOCK SEN/CIRC-B1

EC-1401

P0328

0328

KNOCK SEN/CIRC-B1

EC-1401

P0335

0335

CKP SEN/CIRCUIT

EC-1405

P0340

0340

CMP SEN/CIRC-B1

EC-1413

P0605

0605

ECM

EC-1420

P1065

1065

ECM BACK UP/CIRCUIT*5

EC-1423

P1111

1111

INT/V TIM V/CIR-B1

EC-1425

P1121

1121

ETC ACTR

EC-1430

P1122

1122

ETC FUNCTION/CIRC

EC-1433

P1124

1124

ETC MOT PWR

EC-1439

P1126

1126

ETC MOT PWR

EC-1439

P1128

1128

ETC MOT

EC-1445

P1212

1212

TCS/CIRC

EC-1450

P1217

1217

ENG OVER TEMP

EC-1451

P1225

1225

CTP LEARNING

EC-1467

P1226

1226

CTP LEARNING

EC-1469

EC-1239

E

H

I

J

K

L

M

INDEX FOR DTC
[HR (WITHOUT EURO-OBD)]
DTC*1

Items
(CONSULT-II screen terms)

Reference page

CONSULT-II

ECM*2

P1229

1229

P1610 — P1615

1610 — 1615

NATS MALFUNCTION

BL-215

P1706

1706

P-N POS SW/CIRCUIT

EC-1479

P1805

1805

BRAKE SW/CIRCUIT

EC-1487

P2122

2122

APP SEN 1/CIRC

EC-1492

P2123

2123

APP SEN 1/CIRC

EC-1492

P2127

2127

APP SEN 2/CIRC

EC-1501

P2128

2128

APP SEN 2/CIRC

EC-1501

P2135

2135

TP SENSOR

EC-1511

P2138

2138

APP SENSOR

EC-1517

SENSOR POWER/CIRC

EC-1471

*1: 1st trip DTC No. is the same as DTC No.
*2: In Diagnostic Test Mode II (Self-diagnostic results).
*3: The troubleshooting for this DTC needs CONSULT-II.
*4: When engine is running, MI may flash. For details, refer to EC-1269, «MI Flashing Without DTC» .
*5: This self-diagnosis is not for ECM power supply circuit, even though “ECM BACK UP/CIRCUIT” is displayed on CONSULT-II screen.

EC-1240

INDEX FOR DTC
[HR (WITHOUT EURO-OBD)]

Alphabetical Index

BBS004K3

A
NOTE:
●
If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC
U1000, U1001. Refer to EC-1344, «DTC U1000, U1001 CAN COMMUNICATION LINE» .
●
If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer EC
to EC-1347, «DTC U1010 CAN COMMUNICATION» .
Items
(CONSULT-II screen terms)

DTC*1

Reference page
ECM*

APP SEN 1/CIRC

P2122

2122

EC-1492

APP SEN 1/CIRC

P2123

2123

EC-1492

APP SEN 2/CIRC

P2127

2127

EC-1501

APP SEN 2/CIRC

P2128

2128

EC-1501

APP SENSOR

P2138

2138

EC-1517

BRAKE SW/CIRCUIT

P1805

1805

EC-1487

3

CAN COMM CIRCUIT

U1000

1000*

EC-1344

CAN COMM CIRCUIT

U1001

1001*3

EC-1344

CONTROL UNIT(CAN)

U1010

1010

EC-1347

CKP SEN/CIRCUIT

P0335

0335

EC-1405

CMP SEN/CIRC-B1

P0340

0340

EC-1413

CTP LEARNING

P1225

1225

EC-1467

CTP LEARNING

P1226

1226

EC-1469

ECM

P0605

0605

EC-1420

P1065

1065

EC-1423

ECT SEN/CIRC

P0117

0117

EC-1361

ECT SEN/CIRC

P0118

0118

EC-1361

ENG OVER TEMP

P1217

1217

EC-1451

ETC ACTR

P1121

1121

EC-1430

ETC FUNCTION/CIRC

P1122

1122

EC-1433

ECM BACK

UP/CIRCUIT*5

ETC MOT

P1128

1128

EC-1445

ETC MOT PWR

P1124

1124

EC-1439

ETC MOT PWR

P1126

1126

EC-1439

HO2S1 (B1)

P0132

0132

EC-1373

HO2S1 (B1)

P0134

0134

EC-1381

HO2S2 (B1)

P0138

0138

EC-1388

INT/V TIM CONT-B1

P0011

0011

EC-1349

INT/V TIM V/CIR-B1

P1111

1111

EC-1425

KNOCK SEN/CIRC-B1

P0327

0327

EC-1401

KNOCK SEN/CIRC-B1

P0328

0328

EC-1401

MAF SEN/CIRCUIT

P0102

0102

EC-1354

MAF SEN/CIRCUIT

P0103

0103

EC-1354

P1610 — P1615

1610 — 1615

BL-215

No DTC

Flashing*4

EC-1269

NATS MALFUNCTION
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

EC-1241

C

2

CONSULT-II

D

E

F

G

H

I

J

K

L

M

INDEX FOR DTC
[HR (WITHOUT EURO-OBD)]
Items
(CONSULT-II screen terms)

DTC*1
Reference page
CONSULT-II

ECM*2

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

P0000

0000

—

P-N POS SW/CIRCUIT

P1706

1706

EC-1479

SENSOR POWER/CIRC

P1229

1229

EC-1471

TCS/CIRC

P1212

1212

EC-1450

TP SEN 1/CIRC

P0222

0222

EC-1395

TP SEN 1/CIRC

P0223

0223

EC-1395

TP SEN 2/CIRC

P0122

0122

EC-1367

TP SEN 2/CIRC

P0123

0123

EC-1367

TP SENSOR

P2135

2135

EC-1511

*1: 1st trip DTC No. is the same as DTC No.
*2: In Diagnostic Test Mode II (Self-diagnostic results).
*3: The troubleshooting for this DTC needs CONSULT-II.
*4: When engine is running, MI may flash. For details, refer to EC-1269, «MI Flashing Without DTC» .
*5: This self-diagnosis is not for ECM power supply circuit, even though “ECM BACK UP/CIRCUIT” is displayed on CONSULT-II screen.

EC-1242

PRECAUTIONS
[HR (WITHOUT EURO-OBD)]

PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

A

BBS004K4

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along EC
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
C
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be perD
formed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
E
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
F

Maintenance Information

BBS005AT

If any of following part is replaced, always replace with new* one.
If it’s not (or fail to do so), the electrical system may not be operated properly.
*: New one means a virgin control unit that has never been energized on-board.

G

RHD MODELS

H

●
●
●
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM
IPDM E/R
Combination meter
EPS control unit

I

J

LHD MODELS
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM

Precautions for Procedures without Cowl Top Cover

K

L
BBS00586

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

M

PIIB3706J

On Board Diagnostic (OBD) System of Engine

BBS004K6

The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of
a malfunction causing emission deterioration.
CAUTION:
●
Be sure to turn the ignition switch OFF and disconnect the negative battery cable before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves,
etc. will cause the MI to light up.

EC-1243

PRECAUTIONS
[HR (WITHOUT EURO-OBD)]
●

●

●

●

Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)
Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to PG-88, «HARNESS CONNECTOR» .
Be sure to route and secure the harnesses properly after work. The interference of the harness
with a bracket, etc. may cause the MI to light up due to the short circuit.
Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM
before returning the vehicle to the customer.

Precaution
●
●

●

●

BBS004K7

Always use a 12 volt battery as power source.
Do not attempt to disconnect battery cables while engine is
running.
Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect negative
battery cable. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned OFF.
Before removing parts, turn ignition switch OFF and then
disconnect negative battery cable.
SEF289H

●
●

●

–
–
–
–
●

–
–

Do not disassemble ECM.
If a battery cable is disconnected, the memory will return to
the ECM value.
The ECM will now start to self-control at its initial value.
Engine operation can vary slightly when the terminal is disconnected. However, this is not an indication of a malfunction. Do not replace parts because of a slight variation.
If the battery is disconnected, the following emissionrelated diagnostic information will be lost within 24 hours.
Diagnostic trouble codes
1st trip diagnostic trouble codes
Freeze frame data
1st trip freeze frame data
When connecting ECM harness connector, fasten (B) it
securely with a lever (1) as far as it will go as shown in the
figure.
ECM (2)
Loosen (A)

PBIA9222J

PBIB2947E

EC-1244

PRECAUTIONS
[HR (WITHOUT EURO-OBD)]
●

●

●

●
●

●
●

●
●

●

●

When connecting or disconnecting pin connectors into or
from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.
Securely connect ECM harness connectors.
A poor connection can cause an extremely high (surge)
voltage to develop in coil and condenser, thus resulting in
damage to ICs.
Keep engine control system harness at least 10 cm (4 in)
away from adjacent harness, to prevent engine control system malfunctions due to receiving external noise, degraded
operation of ICs, etc.
Keep engine control system parts and harness dry.
Before replacing ECM, perform ECM Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-1304, «ECM Terminals and Reference
Value» .
Handle mass air flow sensor carefully to avoid damage.
Do not clean mass air flow sensor with any type of detergent.
Do not disassemble electric throttle control actuator.
Even a slight leak in the air intake system can cause serious incidents.
Do not shock or jar the camshaft position sensor (PHASE),
crankshaft position sensor (POS).
After performing each TROUBLE DIAGNOSIS, perform DTC
Confirmation Procedure or Overall Function Check.
The DTC should not be displayed in the DTC Confirmation
Procedure if the repair is completed. The Overall Function
Check should be a good result if the repair is completed.

A

EC

C
PBIB0090E

D

E

F

G

MEF040D

H

I

J

K

SAT652J

L

M

EC-1245

PRECAUTIONS
[HR (WITHOUT EURO-OBD)]
●

●

When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact.
Accidental contact of probes will cause a short circuit and
damage the ECM power transistor.
Do not use ECM ground terminals when measuring input/
output voltage. Doing so may result in damage to the ECM’s
transistor. Use a ground other than ECM terminals, such as
the ground.

SEF348N

●
●

Do not operate fuel pump when there is no fuel in lines.
Tighten fuel hose clamps to the specified torque.

MBIB0291E

●
●

●

Do not depress accelerator pedal when starting.
Immediately after starting, do not rev up engine unnecessarily.
Do not rev up engine just prior to shutdown.

SEF709Y

●

–

–

–

When installing C.B. ham radio or a mobile phone, be sure
to observe the following as it may adversely affect electronic control systems depending on installation location.
Keep the antenna as far as possible from the electronic
control units.
Keep the antenna feeder line more than 20 cm (8 in) away
from the harness of electronic controls.
Do not let them run parallel for a long distance.
Adjust the antenna and feeder line so that the standingwave radio can be kept smaller.
SEF708Y

EC-1246

PRECAUTIONS
[HR (WITHOUT EURO-OBD)]
–

Be sure to ground the radio to vehicle body.
A

EC

C

D

E

F

G

H

I

J

K

L

M

EC-1247

PREPARATION
[HR (WITHOUT EURO-OBD)]

PREPARATION
Special Service Tools

PFP:00002
BBS004K8

Tool number
Tool name

Description

KV10117100
Heated oxygen
sensor wrench

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

S-NT379

KV10114400
Heated oxygen
sensor wrench

Loosening or tightening heated oxygen sensor
a: 22 mm (0.87 in)

S-NT636

EG17650301
Radiator cap tester
adapter

Adapting radiator cap tester to radiator cap and
radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
S-NT564

EG17550000
Break-out box

Measuring ECM signals with a circuit tester

ZZA1194D

EG17680000
Y-cable adapter

Measuring ECM signals with a circuit tester

PBIA9379J

KV10118400
Fuel tube adapter

Measuring fuel pressure

PBIB3043E

EC-1248

PREPARATION
[HR (WITHOUT EURO-OBD)]

Commercial Service Tools

BBS004K9

A
Tool name

Description

Quick connector
release

Removing fuel tube quick connectors in engine
room
(Available in SEC. 164 of PARTS CATALOG: Part
No. 16441 6N210)

EC

C
PBIC0198E

Fuel filler cap adapter

Checking fuel tank vacuum relief valve opening
pressure

D

E

S-NT653

Socket wrench

Removing and installing engine coolant
temperature sensor

F

G

H

S-NT705

Oxygen sensor thread
cleaner

Reconditioning the exhaust system threads
before installing a new oxygen sensor. Use with
anti-seize lubricant shown below.
a: 18 mm diameter with pitch 1.5 mm for
Zirconia Oxygen Sensor
b: 12 mm diameter with pitch 1.25 mm for
Titania Oxygen Sensor

J

Lubricating oxygen sensor thread cleaning tool
when reconditioning exhaust system threads.

K

I

AEM488

Anti-seize lubricant
i.e.: (PermatexTM
133AR or equivalent
meeting MIL
specification MIL-A907)

L
S-NT779

M

EC-1249

ENGINE CONTROL SYSTEM
[HR (WITHOUT EURO-OBD)]

ENGINE CONTROL SYSTEM
System Diagram

PFP:23710
BBS004KA

MBIB1449E

EC-1250

ENGINE CONTROL SYSTEM
[HR (WITHOUT EURO-OBD)]

Multiport Fuel Injection (MFI) System

BBS004KB

A

INPUT/OUTPUT SIGNAL CHART
Sensor
Crankshaft position sensor (POS)

Input Signal to ECM

Camshaft position sensor (PHASE)

Engine speed*3
Piston position

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Heated oxygen sensor 1

Density of oxygen in exhaust gas

Throttle position sensor

Throttle position

Accelerator pedal position sensor

Accelerator pedal position

Park/neutral position (PNP) switch

Gear position

Battery

Battery voltage*3

Knock sensor

Engine knocking condition

EPS control unit

Power steering operation*2

Heated oxygen sensor 2*1

Density of oxygen in exhaust gas

Air conditioner switch

Air conditioner operation*2

Wheel sensor

Vehicle speed*2

ECM function

Actuator

EC

C

D
Fuel injection
& mixture ratio
control

Fuel injector

*1: This sensor is not used to control the engine system under normal conditions.
*2: This signal is sent to the ECM through CAN communication line.
*3: ECM determines the start signal status by the signals of engine speed and battery voltage.

E

F

G

H

SYSTEM DESCRIPTION
The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of
time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the
ECM memory. The program value is preset by engine operating conditions. These conditions are determined
by input signals (for engine speed and intake air) from the crankshaft position sensor (POS), camshaft position
sensor (PHASE) and the mass air flow sensor.

I

J

VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION
In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below.

●
During warm-up
●
When starting the engine
●
During acceleration
●
Hot-engine operation
●
When shift lever is changed from N to D (A/T models)
●
High-load, high-speed operation

●
During deceleration
●
During high engine speed operation

EC-1251

K

L

M

ENGINE CONTROL SYSTEM
[HR (WITHOUT EURO-OBD)]
MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL)

PBIB2953E

The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control.
The three way catalyst (manifold) can then better reduce CO, HC and NOx emissions. This system uses
heated oxygen sensor 1 in the exhaust manifold to monitor whether the engine operation is rich or lean. The
ECM adjusts the injection pulse width according to the sensor voltage signal. For more information about
heated oxygen sensor 1, refer to EC-1373, «DTC P0132 HO2S1» . This maintains the mixture ratio within the
range of stoichiometric (ideal air-fuel mixture).
This stage is referred to as the closed loop control condition.
Heated oxygen sensor 2 is located downstream of the three way catalyst (manifold). Even if the switching
characteristics of heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal
from heated oxygen sensor 2.

Open Loop Control
The open loop system condition refers to when the ECM detects any of the following conditions. Feedback
control stops in order to maintain stabilized fuel combustion.
●
Deceleration and acceleration
●
High-load, high-speed operation
●
Malfunction of heated oxygen sensor 1 or its circuit
●
Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature
●
High engine coolant temperature
●
During warm-up
●
After shifting from N to D (A/T models)
●
When starting the engine

MIXTURE RATIO SELF-LEARNING CONTROL
The mixture ratio feedback control system monitors the mixture ratio signal transmitted from heated oxygen
sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to
the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. Both manufacturing differences (i.e., mass air flow sensor hot wire) and characteristic
changes during operation (i.e., fuel injector clogging) directly affect mixture ratio.
Accordingly, the difference between the basic and theoretical mixture ratios is monitored in this system. This is
then computed in terms of “injection pulse duration” to automatically compensate for the difference between
the two ratios.
“Fuel trim” refers to the feedback compensation value compared against the basic injection duration. Fuel trim
includes short term fuel trim and long term fuel trim.
“Short term fuel trim” is the short-term fuel compensation used to maintain the mixture ratio at its theoretical
value. The signal from heated oxygen sensor 1 indicates whether the mixture ratio is RICH or LEAN compared
to the theoretical value. The signal then triggers a reduction in fuel volume if the mixture ratio is rich, and an
increase in fuel volume if it is lean.
“Long term fuel trim” is overall fuel compensation carried out long-term to compensate for continual deviation
of the short term fuel trim from the central value. Such deviation will occur due to individual engine differences,
wear over time and changes in the usage environment.

EC-1252

ENGINE CONTROL SYSTEM
[HR (WITHOUT EURO-OBD)]
FUEL INJECTION TIMING
A

EC

C

SEF337W

D

Two types of systems are used.

Sequential Multiport Fuel Injection System
Fuel is injected into each cylinder during each engine cycle according to the firing order. This system is used
when the engine is running.

Simultaneous Multiport Fuel Injection System
Fuel is injected simultaneously into all four cylinders twice each engine cycle. In other words, pulse signals of
the same width are simultaneously transmitted from the ECM.
The four fuel injectors will then receive the signals two times for each engine cycle.
This system is used when the engine is being started and/or if the fail-safe system (CPU) is operating.

E

F

G

FUEL SHUT-OFF
Fuel to each cylinder is cut off during deceleration, operation of the engine at excessively high speeds or operation of the vehicle at excessively high speeds.

Electronic Ignition (EI) System

BBS004KC

INPUT/OUTPUT SIGNAL CHART
Sensor
Crankshaft position sensor (POS)

I
Input Signal to ECM

Camshaft position sensor (PHASE)

Engine speed*2
Piston position

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Throttle position sensor

Throttle position

Accelerator pedal position sensor

Accelerator pedal position

Battery

Battery voltage*2

Knock sensor

Engine knocking

Park/neutral position (PNP) switch

Gear position

Wheel sensor

H

ECM function

Actuator

J

K
Ignition timing
control

Power transistor

L

M
1

Vehicle speed*

*1: This signal is sent to the ECM through CAN communication line.
*2: ECM determines the start signal status by the signals of engine speed and battery voltage.

SYSTEM DESCRIPTION
Firing order: 1 — 3 — 4 — 2
The ignition timing is controlled by the ECM to maintain the best air-fuel ratio for every running condition of the
engine. The ignition timing data is stored in the ECM.
The ECM receives information such as the injection pulse width and camshaft position sensor (PHASE) signal. Computing this information, ignition signals are transmitted to the power transistor.
During the following conditions, the ignition timing is revised by the ECM according to the other data stored in
the ECM.
●
At starting
●
During warm-up
●
At idle
●
At low battery voltage

EC-1253

ENGINE CONTROL SYSTEM
[HR (WITHOUT EURO-OBD)]
●
During acceleration
The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed
within the anti-knocking zone, if recommended fuel is used under dry conditions. The retard system does not
operate under normal driving conditions. If engine knocking occurs, the knock sensor monitors the condition.
The signal is transmitted to the ECM. The ECM retards the ignition timing to eliminate the knocking condition.

Fuel Cut Control (at No Load and High Engine Speed)

BBS004KD

INPUT/OUTPUT SIGNAL CHART
Sensor

Input Signal to ECM

Park/neutral position (PNP) switch

Neutral position

Accelerator pedal position sensor

Accelerator pedal position

Engine coolant temperature sensor

Engine coolant temperature

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed

Wheel sensor

Vehicle speed*

ECM function

Fuel cut control

Actuator

Fuel injector

*: This signal is sent to the ECM through CAN communication line.

SYSTEM DESCRIPTION
If the engine speed is above 2,500 rpm under no load (for example, the shift lever position is neutral and
engine speed is over 2,500 rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies based on engine speed.
Fuel cut will be operated until the engine speed reaches 2,000 rpm, then fuel cut will be cancelled.
NOTE:
This function is different from deceleration control listed under EC-1251, «Multiport Fuel Injection (MFI) System» .

EC-1254

AIR CONDITIONING CUT CONTROL
[HR (WITHOUT EURO-OBD)]

AIR CONDITIONING CUT CONTROL
Input/Output Signal Chart
Sensor

PFP:23710

A
BBS004KE

Input Signal to ECM

Air conditioner switch

Air conditioner ON signal*

Accelerator pedal position sensor

Accelerator pedal position

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*2

Engine coolant temperature sensor

Engine coolant temperature

Battery

Battery voltage*2

Refrigerant pressure sensor

Refrigerant pressure

EPS control unit

Power steering operation*1

Wheel sensor

ECM function

Actuator

EC

1

C
Air conditioner
cut control

Air conditioner relay

D

E

1

Vehicle speed*

*1: This signal is sent to the ECM through CAN communication line.
*2: ECM determines the start signal status by the signals of engine speed and battery voltage.

System Description

F
BBS004KF

This system improves engine operation when the air conditioner is used.
Under the following conditions, the air conditioner is turned OFF.
●
When the accelerator pedal is fully depressed.
●
When cranking the engine.
●
At high engine speeds.
●
When the engine coolant temperature becomes excessively high.
●
When operating power steering during low engine speed or low vehicle speed.
●
When engine speed is excessively low.
●
When refrigerant pressure is excessively low or high.

G

H

I

J

K

L

M

EC-1255

CAN COMMUNICATION
[HR (WITHOUT EURO-OBD)]

CAN COMMUNICATION
System Description

PFP:23710
BBS004KG

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
Refer to LAN-21, «CAN COMMUNICATION» , about CAN communication for detail.

EC-1256

EVAPORATIVE EMISSION SYSTEM
[HR (WITHOUT EURO-OBD)]

EVAPORATIVE EMISSION SYSTEM
Description

PFP:14950

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BBS004KH

SYSTEM DESCRIPTION
EC

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PBIB3039E

The evaporative emission system is used to reduce hydrocarbons emitted into the atmosphere from the fuel
system. This reduction of hydrocarbons is accomplished by activated charcoals in the EVAP canister.
The fuel vapor in the sealed fuel tank is led into the EVAP canister which contains activated carbon and the
vapor is stored there when the engine is not operating or when refueling to the fuel tank.
The vapor in the EVAP canister is purged by the air through the purge line to the intake manifold when the
engine is operating. EVAP canister purge volume control solenoid valve is controlled by ECM. When the
engine operates, the flow rate of vapor controlled by EVAP canister purge volume control solenoid valve is
proportionally regulated as the air flow increases.
EVAP canister purge volume control solenoid valve also shuts off the vapor purge line during decelerating.

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EC-1257

EVAPORATIVE EMISSION SYSTEM
[HR (WITHOUT EURO-OBD)]
EVAPORATIVE EMISSION LINE DRAWING

PBIB2946E

: Vehicle front
1.

Intake manifold

: From next page
2.

EVAP canister purge volume control
solenoid valve

3.

EVAP purge resonator

NOTE:
Do not use soapy water or any type of solvent while installing vacuum hose or purge hoses.

EC-1258

EVAPORATIVE EMISSION SYSTEM
[HR (WITHOUT EURO-OBD)]
A

EC

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MBIB1450E

: Vehicle front
1.

: To previous page

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EVAP canister

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EC-1259

EVAPORATIVE EMISSION SYSTEM
[HR (WITHOUT EURO-OBD)]

Component Inspection

BBS004KI

EVAP CANISTER
Check EVAP canister as follows:
1. Block port (B).
2. Blow air into port (A) and check that it flows freely out of port (C).
3. Release blocked port (B).
4. Apply vacuum pressure to port (B) and check that vacuum pressure exists at the ports (A) and (C).
5. Block port (A) and (B).
6. Apply pressure to port (C) and check that there is no leakage.
PBIB2961E

FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP)
1.

Wipe clean valve housing.

SEF989X

2.

Check valve opening pressure and vacuum.
Pressure:
Vacuum:

3.

15.3 — 20.0 kPa (0.153 — 0.200 bar,
0.156 — 0.204 kg/cm2 , 2.22 — 2.90 psi)
−6.0 to −3.3 kPa (−0.060 to −0.034 bar,
−0.061 to −0.035 kg/cm2 , −0.87 to −0.49 psi)

If out of specification, replace fuel filler cap as an assembly.

SEF943S

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
Refer to EC-1530, «EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE» .

EC-1260

NATS (NISSAN ANTI-THEFT SYSTEM)
[HR (WITHOUT EURO-OBD)]

NATS (NISSAN ANTI-THEFT SYSTEM)
Description
●

●

●

PFP:25386

A
BBS004KJ

If the security indicator lights up with the ignition switch in
the ON position or “NATS MALFUNCTION” is displayed on
EC
“SELF-DIAG RESULTS” screen, perform self-diagnostic
results mode with CONSULT-II using NATS program card.
Refer to BL-215, «NATS (Nissan Anti-Theft System)» .
C
Confirm no self-diagnostic results of NATS is displayed
before touching “ERASE” in “SELF-DIAG RESULTS” mode
with CONSULT-II.
D
When replacing ECM, initialization of NATS system and registration of all NATS ignition key IDs must be carried out
SEF515Y
with CONSULT-II using NATS program card.
Therefore, be sure to receive all keys from vehicle owner.
E
Regarding the procedures of NATS initialization and all NATS ignition key ID registration, refer to
CONSULT-II operation manual, NATS.
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EC-1261

POSITIVE CRANKCASE VENTILATION
[HR (WITHOUT EURO-OBD)]

POSITIVE CRANKCASE VENTILATION
Description

PFP:11810
BBS004KK

SYSTEM DESCRIPTION

PBIB2962E

This system returns blow-by gas to the intake manifold.
The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake
manifold.
During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the PCV
valve.
Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air.
The ventilating air is then drawn from the air inlet tubes into the crankcase. In this process the air passes
through the hose connecting air inlet tubes to rocker cover.
Under full-throttle condition, the manifold vacuum is insufficient to draw the blow-by flow through the valve.
The flow goes through the hose connection in the reverse direction.
On vehicles with an excessively high blow-by, the valve does not
meet the requirement. This is because some of the flow will go
through the hose connection to the air inlet tubes under all conditions.

PBIB1588E

Component Inspection

BBS004KL

PCV (POSITIVE CRANKCASE VENTILATION) VALVE
With engine running at idle, remove PCV valve from rocker cover. A
properly working valve makes a hissing noise as air passes through
it. A strong vacuum should be felt immediately when a finger is
placed over valve inlet.

PBIB1589E

EC-1262

POSITIVE CRANKCASE VENTILATION
[HR (WITHOUT EURO-OBD)]
PCV VALVE VENTILATION HOSE
1.
2.

A

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

EC

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S-ET277

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EC-1263

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITHOUT EURO-OBD)]

ON BOARD DIAGNOSTIC (OBD) SYSTEM
Introduction

PFP:00028
BBS004KM

The ECM has an on board diagnostic system, which detects malfunctions related to engine sensors or actuators. The ECM also records various emission-related diagnostic information including:
Emission-related diagnostic information
Diagnostic Trouble Code (DTC)
Freeze Frame data
1st Trip Diagnostic Trouble Code (1st Trip DTC)
1st Trip Freeze Frame data

The above information can be checked using procedures listed in the table below.

×: Applicable

—: Not applicable

DTC

1st trip DTC

Freeze Frame data

1st trip Freeze Frame
data

CONSULT-II

×

×

×

×

ECM

×

×*

—

—

*: When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other.

The malfunction indicator (MI) on the instrument panel lights up when the same malfunction is detected in two
consecutive trips (Two trip detection logic), or when the ECM enters fail-safe mode. (Refer to EC-1291, «FailSafe Chart» .)

Two Trip Detection Logic

BBS004KN

When a malfunction is detected for the first time, 1st trip DTC and 1st trip Freeze Frame data are stored in the
ECM memory. The MI will not light up at this stage. <1st trip>
If the same malfunction is detected again during the next drive, the DTC and Freeze Frame data are stored in
the ECM memory, and the MI lights up. The MI lights up at the same time when the DTC is stored. <2nd trip>
The “trip” in the “Two Trip Detection Logic” means a driving mode in which self-diagnosis is performed during
vehicle operation.
When there is an open circuit on MI circuit, the ECM cannot warn the driver by lighting up MI when there is
malfunction on engine control system.
Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as
NG for 5 trips, ECM warns the driver that engine control system malfunctions and MI circuit is open by means
of operating fail-safe function.
The fail-safe function also operates when above diagnoses except MI circuit are detected and demands the
driver to repair the malfunction.
Engine operating condition in fail-safe mode

Engine speed will not rise more than 2,500 rpm due to the fuel cut

Emission-related Diagnostic Information

BBS004KO

EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS
Items
(CONSULT-II screen terms)

×:Applicable —: Not applicable

DTC*1
Trip

MI

Reference
page

2

CONSULT-II

ECM*

CAN COMM CIRCUIT

U1000

1000*3

2

—

EC-1344

CAN COMM CIRCUIT

U1001

1001*3

2

—

EC-1344

CONTROL UNIT(CAN)

U1010

1010

2

—

EC-1347

NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.

P0000

0000

—

Flashing*4

EC-1269

INT/V TIM CONT-B1

P0011

0011

2

—

EC-1349

MAF SEN/CIRCUIT

P0102

0102

1

×

EC-1354

MAF SEN/CIRCUIT

P0103

0103

1

×

EC-1354

ECT SEN/CIRC

P0117

0117

2

×

EC-1361

EC-1264

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITHOUT EURO-OBD)]
DTC*1
Trip

MI

Reference
page

0118

2

×

EC-1361

P0122

0122

1

×

EC-1367

TP SEN 2/CIRC

P0123

0123

1

×

EC-1367

HO2S1 (B1)

P0132

0132

2

×

EC-1373

HO2S1 (B1)

P0134

0134

2

×

EC-1381

Items
(CONSULT-II screen terms)

CONSULT-II

ECM*2

ECT SEN/CIRC

P0118

TP SEN 2/CIRC

HO2S2 (B1)

P0138

0138

2

×

EC-1388

TP SEN 1/CIRC

P0222

0222

1

×

EC-1395

TP SEN 1/CIRC

P0223

0223

1

×

EC-1395

KNOCK SEN/CIRC-B1

P0327

0327

2

—

EC-1401

KNOCK SEN/CIRC-B1

P0328

0328

2

—

EC-1401

CKP SEN/CIRCUIT

P0335

0335

2

×

EC-1405

CMP SEN/CIRC-B1

P0340

0340

2

×

EC-1413

ECM

P0605

0605

1 or 2

× or —

EC-1420

ECM BACK UP/CIRCUIT*5

P1065

1065

2

×

EC-1423

INT/V TIM V/CIR-B1

P1111

1111

2

×

EC-1425

ETC ACTR

P1121

1121

1

×

EC-1430

ETC FUNCTION/CIRC

P1122

1122

1

×

EC-1433

ETC MOT PWR

P1124

1124

1

×

EC-1439

ETC MOT PWR

P1126

1126

1

×

EC-1439

ETC MOT

P1128

1128

1

×

EC-1445

TCS/CIRC

P1212

1212

2

—

EC-1450

ENG OVER TEMP

P1217

1217

1

×

EC-1451

CTP LEARNING

P1225

1225

2

—

EC-1467

CTP LEARNING

P1226

1226

2

—

EC-1469

SENSOR POWER/CIRC

P1229

1229

1

×

EC-1471

NATS MALFUNCTION

P1610 — P1615

1610 — 1615

2

—

BL-215

P-N POS SW/CIRCUIT

P1706

1706

2

×

EC-1479

BRAKE SW/CIRCUIT

P1805

1805

1

×

EC-1487

APP SEN 1/CIRC

P2122

2122

1

×

EC-1492

APP SEN 1/CIRC

P2123

2123

1

×

EC-1492

APP SEN 2/CIRC

P2127

2127

1

×

EC-1501

APP SEN 2/CIRC

P2128

2128

1

×

EC-1501

TP SENSOR

P2135

2135

1

×

EC-1511

APP SENSOR

P2138

2138

1

×

EC-1517

*1: 1st trip DTC No. is the same as DTC No.
*2: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN.
*3: The troubleshooting for this DTC needs CONSULT-II.
*4: When engine is running, MI may flash. For details, refer to EC-1269, «MI Flashing Without DTC» .
*5: This self-diagnosis is not for ECM power supply circuit, even though “ECM BACK UP/CIRCUIT” is displayed on CONSULT-II screen.

DTC AND 1ST TRIP DTC
The 1st trip DTC (whose number is the same as the DTC number) is displayed for the latest self-diagnostic
result obtained. If the ECM memory was cleared previously, and the 1st trip DTC did not reoccur, the 1st trip
DTC will not be displayed.
If a malfunction is detected during the 1st trip, the 1st trip DTC is stored in the ECM memory. The MI will not
light up (two trip detection logic). If the same malfunction is not detected in the 2nd trip (meeting the required

EC-1265

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EC

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ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITHOUT EURO-OBD)]
driving pattern), the 1st trip DTC is cleared from the ECM memory. If the same malfunction is detected in the
2nd trip, both the 1st trip DTC and DTC are stored in the ECM memory and the MI lights up. In other words,
the DTC is stored in the ECM memory and the MI lights up when the same malfunction occurs in two consecutive trips. If a 1st trip DTC is stored and a non-diagnostic operation is performed between the 1st and 2nd
trips, only the 1st trip DTC will continue to be stored. For malfunctions that blink or light up the MI during the
1st trip, the DTC and 1st trip DTC are stored in the ECM memory.
Procedures for clearing the DTC and the 1st trip DTC from the ECM memory are described in EC-1267, «HOW
TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .
When a 1st trip DTC is detected, check, print out or write down and erase (1st trip) DTC and Freeze Frame
data as specified in Work Flow procedure Step 2, refer to EC-1285, «WORK FLOW» . Then perform DTC Confirmation Procedure or Overall Function Check to try to duplicate the malfunction. If the malfunction is duplicated, the item requires repair.

How to Read DTC and 1st Trip DTC
DTC and 1st trip DTC can be read by the following methods.
With CONSULT-II
CONSULT-II displays the DTC in “SELF-DIAG RESULTS” mode. Examples: P0117, P0340, P1217, etc.
(CONSULT-II also displays the malfunctioning component or system.)
Without CONSULT-II
The number of blinks of the MI in the Diagnostic Test Mode II (Self-Diagnostic Results) indicates the DTC.
Example: 0117, 0340, 1217, etc.
●
1st trip DTC No. is the same as DTC No.
●
Output of a DTC indicates a malfunction. However, the Diagnostic Test Mode II do not indicate
whether the malfunction is still occurring or has occurred in the past and has returned to normal.
CONSULT-II can identify malfunction status as shown below. Therefore, using CONSULT-II (if available) is recommended.
A sample of CONSULT-II display for DTC and 1st trip DTC is shown below. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many times
the vehicle was driven after the last detection of a DTC.
If the DTC is being detected currently, the time data will be [0].
If a 1st trip DTC is stored in the ECM, the time data will be [1t].

PBIB0911E

FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA
The ECM records the driving conditions such as fuel system status, calculated load value, engine coolant temperature, short term fuel trim, long term fuel trim, engine speed, vehicle speed, base fuel schedule and intake
air temperature at the moment a malfunction is detected.
Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data.
The data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II. For
details, see EC-1314, «Freeze Frame Data and 1st Trip Freeze Frame Data» .
Only one set of freeze frame data (either 1st trip freeze frame data or freeze frame data) can be stored in the
ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no priority
for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once
freeze frame data (2nd trip detection/MI on) is stored in the ECM memory, 1st trip freeze frame data is no
longer stored. Remember, only one set of freeze frame data can be stored in the ECM.
Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased. Procedures for clearing the ECM memory are described in EC-1267, «HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .

EC-1266

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITHOUT EURO-OBD)]
HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION
How to Erase DTC

A

WITH CONSULT-II
The emission related diagnostic information in the ECM can be erased by selecting “ERASE” in the “SELFEC
DIAG RESULTS” mode with CONSULT-II.
1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10
seconds and then turn it ON (engine stopped) again.
C
2. Touch “ENGINE”.
3. Touch “SELF-DIAG RESULTS”.
4. Touch “ERASE”. (The DTC in the ECM will be erased.)
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PBIB2454E

Without CONSULT-II
1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once.
2. Wait at least 10 seconds and then turn it ON (engine stopped) again.
3. Change the diagnostic test mode from Mode II to Mode I by depressing the accelerator pedal. Refer to
EC-1269, «HOW TO SWITCH DIAGNOSTIC TEST MODE» .
●
If the battery is disconnected, the emission-related diagnostic information will be lost within 24
hours.
●
The following data are cleared when the ECM memory is erased.
–
Diagnostic trouble codes
–
1st trip diagnostic trouble codes
–
Freeze frame data
–
1st trip freeze frame data
Actual work procedures are explained using a DTC as an example. Be careful so that not only the DTC, but all
of the data listed above, are cleared from the ECM memory during work procedures.

EC-1267

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ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITHOUT EURO-OBD)]

Malfunction Indicator (MI)

BBS004KP

DESCRIPTION
The MI is located on the instrument panel.
1. The MI will light up when the ignition switch is turned ON without
the engine running. This is a bulb check.
If the MI does not light up, refer to DI-32, «WARNING LAMPS» ,
or see EC-1596, «MI & DATA LINK CONNECTORS» .
2. When the engine is started, the MI should go off.
If the MI remains on, the on board diagnostic system has
detected an engine system malfunction.

SAT652J

ON BOARD DIAGNOSTIC SYSTEM FUNCTION
The on board diagnostic system has the following four functions.
Diagnostic Test
Mode

KEY and ENG.
Status

Function

Explanation of Function

Mode I

Ignition switch in
ON position

BULB CHECK

This function checks the MI bulb for damage (blown, open
circuit, etc.).
If the MI does not come on, check MI circuit.

Engine running

MALFUNCTION
WARNING

This is a usual driving condition. When a malfunction is
detected twice in two consecutive driving cycles (two trip
detection logic), the MI will light up to inform the driver that
a malfunction has been detected.
One trip detection diagnoses will light up the MI in the 1st
trip.

Ignition switch in
ON position

SELF-DIAGNOSTIC
RESULTS

This function allows DTCs and 1st trip DTCs to be read.

HEATED OXYGEN SENSOR 1
MONITOR

This function allows the fuel mixture condition (lean or
rich), monitored by heated oxygen sensor 1, to be read.

Engine stopped

Mode II

Engine stopped

Engine running

When there is an open circuit on MI circuit, the ECM cannot warn the driver by lighting up MI when there is
malfunction on engine control system.
Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as
NG for 5 trips, ECM warns the driver that engine control system malfunctions and MI circuit is open by means
of operating fail-safe function.
The fail-safe function also operates when above diagnoses except MI circuit are detected and demands the
driver to repair the malfunction.
Engine operating condition in fail-safe mode

Engine speed will not rise more than 2,500 rpm due to the fuel cut

EC-1268

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITHOUT EURO-OBD)]
MI Flashing Without DTC
If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM diag- A
nostic test mode. Refer to EC-1269, «HOW TO SWITCH DIAGNOSTIC TEST MODE» .
How to switch the diagnostic test (function) modes, and details of the above functions are described later.
Refer to EC-1269, «HOW TO SWITCH DIAGNOSTIC TEST MODE» .
EC
The following emission-related diagnostic information is cleared when the ECM memory is erased.
●
Diagnostic trouble codes
●
1st trip diagnostic trouble codes
C
●
Freeze frame data
●
1st trip freeze frame data
D

HOW TO SWITCH DIAGNOSTIC TEST MODE

NOTE:
●
It is better to count the time accurately with a clock.
●
It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit
has a malfunction.
●
Always ECM returns to Diagnostic Test Mode I after ignition switch is turned OFF.

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How to Set Diagnostic Test Mode II (Self-diagnostic Results)
1.
2.
a.
b.
3.
4.

Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds.
Repeat the following procedure quickly five times within 5 seconds.
Fully depress the accelerator pedal.
Fully release the accelerator pedal.
Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 10 seconds until the MI starts
blinking.
Fully release the accelerator pedal.
ECM has entered to Diagnostic Test Mode II (Self-diagnostic results).
NOTE:
Wait until the same DTC (or 1st trip DTC) appears to confirm all DTCs certainly.

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PBIB0092E

How to Set Diagnostic Test Mode II (Heated Oxygen Sensor 1 Monitor)
1.
2.

Set the ECM in Diagnostic Test Mode II (Self-diagnostic results).
Refer to EC-1269, «How to Set Diagnostic Test Mode II (Self-diagnostic Results)» .
Start Engine.
ECM has entered to Diagnostic Test Mode II (Heated oxygen sensor 1 monitor).

How to Erase Diagnostic Test Mode II (Self-diagnostic Results)
1.
2.
3.

Set ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-1269, «How to Set Diagnostic
Test Mode II (Self-diagnostic Results)» .
Fully depress the accelerator pedal and keep it for more than 10 seconds.
The emission-related diagnostic information has been erased from the backup memory in the ECM.
Fully release the accelerator pedal, and confirm the DTC 0000 is displayed.

DIAGNOSTIC TEST MODE I — BULB CHECK
In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to DI-32,
«WARNING LAMPS» or see EC-1596, «MI & DATA LINK CONNECTORS» .

EC-1269

M

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITHOUT EURO-OBD)]
DIAGNOSTIC TEST MODE I — MALFUNCTION WARNING
MI

Condition

ON

When the malfunction is detected.

OFF

No malfunction.

This DTC number is clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS)

DIAGNOSTIC TEST MODE II — SELF-DIAGNOSTIC RESULTS
In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI as shown below.
The DTC and 1st trip DTC are displayed at the same time. If the MI does not illuminate in diagnostic test mode
I (Malfunction warning), all displayed items are 1st trip DTCs. If only one code is displayed when the MI illuminates in diagnostic test mode II (SELF-DIAGNOSTIC RESULTS), it is a DTC; if two or more codes are displayed, they may be either DTCs or 1st trip DTCs. DTC No. is same as that of 1st trip DTC. These unidentified
codes can be identified by using CONSULT-II. A DTC will be used as an example for how to read a code.

PBIA3905E

A particular trouble code can be identified by the number of four-digit numeral flashes. The “zero” is indicated
by the number of ten flashes. The length of time the 1,000th-digit numeral flashes on and off is 1.2 seconds
consisting of an ON (0.6-second) — OFF (0.6-second) cycle.
The 100th-digit numeral and lower digit numerals consist of a 0.3-second ON and 0.3-second OFF cycle.
A change from one digit numeral to another occurs at an interval of 1.0-second OFF. In other words, the later
numeral appears on the display 1.3 seconds after the former numeral has disappeared.
A change from one trouble code to another occurs at an interval of 1.8-second OFF.
In this way, all the detected malfunctions are classified by their DTC numbers. The DTC 0000 refers to no malfunction. (See EC-1239, «INDEX FOR DTC» )

How to Erase Diagnostic Test Mode II (Self-diagnostic Results)
The DTC can be erased from the back up memory in the ECM by depressing accelerator pedal. Refer to EC1269, «How to Erase Diagnostic Test Mode II (Self-diagnostic Results)» .
●
If the battery is disconnected, the DTC will be lost from the backup memory within 24 hours.
●
Be careful not to erase the stored memory before starting trouble diagnoses.

EC-1270

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[HR (WITHOUT EURO-OBD)]
DIAGNOSTIC TEST MODE II — HEATED OXYGEN SENSOR 1 MONITOR
In this mode, the MI displays the condition of the fuel mixture (lean or rich) which is monitored by the heated
oxygen sensor 1.
MI

Fuel mixture condition in the exhaust gas

ON

Lean

OFF

Rich

*Remains ON or OFF

Any condition

A

Air fuel ratio feedback control condition

EC
Closed loop system
Open loop system

C

*: Maintains conditions just before switching to open loop.

To check the heated oxygen sensor 1 function, start engine in the Diagnostic Test Mode II and warm it up until
engine coolant temperature indicator points to the middle of the gauge.
Next run engine at about 2,000 rpm for about 2 minutes under no load conditions. Then make sure that the MI
comes ON more than 5 times within 10 seconds with engine running at 2,000 rpm under no load.

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EC-1271

BASIC SERVICE PROCEDURE
[HR (WITHOUT EURO-OBD)]

BASIC SERVICE PROCEDURE
Basic Inspection

PFP:00018
BBS004KQ

1. INSPECTION START
1.
2.
–
–
–
–
–
–

3.
–
–
–
–

4.

Check service records for any recent repairs that may indicate a related malfunction, or a current need for
scheduled maintenance.
Open engine hood and check the following:
Harness connectors for improper connections
Wiring harness for improper connections, pinches and cut
Vacuum hoses for splits, kinks and improper connections
Hoses and ducts for leaks
Air cleaner clogging
Gasket
Confirm that electrical or mechanical loads are not applied.
Headlamp switch is OFF.
SEF983U
Air conditioner switch is OFF.
Rear window defogger switch is OFF.
Steering wheel is in the straight-ahead position, etc.
Start engine and warm it up until engine coolant temperature
indicator points the middle of gauge.
Ensure engine stays below 1,000 rpm.

SEF976U

5.

Run engine at about 2,000 rpm for about 2 minutes under no
load.
6. Make sure that no DTC is displayed with CONSULT-II.
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

SEF977U

2. REPAIR OR REPLACE
Repair or replace components as necessary according to corresponding Diagnostic Procedure.
>> GO TO 3

EC-1272

BASIC SERVICE PROCEDURE
[HR (WITHOUT EURO-OBD)]

3. CHECK TARGET IDLE SPEED
1.
2.

A

With CONSULT-II
Run engine at about 2,000 rpm for about 2 minutes under no load.
Rev engine (2,000 to 3,000 rpm) two or three times under no
load, then run engine at idle speed for about 1 minute.

EC

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PBIA8513J

3.

Read idle speed in “DATA MONITOR” mode with CONSULT-II.
Refer to EC-1277, «IDLE SPEED» .
A/T:
M/T:

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700 ± 50 rpm (in P or N position)
650 ± 50 rpm (in Neutral position)

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Without CONSULT-II
1. Run engine at about 2,000 rpm for about 2 minutes under no load.
2. Rev engine (2,000 to 3,000 rpm) two or three times under no load, then run engine at idle speed for about
1 minute.
3. Check idle speed.
Refer to EC-1277, «IDLE SPEED» .
A/T:
M/T:

700 ± 50 rpm (in P or N position)
650 ± 50 rpm (in Neutral position)

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 4.

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4. PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING
1.
2.

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Stop engine.
Perform EC-1278, «Accelerator Pedal Released Position Learning» .
>> GO TO 5.

5. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING
Perform EC-1279, «Throttle Valve Closed Position Learning» .
>> GO TO 6.

EC-1273

BASIC SERVICE PROCEDURE
[HR (WITHOUT EURO-OBD)]

6. PERFORM IDLE AIR VOLUME LEARNING
Refer to EC-1279, «Idle Air Volume Learning» .
Is Idle Air Volume Learning carried out successfully?
Yes or No
Yes
>> GO TO 7.
No
>> 1. Follow the instruction of Idle Air Volume Learning.
2. GO TO 4.

7. CHECK TARGET IDLE SPEED AGAIN
1.
2.

With CONSULT-II
Start engine and warm it up to normal operating temperature.
Read idle speed in “DATA MONITOR” mode with CONSULT-II.
Refer to EC-1277, «IDLE SPEED» .
A/T:
M/T:

700 ± 50 rpm (in P or N position)
650 ± 50 rpm (in Neutral position)

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Check idle speed.
Refer to EC-1277, «IDLE SPEED» .
A/T:
M/T:

700 ± 50 rpm (in P or N position)
650 ± 50 rpm (in Neutral position)

SEF174Y

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 8.

8. DETECT MALFUNCTIONING PART
Check the Following.
●
Check camshaft position sensor (PHASE) and circuit. Refer to EC-1413, «DTC P0340 CMP SENSOR
(PHASE)» .
●
Check crankshaft position sensor (POS) and circuit. Refer to EC-1405, «DTC P0335 CKP SENSOR
(POS)» .
OK or NG
OK
>> GO TO 9.
NG
>> 1. Repair or replace.
2. GO TO 4.

9. CHECK ECM FUNCTION
1.
2.

Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but
this is a rare case.)
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
>> GO TO 4.

EC-1274

BASIC SERVICE PROCEDURE
[HR (WITHOUT EURO-OBD)]

10. CHECK IGNITION TIMING
1.
2.
–

A

Run engine at idle.
Check ignition timing with a timing light.
Refer to EC-1277, «IGNITION TIMING» .
Timing indicator (1)
A/T:
M/T:

EC

6 ± 5° BTDC (in P or N position)
6 ± 5° BTDC (in Neutral position)

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OK or NG
OK
>> INSPECTION END
NG
>> GO TO 11.

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MBIB1331E

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11. PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING
1.
2.

Stop engine.
Perform EC-1278, «Accelerator Pedal Released Position Learning» .

F

>> GO TO 12.

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12. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING
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Perform EC-1279, «Throttle Valve Closed Position Learning» .
>> GO TO 13.

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13. PERFORM IDLE AIR VOLUME LEARNING
Refer to EC-1279, «Idle Air Volume Learning» .
Is Idle Air Volume Learning carried out successfully?
Yes or No
Yes
>> GO TO 14.
No
>> 1. Follow the instruction of Idle Air Volume Learning.
2. GO TO 4.

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14. CHECK TARGET IDLE SPEED AGAIN
With CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Read idle speed in “DATA MONITOR” mode with CONSULT-II.
Refer to EC-1277, «IDLE SPEED» .
A/T:
M/T:

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700 ± 50 rpm (in P or N position)
650 ± 50 rpm (in Neutral position)

Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Check idle speed.
Refer to EC-1277, «IDLE SPEED» .
A/T:
M/T:

700 ± 50 rpm (in P or N position)
650 ± 50 rpm (in Neutral position)

OK or NG
OK
>> GO TO 15.
NG
>> GO TO 17.

EC-1275

SEF174Y

BASIC SERVICE PROCEDURE
[HR (WITHOUT EURO-OBD)]

15. CHECK IGNITION TIMING AGAIN
1.
2.
–

Run engine at idle.
Check ignition timing with a timing light.
Refer to EC-1277, «IGNITION TIMING» .
Timing indicator (1)
A/T:
M/T:

6 ± 5° BTDC (in P or N position)
6 ± 5° BTDC (in Neutral position)

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 16.
MBIB1331E

16. CHECK TIMING CHAIN INSTALLATION
Check timing chain installation. Refer to EM-142, «TIMING CHAIN» .
OK or NG
OK
>> GO TO 17.
NG
>> 1. Repair the timing chain installation.
2. GO TO 4.

17. DETECT MALFUNCTIONING PART
Check the following.
●
Check camshaft position sensor (PHASE) and circuit. Refer to EC-1413, «DTC P0340 CMP SENSOR
(PHASE)» .
●
Check crankshaft position sensor (POS) and circuit. Refer to EC-1405, «DTC P0335 CKP SENSOR
(POS)» .
OK or NG
OK
>> GO TO 18.
NG
>> 1. Repair or replace.
2. GO TO 4.

18. CHECK ECM FUNCTION
1.
2.

Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but
this is a rare case.)
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
>> GO TO 4.

EC-1276

BASIC SERVICE PROCEDURE
[HR (WITHOUT EURO-OBD)]

Idle Speed and Ignition Timing Check

BBS004KR

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IDLE SPEED
With CONSULT-II
Check idle speed in “DATA MONITOR” mode with CONSULT-II.

EC

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SEF058Y

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Without CONSULT-II
Check the idle speed by installing the pulse type tachometer clamp on the loop wire or on suitable high-tension
wire which installed between ignition coil No.4 and spark plug No.4.
NOTE:
For the method of installing the tachometer, refer to EC-1277, «IGNITION TIMING» .

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IGNITION TIMING

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Any of following two methods may be used.

Method A
1.

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Attach timing light A to loop wire (1) as shown.
●

: Vehicle front
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2.

Check ignition timing.
● Timing indicator (1)

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MBIB1331E

EC-1277

BASIC SERVICE PROCEDURE
[HR (WITHOUT EURO-OBD)]
Method B
1.

Remove ignition coil No. 4 (1).
●

: Vehicle front

MBIB1457E

2.

Connect ignition coil No. 4 (1) and spark plug No. 4 with suitable
high-tension wire A as shown, and attach timing light clamp B to
this wire.

MBIB1541E

SEF166Y

3.

Check ignition timing.
● Timing indicator (1)

MBIB1331E

Accelerator Pedal Released Position Learning

BBS004KS

DESCRIPTION
Accelerator Pedal Released Position Learning is an operation to learn the fully released position of the accelerator pedal by monitoring the accelerator pedal position sensor output signal. It must be performed each time
harness connector of accelerator pedal position sensor or ECM is disconnected.

OPERATION PROCEDURE
1.
2.
3.

Make sure that accelerator pedal is fully released.
Turn ignition switch ON and wait at least 2 seconds.
Turn ignition switch OFF and wait at least 10 seconds.

EC-1278

BASIC SERVICE PROCEDURE
[HR (WITHOUT EURO-OBD)]
4.
5.

Turn ignition switch ON and wait at least 2 seconds.
Turn ignition switch OFF and wait at least 10 seconds.

Throttle Valve Closed Position Learning

A
BBS004KT

DESCRIPTION
Throttle Valve Closed Position Learning is an operation to learn the fully closed position of the throttle valve by
monitoring the throttle position sensor output signal. It must be performed each time harness connector of
electric throttle control actuator or ECM is disconnected.

OPERATION PROCEDURE
1.
2.
3.

Make sure that accelerator pedal is fully released.
Turn ignition switch ON.
Turn ignition switch OFF and wait at least 10 seconds.
Make sure that throttle valve moves during above 10 seconds by confirming the operating sound.

Idle Air Volume Learning

EC

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BBS004KU

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DESCRIPTION
Idle Air Volume Learning is an operation to learn the idle air volume that keeps each engine within the specific
range. It must be performed under any of the following conditions:
●
Each time electric throttle control actuator or ECM is replaced.
●
Idle speed or ignition timing is out of specification.

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PREPARATION
Before performing Idle Air Volume Learning, make sure that all of the following conditions are satisfied.
Learning will be cancelled if any of the following conditions are missed for even a moment.
●
Battery voltage: More than 12.9V (At idle)
●
Engine coolant temperature: 70 — 95°C (158 — 203°F)
●
PNP switch: ON
●
Electric load switch: OFF
(Air conditioner, headlamp, rear window defogger)
On vehicles equipped with daytime light systems, set lighting switch to the 1st position to light
only small lamps.
●
Steering wheel: Neutral (Straight-ahead position)
●
Vehicle speed: Stopped
●
Transmission: Warmed-up
–
A/T models
•
With CONSULT-II: Drive vehicle until “FLUID TEMP SE” in “DATA MONITOR” mode of “A/T” system indicates less than 0.9V.
•
Without CONSULT-II: Drive vehicle for 10 minutes.
–
M/T models
•
Drive vehicle for 10 minutes.

OPERATION PROCEDURE
With CONSULT-II
1.
2.
3.
4.

F

Perform EC-1278, «Accelerator Pedal Released Position Learning» .
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Start engine and warm it up to normal operating temperature.
Check that all items listed under the topic PREPARATION (previously mentioned) are in good order.

EC-1279

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BASIC SERVICE PROCEDURE
[HR (WITHOUT EURO-OBD)]
5.

Select “IDLE AIR VOL LEARN” in “WORK SUPPORT” mode.

SEF217Z

6.

Touch “START” and wait 20 seconds.

SEF454Y

7.

8.

Make sure that “CMPLT” is displayed on CONSULT-II screen. If
“CMPLT” is not displayed, Idle Air Volume Learning will not be
carried out successfully. In this case, find the cause of the incident by referring to the DIAGNOSTIC PROCEDURE below.
Rev up the engine two or three times and make sure that idle
speed and ignition timing are within the specifications.

ITEM

SPECIFICATION

Idle speed

A/T: 700 ± 50 rpm (in P or N position)
M/T: 650 ± 50 rpm (in Neutral position)

Ignition timing

A/T: 6 ± 5° BTDC (in P or N position)
M/T: 6 ± 5° BTDC (in Neutral position)

MBIB0238E

Without CONSULT-II
NOTE:
●
It is better to count the time accurately with a clock.
●
It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit
has a malfunction.
1. Perform EC-1278, «Accelerator Pedal Released Position Learning» .
2. Perform EC-1279, «Throttle Valve Closed Position Learning» .
3. Start engine and warm it up to normal operating temperature.
4. Check that all items listed under the topic PREPARATION (previously mentioned) are in good order.
5. Turn ignition switch OFF and wait at least 10 seconds.
6. Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds.
7. Repeat the following procedure quickly five times within 5 seconds.
a. Fully depress the accelerator pedal.
b. Fully release the accelerator pedal.
8. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 20 seconds until the MI stops
blinking and turned ON.
9. Fully release the accelerator pedal within 3 seconds after the MI turned ON.
10. Start engine and let it idle.

EC-1280

BASIC SERVICE PROCEDURE
[HR (WITHOUT EURO-OBD)]
11. Wait 20 seconds.
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EC

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PBIB0665E

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12. Rev up the engine two or three times and make sure that idle speed and ignition timing are within the
specifications.
E
ITEM

SPECIFICATION

Idle speed

A/T: 700 ± 50 rpm (in P or N position)
M/T: 650 ± 50 rpm (in Neutral position)

Ignition timing

A/T: 6 ± 5° BTDC (in P or N position)
M/T: 6 ± 5° BTDC (in Neutral position)

F

13. If idle speed and ignition timing are not within the specification, Idle Air Volume Learning will not be carried
out successfully. In this case, find the cause of the incident by referring to the Diagnostic Procedure below.

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DIAGNOSTIC PROCEDURE
If idle air volume learning cannot be performed successfully, proceed as follows:
1. Check that throttle valve is fully closed.
2. Check PCV valve operation.
3. Check that downstream of throttle valve is free from air leakage.
4. When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the incident.
It is useful to perform EC-1597, «SERVICE DATA AND SPECIFICATIONS (SDS)» .
5. If any of the following conditions occur after the engine has started, eliminate the cause of the
incident and perform Idle Air Volume Learning all over again:
●
Engine stalls.
●
Erroneous idle.

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Fuel Pressure Check

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FUEL PRESSURE RELEASE
With CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON.
Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT”
mode with CONSULT-II.
Start engine.
After engine stalls, crank it two or three times to release all fuel
pressure.
Turn ignition switch OFF.

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SEF214Y

EC-1281

BASIC SERVICE PROCEDURE
[HR (WITHOUT EURO-OBD)]
Without CONSULT-II
1.
2.
3.
4.
5.

Remove fuel pump fuse located in IPDM E/R.
Start engine.
After engine stalls, crank it 2 or 3 times to release all fuel pressure.
Turn ignition switch OFF.
Reinstall fuel pump fuse after servicing fuel system.

MBIB0277E

FUEL PRESSURE CHECK
CAUTION:
●
Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger.
●
The fuel hose connection method used when taking fuel pressure check must not be used for
other purposes.
●
Be careful not to scratch or put debris around connection area when servicing, so that the quick
connector maintains sealability with O-rings inside.
●
Do not perform fuel pressure check with electrical systems operating (i.e. lights, rear defogger, A/
C, etc.) Fuel pressure gauge may indicate false readings due to varying engine load and changes
in manifold vacuum.
NOTE:
Prepare pans or saucers under the disconnected fuel line because the fuel may spill out. The fuel pressure cannot be completely released because E11 models do not have fuel return system.
1. Release fuel pressure to zero. Refer to EC-1281, «FUEL PRESSURE RELEASE» .
2. Prepare fuel hose for fuel pressure check B and fuel tube
adapter (KV10118400) D, then connect fuel pressure gauge A.
●

: To quick connector

: To fuel tube (engine side)
● C: Clamp
● Use suitable fuel hose for fuel pressure check (genuine NISSAN fuel hose without quick connector).
● To avoid unnecessary force or tension to hose, use moderately long fuel hose for fuel pressure check.
● Do not use the fuel hose for checking fuel pressure with damage or cracks on it.
● Use Pressure Gauge to check fuel pressure.
Remove fuel hose. Refer to EM-120, «INTAKE MANIFOLD» .
● Do not twist or kink fuel hose because it is plastic hose.
Connect fuel hose for fuel pressure check (1) to fuel tube
(engine side) with clamp (2) as shown in the figure.
● No.2 spool (5)
● Wipe off oil or dirt from hose insertion part using cloth moistened with gasoline.
● Apply proper amount of gasoline between top of the fuel tube
(3) and No.1 spool (4).
● Insert fuel hose for fuel pressure check until it touches the
No.1 spool on fuel tube.
● Use NISSAN genuine hose clamp (part number: 16439
N4710 or 16439 40U00).
● When reconnecting fuel line, always use new clamps.
● Use a torque driver to tighten clamps.
●

3.
4.

EC-1282

PBIB2982E

PBIB2983E

BASIC SERVICE PROCEDURE
[HR (WITHOUT EURO-OBD)]
●

Install hose clamp to the position within 1 — 2 mm (0.04 — 0.08 in).
Tightening torque:

A

1 — 1.5 N·m (0.1 — 0.15 kg-m, 9 — 13 in-lb)

Make sure that clamp screw does not contact adjacent parts.
Connect fuel tube adapter to quick connector.
● A: Fuel pressure gauge
● B: Fuel hose for fuel pressure check
After connecting fuel hose for fuel pressure check, pull the hose
with a force of approximately 98 N (10 kg, 22 lb) to confirm fuel
tube does not come off.
Turn ignition switch ON and check for fuel leakage.
Start engine and check for fuel leakage.
Read the indication of fuel pressure gauge.
● Do not perform fuel pressure check with system operating.
Fuel pressure gauge may indicate false readings.
● During fuel pressure check, confirm for fuel leakage from fuel connection every 3 minutes.
●

5.

6.

7.
8.
9.

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PBIB2984E

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At idling:

Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi)

10. If result is unsatisfactory, go to next step.
11. Check the following.
● Fuel hoses and fuel tubes for clogging
● Fuel filter for clogging
● Fuel pump
● Fuel pressure regulator for clogging
If OK, replace fuel pressure regulator.
If NG, repair or replace.

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EC-1283

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]

TROUBLE DIAGNOSIS
Trouble Diagnosis Introduction

PFP:00004
BBS004KW

INTRODUCTION
The engine has an ECM to control major systems such as fuel control, ignition control, idle air control system, etc. The ECM accepts
input signals from sensors and instantly drives actuators. It is essential that both input and output signals are proper and stable. At the
same time, it is important that there are no malfunctions such as vacuum leaks, fouled spark plugs, or other malfunctions with the engine.

MEF036D

It is much more difficult to diagnose an incident that occurs intermittently rather than continuously. Most intermittent incidents are
caused by poor electric connections or improper wiring. In this case,
careful checking of suspected circuits may help prevent the replacement of good parts.

SEF233G

A visual check only may not find the cause of the incidents. A road
test with CONSULT-II or a circuit tester connected should be performed. Follow the Work Flow on EC-1285, «WORK FLOW» .
Before undertaking actual checks, take a few minutes to talk with a
customer who approaches with a driveability complaint. The customer can supply good information about such incidents, especially
intermittent ones. Find out what symptoms are present and under
what conditions they occur. A Diagnostic Worksheet like the example
on EC-1289, «Worksheet Sample» should be used.
Start your diagnosis by looking for conventional malfunctions first.
This will help troubleshoot driveability malfunctions on an electronically controlled engine vehicle.

EC-1284

SEF234G

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
WORK FLOW
Overall Sequence

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PBIB2267E

EC-1285

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
Detailed Flow

1. GET INFORMATION FOR SYMPTOM
Get the detailed information from the customer about the symptom (the condition and the environment when
the incident/malfunction occurred) using the EC-1288, «DIAGNOSTIC WORKSHEET» .
>> GO TO 2.

2. CHECK DTC*1
1.

Check DTC*1 .

2.

Perform the following procedure if DTC*1 is displayed.

–

Record DTC*1 and freeze frame data*2 . (Print them out with CONSULT-II.)

–

Erase DTC*1 . (Refer to EC-1267, «HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .)

Study the relationship between the cause detected by DTC*1 and the symptom described by the customer. (Symptom Matrix Chart is useful. Refer to EC-1292, «Symptom Matrix Chart» .)
3. Check related service bulletins for information.
Is any symptom described and any DTC detected?

–

Symptom is described, DTC*1 is displayed>>GO TO 3.
Symptom is described, DTC*1 is not displayed>>GO TO 4.
Symptom is not described, DTC*1 is displayed>>GO TO 5.

3. CONFIRM THE SYMPTOM
Try to confirm the symptom described by the customer (except MI ON).
DIAGNOSIS WORK SHEET is useful to verify the incident.
Connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis
results.
Verify relation between the symptom and the condition when the symptom is detected.
>> GO TO 5.

4. CONFIRM THE SYMPTOM
Try to confirm the symptom described by the customer.
DIAGNOSIS WORK SHEET is useful to verify the incident.
Connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis
results.
Verify relation between the symptom and the condition when the symptom is detected.
>> GO TO 6.

EC-1286

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]

5. PERFORM DTC CONFIRMATION PROCEDURE

A
1

1

Perform DTC Confirmation Procedure for the displayed DTC* , and then make sure that DTC* is detected
again.
At this time, always connect CONSULT-II to the vehicle, and check diagnostic results in real time on “DATA EC
MONITOR (AUTO TRIG)”.
If two or more DTCs*1 are detected, refer to EC-1290, «DTC Inspection Priority Chart» and determine trouble diagnosis order.
C
NOTE:
●
Freeze frame data*2 is useful if the DTC*1 is not detected.
●
Perform Overall Function Check if DTC Confirmation Procedure is not included on Service Manual. This D
simplified check procedure is an effective alternative though DTC*1 cannot be detected during this
check.
If the result of Overall Function Check is NG, it is the same as the detection of DTC*1 by DTC Confirma- E
tion Procedure.
Is DTC*1 detected?
Yes
>> GO TO 10.
No
>> Check according to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

F

6. PERFORM BASIC INSPECTION

G

Perform EC-1272, «Basic Inspection» .
H

With CONSULT-II>>GO TO 7.
Without CONSULT-II>>GO TO 9.

7. PERFORM DATA MONITOR (SPEC) MODE

I

With CONSULT-II
Make sure that “MAS A/F SE-B1”, “B/FUEL SCHDL”, and “A/F
ALPHA-B1” are within the SP value using CONSULT-II “DATA MONITOR (SPEC)” mode. Refer to EC-1326, «Inspection Procedure» .
Are they within the SP value?
Yes
>> GO TO 9.
No
>> GO TO 8.

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SEF601Z

8. DETECT MALFUNCTIONING PART BY TROUBLE DIAGNOSIS — SPECIFICATION VALUE
Detect malfunctioning part according to EC-1327, «Diagnostic Procedure» .
Is malfunctioning part detected?
Yes
>> GO TO 11.
No
>> GO TO 9.

9. DETECT MALFUNCTIONING SYSTEM BY SYMPTOM MATRIX CHART
Detect malfunctioning system according to EC-1292, «Symptom Matrix Chart» based on the confirmed symptom in step 4, and determine the trouble diagnosis order based on possible causes and symptom.
>> GO TO 10.

EC-1287

M

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]

10. DETECT MALFUNCTIONING PART BY DIAGNOSTIC PROCEDURE
Inspect according to Diagnostic Procedure of the system.
NOTE:
The Diagnostic Procedure in EC section described based on open circuit inspection. A short circuit inspection
is also required for the circuit check in the Diagnostic Procedure. For details, refer to Circuit Inspection in GI25, «How to Perform Efficient Diagnosis for an Electrical Incident» .
Is malfunctioning part detected?
Yes
>> GO TO 11.
No
>> Monitor input data from related sensors or check voltage of related ECM terminals using CONSULT-II. Refer to EC-1304, «ECM Terminals and Reference Value» , EC-1321, «CONSULT-II Reference Value in Data Monitor» .

11. REPAIR OR REPLACE THE MALFUNCTIONING PART
1.
2.
3.

Repair or replace the malfunctioning part.
Reconnect parts or connectors disconnected during Diagnostic Procedure again after repair and replacement.
Check DTC. If DTC is displayed, erase it, refer to EC-1267, «HOW TO ERASE EMISSION-RELATED
DIAGNOSTIC INFORMATION» .
>> GO TO 12.

12. FINAL CHECK
When DTC was detected in step 2, perform DTC Confirmation Procedure or Overall Function Check again,
and then make sure that the malfunction have been repaired securely.
When symptom was described from the customer, refer to confirmed symptom in step 3 or 4, and make sure
that the symptom is not detected.
OK or NG
NG (DTC*1 is detected)>>GO TO 10.
NG (Symptom remains)>>GO TO 6.
OK
>> 1. Before returning the vehicle to the customer, make sure to erase unnecessary DTC*1 in ECM.
(Refer to EC-1267, «HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .)
2. INSPECTION END
*1: Include 1st trip DTC.
*2: Include 1st trip freeze frame data.

DIAGNOSTIC WORKSHEET
Description
There are many operating conditions that lead to the malfunction of
engine components. A good grasp of such conditions can make troubleshooting faster and more accurate.
In general, each customer feels differently about a incident. It is
important to fully understand the symptoms or conditions for a customer complaint.
Utilize a diagnostic worksheet like the one on the next page in order
to organize all the information for troubleshooting.

SEF907L

EC-1288

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
Worksheet Sample
A

EC

C

D

E

F

G

H

I

J

K

L

M

MTBL0017

EC-1289

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]

DTC Inspection Priority Chart

BBS004KX

If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
chart.
NOTE:
●
If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC
U1000, U1001. Refer to EC-1344, «DTC U1000, U1001 CAN COMMUNICATION LINE» .
●
If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer
to EC-1347, «DTC U1010 CAN COMMUNICATION» .
Priority
1

2

3

Detected items (DTC)
●

U1000 U1001 CAN communication line

●

U1010 CAN communication

●

P0102 P0103 Mass air flow sensor

●

P0117 P0118 Engine coolant temperature sensor

●

P0122 P0123 P0222 P0223 P1225 P1226 P2135 Throttle position sensor

●

P0327 P0328 Knock sensor

●

P0335 Crankshaft position sensor (POS)

●

P0340 Camshaft position sensor (PHASE)

●

P0605 ECM

●

P1229 Sensor power supply

●

P1610 — P1615 NATS

●

P1706 Park/Neutral position (PNP) switch

●

P2122 P2123 P2127 P2128 P2138 Accelerator pedal position sensor

●

P0132 P0134 Heated oxygen sensor 1

●

P0138 Heated oxygen sensor 2

●

P1065 ECM

●

P1111 Intake valve timing control solenoid valve

●

P1122 Electric throttle control function

●

P1124 P1126 Throttle control motor relay

●

P1128 Throttle control motor

●

P1217 Engine over temperature (OVERHEAT)

●

P1805 Brake switch

●

P0011 Intake valve timing control

●

P1121 Electric throttle control actuator

●

P1212 ESP communication line

EC-1290

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]

Fail-Safe Chart

BBS004KY

When the DTC listed below is detected, the ECM enters fail-safe mode and the MI lights up.
DTC No.

Detected items

Engine operating condition in fail-safe mode

P0102
P0103

Mass air flow sensor circuit

Engine speed will not rise more than 2,400 rpm due to the fuel cut.

P0122
P0123
P0222
P0223
P2135

Throttle position sensor

The ECM controls the electric throttle control actuator in regulating the throttle opening
in order for the idle position to be within +10 degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

P1121

Electric throttle control actuator

(When electric throttle control actuator does not function properly due to the return
spring malfunction:)
ECM controls the electric throttle actuator by regulating the throttle opening around the
idle position. The engine speed will not rise more than 2,000 rpm.

A

EC

C

D

E

(When throttle valve opening angle in fail-safe mode is not in specified range:)
ECM controls the electric throttle control actuator by regulating the throttle opening to
20 degrees or less.
(When ECM detects the throttle valve is stuck open:)
While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops,
the engine stalls.
The engine can restart in N or P (A/T), Neutral (M/T) position, and engine speed will
not exceed 1,000 rpm or more.
P1122

Electric throttle control function

ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.

P1124
P1126

Throttle control relay

ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.

P1128

Throttle control motor

ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.

P1229

Sensor power supply

ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.

P1805

Brake switch

ECM controls the electric throttle control actuator by regulating the throttle opening to a
small range.
Therefore, acceleration will be poor.

P2122
P2123
P2127
P2128
P2138
●

Accelerator pedal position
sensor

Vehicle condition

Driving condition

When engine is idling

Normal

When accelerating

Poor acceleration

The ECM controls the electric throttle control actuator in regulating the throttle opening
in order for the idle position to be within +10 degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

When there is an open circuit on MI circuit, the ECM cannot warn the driver by lighting up MI when there
is malfunction on engine control system.
Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected
as NG for 5 trips, ECM warns the driver that engine control system malfunctions and MI circuit is open by
means of operating fail-safe function.
The fail-safe function also operates when above diagnoses except MI circuit are detected and demands
the driver to repair the malfunction.
Engine operating condition in fail-safe mode

Engine speed will not rise more than 2,500 rpm due to the fuel cut

EC-1291

F

G

H

I

J

K

L

M

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]

Symptom Matrix Chart

BBS004KZ

SYSTEM — BASIC ENGINE CONTROL SYSTEM

1

1

2

3

2

Fuel pressure regulator system

3

3

4

4

4

Fuel injector circuit

1

1

2

3

2

Evaporative emission system

3

3

4

4

4

Air

Positive crankcase ventilation system

4

4

4

3

3

Incorrect idle speed adjustment

Ignition

BATTERY DEAD (UNDER CHARGE)

Fuel pump circuit

EXCESSIVE OIL CONSUMPTION

Fuel

EXCESSIVE FUEL CONSUMPTION

AE

OVERHEATS/WATER TEMPERATURE HIGH

LACK OF POWER/POOR ACCELERATION

AD

SLOW/NO RETURN TO IDLE

SPARK KNOCK/DETONATION

AC

IDLING VIBRATION

HESITATION/SURGING/FLAT SPOT

AB

ROUGH IDLE/HUNTING

ENGINE STALL

AA

Warranty symptom code

HIGH IDLE/LOW IDLE

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

AF

AG

AH

AJ

AK

AL

AM

HA

2

2

4

4

2

2

4

4

4

4

4

1
2

4

3
4

2

Reference
page

EC-1543

4

EC-1282

2

EC-1537

4

4

EC-1257

4

4

4

1

1

1

1

2

2

2

2

1

EC-1262
EC-1272

1

1

2

3

3

Incorrect ignition timing adjustment

3

3

1

1

1

1

1

1

EC-1272

Ignition circuit

1

1

2

2

2

2

2

2

EC-1580

2

2

3

3

3

3

3

Main power supply and ground circuit
Mass air flow sensor circuit
Engine coolant temperature sensor circuit

2

3

2
3

3

EC-1361

3
Heated oxygen sensor 1 circuit
2

2

2

2

2

2
3

Knock sensor circuit

2

2

EC-1373,
EC-1381 ,
EC-1549
EC-1367,
EC-1395 ,
EC-1467 ,
EC-1469 ,
EC-1511

Throttle position sensor circuit

Accelerator pedal position sensor circuit

EC-1337
EC-1354

1

1

2

EC-1430,
EC-1433

Electric throttle control actuator

2

EC-1471,
EC-1492 ,
EC-1501 ,
EC-1517

1

3

EC-1401

Crankshaft position sensor (POS) circuit

2

2

EC-1405

Camshaft position sensor (PHASE) circuit

3

2

EC-1413

Vehicle speed signal circuit
ECM
Intake valve timing control solenoid valve circuit

2

2

3

2

3

3

2

3
3

3

3

3

3

3

1

3

2

2

3

EC-1292

3

3

EC-1595

3

EC-1420,
EC-1423

3

EC-1425

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
SYMPTOM

HARD/NO START/RESTART (EXCP. HA)

ENGINE STALL

HESITATION/SURGING/FLAT SPOT

SPARK KNOCK/DETONATION

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

Warranty symptom code

AA

AB

AC

AD

AE

AF

AG

AH

AJ

AK

AL

AM

HA

PNP switch circuit

3

Refrigerant pressure sensor circuit

3

2

2

2

ABS actuator and electric unit (control unit)

3

3

3

Electrical load signal circuit
Air conditioner circuit

A

3

3

3

3

3

EC

Reference
page

D

E

3

EC-1479

4

EC-1590

3

EC-1528

3

ATC-20,
MTC-20

3

3

3

2

BRC-8,
BRC-49

4

C

1 — 6: The numbers refer to the order of inspection.
(continued on next page)

F

G

H

I

SYSTEM — ENGINE MECHANICAL & OTHER
SYMPTOM

Fuel

Fuel tank

HARD/NO START/RESTART (EXCP. HA)

ENGINE STALL

HESITATION/SURGING/FLAT SPOT

SPARK KNOCK/DETONATION

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

Warranty symptom code

J

AA

AB

AC

AD

AE

AF

AG

AH

AJ

AK

AL

AM

HA

Fuel piping

5

5

5

5

5

5

FL-14

—
5

5

5

5

5

5

5
—

EC-1293

L

M

—

5

Valve deposit
Poor fuel (Heavy weight gasoline, Low octane)

Reference
page

FL-19

5

Vapor lock

K

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]

Air

ENGINE STALL

HESITATION/SURGING/FLAT SPOT

SPARK KNOCK/DETONATION

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

Warranty symptom code

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

AA

AB

AC

AD

AE

AF

AG

AH

AJ

AK

AL

AM

HA

Air duct

EM-118

Air cleaner

EM-118

Air leakage from air duct
(Mass air flow sensor — electric
throttle control actuator)
Electric throttle control actuator

5

5

5

5
5

5

5

5

EM-118

5
5

EM-120

Air leakage from intake manifold/
Collector/Gasket
Cranking

EM-120

Battery
Generator circuit

SC-5
1

Starter circuit

3

Signal plate

6

PNP switch

Engine

Reference
page

1

1

1

1

1

1

SC-15
SC-45
EM-189

1

MT-16, MT46 , AT105 , AT293

4

Cylinder head
Cylinder head gasket

5

5

5

5

5

5

5

4

5

3

EM-173

Cylinder block
Piston

4

Piston ring
Connecting rod

6

6

6

6

6

6

6

6

EM-189

Bearing
Crankshaft
Valve
mechanism

Timing chain

EM-142

Camshaft

EM-151

Intake valve timing control

5

5

5

5

5

5

5

EM-151

5

Intake valve
3

Exhaust valve
Exhaust

Exhaust manifold/Tube/Muffler/
Gasket

5

5

5

5

5

Three way catalyst

EC-1294

5

5

5

EM-173

EX-3, EM124

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
SYMPTOM

Lubrication

Oil pan/Oil strainer/Oil pump/Oil
filter/Oil gallery

HARD/NO START/RESTART (EXCP. HA)

ENGINE STALL

HESITATION/SURGING/FLAT SPOT

SPARK KNOCK/DETONATION

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

Warranty symptom code

A

AA

AB

AC

AD

AE

AF

AG

AH

AJ

AK

AL

AM

HA

5

5

5

5

5

5

5

5

Oil level (Low)/Filthy oil
Cooling

Radiator/Hose/Radiator filler cap

C

D

E

EM-127,
LU-16 ,
LU-19

F

G

CO-31
5

CO-38

Water pump

H

CO-36
5

5

5

5

5

5

5

4

Cooling fan

5

CO-26
CO-31

5

Coolant level (Low)/Contaminated coolant
NATS (Nissan Anti-Theft System)

Reference
page

LU-16

Thermostat

Water gallery

EC

1

1

I

CO-27
BL-215

J

1 — 6: The numbers refer to the order of inspection.

K

L

M

EC-1295

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]

Engine Control Component Parts Location

BBS004L0

MBIB1542E

1.

Ignition coil (with power transistor)
and spark plug

2.

Intake valve timing control solenoid
valve

3.

Refrigerant pressure sensor

4.

Knock sensor

5.

Fuel injector

6.

Cooling fan motor

7.

Camshaft position sensor (PHASE)

8.

IPDM E/R

9.

ECM

11.

Engine coolant temperature sensor

12. Electric throttle control actuator
(with built-in throttle position sensor,
throttle control motor)

10. Mass air flow sensor
(with intake air temperature sensor)
13. EVAP canister purge volume control
solenoid valve

EC-1296

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
A

EC

C

D

E

F

G

H

I

J

K

L

M
PBIB2940E

: Vehicle front
1.

Mass air flow sensor
(with intake air temperature sensor)

2.

Engine coolant temperature sensor

3.

Electric throttle control actuator

4.

Camshaft position sensor (PHASE)

5.

Ignition coil (with power transistor)

6.

Fuel injector

7.

EVAP canister purge volume control
solenoid valve

EC-1297

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]

MBIB1543E

: Vehicle front
1.

ECM harness connectors

2.

ECM

3.

IPDM E/R

4.

Fuel pump fuse (15A)

5.

Intake valve timing control solenoid
valve

6.

Knock sensor

7.

Refrigerant pressure sensor

8.

PCV valve

EC-1298

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
A

EC

C

D

E
PBIB2942E

F

G

H

I
PBIB2943E

: Vehicle front
1.

Exhaust manifold

4.

Heated oxygen sensor 2 harness
connector

2.

Heated oxygen sensor 1

3.

Heated oxygen sensor 2

J

K

L

M

EC-1299

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]

MBIB1544E

1.

Cooling fan motor

2.

Crankshaft position sensor (POS)

3.

Stop lamp switch

4.

Brake pedal

5.

Accelerator pedal position sensor
harness connector

6.

Accelerator pedal position sensor

7.

Accelerator pedal

8.

Fuel level sensor unit and fuel pump
harness connector

9.

Fuel pump and fuel filter

10. Fuel pressure regulator

11. Fuel level sensor unit

EC-1300

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]

Vacuum Hose Drawing

BBS004L1

A

EC

C

D

E

F

G

H

I

J

K

L

M

PBIB2946E

: Vehicle front
1.

Intake manifold

: To EVAP canister
2.

EVAP canister purge volume control
solenoid valve

3.

EVAP purge resonator

NOTE:
Do not use soapy water or any type of solvent while installing vacuum hoses or purge hoses.

Refer to EC-1250, «System Diagram» for Vacuum Control System.

EC-1301

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]

Circuit Diagram

BBS004L2

MBWA1453E

EC-1302

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1454E

EC-1303

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]

ECM Harness Connector Terminal Layout

BBS004L3

PBIA9221J

ECM Terminals and Reference Value

BBS004L4

PREPARATION
1.

ECM (1) is located in the engine room left side near battery.
●

: Vehicle front

PBIB2959E

2.

3.

Disconnect ECM harness connector.
● When disconnecting ECM harness connector, loosen (A) it
with levers (1) as far as they will go as shown in the figure.
– ECM (2)
– Fasten (B)
Connect a break-out box (SST) and Y-cable adapter (SST)
between the ECM and ECM harness connector.
● Use extreme care not to touch 2 pins at one time.
● Data is for comparison and may not be exact.
PBIB2947E

ECM INSPECTION TABLE
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECMs transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Approximately 3.2V
[Ignition switch: ON]
1

P

Throttle control motor
(Open)

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed
PBIA8150J

2

LG

Throttle control motor power
supply

[Ignition switch: ON]

EC-1304

BATTERY VOLTAGE
(11 — 14V)

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

A

Approximately 10V

EC
[Engine is running]

3

Y

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

C

Heated oxygen sensor 1
heater
PBIA8148J

D

[Ignition switch: ON]
●

Engine stopped

[Engine is running]
●

BATTERY VOLTAGE
(11 — 14V)

E

Engine speed: Above 3,600 rpm
Approximately 1.8V

F

[Ignition switch: ON]
4

L

Throttle control motor
(Close)

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

G
PBIA8149J

[Engine is running]

5

GR

●

Below 3,600 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between
3,500 and 4,000 rpm for 1 minute and at
idle for 1 minute under no load

Heated oxygen sensor 2
heater

H

Approximately 10V

I

PBIA8148J

J

[Ignition switch: ON]
●

Engine stopped

[Engine is running]
●

BATTERY VOLTAGE
(11 — 14V)

K

BATTERY VOLTAGE

L

Engine speed: Above 3,600 rpm

(11 — 14V)
[Engine is running]
●

9

LG

M

Idle speed

EVAP canister purge volume control solenoid valve

PBIB0050E

Approximately 10V
[Engine is running]
●

Engine speed: About 2,000 rpm (More
than 100 seconds after starting engine)

PBIB0520E

10
11

B
B/W

ECM ground

[Engine is running]
●

Idle speed

EC-1305

Body ground

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

[Engine is running]
●

Warm-up condition

●

Idle speed

DATA (DC Voltage)

3 — 5V

NOTE:
The pulse cycle changes depending on
rpm at idle.
PBIA8164J

13

L

Tachometer signal
3 — 5V
[Engine is running]
●
●

Warm-up condition
Engine speed: 2,000 rpm

PBIA8165J

15

G

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 1.0V

Throttle control motor relay

[Engine is running]

17
18
21
22

V
BR
G
Y

●

Warm-up condition

●

Idle speed

0 — 0.3V

NOTE:
The pulse cycle changes depending on
rpm at idle.

Ignition signal No. 1
Ignition signal No. 2
Ignition signal No. 4
Ignition signal No. 3

PBIA9265J

0.2 — 0.5V
[Engine is running]
●
●

Warm-up condition
Engine speed: 2,500 rpm

PBIA9266J

[Ignition switch: ON]
●

23

R

Fuel pump relay

For 1 second after turning ignition switch
ON

0 — 1.0V

[Engine is running]
[Ignition switch: ON]
●

More than 1 second after turning ignition
switch ON

EC-1306

BATTERY VOLTAGE
(11 — 14V)

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

A

BATTERY VOLTAGE
[Engine is running]

25
29
30
31

R
O
GR
L

●

Warm-up condition

●

Idle speed

EC

(11 — 14V)

C

NOTE:
The pulse cycle changes depending on
rpm at idle.

Fuel injector No. 4
Fuel injector No. 3
Fuel injector No. 2
Fuel injector No. 1

PBIB0529E

D

BATTERY VOLTAGE
(11 — 14V)

E
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

F
PBIA4943J

[Engine is running]
[Ignition switch: OFF]
●

32

P

ECM relay
(Self shut-off)

For a few seconds after turning ignition
switch OFF

[Ignition switch: OFF]
●

More than a few seconds after turning
ignition switch OFF

G
0 — 1.0V

H
BATTERY VOLTAGE
(11 — 14V)

I

[Ignition switch: ON]

33

Y

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

More than 0.36V

J

Throttle position sensor 1
[Ignition switch: ON]
●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

K
Less than 4.75V

L

[Ignition switch: ON]

34

R

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

Throttle position sensor 2

Less than 4.75V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

More than 0.36V

[Engine is running]
36

37

BR

W

Sensor ground
(Throttle position sensor)

Knock sensor

●

Warm-up condition

●

Idle speed

[Engine is running]
●

38

P

Engine coolant temperature
sensor

Idle speed

[Engine is running]

EC-1307

Approximately 0V

Approximately 2.5V
Approximately 0 — 4.8V
Output voltage varies with engine
coolant temperature.

M

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]
40

—

Sensor ground
(Knock sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
41

44

BR

Refrigerant pressure sensor

B

Sensor ground
(Engine coolant temperature
sensor)

●

Warm-up condition

●

Both A/C switch and blower fan switch:
ON
(Compressor operates.)

1.0 — 4.0V

[Engine is running]
●

Warm-up condition

●

Idle speed

[Ignition switch: ON]
●

Engine stopped

Approximately 0V

Approximately 0.4V

[Engine is running]
45

G

Mass air flow sensor

●

Warm-up condition

●

Idle speed

[Engine is running]

46

V

Intake air temperature
sensor

48

Y

Sensor ground
(Refrigerant pressure sensor)

●

Warm-up condition

●

Engine is revving from idle to about 4,000
rpm

[Engine is running]

1.0 — 1.3V

1.0 — 1.3 to Approximately 2.4V
(Check for linear voltage rise in
response to engine being
increased to about 4,000 rpm.)
Approximately 0 — 4.8V
Output voltage varies with intake
air temperature.

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
49

BR

Heated oxygen sensor 1

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

[Engine is running]

50

B

Heated oxygen sensor 2

●

Revving engine from idle to 3,000 rpm
quickly after the following conditions are
met.

–

Engine: After warming up

–

Keeping the engine speed between
3,500 and 4,000 rpm for 1 minute and at
idle for 1 minute under no load.

0 — Approximately 1.0V

[Engine is running]
52

55

LG

O

Sensor ground
(Mass air flow sensor)
Sensor ground
(Intake air temperature sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
56

R

Sensor ground
(Heated oxygen sensor 1)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
59

LG

Sensor ground
(Heated oxygen sensor 2)

●

Warm-up condition

●

Idle speed

EC-1308

Approximately 0V

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

[Engine is running]
●

Warm-up condition

●

Idle speed

DATA (DC Voltage)

0 — 1.0V

EC

NOTE:
The pulse cycle changes depending on
rpm at idle.
61

Y

A

C
MBIB1453E

Crankshaft position sensor
(POS)

D

0 — 1.0V

E

[Engine is running]
●

Engine speed: 2,000 rpm

F
MBIB1454E

62

63

W

B

Sensor ground
[Crankshaft position sensor
(POS)]

[Engine is running]

Sensor ground
[Camshaft position sensor
(PHASE)]

[Engine is running]

●

Warm-up condition

●

Idle speed

●

Warm-up condition

●

Idle speed

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0V

G

Approximately 0V

H

0 — 1.0V

I

J

NOTE:
The pulse cycle changes depending on
rpm at idle.
65

R

MBIB1455E

Camshaft position sensor
(PHASE)

K

0 — 1.0V

L

[Engine is running]
●

Engine speed: 2,000 rpm

M
MBIB1456E

[Ignition switch: ON]
70

GR

Park/Neutral position (PNP)
switch

●

Shift lever: P or N (A/T models)

●

Shift lever: Neutral (M/T models)

[Ignition switch: ON]
●

72

L

Sensor power supply
(Throttle position sensor)

Except above position

[Ignition switch: ON]

EC-1309

Approximately 0V

BATTERY VOLTAGE
(11 — 14V)
Approximately 5V

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]
●

Warm-up condition

●

Idle speed

BATTERY VOLTAGE
(11 — 14V)
7 — 10V

73

LG

Intake valve timing control
solenoid valve

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

PBIA4937J

74

W

Sensor power supply
(Refrigerant pressure
sensor)

[Ignition switch: ON]

Approximately 5V

75

G

Sensor power supply
[Crankshaft position sensor
(POS)]

[Ignition switch: ON]

Approximately 5V

78

O

Sensor power supply
[Camshaft position sensor
(PHASE)]

[Ignition switch: ON]

Approximately 5V

83

Y

CAN communication line

[Ignition switch: ON]

Approximately 1.7 — 2.3V

84

L

CAN communication line

[Ignition switch: ON]

Approximately 2.6 — 3.2V

88

LG

DATA link connector

[Ignition switch: ON]
●

93

O

CONSULT-II: Disconnected.

[Ignition switch: OFF]

0V

[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)

Ignition switch
[Ignition switch: OFF]
●

99

R

Stop lamp switch

Brake pedal: Fully released

[Ignition switch: OFF]
●

102

BR

Sensor power supply
(Accelerator pedal position
sensor 2)

Approximately 2.7V

Brake pedal: Slightly depressed

[Ignition switch: ON]

Approximately 0V
BATTERY VOLTAGE
(11 — 14V)
Approximately 5V

[Ignition switch: ON]

103

104

G

B

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

Sensor ground
(Accelerator pedal position
sensor 2)

[Engine is running]
●

Warm-up condition

●

Idle speed

1.95 — 2.4V

Approximately 0V

105

G

Power supply for ECM

[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)

106

O

Sensor power supply
(Accelerator pedal position
sensor 1)

[Ignition switch: ON]

Approximately 5V

108

B

ECM ground

[Engine is running]
●

Idle speed

EC-1310

Body ground

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

A

[Ignition switch: ON]

110

111

W

B

Accelerator pedal position
sensor 1

Sensor ground
(Accelerator pedal position
sensor 1)

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

EC

3.9 — 4.7V

C

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

[Engine is running]
●

Warm-up condition

●

Idle speed

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Approximately 0V

D

E

F

G

H

I

J

K

L

M

EC-1311

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]

CONSULT-II Function (ENGINE)

BBS004L5

FUNCTION
Diagnostic test mode

Function

Work support

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

Self-diagnostic results

Self-diagnostic results such as 1st trip DTC, DTCs and 1st trip freeze frame data or freeze frame data
can be read and erased quickly.*

Data monitor

Input/Output data in the ECM can be read.

Data monitor (SPEC)

Input/Output of the specification for Basic fuel schedule, AFM, A/F feedback control value and the
other data monitor items can be read.

CAN diagnostic support
monitor

The results of transmit/receive diagnosis of CAN communication can be read.

Active test

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

Function test

This mode is used to inform customers when their vehicle condition requires periodic maintenance.

ECM part number

ECM part number can be read.

*: The following emission-related diagnostic information is cleared when the ECM memory is erased.
●

Diagnostic trouble codes

●

1st trip diagnostic trouble codes

●

Freeze frame data

●

1st trip freeze frame data

ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
DIAGNOSTIC TEST MODE
SELF-DIAGNOSTIC
RESULTS
Item

WORK
SUPPORT

1

DTC*

FREEZE
FRAME

DATA
MONITOR

DATA
MONITOR
(SPEC)

ACTIVE
TEST

INPUT

ENGINE CONTROL COMPONENT PARTS

DATA*2
Crankshaft position sensor (POS)

×

×

×

×

Camshaft position sensor (PHASE)

×

×

×

×

Mass air flow sensor

×

×

×

Engine coolant temperature sensor

×

×

×

Heated oxygen sensor 1

×

×

×

Heated oxygen sensor 2

×

×

×

Wheel sensor

×

×

×

Accelerator pedal position sensor

×

×

×

Throttle position sensor

×

×

×

Intake air temperature sensor

×

×

×

Knock sensor

×

EPS control unit

×

×

Refrigerant pressure sensor

×

×

Closed throttle position switch (accelerator
pedal position sensor signal)

×

×

Air conditioner switch

×

×

×

×

×

Park/neutral position (PNP) switch

×

×

×

Stop lamp switch

×

×

×

Battery voltage

×

×

Load signal

×

×

EC-1312

×

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
DIAGNOSTIC TEST MODE
SELF-DIAGNOSTIC
RESULTS

A
DATA
MONITOR

DATA
MONITOR
(SPEC)

ACTIVE
TEST

EC

Fuel injector

×

×

×

C

Power transistor (Ignition timing)

×

×

×

×

×

Item

WORK
SUPPORT

DTC*

1

FREEZE
FRAME

OUTPUT

ENGINE CONTROL COMPONENT PARTS

DATA*2

Throttle control motor relay

×

Throttle control motor

×

EVAP canister purge volume control solenoid valve

×

Air conditioner relay
×

Fuel pump relay

D
×

×

×

×

×

×

×
×

Cooling fan relay

×

×

×

Heated oxygen sensor 1 heater

×

×

×

Heated oxygen sensor 2 heater

×

×

×

Intake valve timing control solenoid valve

×

×

×

×

E

×

X: Applicable
*1: This item includes 1st trip DTCs.
*2: This mode includes 1st trip freeze frame data or freeze frame data. The items appear on CONSULT-II screen in freeze frame data
mode only if a 1st trip DTC or DTC is detected. For details, refer to EC-1266 .

F

G

H

INSPECTION PROCEDURE
Refer to GI-36, «CONSULT-II Start Procedure» .

I

WORK SUPPORT MODE
Work Item

J

WORK ITEM
FUEL PRESSURE RELEASE

IDLE AIR VOL LEARN

SELF-LEARNING CONT

CONDITION
●

●

●

USAGE

FUEL PUMP WILL STOP BY TOUCHING “START” DURING IDLING.
CRANK A FEW TIMES AFTER ENGINE STALLS.

When releasing fuel pressure
from fuel line

THE IDLE AIR VOLUME THAT KEEPS THE ENGINE
WITHIN THE SPECIFIED RANGE IS MEMORIZED IN
ECM.

When learning the idle air volume

THE COEFFICIENT OF SELF-LEARNING CONTROL
MIXTURE RATIO RETURNS TO THE ORIGINAL COEFFICIENT.

When clearing the coefficient of
self-learning control value

L

TARGET IDLE RPM ADJ*

●

IDLE CONDITION

When setting target idle speed

TARGET IGN TIM ADJ*

●

IDLE CONDITION

When adjusting target ignition timing

*: This function is not necessary in the usual service procedure.

SELF-DIAG RESULTS MODE
Self Diagnostic Item
Regarding items of DTC and 1st trip DTC, refer to EC-1264, «EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS» .

EC-1313

K

M

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
Freeze Frame Data and 1st Trip Freeze Frame Data
Freeze frame data
item*
DIAG TROUBLE
CODE
[PXXXX]

Description
●

The engine control component part/control system has a trouble code, it is displayed as PXXXX. (Refer to
EC-1239, «INDEX FOR DTC» .)

●

“Fuel injection system status” at the moment a malfunction is detected is displayed.

●

One mode in the following is displayed.
Mode2: Open loop due to detected system malfunction
Mode3: Open loop due to driving conditions (power enrichment, deceleration enleanment)
Mode4: Closed loop — using oxygen sensor(s) as feedback for fuel control
Mode5: Open loop — has not yet satisfied condition to go to closed loop

CAL/LD VALUE [%]

●

The calculated load value at the moment a malfunction is detected is displayed.

COOLANT TEMP
[°C] or [°F]

●

The engine coolant temperature at the moment a malfunction is detected is displayed.

●

“Long-term fuel trim” at the moment a malfunction is detected is displayed.

●

The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule
than short-term fuel trim.

●

“Short-term fuel trim” at the moment a malfunction is detected is displayed.

S-FUEL TRM-B1 [%]

●

The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel
schedule.

ENGINE SPEED
[rpm]

●

The engine speed at the moment a malfunction is detected is displayed.

VEHICL SPEED
[km/h] or [mph]

●

The vehicle speed at the moment a malfunction is detected is displayed.

B/FUEL SCHDL
[msec]

●

The base fuel schedule at the moment a malfunction is detected is displayed.

INT/A TEMP SE
[°C] or [°F]

●

The intake air temperature at the moment a malfunction is detected is displayed.

FUEL SYS-B1

L-FUEL TRM-B1 [%]

*: The items are the same as those of 1st trip freeze frame data.

DATA MONITOR MODE
Monitored Item
Monitored item
[Unit]

ECM
INPUT
SIGNALS

×: Applicable
MAIN
SIGNALS

Description

●

ENG SPEED [rpm]

×

×

MAS A/F SE-B1 [V]

×

×

B/FUEL SCHDL
[msec]

A/F ALPHA-B1 [%]

●

The signal voltage of the mass air flow sensor
is displayed.

●

“Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior
to any learned on board correction.

×

×

Indicates the engine speed computed from the
signals of the crankshaft position sensor
(POS) and camshaft position sensor (PHASE).

●

The mean value of the air-fuel ratio feedback
correction factor per cycle is indicated.

EC-1314

Remarks
●

Accuracy becomes poor if engine
speed drops below the idle rpm.

●

If the signal is interrupted while
the engine is running, an abnormal value may be indicated.

●

When the engine is stopped, a
certain value is indicated.

●

When the engine is stopped, a
certain value is indicated.

●

This data also includes the data
for the air-fuel ratio learning control.

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
Monitored item
[Unit]

ECM
INPUT
SIGNALS

MAIN
SIGNALS

Description

Remarks
●

COOLAN TEMP/S
[°C] or [°F]

●

×

HO2S1 (B1) [V]

×

HO2S2 (B1) [V]

×

×

×

The engine coolant temperature (determined
by the signal voltage of the engine coolant
temperature sensor) is displayed.

●

The signal voltage of the heated oxygen sensor 1 is displayed.

●

The signal voltage of the heated oxygen sensor 2 is displayed.

●

Display of heated oxygen sensor 1 signal during air-fuel ratio feedback control:
RICH: means the mixture became “rich”, and
control is being affected toward a leaner mixture.
LEAN: means the mixture became “lean”, and
control is being affected toward a rich mixture.

×

×

●

Display of heated oxygen sensor 2 signal:
RICH: means the amount of oxygen after three
way catalyst is relatively small.
LEAN: means the amount of oxygen after
three way catalyst is relatively large.

HO2S2 MNTR (B1)
[RICH/LEAN]

×

VHCL SPEED SE
[km/h] or [mph]

×

×

●

BATTERY VOLT [V]

×

×

●

The power supply voltage of ECM is displayed.

ACCEL SEN 1 [V]

×

×
●

The accelerator pedal position sensor signal
voltage is displayed.

ACCEL SEN 2 [V]

×

THRTL SEN 1 [V]

×

THRTL SEN 2 [V]

×

INT/A TEMP SE
[°C] or [°F]

×

START SIGNAL
[ON/OFF]

×

×

CLSD THL POS
[ON/OFF]

×

×

AIR COND SIG
[ON/OFF]

×

×

P/N POSI SW
[ON/OFF]

×

×

PW/ST SIGNAL
[ON/OFF]

×

×

●

●

×

●

●

After turning ON the ignition
switch, “RICH” is displayed until
air-fuel mixture ratio feedback
control begins.
When the air-fuel ratio feedback
is clamped, the value just before
the clamping is displayed continuously.

When the engine is stopped, a
certain value is indicated.

The vehicle speed computed from the vehicle
speed signal is displayed.

×

●

ACCEL SEN 2 signal is converted by ECM internally. Thus, it
differs from ECM terminal voltage
signal.

●

THRTL SEN 2 signal is converted by ECM internally. Thus, it
differs from ECM terminal voltage
signal.

The intake air temperature (determined by the
signal voltage of the intake air temperature
sensor) is indicated.
Indicates start signal status [ON/OFF] computed by the ECM according to the signals of
engine speed and battery voltage.

●

Indicates idle position [ON/OFF] computed by
the ECM according to the accelerator pedal
position sensor signal.

●

Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioner signal.

●

Indicates [ON/OFF] condition from the park/
neutral position (PNP) switch signal.

●

[ON/OFF] condition of the power steering system (determined by the signal sent from EPS
control unit) is indicated.

EC-1315

C

E

F

G

H

I

The throttle position sensor signal voltage is
displayed.

●

EC

D
●

HO2S1 MNTR (B1)
[RICH/LEAN]

When the engine coolant temperature sensor is open or shortcircuited, ECM enters fail-safe
mode. The engine coolant temperature determined by the ECM
is displayed.

A

J

K

L

M
●

After starting the engine, [OFF] is
displayed regardless of the
starter signal.

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
Monitored item
[Unit]

ECM
INPUT
SIGNALS

MAIN
SIGNALS

Description
●

Indicates [ON/OFF] condition from the electrical load signal.
ON: Rear window defogger switch is ON and/
or lighting switch is in 2nd position.
OFF: Both rear window defogger switch and
lighting switch are OFF.

Remarks

LOAD SIGNAL
[ON/OFF]

×

IGNITION SW
[ON/OFF]

×

●

Indicates [ON/OFF] condition from ignition
switch.

HEATER FAN SW
[ON/OFF]

×

●

Indicates [ON/OFF] condition from the heater
fan switch signal.

BRAKE SW
[ON/OFF]

×

●

Indicates [ON/OFF] condition from the stop
lamp switch signal.

●

Indicates the actual fuel injection pulse width
compensated by ECM according to the input
signals.

●

When the engine is stopped, a
certain computed value is indicated.

●

Indicates the ignition timing computed by ECM
according to the input signals.

●

When the engine is stopped, a
certain value is indicated.

●

Indicates the EVAP canister purge volume
control solenoid valve control value computed
by the ECM according to the input signals.

●

The opening becomes larger as the value
increases.

●

Indicates [°CA] of intake camshaft advanced
angle.

●

The control value of the intake valve timing
control solenoid valve (determined by ECM
according to the input signal) is indicated.

●

The advance angle becomes larger as the
value increases

●

The air conditioner relay control condition
(determined by ECM according to the input
signals) is indicated.

●

Indicates the fuel pump relay control condition
determined by ECM according to the input signals.

●

Indicates the throttle control motor relay control condition determined by the ECM according to the input signals.

●

Indicates the condition of the cooling fan
(determined by ECM according to the input
signals).
HI: High speed operation
LOW: Low speed operation
OFF: Stop

●

Indicates [ON/OFF] condition of heated oxygen sensor 1 heater determined by ECM
according to the input signals.

●

Indicates [ON/OFF] condition of heated oxygen sensor 2 heater determined by ECM
according to the input signals.

×

INJ PULSE-B1
[msec]

×

IGN TIMING [BTDC]

×

PURG VOL C/V [%]

INT/V TIM (B1)
[°CA]

INT/V SOL (B1) [%]

AIR COND RLY
[ON/OFF]

×

FUEL PUMP RLY
[ON/OFF]

×

THRTL RELAY
[ON/OFF]

×

COOLING FAN
[HI/LOW/OFF]

HO2S1 HTR (B1)
[ON/OFF]
HO2S2 HTR (B1)
[ON/OFF]

EC-1316

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
Monitored item
[Unit]

ECM
INPUT
SIGNALS

MAIN
SIGNALS

Description
●

IDL A/V LEARN
[YET/CMPLT]

O2SEN HTR DTY
[%]

Remarks

Display the condition of idle air volume learning
YET: Idle Air Volume Learning has not been
performed yet.
CMPLT: Idle Air Volume Learning has already
been performed successfully.

●

Indicates the heated oxygen sensor 1 heater
control value computed by the ECM according
to the input signals.
Indicates the engine speed computed from the
furbine revolution sensor signal.
The signal voltage from the refrigerant pressure sensor is displayed.

I/P PULLY SPD
[km/h] or [MPH]

×

●

AC PRESS SEN [V]

×

●

A

EC

C

D

E

Voltage [V]
Frequency
[msec], [Hz] or [%]
●

DUTY-HI
DUTY-LOW

Voltage, frequency, duty cycle or pulse width
measured by the probe.

PLS WIDTH-HI

●

Only “#” is displayed if item is
unable to be measured.

●

Figures with “#”s are temporary
ones. They are the same figures
as an actual piece of data which
was just previously measured.

PLS WIDTH-LOW

F

G

H

NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

I

DATA MONITOR (SPEC) MODE
Monitored Item
Monitored item [Unit]

ENG SPEED [rpm]

MAS A/F SE-B1 [V]

B/FUEL SCHDL
[msec]

ECM
INPUT
SIGNALS

×

×

J

MAIN
SIGNALS

Description

●

Indicates the engine speed computed
from the signal of the crankshaft position
sensor (POS) and camshaft position
sensor (PHASE).

●

The signal voltage of the mass air flow
sensor specification is displayed.

●

“Base fuel schedule” indicates the fuel
injection pulse width programmed into
ECM, prior to any learned on board correction.

×

×

×

●

A/F ALPHA-B1 [%]

×

The mean value of the air-fuel ratio feedback correction factor per cycle is indicated.

Remarks

K

L
●

When engine is running specification
range is indicated.

●

When engine is running specification
range is indicated.

●

When engine is running specification
range is indicated.

●

This data also includes the data for the
air-fuel ratio learning control.

M

NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

EC-1317

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
ACTIVE TEST MODE
Test Item
TEST ITEM

CONDITION
●

FUEL INJECTION

●

IGNITION TIMING

POWER BALANCE

COOLING FAN*

Engine: Return to the original
trouble condition

●

Timing light: Set

●

Retard the ignition timing using
CONSULT-II.

●

Engine: After warming up, idle
the engine.

●

A/C switch OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

Ignition switch: ON

●

Turn the cooling fan “LOW”,
“MID”, “HI” and “OFF” with CONSULT-II.

FUEL PUMP
RELAY

PURG VOL
CONT/V

●

Engine: Return to the original
trouble condition

●

Change the engine coolant temperature using CONSULT-II.

●

Ignition switch: ON (Engine
stopped)

●

Turn the fuel pump relay ON and
OFF using CONSULT-II and listen to operating sound.

●

Engine: After warming up, run
engine at 1,500 rpm.

●

Change the EVAP canister purge
volume control solenoid valve
opening percent using CONSULT-II.

●

V/T ASSIGN
ANGLE

●

Engine: Return to the original
trouble condition
Change intake valve timing using
CONSULT-II.

CHECK ITEM (REMEDY)
●

Harness and connectors

●

Fuel injector

●

Air fuel ratio (A/F) sensor 1

●

Perform Idle Air Volume Learning.

●

Harness and connectors

●

Compression

●

Fuel injector

●

Power transistor

●

Spark plug

●

Ignition coil

●

Harness and connectors

●

Cooling fan relay

●

Cooling fan motor

●

Harness and connectors

●

Engine coolant temperature sensor

●

Fuel injector

Fuel pump relay makes the operating sound.

●

Harness and connectors

●

Fuel pump relay

Engine speed changes according to
the opening percent.

●

Harness and connectors

●

Solenoid valve

●

Harness and connectors

●

Intake valve timing control solenoid valve

If trouble symptom disappears, see
CHECK ITEM.

If trouble symptom disappears, see
CHECK ITEM.

Engine runs rough or dies.

Cut off each fuel injector signal
one at a time using CONSULT-II.

●

, *2 , *3

ENG COOLANT
TEMP

Change the amount of fuel injection using CONSULT-II.

●

●

1

Engine: Return to the original
trouble condition

JUDGEMENT

Cooling fan moves and stops.

If trouble symptom disappears, see
CHECK ITEM.

If trouble symptom disappears, see
CHECK ITEM.

*1: Leaving cooling fan OFF with CONSULT-II while engine is running may cause the engine to overheat.
*2: With A/C: “OFF”, “LOW”, “MID” or “HI” is displayed on CONSULT-II screen. But cooling fan operates at the same speed when “MID”
or “HI” is displayed.
*3: Without A/C: “OFF”, “LOW”, “MID” or “HI” is displayed on CONSULT-II screen. But cooling fan operates at the same speed when an
item other than “OFF” is displayed.

EC-1318

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA)
Description

A

CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR”
mode.
EC
1. “AUTO TRIG” (Automatic trigger):
● The malfunction will be identified on the CONSULT-II screen
in real time.
C
In other words, DTC/1st trip DTC and malfunction item will be
displayed if the malfunction is detected by ECM.
At the moment a malfunction is detected by ECM, “MONITOR” in “DATA MONITOR” screen is changed to “Recording
D
Data … xx%” as shown at right, and the data after the malfunction detection is recorded. Then when the percentage
reached 100%, “REAL-TIME DIAG” screen is displayed. If
E
“STOP” is touched on the screen during “Recording Data …
PBIB1593E
xx%”, “REAL-TIME DIAG” screen is also displayed.
The recording time after the malfunction detection and the
recording speed can be changed by “TRIGGER POINT” and
F
“Recording Speed”. Refer to CONSULT-II OPERATION MANUAL.
2. “MANU TRIG” (Manual trigger):
G
● DTC/1st trip DTC and malfunction item will not be displayed
automatically on CONSULT-II screen even though a malfunction is detected by ECM.
H
DATA MONITOR can be performed continuously even though
a malfunction is detected.
SEF707X

I

J

K

L

M

EC-1319

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
Operation
1.

2.

“AUTO TRIG”
● While trying to detect the DTC/1st trip DTC by performing the “DTC Confirmation Procedure”, be sure
to select to “DATA MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is
detected.
● While narrowing down the possible causes, CONSULT-II should be set in “DATA MONITOR (AUTO
TRIG)” mode, especially in case the incident is intermittent.
When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components and harness in the “DTC Confirmation Procedure”, the moment a malfunction is found the DTC/
1st trip DTC will be displayed. (Refer to “INCIDENT SIMULATION TESTS” in GI-25, «How to Perform
Efficient Diagnosis for an Electrical Incident» .)
“MANU TRIG”
● If the malfunction is displayed as soon as “DATA MONITOR” is selected, reset CONSULT-II to “MANU
TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The data can be utilized for further diagnosis, such as a comparison with the value for the normal operating condition.

PBIB0197E

EC-1320

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]

CONSULT-II Reference Value in Data Monitor

BBS004L6

Remarks:
● Specification data are reference values.
● Specification data are output/input values which are detected or supplied by the ECM at the connector.
* Specification data may not be directly related to their components signals/values/operations.
i.e. Adjust ignition timing with a timing light before monitoring IGN TIMING, because the monitor may show the specification data in
spite of the ignition timing not being adjusted to the specification data. This IGN TIMING monitors the data calculated by the ECM
according to the signals input from the camshaft position sensor and other ignition timing related sensors.
MONITOR ITEM
CONDITION
SPECIFICATION
●

ENG SPEED

Run engine and compare CONSULT-II value with the tachometer indication.

MAS A/F SE-B1

See EC-1326, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .

B/FUEL SCHDL

See EC-1326, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .

A/F ALPHA-B1

See EC-1326, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .

COOLAN TEMP/S

●

Almost the same speed as
the tachometer indication.

More than 70°C (158°F)

●

Engine: After warming up

0 — 0.3V ←→ Approx. 0.6 1.0V

●

Revving engine from idle to 3,000 rpm quickly after the following conditions
are met.

–

Engine: After warming up.

–

Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute
and idle for 1 minute under no load.

●

Engine: After warming up

●

Revving engine from idle to 3,000 rpm quickly after the following conditions
are met.

–

Engine: After warming up.

–

Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute
and idle for 1 minute under no load.

●

Turn drive wheels and compare CONSULT-II value with the speedometer
indication.

Almost the same speed as
the speedometer indication.

●

Ignition switch: ON (Engine stopped)

11 — 14V

●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

4.0 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

3.9 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

More than 0.36V

●

Shift lever: D (A/T), 1st (M/T)

Accelerator pedal: Fully depressed

Less than 4.75V

START SIGNAL

●

Ignition switch: ON → START → ON

CLSD THL POS

●

Ignition switch: ON

HO2S2 (B1)

HO2S1 MNTR (B1)

HO2S2 MNTR (B1)

VHCL SPEED SE
BATTERY VOLT
ACCEL SEN 1

ACCEL SEN 2*1

●

THRTL SEN 1
THRTL SEN 2*

●

1

AIR COND SIG

P/N POSI SW

PW/ST SIGNAL

●

●

●

Engine: After warming up, idle
the engine

Ignition switch: ON
Engine: After warming up, idle
the engine

Maintaining engine speed at 2,000 rpm

Maintaining engine speed at 2,000 rpm

C

E

F
0 — 0.3V ←→ Approx. 0.6 1.0V

G
LEAN ←→ RICH
Changes more than 5 times
during 10 seconds.

LEAN ←→ RICH

OFF → ON → OFF

Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates.)

ON

Shift lever: P or N (A/T), Neutral (M/T)

ON

Shift lever: Except above

OFF

Steering wheel: Not being turned.

OFF

Steering wheel: Being turned.

ON

EC-1321

EC

D

Engine: After warming up

HO2S1 (B1)

A

H

I

J

K

L

M

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
MONITOR ITEM

LOAD SIGNAL

CONDITION

●

Ignition switch: ON

IGNITION SW

●

Ignition switch: ON → OFF → ON

HEATER FAN SW

●

Ignition switch: ON

Rear window defogger switch: ON
and/or
Lighting switch: 2nd

ON

Rear window defogger switch and
lighting switch: OFF

OFF
ON → OFF → ON

Heater fan: Operating.

BRAKE SW

INJ PULSE-B1

IGN TIMING

PURG VOL C/V

INT/V TIM (B1)

INT/V SOL (B1)

AIR COND RLY

FUEL PUMP RLY

THRTL RELAY

●

Ignition switch: ON

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

●

Engine: After warming up, idle
the engine

SPECIFICATION

ON

Heater fan: Not operating

OFF

Brake pedal: Fully released

OFF

Brake pedal: Slightly depressed

ON

Idle

2.0 — 3.0 msec

2,000 rpm

1.9 — 2.9 msec

Idle

1° — 11° BTDC

2,000 rpm

25° — 45° BTDC

Idle

0%

2,000 rpm

0 — 50%

Idle

−5° — 5°CA

2,500 rpm

Approx. 0° — 40°CA

Idle

0% — 2%

2,500 rpm

Approx. 0% — 90%

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates)

ON

●

For 1 second after turning ignition switch ON

●

Engine running or cranking

●

Except above conditions

OFF

●

Ignition switch: ON

ON

●

COOLING FAN
●

Engine: After warming up, idle
the engine
Air conditioner switch: OFF

ON

Engine coolant temperature is 94°C
(201°F) or less

OFF

Engine coolant temperature is between
95°C (203°F) and 99°C (210°F)

LOW*2

Engine coolant temperature is 100°C
(212°F) or more

HIGH*2

EC-1322

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
MONITOR ITEM

CONDITION
●

HO2S1 HTR (B1)

HO2S2 HTR (B1)

I/P PULLY SPD

SPECIFICATION

A

Engine: After warming up

ON

●

Engine speed: Below 3,600 rpm

●

Engine speed: Above 3,600 rpm

●

Below 3,600 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and
at idle for 1 minute under no load

●

Engine speed: Above 3,600 rpm

OFF

●

Vehicle speed: More than 20 km/h (12 MPH)

Almost the same speed as
the tachometer indication

D

●

Engine coolant temperature when engine started: More than 80°C (176°F)
Engine speed: below 3,600 rpm

Approx. 30%

●

E

●

Engine: Idle

●

Air conditioner switch: ON (Compressor operates)

O2SEN HTR DTY

AC PRESS SEN

OFF

EC

ON

C

1.0 — 4.0V

*1: Accelerator pedal position sensor 2 signal and throttle position sensor 2 signal are converted by ECM internally. Thus, they differ
from ECM terminals voltage signal.
*2: Models without air conditioner, cooling fan operates only ON and OFF operation, but CONSULT-II display will change OFF, LOW and
HI depends on engine coolant temperature.

F

G

H

I

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K

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M

EC-1323

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]

Major Sensor Reference Graph in Data Monitor Mode

BBS004L7

The following are the major sensor reference graphs in “DATA MONITOR” mode.

CLSD THL POS, ACCEL SEN 1, THRTL SEN 1
Below is the data for “CLSD THL POS”, “ACCEL SEN 1” and “THRTL SEN 1” when depressing the accelerator pedal with the ignition switch ON and with shift lever in D position (A/T), 1st position (M/T).
The signal of “ACCEL SEN 1” and “THRTL SEN 1” should rise gradually without any intermittent drop or rise
after “CLSD THL POS” is changed from “ON” to “OFF”.

PBIB0198E

ENG SPEED, MAS A/F SE-B1, THRTL SEN 1, HO2S2 (B1), INJ PULSE-B1
Below is the data for “ENG SPEED”, “MAS A/F SE-B1”, “THRTL SEN 1”, “HO2S2 (B1)” and “INJ PULSE-B1”
when revving engine quickly up to 4,800 rpm under no load after warming up engine sufficiently.
Each value is for reference, the exact value may vary.

PBIB2445E

EC-1324

TROUBLE DIAGNOSIS
[HR (WITHOUT EURO-OBD)]
A

EC

C

D

E

F

G

H

I

J

K

L

M

PBIB0668E

EC-1325

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITHOUT EURO-OBD)]

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
Description

PFP:00031
BBS004L8

The specification (SP) value indicates the tolerance of the value that is displayed in “DATA MONITOR (SPEC)”
mode of CONSULT-II during normal operation of the Engine Control System. When the value in “DATA MONITOR (SPEC)” mode is within the SP value, the Engine Control System is confirmed OK. When the value in
“DATA MONITOR (SPEC)” mode is NOT within the SP value, the Engine Control System may have one or
more malfunctions.
The SP value is used to detect malfunctions that may affect the Engine Control System, but will not light the
MI.
The SP value will be displayed for the following three items:
●
B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board correction)
●
A/F ALPHA-B1 (The mean value of air-fuel ratio feedback correction factor per cycle)
●
MAS A/F SE-B1 (The signal voltage of the mass air flow sensor)

Testing Condition
●
●
●
●
●
●
–

–
●
–

BBS004L9

Vehicle driven distance: More than 5,000 km (3,107 miles)
Barometric pressure: 98.3 — 104.3 kPa (0.983 — 1.043 bar, 1.003 — 1.064 kg/cm2 , 14.25 — 15.12 psi)
Atmospheric temperature: 20 — 30°C (68 — 86°F)
Engine coolant temperature: 75 — 95°C (167 — 203°F)
Engine speed: Idle
Transmission: Warmed-up
A/T models: After the engine is warmed up to normal operating temperature, drive vehicle until “FLUID
TEMP SE” (A/T fluid temperature sensor signal) indicates more than 60°C (140°F).
M/T models: After the engine is warmed up to normal operating temperature, drive vehicle for 5 minutes.
Electrical load: Not applied
Rear window defogger switch, air conditioner switch, lighting switch are OFF. Steering wheel is straight
ahead.

Inspection Procedure

BBS004LA

NOTE:
Perform “DATA MONITOR (SPEC)” mode in maximum scale display.
1. Perform EC-1272, «Basic Inspection» .
2. Confirm that the testing conditions indicated above are met.
3. Select “B/FUEL SCHDL”, “A/F ALPHA-B1” and “MAS A/F SEB1” in “DATA MONITOR (SPEC)” mode with CONSULT-II.
4. Make sure that monitor items are within the SP value.
5. If NG, go to EC-1327, «Diagnostic Procedure» .

SEF601Z

EC-1326

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004LB

A

OVERALL SEQUENCE

EC

C

D

E

F

G

H

I

J

K

L

M

PBIB2384E

EC-1327

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITHOUT EURO-OBD)]

PBIB3213E

EC-1328

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITHOUT EURO-OBD)]
DETAILED PROCEDURE
A

1. CHECK “A/F ALPHA-B1”
1.
2.
3.

Start engine.
Confirm that the testing conditions are met. Refer to EC-1326, «Testing Condition» .
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode,
and make sure that the each indication is within the SP value.
NOTE:
Check “A/F ALPHA-B1” for approximately 1 minute because
they may fluctuate. It is NG if the indication is out of the SP value
even a little.
OK or NG
OK
>> GO TO 17.
NG (Less than the SP value)>>GO TO 2.
NG (More than the SP value)>>GO TO 3.

EC

C

D

E
PBIB2369E

2. CHECK “B/FUEL SCHDL”

F

Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and
make sure that the indication is within the SP value.
OK or NG
OK
>> GO TO 4.
NG (More than the SP value)>>GO TO 19.

G

H

I
PBIB2332E

J

3. CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and
make sure that the indication is within the SP value.
OK or NG
OK
>> GO TO 6.
NG (More than the SP value)>>GO TO 6.
NG (Less than the SP value)>>GO TO 25.

K

L

M

PBIB2332E

4. CHECK “A/F ALPHA-B1”
1.
2.
3.
4.

Stop the engine.
Disconnect PCV hose, and then plug it.
Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is
within the SP value.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 6.

EC-1329

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITHOUT EURO-OBD)]

5. CHANGE ENGINE OIL
1.
2.

Stop the engine.
Change engine oil.
NOTE:
This symptom may occur when a large amount of gasoline is mixed with engine oil because of driving
conditions (such as when engine oil temperature does not rise enough since a journey distance is too
short during winter). The symptom will not be detected after changing engine oil or changing driving condition.
>> INSPECTION END

6. CHECK FUEL PRESSURE
Check fuel pressure. (Refer to EC-1282, «FUEL PRESSURE CHECK» .)
OK or NG
OK
>> GO TO 9.
NG (Fuel pressure is too high)>>Replace fuel pressure regulator, refer to EC-1282, «FUEL PRESSURE
CHECK» . GO TO 8.
NG (Fuel pressure is too low)>>GO TO 7.

7. DETECT MALFUNCTIONING PART
1.
–
–
–

2.

Check the following.
Clogged and bent fuel hose and fuel tube
Clogged fuel filter
Fuel pump and its circuit (Refer to EC-1543, «FUEL PUMP» .)
If NG, repair or replace the malfunctioning part. (Refer to EC-1282, «FUEL PRESSURE CHECK» .)
If OK, replace fuel pressure regulator.
>> GO TO 8.

8. CHECK “A/F ALPHA-B1”
1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is
within the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 9.

9. PERFORM POWER BALANCE TEST
1.
2.

Perform “POWER BALANCE” in “ACTIVE TEST” mode.
Make sure that the each cylinder produces a momentary engine
speed drop.
OK or NG
OK
>> GO TO 12.
NG
>> GO TO 10.

PBIB0133E

EC-1330

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITHOUT EURO-OBD)]

10. DETECT MALFUNCTIONING PART
1.
–
–
–
–

2.

A

Check the following.
Ignition coil and its circuit (Refer to EC-1580, «IGNITION SIGNAL» .)
Fuel injector and its circuit (Refer to EC-1537, «FUEL INJECTOR» .)
Intake air leakage
Low compression pressure (Refer to EM-173, «CHECKING COMPRESSION PRESSURE» .)
If NG, repair or replace the malfunctioning part.
If OK, replace fuel injector. (It may be caused by leakage from fuel injector or clogging.)

EC

C

D

>> GO TO 11.

11. CHECK “A/F ALPHA-B1”

E

1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is
within the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 12.

F

G

12. CHECK HEATED OXYGEN SENSOR 1 FUNCTION
1.
2.
3.

H

Run engine at about 2,000 rpm for about 2 minutes under no load.
Select “HO2S1 MNTR (B1)”, in “DATA MONITOR” mode.
Running engine at 2,000 rpm under no load (The engine is
warmed up to normal operating temperature.), check that the
monitor fluctuates between LEAN and RICH more than 5 times
during 10 seconds.
1 time
2 times

I

J

: RICH → LEAN → RICH
: RICH → LEAN → RICH → LEAN → RICH

K

OK or NG
OK
>> GO TO 15.
NG
>> GO TO 13.
SEF820Y

L

13. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT
Check heated oxygen sensor 1 and its circuit. Refer to EC-1381, «DTC P0134 HO2S1» .
>> GO TO 14.

14. CHECK “A/F ALPHA-B1”
1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is
within the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 15.

EC-1331

M

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITHOUT EURO-OBD)]

15. DISCONNECT AND RECONNECT ECM HARNESS CONNECTOR
1.
2.

Stop the engine.
Disconnect ECM harness connector. Check pin terminal and connector for damage, and then reconnect it.
>> GO TO 16.

16. CHECK “A/F ALPHA-B1”
1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is
within the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> Detect malfunctioning part according to EC-1292, «Symptom Matrix Chart»

17. CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and
make sure that the indication is within the SP value.
OK or NG
OK
>> INSPECTION END
NG (More than the SP value)>>GO TO 18.
NG (Less than the SP value)>>GO TO 25.

PBIB2332E

18. DETECT MALFUNCTIONING PART
1.
–
–
–
–
–

2.
–
–
–

Check for the cause of large engine friction. Refer to the following.
Engine oil level is too high
Engine oil viscosity
Belt tension of power steering, alternator, A/C compressor, etc. is excessive
Noise from engine
Noise from transmission, etc.
Check for the cause of insufficient combustion. Refer to the following.
Valve clearance malfunction
Intake valve timing control function malfunction
Camshaft sprocket installation malfunction, etc.
>> Repair or replace malfunctioning part, and then GO TO 30.

19. CHECK INTAKE SYSTEM
Check for the cause of uneven air flow through mass air flow sensor. Refer to the following.
●
Crushed air ducts
●
Malfunctioning seal of air cleaner element
●
Uneven dirt of air cleaner element
●
Improper specification of intake air system
OK or NG
OK
>> GO TO 21.
NG
>> Repair or replace malfunctioning part, and then GO TO 20.

EC-1332

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITHOUT EURO-OBD)]

20. CHECK “A/F ALPHA-B1” AND “B/FUEL SCHDL”

A
Select “A/F ALPHA-B1” and “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the
each indication is within the SP value.
EC
OK or NG
OK
>> INSPECTION END
NG (“B/FUEL SCHDL” is more, “A/F ALPHA-B1” is less than the SP value)>>GO TO 21.
C
DISCONNECT AND RECONNECT MASS AIR FLOW SENSOR HARNESS CONNECTOR

21.
1.
2.

Stop the engine.
Disconnect mass air flow sensor harness connector. Check pin terminal and connector for damage and
then reconnect it again.

D

E

>> GO TO 22.

22. CHECK “A/F ALPHA-B1”

F

1.
2.

Start engine.
Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is
within the SP value.
OK or NG
OK
>> 1. Detect malfunctioning part of mass air flow sensor circuit and repair it. Refer to EC-1354, «DTC
P0102, P0103 MAF SENSOR» .
2. GO TO 29.
NG
>> GO TO 23.

G

H

I

23. CHECK “MAS A/F SE-B1”
Select “MAS A/F SE-B1” in “DATA MONITOR (SPEC)” mode, and
make sure that the indication is within the SP value.
OK or NG
OK
>> GO TO 24.
NG (More than the SP value)>>Replace mass air flow sensor, and
then GO TO 29.

J

K

L

PBIB2370E

24. REPLACE ECM
1.
2.
3.
4.
5.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
Perform EC-1278, «Accelerator Pedal Released Position Learning» .
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .
>> GO TO 29.

EC-1333

M

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITHOUT EURO-OBD)]

25. CHECK INTAKE SYSTEM
Check for the cause of uneven air flow through mass air flow sensor. Refer to the following.
●
Crushed air ducts
●
Malfunctioning seal of air cleaner element
●
Uneven dirt of air cleaner element
●
Improper specification of intake air system
OK or NG
OK
>> GO TO 27.
NG
>> Repair or replace malfunctioning part, and then GO TO 26.

26. CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the
SP value.
OK or NG
OK
>> INSPECTION END
NG (Less than the SP value)>>GO TO 27.

27. CHECK “MAS A/F SE-B1”
Select “MAS A/F SE-B1” in “DATA MONITOR (SPEC)” mode, and
make sure that the indication is within the SP value.
OK or NG
OK
>> GO TO 28.
NG (Less than the SP value)>>Replace mass air flow sensor, and
then GO TO 30.

PBIB2370E

28. CHECK INTAKE SYSTEM
Check for the cause of air leak after the mass air flow sensor. Refer to the following.
●
Disconnection, looseness, and cracks in air duct
●
Looseness of oil filler cap
●
Disconnection of oil level gauge
●
Open stuck, breakage, hose disconnection, or cracks of PCV valve
●
Disconnection or cracks of EVAP purge hose, open stuck of EVAP canister purge volume control solenoid
valve
●
Malfunctioning seal of rocker cover gasket
●
Disconnection, looseness, or cracks of hoses, such as vacuum hose, connecting to intake air system
parts
●
Malfunctioning seal of intake air system, etc.
>> GO TO 30.

29. CHECK “A/F ALPHA-B1” AND “B/FUEL SCHDL”
Select “A/F ALPHA-B1” and “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the
each indication is within the SP value.
OK or NG
OK
>> INSPECTION END
NG
>> Detect malfunctioning part according to EC-1292, «Symptom Matrix Chart» .

EC-1334

TROUBLE DIAGNOSIS — SPECIFICATION VALUE
[HR (WITHOUT EURO-OBD)]

30. CHECK “B/FUEL SCHDL”

A
Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and then make sure that the indication is within
the SP value.
EC
OK or NG
OK
>> INSPECTION END
NG
>> Detect malfunctioning part according to EC-1292, «Symptom Matrix Chart» .
C

D

E

F

G

H

I

J

K

L

M

EC-1335

TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT
[HR (WITHOUT EURO-OBD)]

TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT
Description

PFP:00006
BBS004LC

Intermittent incidents may occur. In many cases, the malfunction resolves itself (the part or circuit function
returns to normal without intervention). It is important to realize that the symptoms described in the customer’s
complaint often do not recur on (1st trip) DTC visits. Realize also that the most frequent cause of intermittent
incidents occurrences is poor electrical connections. Because of this, the conditions under which the incident
occurred may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may
not indicate the specific malfunctioning area.
Common Intermittent Incidents Report Situations
STEP in Work Flow
2
3 or 4

Situation
The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than [0] or [1t].
The symptom described by the customer does not recur.

5

(1st trip) DTC does not appear during the DTC Confirmation Procedure.

10

The Diagnostic Procedure for PXXXX does not indicate the malfunctioning area.

Diagnostic Procedure

BBS004LD

1. INSPECTION START
Erase (1st trip) DTCs. Refer to EC-1267, «HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION» .
>> GO TO 2.

2. CHECK GROUND TERMINALS
Check ground terminals for corroding or loose connection.
Refer to EC-1342, «Ground Inspection» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

3. SEARCH FOR ELECTRICAL INCIDENT
Perform GI-25, «How to Perform Efficient Diagnosis for an Electrical Incident» , “INCIDENT SIMULATION
TESTS”.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace.

EC-1336

POWER SUPPLY AND GROUND CIRCUIT
[HR (WITHOUT EURO-OBD)]

POWER SUPPLY AND GROUND CIRCUIT
Wiring Diagram

PFP:24110

A
BBS004LE

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1455E

EC-1337

POWER SUPPLY AND GROUND CIRCUIT
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
10
11

WIRE
COLOR
B
B/W

ITEM

ECM ground

CONDITION
[Engine is running]
●

Idle speed

[Engine is running]
[Ignition switch: OFF]
●

32

P

ECM relay
(Self shut-off)

For a few seconds after turning ignition switch
OFF

[Ignition switch: OFF]
●

93

O

Ignition switch

105

G

Power supply for
ECM

108

B

ECM ground

More than a few seconds after turning ignition
switch OFF

DATA (DC Voltage)

Body ground

0 — 1.0V

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: OFF]

0V

[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
●

Idle speed

Diagnostic Procedure

Body ground

BBS004LF

1. INSPECTION START
Start engine.
Is engine running?
Yes or No
Yes
>> GO TO 8.
No
>> GO TO 2.

2. CHECK ECM POWER SUPPLY CIRCUIT-I
1.
2.

Turn ignition switch OFF and then ON.
Check voltage between ECM terminal 93 and ground with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

PBIA9561J

EC-1338

POWER SUPPLY AND GROUND CIRCUIT
[HR (WITHOUT EURO-OBD)]

3. DETECT MALFUNCTIONING PART

A

Check the following.
●
Harness connectors M1, E101
●
Fuse block (J/B) connector M7
●
10A fuse
●
Harness for open or short between ECM and fuse

EC

C

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK GROUND CONNECTIONS-1
1.
2.

D

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

E

F

G

H
MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

Body ground

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace ground connections.

5. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-I
1.
2.

Disconnect ECM harness connector.
Check harness continuity between ECM terminals 10, 11, 108 and ground.
Refer to Wiring Diagram.

I

J

K

L

Continuity should exist.
3. Also check harness for short to power.
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

M

6. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors F1, E59
●
Harness for open or short between ECM and ground
>> Repair open circuit or short to power in harness or connectors.

EC-1339

POWER SUPPLY AND GROUND CIRCUIT
[HR (WITHOUT EURO-OBD)]

7. CHECK ECM POWER SUPPLY CIRCUIT-II
1.
2.
3.

Reconnect ECM harness connector.
Turn ignition switch ON.
Check voltage between IPDM E/R terminal 33 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> Go to EC-1580, «IGNITION SIGNAL» .
NG
>> GO TO 8.

MBIB1353E

8. CHECK ECM POWER SUPPLY CIRCUIT-III
1.
2.
3.

Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON and then OFF.
Check voltage between ECM terminal 105 and ground with
CONSULT-II or tester.
Voltage:

After turning ignition switch OFF, battery
voltage will exist for a few seconds, then
drop approximately 0V.

OK or NG
OK
>> GO TO 14.
NG (Battery voltage does not exist.)>>GO TO 9.
NG (Battery voltage exists for more than a few seconds.)>>GO TO
11.

PBIB3037E

9. CHECK ECM POWER SUPPLY CIRCUIT-IV
1.
2.

Turn ignition switch OFF and wait at least 10 seconds.
Check voltage between ECM terminal 32 and ground with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 11.

PBIA9562J

EC-1340

POWER SUPPLY AND GROUND CIRCUIT
[HR (WITHOUT EURO-OBD)]

10. CHECK ECM POWER SUPPLY CIRCUIT-V
1.
2.
3.

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between ECM terminal 105 and IPDM E/R terminal 32.
Refer to Wiring Diagram.
Continuity should exist.

EC

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 17.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

11. CHECK ECM POWER SUPPLY CIRCUIT-VI
1.
2.
3.

A

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between ECM terminal 32 and IPDM E/R terminal 29.
Refer to Wiring Diagram.
Continuity should exist.

D

E

F

G

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 13.
NG
>> GO TO 12.

H

12. DETECT MALFUNCTIONING PART

I

Check the following.
Harness or connectors E59, F1
●
Harness for open or short between ECM and IPDM E/R

J

●

>> Repair open circuit or short to ground or short to power in harness or connectors.

K

13. CHECK 20A FUSE
L

1. Disconnect 20A fuse from IPDM E/R.
2. Check 20A fuse.
OK or NG
OK
>> GO TO 17.
NG
>> Replace 20A fuse.

M

EC-1341

POWER SUPPLY AND GROUND CIRCUIT
[HR (WITHOUT EURO-OBD)]

14. CHECK GROUND CONNECTIONS-II
1.

Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

Body ground

OK or NG
OK
>> GO TO 15.
NG
>> Repair or replace ground connections.

15. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-II
1.
2.

Disconnect ECM harness connector.
Check harness continuity between ECM terminals 10, 11, 108 and ground.
Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 17.
NG
>> GO TO 16.

16. DETECT MALFUNCTIONING PART
Check the following.
●
Harness or connectors F1, E59
●
Harness for open or short between ECM and ground
>> Repair open circuit or short to power in harness or connectors.

17. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair open circuit or short to power in harness or connectors.

Ground Inspection

BBS004LG

Ground connections are very important to the proper operation of electrical and electronic circuits. Ground
connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can
become an unwanted resistance. This unwanted resistance can change the way a circuit works.
Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even
when the ground connection looks clean, there can be a thin film of rust on the surface.
When inspecting a ground connection follow these rules:

EC-1342

POWER SUPPLY AND GROUND CIRCUIT
[HR (WITHOUT EURO-OBD)]
Remove the ground bolt or screw.
A
Inspect all mating surfaces for tarnish, dirt, rust, etc.
●
Clean as required to assure good contact.
●
Reinstall bolt or screw securely.
EC
●
Inspect for “add-on” accessories which may be interfering with the ground circuit.
●
If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the
wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one
C
eyelet make sure no ground wires have excess wire insulation.
For detailed ground distribution information, refer to PG-38, «Ground Distribution» .
●
●

D

E

F

G

H

I
PBIB1870E

J

K

L

M

EC-1343

DTC U1000, U1001 CAN COMMUNICATION LINE
[HR (WITHOUT EURO-OBD)]

DTC U1000, U1001 CAN COMMUNICATION LINE
Description

PFP:23710
BBS004LH

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

On Board Diagnosis Logic

BBS004LI

The MI will not light up for these self-diagnoses.
DTC No.
U1000
1000
U1001
1001

Trouble diagnosis
name

DTC detecting condition
●

CAN communication
line

●

ECM cannot communicate to other control
units.
ECM cannot communicate for more than the
specified time.

DTC Confirmation Procedure
1.
2.
3.

Possible cause

●

Harness or connectors
(CAN communication line is open or
shorted.)

BBS004LJ

Turn ignition switch ON and wait at least 3 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
If 1st trip DTC is detected, go to EC-1346, «Diagnostic Procedure» .

EC-1344

DTC U1000, U1001 CAN COMMUNICATION LINE
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004LK

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1456E

EC-1345

DTC U1000, U1001 CAN COMMUNICATION LINE
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004LL

Go to LAN-3, «Precautions When Using CONSULT-II» .

EC-1346

DTC U1010 CAN COMMUNICATION
[HR (WITHOUT EURO-OBD)]

DTC U1010 CAN COMMUNICATION
Description

PFP:23710

A
BBS004LM

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- EC
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
C
Each control unit transmits/receives data but selectively reads required data only.

On Board Diagnosis Logic

BBS004LN

D

The MI will not light up for this self-diagnosis.
DTC No.
U1010
1010

Trouble diagnosis name
CAN communication bus

DTC detecting condition
Initializing CAN communication bus is malfunctioning.

DTC Confirmation Procedure

Possible cause
●

E

ECM
BBS004LO

WITH CONSULT-II
1.
2.
3.

F

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
If 1st trip DTC is detected, go to EC-1348, «Diagnostic Procedure» .

G

H

I
SEF058Y

J

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

Turn ignition switch ON.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-1348, «Diagnostic Procedure» .

K

L

M

EC-1347

DTC U1010 CAN COMMUNICATION
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004LP

1. INSPECTION START
1.
2.
3.
4.
5.

With CONSULT-II
Turn ignition switch ON.
Select “SELF-DIAG RESULTS” mode with CONSULT-II.
Touch “ERASE”.
Perform DTC Confirmation Procedure.
See EC-1347, «DTC Confirmation Procedure» .
Is the 1st trip DTC U1010 displayed again?

Without CONSULT-II
1. Turn ignition switch ON.
2. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-1267, «HOW TO ERASE
EMISSION-RELATED DIAGNOSTIC INFORMATION» .
3. Perform DTC Confirmation Procedure.
See EC-1347, «DTC Confirmation Procedure» .
4. Is the 1st trip DTC 1010 displayed again?
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END

2. REPLACE ECM
1.
2.
3.
4.
5.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
Perform EC-1278, «Accelerator Pedal Released Position Learning» .
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .
>> INSPECTION END

EC-1348

DTC P0011 IVT CONTROL
[HR (WITHOUT EURO-OBD)]

DTC P0011 IVT CONTROL
Description

PFP:23796

A
BBS004LQ

SYSTEM DESCRIPTION
Sensor

Input signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed and piston position

Engine coolant temperature sensor

Engine coolant temperature

Wheel sensor

Vehicle speed*

ECM function

Intake valve
timing control

Actuator

EC

Intake valve timing control
solenoid valve

C

*: This signal is sent to the ECM through CAN communication line.

D

E

F

G

H

I
MBIB1560E

This mechanism hydraulically controls cam phases continuously with the fixed operating angle of the intake
valve.
The ECM receives signals such as crankshaft position, camshaft position, engine speed, and engine coolant
temperature. Then, the ECM sends ON/OFF pulse duty signals to the intake valve timing control solenoid
valve depending on driving status. This makes it possible to control the shut/open timing of the intake valve to
increase engine torque in low/mid speed range and output in high-speed range.

CONSULT-II Reference Value in Data Monitor Mode

BBS004LR

J

K

L

Specification data are reference values.
MONITOR ITEM

INT/V TIM (B1)

INT/V SOL (B1)

CONDITION
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

SPECIFICATION

Idle

−5° — 5°CA

2,500 rpm

Approx. 0° — 40°CA

Idle

0% — 2%

2,500 rpm

Approx. 0% — 90%

EC-1349

M

DTC P0011 IVT CONTROL
[HR (WITHOUT EURO-OBD)]

On Board Diagnosis Logic

BBS004LS

The MI will not light up for this self-diagnosis.
Trouble diagnosis
name

DTC No.

P0011
0011

Intake valve timing
control performance

Detecting condition

There is a gap between angle of target and
phase-control angle degree.

Possible cause
●

Crankshaft position sensor (POS)

●

Camshaft position sensor (PHASE)

●

Intake valve timing control solenoid valve

●

Accumulation of debris to the signal pick-up
portion of the camshaft

●

Timing chain installation

●

Foreign matter caught in the oil groove for
intake valve timing control

FAIL-SAFE MODE
ECM enters in fail-safe mode when the malfunction is detected.
Detected items

Engine operating condition in fail-safe mode

Intake valve timing control

The signal is not energized to the solenoid valve and the valve control does not function

DTC Confirmation Procedure

BBS004LT

CAUTION:
Always drive at a safe speed.
NOTE:
●
If DTC P0011 is displayed with DTC P1111, first perform trouble diagnosis for DTC P1111. See EC1425, «DTC P1111 IVT CONTROL SOLENOID VALVE» .
●
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
at least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is between 10V and 16V at
idle.

WITH CONSULT-II
1.
2.
3.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and warm it up to the normal operating temperature.
Maintain the following conditions for at least 6 consecutive seconds.
Hold the accelerator pedal as steady as possible.

ENG SPEED

1,200 — 2,000 rpm (A constant rotation is maintained.)

COOLANT TEMPS

60 — 120°C (140 — 248°F)

B/FUEL SCHDL

More than 3.5 msec

Shift lever

A/T: P or N position
M/T: Neutral position

4.
5.
6.

SEF174Y

Let engine idle for 10 seconds.
If the 1st trip DTC is detected, go to EC-1352, «Diagnostic Procedure» .
If the 1st trip DTC is not detected, go to next step.
Maintain the following conditions for at least 20 consecutive seconds.

ENG SPEED

1,700 — 3,175 rpm (A constant rotation is maintained.)

COOLANT TEMPS

70 — 105°C (158 — 221°F)

EC-1350

DTC P0011 IVT CONTROL
[HR (WITHOUT EURO-OBD)]
Shift lever

1st or 2nd position

Driving location uphill

Driving vehicle uphill
(Increased engine load will help maintain the driving
conditions required for this test.)

7.

A

EC

If 1st trip DTC is detected, go to EC-1352, «Diagnostic Procedure» .

Overall Function Check

BBS004LU

Use this procedure to check the overall function of the intake valve timing control system. During this check, a
1st trip DTC might not be confirmed.

WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.

D

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON.
Set the tester probe between ECM terminal 73 (IVT control solenoid valve signal) and ground.
Start engine and let it idle.
Check the voltage under the following conditions.
Verify that the oscilloscope screen shows the signal wave as
shown below.
Conditions

At idle

C

E

F

G

Voltage
BATTERY VOLTAGE
(11 — 14V)

H

7V — 10V

I

Engine speed: 2,000 rpm
PBIB3036E

J
PBIA4937J

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

7.

If NG, go to EC-1352, «Diagnostic Procedure» .

K

L

M

EC-1351

DTC P0011 IVT CONTROL
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004LV

1. CHECK OIL PRESSURE WARNING LAMP
1.
2.

Start engine.
Check oil pressure warning lamp and confirm it is not illuminated.
OK or NG
OK
>> GO TO 2.
KG
>> Go to LU-16, «OIL PRESSURE CHECK» .

PBIA8559J

2. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE
Refer to EC-1353, «Component Inspection» .
OK or NG
OK
>> GO TO 3.
NG
>> Replace intake valve timing control solenoid valve.

3. CHECK CRANKSHAFT POSITION SENSOR (POS)
Refer to EC-1412, «Component Inspection» .
OK or NG
OK
>> GO TO 4.
NG
>> Replace crankshaft position sensor (POS).

4. CHECK CAMSHAFT POSITION SENSOR (PHASE)
Refer to EC-1418, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace camshaft position sensor (PHASE).

5. CHECK CAMSHAFT (INTAKE)
Check the following.
●
Accumulation of debris to the signal plate of camshaft (1) rear
end
●
Chipping signal plate of camshaft rear end
OK or NG
OK
>> GO TO 6.
NG
>> Remove debris and clean the signal plate of camshaft
rear end or replace camshaft.
PBIA9557J

6. CHECK TIMING CHAIN INSTALLATION
Check service records for any recent repairs that may cause timing chain misaligned.
Are there any service records that may cause timing chain misaligned?
Yes or No
Yes
>> Check timing chain installation. Refer to EM-142, «TIMING CHAIN» .
No
>> GO TO 7.

EC-1352

DTC P0011 IVT CONTROL
[HR (WITHOUT EURO-OBD)]

7. CHECK LUBRICATION CIRCUIT

A

Refer to EM-166, «Inspection of Camshaft Sprocket (INT) Oil Groove» .
OK or NG
OK
>> GO TO 8.
NG
>> Clean lubrication line.

EC

8. CHECK INTERMITTENT INCIDENT

C

Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
For Wiring Diagram, refer to EC-1407, «Wiring Diagram» for CKP sensor (POS) and EC-1415, «Wiring Diagram» for CMP sensor (PHASE).

D

>> INSPECTION END

E

Component Inspection

BBS004LW

INTAKE VALVE TIMING CONTROL SOLENOID VALVE
1.
2.

3.
4.

Disconnect intake valve timing control solenoid valve harness connector.
Check resistance between intake valve timing control solenoid
valve as follows.

F

G

Terminal

Resistance

1 and 2

6.7 — 7.7Ω [at 20°C (68°F)]

1 or 2 and ground

∞Ω
(Continuity should not exist.)

If NG, replace intake valve timing control solenoid valve.
If OK, go to next step.
Remove intake valve timing control solenoid valve.
Provide 12V DC between intake valve timing control solenoid
valve terminals and then interrupt it. Make sure that the plunger
moves as shown in the figure.
CAUTION:
Do not apply 12V DC continuously for 5 seconds or more.
Doing so may result in damage to the coil in intake valve
timing control solenoid valve.
If NG, replace intake valve timing control solenoid valve.
NOTE:
Always replace O-ring when intake valve timing control
solenoid valve is removed.

Removal and Installation

H

I
PBIB0193E

J

K

L

PBIB2275E

BBS004LX

INTAKE VALVE TIMING CONTROL SOLENOID VALVE
Refer to EM-142, «TIMING CHAIN» .

EC-1353

M

DTC P0102, P0103 MAF SENSOR
[HR (WITHOUT EURO-OBD)]

DTC P0102, P0103 MAF SENSOR
Component Description

PFP:22680
BBS004LY

The mass air flow sensor (1) is placed in the stream of intake air. It
measures the intake flow rate by measuring a part of the entire
intake flow. The mass air flow sensor controls the temperature of the
hot wire to a certain amount. The heat generated by the hot wire is
reduced as the intake air flows around it. The more air, the greater
the heat loss.
Therefore, the electric current supplied to hot wire is changed to
maintain the temperature of the hot wire as air flow increases. The
ECM detects the air flow by means of this current change.
PBIA9559J

CONSULT-II Reference Value in Data Monitor Mode

BBS004LZ

Specification data are reference values.
MONITOR ITEM
MAS A/F SE-B1

CONDITION

SPECIFICATION

See EC-1326, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .

On Board Diagnosis Logic

BBS004M0

These self-diagnoses have the one trip detection logic.
DTC No.

P0102
0102

P0103
0103

Trouble diagnosis
name

Mass air flow sensor
circuit low input

Mass air flow sensor
circuit high input

DTC detecting condition

An excessively low voltage from the sensor is
sent to ECM.

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Intake air leaks

●

Mass air flow sensor

●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Mass air flow sensor

An excessively high voltage from the sensor is
sent to ECM.

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Detected items
Mass air flow sensor circuit

Engine operating condition in fail-safe mode
Engine speed will not rise more than 2,400 rpm due to the fuel cut.

EC-1354

DTC P0102, P0103 MAF SENSOR
[HR (WITHOUT EURO-OBD)]

DTC Confirmation Procedure

BBS004M1

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

EC

PROCEDURE FOR DTC P0102
With CONSULT-II
1.
2.
3.
4.

A

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and wait at least 5 seconds.
If DTC is detected, go to EC-1357, «Diagnostic Procedure» .

C

D

E

F
SEF058Y

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

G

Start engine and wait at least 5 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1357, «Diagnostic Procedure» .

H

PROCEDURE FOR DTC P0103
With CONSULT-II
1.
2.
3.
4.
5.
6.

I

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 5 seconds.
If DTC is detected, go to EC-1357, «Diagnostic Procedure» .
If DTC is not detected, go to next step.
Start engine and wait at least 5 seconds.
If DTC is detected, go to EC-1357, «Diagnostic Procedure» .

J

K

L

SEF058Y

M

Without CONSULT-II
1.
2.
3.
4.
5.
6.
7.
8.
9.

Turn ignition switch ON and wait at least 5 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1357, «Diagnostic Procedure» .
If DTC is not detected, go to next step.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and wait at least 5 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1357, «Diagnostic Procedure» .

EC-1355

DTC P0102, P0103 MAF SENSOR
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004M2

MBWA1457E

EC-1356

DTC P0102, P0103 MAF SENSOR
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

EC

WIRE
COLOR

ITEM

CONDITION
[Engine is running]
[Ignition switch: OFF]
●

32

P

ECM relay
(Self shut-off)

For a few seconds after turning ignition
switch OFF

[Ignition switch: OFF]
●

More than a few seconds after turning ignition switch OFF

[Ignition switch: ON]
●

Engine stopped

DATA (DC Voltage)

C
0 — 1.0V

D
BATTERY VOLTAGE
(11 — 14V)

E
Approximately 0.4V

[Engine is running]
45

G

A

Mass air flow sensor

●

Warm-up condition

●

Idle speed

[Engine is running]
●

Warm-up condition

●

Engine is revving from idle to about 4,000
rpm

F
1.0 — 1.3V

1.0 — 1.3 to Approximately 2.4V
(Check for linear voltage rise in
response to engine being
increased to about 4,000 rpm.)

G

H

[Engine is running]
52

105

LG

G

Sensor ground
(Mass air flow sensor)

Power supply for ECM

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]

Approximately 0V

I
BATTERY VOLTAGE
(11 — 14V)

J

Diagnostic Procedure

BBS004M3

1. INSPECTION START
K

Which malfunction (P0102 or P0103) is duplicated?
P0102 or P0103
P0102 >> GO TO 2.
P0103 >> GO TO 3.

2. CHECK INTAKE SYSTEM

L

M

Check the following for connection.
●
Air duct
●
Vacuum hoses
●
Intake air passage between air duct to intake manifold
OK or NG
OK
>> GO TO 3.
NG
>> Reconnect the parts.

EC-1357

DTC P0102, P0103 MAF SENSOR
[HR (WITHOUT EURO-OBD)]

3. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

Body ground

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace ground connections.

4. CHECK MAF SENSOR POWER SUPPLY CIRCUIT
1.
2.

Disconnect mass air flow (MAF) sensor (1) harness connector.
Turn ignition switch ON.

PBIB2948E

3.

Check voltage between MAF sensor terminal 2 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

PBIB1168E

5. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between mass air flow sensor and ECM
●
Harness for open or short between mass air flow sensor and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1358

DTC P0102, P0103 MAF SENSOR
[HR (WITHOUT EURO-OBD)]

6. CHECK MAF SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between MAF sensor terminal 3 and ECM terminal 52.
Refer to Wiring Diagram.

EC

Continuity should exist.

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D

7. CHECK MAF SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

E

Check harness continuity between MAF sensor terminal 4 and ECM terminal 45.
Refer to Wiring Diagram.
F

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

G

H

8. CHECK MASS AIR FLOW SENSOR
Refer to EC-1359, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace mass air flow sensor.

I

J

9. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

K

>> INSPECTION END
L

Component Inspection

BBS004M4

MASS AIR FLOW SENSOR
With CONSULT-II
1.
2.
3.
4.

M

Reconnect all harness connectors disconnected.
Start engine and warm it up to normal operating temperature.
Connect CONSULT-II and select “DATA MONITOR” mode.
Select “MAS A/F SE-B1” and check indication under the following conditions.
Condition

MAS A/F SE-B1 (V)

Ignition switch ON (Engine stopped.)

Approx. 0.4

Idle (Engine is warmed-up to normal
operating temperature.)

1.0 — 1.3

Idle to about 4,000 rpm

1.0 — 1.3 to Approx. 2.4*

*: Check for linear voltage rise in response to engine being increased to about
4,000 rpm.
PBIB2371E

5.
a.

If the voltage is out of specification, proceed the following.
Check for the cause of uneven air flow through mass air flow sensor. Refer to following.

EC-1359

DTC P0102, P0103 MAF SENSOR
[HR (WITHOUT EURO-OBD)]
Crushed air ducts
Malfunctioning seal of air cleaner element
● Uneven dirt of air cleaner element
● Improper specification of intake air system parts
If NG, repair or replace malfunctioning part and perform step 2 to 4 again.
If OK, go to next step.
Turn ignition switch OFF.
Disconnect mass air flow sensor harness connector and reconnect it again.
Perform step 2 to 4 again.
If NG, clean or replace mass air flow sensor.
●
●

b.
6.
7.
8.
9.

Without CONSULT-II
1.
2.
3.

Reconnect all harness connectors disconnected.
Start engine and warm it up to normal operating temperature.
Check voltage between ECM terminal 45 (Mass air flow sensor
signal) and ground.
Condition

Voltage V

Ignition switch ON (Engine stopped.)

Approx. 0.4

Idle (Engine is warmed-up to normal
operating temperature.)

1.0 — 1.3

Idle to about 4,000 rpm

1.0 — 1.3 to Approx. 2.4*

*: Check for linear voltage rise in response to engine being increased to about
4,000 rpm.
PBIA9564J

4.
a.

b.
5.
6.
7.
8.

If the voltage is out of specification, proceed the following.
Check for the cause of uneven air flow through mass air flow sensor. Refer to following.
● Crushed air ducts
● Malfunctioning seal of air cleaner element
● Uneven dirt of air cleaner element
● Improper specification of intake air system parts
If NG, repair or replace malfunctioning part and perform step 2 to 3 again.
If OK, go to next step.
Turn ignition switch OFF.
Disconnect mass air flow sensor harness connector and reconnect it again.
Perform step 2 and 3 again.
If NG, clean or replace mass air flow sensor.

Removal and Installation

BBS004M5

MASS AIR FLOW SENSOR
Refer to EM-118, «AIR CLEANER AND AIR DUCT» .

EC-1360

DTC P0117, P0118 ECT SENSOR
[HR (WITHOUT EURO-OBD)]

DTC P0117, P0118 ECT SENSOR
Component Description

PFP:22630

A
BBS004M6

The engine coolant temperature sensor is used to detect the engine
coolant temperature. The sensor modifies a voltage signal from the
ECM. The modified signal returns to the ECM as the engine coolant
temperature input. The sensor uses a thermistor which is sensitive to
the change in temperature. The electrical resistance of the thermistor decreases as temperature increases.

EC

C

D
SEF594K

E

Engine coolant temperature
°C (°F)
–10 (14)

Voltage*

V

Resistance

4.4

F

kΩ

7.0 — 11.4

20 (68)

3.5

2.1 — 2.9

50 (122)

2.2

0.68 — 1.00

90 (194)

0.9

0.236 — 0.260

G

H

*: This data is reference value and is measured between ECM terminal 38 (Engine
coolant temperature sensor) and ground.

SEF012P

CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.

On Board Diagnosis Logic
DTC No.

Trouble Diagnosis
Name

BBS004M7

DTC Detecting Condition

P0117
0117

Engine coolant temperature sensor circuit low input

An excessively low voltage from the sensor is
sent to ECM.

P0118
0118

Engine coolant temperature sensor circuit high input

An excessively high voltage from the sensor is
sent to ECM.

J

Possible Cause

K
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Engine coolant temperature sensor

L

M

FAIL-SAFE MODE
ECM enters fail-safe mode when the malfunction is detected.
Detected items

Engine operating condition in fail-safe mode
Engine coolant temperature will be determined by ECM based on the time after turning ignition switch ON
or START.
CONSULT-II displays the engine coolant temperature decided by ECM.
Condition

Engine coolant temperature sensor circuit

I

Engine coolant temperature decided
(CONSULT-II display)

Just as ignition switch is turned ON or START

40°C (104°F)

More than approx. 4 minutes after ignition ON or START

80°C (176°F)
40 — 80°C (104 — 176°F)
(Depends on the time)

Except as shown above

When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates
while engine is running.

EC-1361

DTC P0117, P0118 ECT SENSOR
[HR (WITHOUT EURO-OBD)]

DTC Confirmation Procedure

BBS004M8

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Wait at least 5 seconds.
If 1st trip DTC is detected, go to EC-1364, «Diagnostic Procedure» .

SEF058Y

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

Turn ignition switch ON and wait at least 5 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-1364, «Diagnostic Procedure» .

EC-1362

DTC P0117, P0118 ECT SENSOR
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004M9

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1459E

EC-1363

DTC P0117, P0118 ECT SENSOR
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004MA

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

2. CHECK ECT SENSOR POWER SUPPLY CIRCUIT
1.

Disconnect engine coolant temperature (ECT) sensor (1) harness connector.

–

: Vehicle front
Turn ignition switch ON.

2.

PBIB2964E

3.

Check voltage between ECT sensor terminal 1 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

PBIB0080E

EC-1364

DTC P0117, P0118 ECT SENSOR
[HR (WITHOUT EURO-OBD)]

3. CHECK ECT SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.
4.

A

Turn ignition switch OFF.
Disconnect ECM harness connector.
Disconnect TCM harness connector.
Check harness continuity between ECM terminal 44, TCM terminal 42 and ECT sensor terminal 2.
Refer to Wiring Diagram.

EC

C

Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

D

E

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between ECM and ECT sensor
●
Harness for open or short between TCM and ECT sensor

F

G

>> Repair open circuit or short to ground or short to power in harness or connectors.
H

5. CHECK ENGINE COOLANT TEMPERATURE SENSOR
Refer to EC-1365, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace engine coolant temperature sensor.

I

J

6. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

K

>> INSPECTION END

Component Inspection

BBS004MB

L

ENGINE COOLANT TEMPERATURE SENSOR
1.

Check resistance between engine coolant temperature sensor
terminals 1 and 2 as shown in the figure.

M

PBIB2005E

EC-1365

DTC P0117, P0118 ECT SENSOR
[HR (WITHOUT EURO-OBD)]

Temperature

2.

°C (°F)

Resistance

kΩ

20 (68)

2.1 — 2.9

50 (122)

0.68 — 1.00

90 (194)

0.236 — 0.260

If NG, replace engine coolant temperature sensor.

SEF012P

Removal and Installation

BBS004MC

ENGINE COOLANT TEMPERATURE SENSOR
Refer to EM-173, «CYLINDER HEAD» .

EC-1366

DTC P0122, P0123 TP SENSOR
[HR (WITHOUT EURO-OBD)]

DTC P0122, P0123 TP SENSOR
Component Description

PFP:16119

A
BBS004MD

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

EC

C

D
PBIB0145E

E

CONSULT-II Reference Value in Data Monitor Mode

BBS004ME

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Ignition switch: ON
(Engine stopped)

●

Shift lever: D (A/T), 1st (M/T)

THRTL SEN 1
THRTL SEN 2*

SPECIFICATION

Accelerator pedal: Fully released

More than 0.36V

Accelerator pedal: Fully depressed

Less than 4.75V

F

G

*: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic

BBS004MF

These self-diagnoses have the one trip detection logic.
NOTE:
If DTC P0122 or P0123 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229.
Refer to EC-1471, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

Trouble diagnosis name

DTC detecting condition

Possible cause

P0122
0122

Throttle position sensor
2 circuit low input

An excessively low voltage from the TP sensor
2 is sent to ECM.

●

Harness or connectors
(TP sensor 2 circuit is open or shorted.)

P0123
0123

Throttle position sensor
2 circuit high input

An excessively high voltage from the TP sensor 2 is sent to ECM.

●

Electric throttle control actuator
(TP sensor 2)

FAIL-SAFE MODE

H

I

J

K

L

When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-1367

M

DTC P0122, P0123 TP SENSOR
[HR (WITHOUT EURO-OBD)]

DTC Confirmation Procedure

BBS004MG

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-1370, «Diagnostic Procedure» .

SEF058Y

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

Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1370, «Diagnostic Procedure» .

EC-1368

DTC P0122, P0123 TP SENSOR
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004MH

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1460E

EC-1369

DTC P0122, P0123 TP SENSOR
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch: ON]

33

Y

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

Throttle position sensor 1

More than 0.36V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

Less than 4.75V

[Ignition switch: ON]

34

R

Throttle position sensor 2

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

Less than 4.75V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

More than 0.36V

[Engine is running]
36

72

BR

L

Sensor ground
(Throttle position sensor)
Sensor power supply
(Throttle position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Ignition switch: ON]

Approximately 5V

Diagnostic Procedure

BBS004MI

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1370

3.

Body ground

DTC P0122, P0123 TP SENSOR
[HR (WITHOUT EURO-OBD)]

2. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT
1.

Disconnect electric throttle control actuator (1) harness connector.

–

: Vehicle front
Turn ignition switch ON.

2.

A

EC

C

D
PBIB2965E

3.

Check voltage between electric throttle control actuator terminal
1 and ground with CONSULT-II or tester.

E

Voltage: Approximately 5V
F

OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

G

PBIA9580J

H

3. CHECK THROTTLE POSITION SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 36.
Refer to Wiring Diagram.

I

J

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

K

L

4. CHECK THROTTLE POSITION SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 34 and electric throttle control actuator terminal 3.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK THROTTLE POSITION SENSOR
Refer to EC-1372, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

EC-1371

M

DTC P0122, P0123 TP SENSOR
[HR (WITHOUT EURO-OBD)]

6. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .
>> INSPECTION END

7. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004MJ

THROTTLE POSITION SENSOR
1.
2.
3.
4.
5.

Reconnect all harness connectors disconnected.
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Turn ignition switch ON.
Set shift lever to D position (A/T) or 1st position (M/T).
Check voltage between ECM terminals 33 (TP sensor 1 signal),
34 (TP sensor 2 signal) and ground under the following conditions.
Terminal

Accelerator pedal

Voltage

33
(Throttle position sensor 1)

Fully released

More than 0.36V

Fully depressed

Less than 4.75V

Fully released

Less than 4.75V

Fully depressed

More than 0.36V

34
(Throttle position sensor 2)

6.
7.
8.

If NG, replace electric throttle control actuator and go to the next
step.
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .

Removal and Installation

PBIB3038E

BBS004MK

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-120, «INTAKE MANIFOLD» .

EC-1372

DTC P0132 HO2S1
[HR (WITHOUT EURO-OBD)]

DTC P0132 HO2S1
Component Description

PFP:22690

A
BBS004ML

The heated oxygen sensor 1 is placed into the exhaust manifold. It
detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.

EC

C

D
SEF463R

E

F

G

H
SEF288D

CONSULT-II Reference Value in Data Monitor Mode

BBS004MM

I

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

J

0 — 0.3V ←→ Approx. 0.6 — 1.0V

HO2S1 (B1)
●

HO2S1 MNTR (B1)

Engine: After warming up

Maintaining engine speed at 2,000 rpm.

LEAN ←→ RICH
Changes more than 5 times during
10 seconds.

On Board Diagnosis Logic

K

BBS004MN

L

To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 output is not inordinately high.

M

PBIB1848E

DTC No.
P0132
0132

Trouble diagnosis name
Heated oxygen sensor 1
circuit high voltage

DTC detecting condition

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 1

An excessively high voltage from the sensor
is sent to ECM.

EC-1373

DTC P0132 HO2S1
[HR (WITHOUT EURO-OBD)]

DTC Confirmation Procedure

BBS004MO

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Restart engine and let it idle for 2 minutes.
If 1st trip DTC is detected, go to EC-1376, «Diagnostic Procedure» .

SEF174Y

WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Restart engine and let it idle for 2 minutes.
Turn ignition switch OFF and wait at least 10 seconds.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-1376, «Diagnostic Procedure» .

EC-1374

DTC P0132 HO2S1
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004MP

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1461E

EC-1375

DTC P0132 HO2S1
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Approximately 10V
[Engine is running]

3

Y

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

Heated oxygen sensor 1
heater
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
●

Engine speed: Above 3,600 rpm

[Engine is running]
49

56

BR

R

Heated oxygen sensor 1

Sensor ground
(Heated oxygen sensor 1)

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

[Engine is running]
●

Approximately 0V

Idle speed

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004MQ

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1376

3.

Body ground

DTC P0132 HO2S1
[HR (WITHOUT EURO-OBD)]

2. RETIGHTEN HEATED OXYGEN SENSOR 1

A

Loosen and retighten heated oxygen sensor 1 (1).
●
●

: Vehicle front
Exhaust manifold (2)

EC

Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb)
C

>> GO TO 3.
D
PBIB2966E

3. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT
1.

Disconnect heated oxygen sensor 1 harness connector (1).

–

: Vehicle front
Disconnect ECM harness connector.
Check harness continuity between HO2S1 terminal 1 and ECM
terminal 56.
Refer to Wiring Diagram.

2.
3.

E

F

G

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

PBIB2967E

I

J

Check harness continuity between HO2S1 terminal 4 and ECM terminal 49.
Refer to Wiring Diagram.
K

Continuity should exist.
2.

H

Check harness continuity between ECM terminal 49 or HO2S1 terminal 4 and ground.
Refer to Wiring Diagram.

L

Continuity should not exist.
3. Also check harness for short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK HO2S1 CONNECTOR FOR WATER
Check heated oxygen sensor 1 connector for water.
Water should not exist.
OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace harness or connectors.

EC-1377

M

DTC P0132 HO2S1
[HR (WITHOUT EURO-OBD)]

6. CHECK HEATED OXYGEN SENSOR 1
Refer to EC-1379, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace heated oxygen sensor 1.

7. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1378

DTC P0132 HO2S1
[HR (WITHOUT EURO-OBD)]

Component Inspection

BBS004MR

A

HEATED OXYGEN SENSOR 1
With CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC
II.
Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
C
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch “RECORD” on CONSULT-II screen.
D

E

SEF646Y

F

6.

Check the following.
● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes
from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds.
5 times (cycles) are counted as shown in the figure.
● “HO2S1 (B1)” voltage goes above 0.6V at least once.
● “HO2S1 (B1)” voltage goes below 0.3V at least once.
● “HO2S1 (B1)” voltage never exceeds 1.0V.

G

H

I
SEF217YA

J

K

L

SEF648Y

CAUTION:
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.
●

Without CONSULT-II
1.
2.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground.

EC-1379

M

DTC P0132 HO2S1
[HR (WITHOUT EURO-OBD)]
3.

Check the following with engine speed held at 2,000 rpm constant under no load.
● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
● The maximum voltage is over 0.6V at least 1 time.
● The minimum voltage is below 0.3V at least 1 time.
● The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V
→ 0 — 0.3V
PBIA9566J
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Removal and Installation

BBS004MS

HEATED OXYGEN SENSOR 1
Refer to EM-124, «EXHAUST MANIFOLD» .

EC-1380

DTC P0134 HO2S1
[HR (WITHOUT EURO-OBD)]

DTC P0134 HO2S1
Component Description

PFP:22690

A
BBS004MT

The heated oxygen sensor 1 is placed into the exhaust manifold. It
detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.

EC

C

D
SEF463R

E

F

G

H
SEF288D

CONSULT-II Reference Value in Data Monitor Mode

BBS004MU

I

Specification data are reference values.
MONITOR ITEM

CONDITION

SPECIFICATION

J

0 — 0.3V ←→ Approx. 0.6 — 1.0V

HO2S1 (B1)
●

HO2S1 MNTR (B1)

Engine: After warming up

Maintaining engine speed at 2,000
rpm.

LEAN ←→ RICH
Changes more than 5 times during 10 seconds.

On Board Diagnosis Logic

BBS004MV

L

Under the condition in which the heated oxygen sensor 1 signal is
not input, the ECM circuits will read a continuous approximately
0.3V. Therefore, for this diagnosis, the time that output voltage is
within 200 to 400 mV range is monitored, and the diagnosis checks
that this time is not inordinately long.

M

SEF237U

DTC No.
P0134
0134

Trouble diagnosis name
Heated oxygen sensor 1
circuit no activity detected

K

DTC detecting condition

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 1

The voltage from the sensor is constantly
approx. 0.3V.

EC-1381

DTC P0134 HO2S1
[HR (WITHOUT EURO-OBD)]

Overall Function Check

BBS004MW

Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st
trip DTC might not be confirmed.

WITH CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” in “DATA MONITOR” mode with CONSULT-II, and select “HO2S1 (B1)”.
Hold engine speed at 2,000 rpm under no load.
Make sure that the indications do not remain in the range
between 0.2V to 0.4V.
If NG, go to EC-1384, «Diagnostic Procedure» .

SEF646Y

WITHOUT CONSULT-II
1.
2.
3.
●

4.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground.
Check the following with engine speed held at 2,000 rpm constant under no load.
The voltage does not remain in the range of 0.2 to 0.4V.
If NG, go to EC-1384, «Diagnostic Procedure» .

PBIA9566J

EC-1382

DTC P0134 HO2S1
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004MX

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1461E

EC-1383

DTC P0134 HO2S1
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

Approximately 10V
[Engine is running]

3

Y

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

Heated oxygen sensor 1
heater
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
●

Engine speed: Above 3,600 rpm

[Engine is running]
49

BR

Heated oxygen sensor 1

●

Warm-up condition

●

Engine speed: 2,000 rpm

0 — Approximately 1.0V
(Periodically change)

[Engine is running]
56

R

Sensor ground
(Heated oxygen sensor 1)

●

Warm-up condition

●

Idle speed

Approximately 0V

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004MY

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1384

3.

Body ground

DTC P0134 HO2S1
[HR (WITHOUT EURO-OBD)]

2. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT
1.

Disconnect heated oxygen sensor 1 harness connector (1).

–

: Vehicle front
Disconnect ECM harness connector.
Check harness continuity between HO2S1 terminal 1 and ECM
terminal 56.
Refer to Wiring Diagram.

2.
3.

A

EC

C

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D
PBIB2967E

E

3. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

F

Check harness continuity between HO2S1 terminal 4 and ECM terminal 49.
Refer to Wiring Diagram.
Continuity should exist.

2.

G

Check harness continuity between ECM terminal 49 or HO2S1 terminal 4 and ground.
Refer to Wiring Diagram.
H

Continuity should not exist.
3. Also check harness for short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

I

J

4. CHECK HEATED OXYGEN SENSOR 1
Refer to EC-1385, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace heated oxygen sensor 1.

K

L

5. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

M

>> INSPECTION END

Component Inspection

BBS004MZ

HEATED OXYGEN SENSOR 1
With CONSULT-II
1.
2.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULTII.

EC-1385

DTC P0134 HO2S1
[HR (WITHOUT EURO-OBD)]
3.
4.
5.

Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch “RECORD” on CONSULT-II screen.

SEF646Y

6.

Check the following.
● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes
from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds.
5 times (cycles) are counted as shown in the figure.
● “HO2S1 (B1)” voltage goes above 0.6V at least once.
● “HO2S1 (B1)” voltage goes below 0.3V at least once.
● “HO2S1 (B1)” voltage never exceeds 1.0V.
SEF217YA

SEF648Y

CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Without CONSULT-II
1.
2.
3.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground.
Check the following with engine speed held at 2,000 rpm constant under no load.
● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
● The maximum voltage is over 0.6V at least 1 time.
● The minimum voltage is below 0.3V at least 1 time.
● The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V
→ 0 — 0.3V
PBIA9566J
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.

EC-1386

DTC P0134 HO2S1
[HR (WITHOUT EURO-OBD)]
●

Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Removal and Installation

A

BBS004N0

HEATED OXYGEN SENSOR 1

EC

Refer to EM-124, «EXHAUST MANIFOLD» .

C

D

E

F

G

H

I

J

K

L

M

EC-1387

DTC P0138 HO2S2
[HR (WITHOUT EURO-OBD)]

DTC P0138 HO2S2
Component Description

PFP:226A0
BBS004N1

The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
SEF327R

CONSULT-II Reference Value in Data Monitor Mode

BBS004N2

Specification data are reference values.
MONITOR ITEM
HO2S2 (B1)

HO2S2 MNTR (B1)

CONDITION

SPECIFICATION

●

Revving engine from idle to 3,000 rpm quickly after the following conditions are met.

0 — 0.3V ←→ Approx. 0.6 — 1.0V

–

Engine: After warming up.

–

Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute
and idle for 1 minute under no load.

LEAN ←→ RICH

On Board Diagnosis Logic

BBS004N3

The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity before the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the voltage is unusually high during
the various driving condition such as fuel-cut.

PBIB1848E

DTC No.
P0138
0138

Trouble diagnosis name
Heated oxygen sensor 2
circuit high voltage

DTC detecting condition

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Heated oxygen sensor 2

An excessively high voltage from the sensor
is sent to ECM.

EC-1388

DTC P0138 HO2S2
[HR (WITHOUT EURO-OBD)]

DTC Confirmation Procedure

BBS004N4

A
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at EC
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

C

Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II.
Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least 1 minute under no load.
Let engine idle for 2 minutes.
If 1st trip DTC is detected, go to EC-1391, «Diagnostic Procedure» .

D

E

F

G
SEF174Y

WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.
7.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 2 minutes.
Turn ignition switch OFF and wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-1391, «Diagnostic Procedure» .

H

I

J

K

L

M

EC-1389

DTC P0138 HO2S2
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004N5

MBWA1463E

EC-1390

DTC P0138 HO2S2
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
Approximately 10V

[Engine is running]

5

GR

●

Below 3,600 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load

Heated oxygen sensor 2
heater

D

E
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

●

F

BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
Engine speed: Above 3,600 rpm

G

[Engine is running]

50

B

Heated oxygen sensor 2

●

Revving engine from idle to 3,000 rpm quickly
after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load.

H

0 — Approximately 1.0V

I

[Engine is running]
59

LG

Sensor ground
(Heated oxygen sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

J

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004N6

K

1. CHECK GROUND CONNECTIONS
1.
2.

L

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

M

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1391

3.

Body ground

DTC P0138 HO2S2
[HR (WITHOUT EURO-OBD)]

2. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT
1.
–

2.
3.

Disconnect heated oxygen sensor 2 harness connector (2).
Heated oxygen sensor 2 (1)
Disconnect ECM harness connector.
Check harness continuity between HO2S2 terminal 1 and ECM
terminal 59.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

PBIB2949E

3. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between HO2S2 terminal 4 ECM terminal 50.
Refer to Wiring Diagram.
Continuity should exist.

2.

Check harness continuity between ECM terminal 50 or HO2S2 terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK HEATED OXYGEN SENSOR 2
Refer to EC-1392, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace heated oxygen sensor 2.

5. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004N7

HEATED OXYGEN SENSOR 2
With CONSULT-II
1.
2.
3.
4.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.

EC-1392

DTC P0138 HO2S2
[HR (WITHOUT EURO-OBD)]
5.

Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select
“HO2S2 (B1)” as the monitor item with CONSULT-II.

A

EC

C
SEF662Y

6.

D

Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%.

E

F

G
PBIB0551E

“HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%.
“HO2S2 (B1)” should be below 0.50V at least once when the “FUEL INJECTION” is −25%.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

H

I

J

Without CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground.
Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.68V at least once during this
procedure.
If the voltage is above 0.68V at step 6, step 7 is not necessary.
7. Keep vehicle idling for 10 minutes, then check voltage. Or check
the voltage when coasting from 80 km/h (50 MPH) in D position
with “OD” OFF (A/T), 3rd gear position (M/T).
The voltage should be below 0.50V at least once during this
PBIB2996E
procedure.
8. If NG, replace heated oxygen sensor 2.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

EC-1393

K

L

M

DTC P0138 HO2S2
[HR (WITHOUT EURO-OBD)]

Removal and Installation

BBS004N8

HEATED OXYGEN SENSOR 2
Refer to EX-3, «EXHAUST SYSTEM» .

EC-1394

DTC P0222, P0223 TP SENSOR
[HR (WITHOUT EURO-OBD)]

DTC P0222, P0223 TP SENSOR
Component Description

PFP:16119

A
BBS004N9

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

EC

C

D
PBIB0145E

E

CONSULT-II Reference Value in Data Monitor Mode

BBS004NA

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Ignition switch: ON
(Engine stopped)

●

Shift lever: D (A/T), 1st (M/T)

THRTL SEN 1
THRTL SEN 2*

SPECIFICATION

Accelerator pedal: Fully released

More than 0.36V

Accelerator pedal: Fully depressed

Less than 4.75V

F

G

*: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic

BBS004NB

These self-diagnoses have the one trip detection logic.
NOTE:
If DTC P0222 or P0223 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229.
Refer to EC-1471, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

Trouble diagnosis name

DTC detecting condition

Possible cause

P0222
0222

Throttle position sensor
1 circuit low input

An excessively low voltage from the TP sensor 1
is sent to ECM.

●

Harness or connectors
(TP sensor 1 circuit is open or shorted.)

P0223
0223

Throttle position sensor
1 circuit high input

An excessively high voltage from the TP sensor
1 is sent to ECM.

●

Electric throttle control actuator
(TP sensor 1)

FAIL-SAFE MODE

H

I

J

K

L

When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-1395

M

DTC P0222, P0223 TP SENSOR
[HR (WITHOUT EURO-OBD)]

DTC Confirmation Procedure

BBS004NC

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-1398, «Diagnostic Procedure» .

SEF058Y

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

Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1398, «Diagnostic Procedure» .

EC-1396

DTC P0222, P0223 TP SENSOR
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004ND

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1466E

EC-1397

DTC P0222, P0223 TP SENSOR
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch: ON]

33

Y

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

Throttle position sensor 1

More than 0.36V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

Less than 4.75V

[Ignition switch: ON]

34

R

Throttle position sensor 2

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

Less than 4.75V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

More than 0.36V

[Engine is running]
36

72

BR

L

Sensor ground
(Throttle position sensor)
Sensor power supply
(Throttle position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Ignition switch: ON]

Approximately 5V

Diagnostic Procedure

BBS004NE

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1398

3.

Body ground

DTC P0222, P0223 TP SENSOR
[HR (WITHOUT EURO-OBD)]

2. CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT-I
1.

Disconnect electric throttle control actuator (1) harness connector.

–

: Vehicle front
Turn ignition switch ON.

2.

A

EC

C

D
PBIB2965E

3.

Check voltage between electric throttle control actuator terminal
1 and ground with CONSULT-II or tester.

E

Voltage: Approximately 5V
F

OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

G

PBIA9580J

H

3. CHECK THROTTLE POSITION SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 36.
Refer to Wiring Diagram.

I

J

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

K

L

4. CHECK THROTTLE POSITION SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 33 and electric throttle control actuator terminal 2.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK THROTTLE POSITION SENSOR
Refer to EC-1400, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

EC-1399

M

DTC P0222, P0223 TP SENSOR
[HR (WITHOUT EURO-OBD)]

6. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .
>> INSPECTION END

7. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004NF

THROTTLE POSITION SENSOR
1.
2.
3.
4.
5.

Reconnect all harness connectors disconnected.
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Turn ignition switch ON.
Set shift lever to D (A/T), 1st (M/T) position.
Check voltage between ECM terminals 33 (TP sensor 1 signal),
34 (TP sensor 2 signal) and ground under the following conditions.
Terminal

Accelerator pedal

Voltage

33
(Throttle position sensor 1)

Fully released

More than 0.36V

Fully depressed

Less than 4.75V

Fully released

Less than 4.75V

Fully depressed

More than 0.36V

34
(Throttle position sensor 2)

6.
7.
8.

If NG, replace electric throttle control actuator and go to the next
step.
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .

Removal and Installation

PBIB3038E

BBS004NG

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-120, «INTAKE MANIFOLD» .

EC-1400

DTC P0327, P0328 KS
[HR (WITHOUT EURO-OBD)]

DTC P0327, P0328 KS
Component Description

PFP:22060

A
BBS004NH

The knock sensor (1) is attached to the cylinder block. It senses
engine knocking using a piezoelectric element. A knocking vibration
from the cylinder block is sensed as vibrational pressure. This pressure is converted into a voltage signal and sent to the ECM.

EC

: Vehicle front

●

C

D
PBIB2969E

E

On Board Diagnosis Logic

BBS004NI

The MI will not light up for these self-diagnoses.
DTC No.

Trouble Diagnosis Name

DTC Detected Condition

F

Possible Cause

P0327
0327

Knock sensor circuit low
input

An excessively low voltage from the sensor is
sent to ECM.

●

Harness or connectors
(The sensor circuit is open or shorted.)

P0328
0328

Knock sensor circuit high
input

An excessively high voltage from the sensor is
sent to ECM.

●

Knock sensor

DTC Confirmation Procedure

BBS004NJ

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

WITH CONSULT-II
1.
2.
3.

G

H

I

J

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Start engine and run it for at least 5 seconds at idle speed.
If 1st trip DTC is detected, go to EC-1403, «Diagnostic Procedure» .

K

L

M
SEF058Y

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

Start engine and run it for at least 5 seconds at idle speed.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-1403, «Diagnostic Procedure» .

EC-1401

DTC P0327, P0328 KS
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004NK

MBWA1467E

EC-1402

DTC P0327, P0328 KS
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
37

WIRE
COLOR
W

A

EC
ITEM

Knock sensor

CONDITION
[Engine is running]
●

Idle speed

DATA (DC Voltage)

C

Approximately 2.5V

[Engine is running]
40

—

Sensor ground
(Knock sensor)

●

Warm-up condition

●

Idle speed

D

Approximately 0V

Diagnostic Procedure

BBS004NL

1. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-I
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check resistance between ECM terminal 37 and ground. Refer to Wiring Diagram.
NOTE:
It is necessary to use an ohmmeter which can measure more than 10 MΩ.

E

F

G

Resistance: Approximately 530 — 590kΩ [at 20°C (68°F)]
H

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 2.

I

2. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-II
1.

Disconnect knock sensor (1) harness connector.

–

: Vehicle front
Check harness continuity between ECM terminal 37 and knock
sensor terminal 1.
Refer to Wiring Diagram.

2.

J

K

L

Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

3. CHECK KNOCK SENSOR
Refer to EC-1404, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace knock sensor.

EC-1403

M
PBIB2969E

DTC P0327, P0328 KS
[HR (WITHOUT EURO-OBD)]

4. CHECK GROUND CONNECTIONS
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

Body ground

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace ground connections.

5. CHECK KNOCK SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT
1.
2.

Reconnect knock sensor harness connector.
Check harness continuity between ECM terminal 40 and knock sensor terminal 2.
Continuity should exist

3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004NM

KNOCK SENSOR
Check resistance between knock sensor terminal 1 and ground.
NOTE:
It is necessary to use an ohmmeter which can measure more
than 10 MΩ.
Resistance: Approximately 530 — 590kΩ [at 20°C (68°F)]
CAUTION:
Do not use any knock sensors that have been dropped or physically damaged. Use only new ones.
SEF227W

Removal and Installation

BBS004NN

KNOCK SENSOR
Refer to EM-189, «CYLINDER BLOCK» .

EC-1404

DTC P0335 CKP SENSOR (POS)
[HR (WITHOUT EURO-OBD)]

DTC P0335 CKP SENSOR (POS)
Component Description

PFP:23731

A
BBS004NO

The crankshaft position sensor (POS) is located on the cylinder
block rear housing facing the gear teeth (cogs) of the signal plate at
the end of the crankshaft. It detects the fluctuation of the engine revolution.
The sensor consists of a permanent magnet and Hall IC.
When the engine is running, the high and low parts of the teeth
cause the gap with the sensor to change.
The changing gap causes the magnetic field near the sensor to
change.
Due to the changing magnetic field, the voltage from the sensor
changes.
The ECM receives the voltage signal and detects the fluctuation of
the engine revolution.
ECM receives the signals as shown in the figure.

EC

C

D
PBIA9209J

E

F

G

H

PBIB2382E

I

CONSULT-II Reference Value in Data Monitor Mode

BBS004NP

Specification data are reference values.
MONITOR ITEM
ENG SPEED

CONDITION
●

J

SPECIFICATION

Run engine and compare CONSULT-II value with the tachometer indication.

Almost the same speed as the
tachometer indication.

K

On Board Diagnosis Logic
DTC No.

Trouble diagnosis name

BBS004NQ

DTC detecting condition

Possible cause
●

●

P0335
0335

Crankshaft position
sensor (POS) circuit

The crankshaft position sensor (POS) signal is not
detected by the ECM during the first few seconds of
engine cranking.

●

The proper pulse signal from the crankshaft position
sensor (POS) is not sent to ECM while the engine is
running.

●

The crankshaft position sensor (POS) signal is not in
the normal pattern during engine running.

EC-1405

Harness or connectors
[Crankshaft position sensor (POS)
circuit is open or shorted.]
(Accelerator pedal position sensor
circuit is shorted.)
(Refrigerant pressure sensor circuit
is shorted.)

●

Crankshaft position sensor (POS)

●

Accelerator pedal position sensor

●

Refrigerant position sensor

●

Signal plate

L

M

DTC P0335 CKP SENSOR (POS)
[HR (WITHOUT EURO-OBD)]

DTC Confirmation Procedure

BBS004NR

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON.

WITH CONSULT-II
1.
2.
3.

Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed.
If 1st trip DTC is detected, go to EC-1409, «Diagnostic Procedure» .

SEF058Y

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

Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-1409, «Diagnostic Procedure» .

EC-1406

DTC P0335 CKP SENSOR (POS)
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004NS

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1468E

EC-1407

DTC P0335 CKP SENSOR (POS)
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

[Engine is running]
●

Warm-up condition

●

Idle speed

DATA (DC Voltage)

0 — 1.0V

NOTE:
The pulse cycle changes depending on rpm
at idle
61

Y

MBIB1453E

Crankshaft position
sensor (POS)

0 — 1.0V

[Engine is running]
●

Engine speed: 2,000 rpm

MBIB1454E

62

W

[Engine is running]

Sensor ground
[Crankshaft position sensor
(POS)]

●

Warm-up condition

●

Idle speed

Approximately 0V

74

W

Sensor power supply
(Refrigerant pressure sensor)

[Ignition switch: ON]

Approximately 5V

75

G

Sensor power supply
[Crankshaft position sensor
(POS)]

[Ignition switch: ON]

Approximately 5V

102

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-1408

DTC P0335 CKP SENSOR (POS)
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004NT

1. CHECK GROUND CONNECTIONS
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

EC

C

D

E
MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

F

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

G

2. CHECK CRANKSHAFT POSITION (CKP) SENSOR (POS) POWER SUPPLY CIRCUIT-I
1.
2.

H

Disconnect crankshaft position (CKP) sensor (POS) (1) harness
connector.
Turn ignition switch ON.

I

J

K
PBIB2970E

3.

Check voltage between CKP sensor (POS) terminal 1 and
ground with CONSULT-II or tester.

L

Voltage: Approximately 5V
M

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 3.

PBIB2609E

EC-1409

DTC P0335 CKP SENSOR (POS)
[HR (WITHOUT EURO-OBD)]

3. CHECK CKP SENSOR (POS) POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between CKP sensor (POS) terminal 1 and ECM terminal 75.
Refer to Wiring Diagram.
Continuity should exist.

OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit

4. CHECK CKP SENSOR (POS) POWER SUPPLY CIRCUIT-III
Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

74

Refrigerant pressure sensor terminal 3

EC-1591, «Wiring Diagram»

75

Crankshaft position sensor (POS) terminal 1

EC-1407, «Wiring Diagram»

102

APP sensor terminal 5

EC-1503, «Wiring Diagram»

OK or NG
OK
>> GO TO 5.
NG
>> Repair short to ground or short to power in harness or connectors.

5. CHECK COMPONENTS
Check the following.
Accelerator pedal position sensor (Refer to EC-1509, «Component Inspection» .)
●
Refrigerant pressure sensor (Refer to ATC-85, «Refrigerant Pressure Sensor» .)
OK or NG
OK
>> GO TO 10.
NG
>> Replace malfunctioning component.
●

6. CHECK CKP SENSOR (POS) GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between CKP sensor (POS) terminal 2 and ECM terminal 62.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

7. CHECK CKP SENSOR (POS) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between CKP sensor (POS) terminal 3 and ECM terminal 61.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1410

DTC P0335 CKP SENSOR (POS)
[HR (WITHOUT EURO-OBD)]

8. CHECK CRANKSHAFT POSITION SENSOR (POS)
Refer to EC-1412, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace crankshaft position sensor (POS).

A

EC

9. CHECK GEAR TOOTH

C

Visually check for chipping signal plate gear tooth.
OK or NG
OK
>> GO TO 10.
NG
>> Replace the signal plate.

D

10. CHECK INTERMITTENT INCIDENT

E

Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
F

>> INSPECTION END
G

H

I

J

K

L

M

EC-1411

DTC P0335 CKP SENSOR (POS)
[HR (WITHOUT EURO-OBD)]

Component Inspection

BBS004NU

CRANKSHAFT POSITION SENSOR (POS)
1.
2.
3.
4.

Loosen the fixing bolt of the sensor.
Disconnect crankshaft position sensor (POS) harness connector.
Remove the sensor.
Visually check the sensor for chipping.

PBIA9210J

5.

Check resistance as shown in the figure.
Terminal No. (Polarity)

Resistance Ω [at 25°C (77°F)]

1 (+) — 2 (-)
1 (+) — 3 (-)

Except 0 or ∞

2 (+) — 3 (-)

6.

If NG, replace crankshaft position sensor (POS).

PBIA9584J

Removal and Installation

BBS004NV

CRANKSHAFT POSITION SENSOR (POS)
Refer to EM-189, «CYLINDER BLOCK» .

EC-1412

DTC P0340 CMP SENSOR (PHASE)
[HR (WITHOUT EURO-OBD)]

DTC P0340 CMP SENSOR (PHASE)
Component Description

PFP:23731

A
BBS004NW

The camshaft position sensor (PHASE) senses the protrusion of
camshaft (INT) to identify a particular cylinder. The camshaft position
sensor (PHASE) senses the piston position.
When the crankshaft position sensor (POS) system becomes inoperative, the camshaft position sensor (PHASE) provides various controls of engine parts instead, utilizing timing of cylinder identification
signals.
The sensor consists of a permanent magnet and Hall IC.
When engine is running, the high and low parts of the teeth cause
the gap with the sensor to change.
The changing gap causes the magnetic field near the sensor to
change.
Due to the changing magnetic field, the voltage from the sensor changes.
ECM receives the signals as shown in the figure.

EC

C

D
PBIA9209J

E

F

G

H

PBIB2382E

I

On Board Diagnosis Logic

BBS004NX

NOTE:
If DTC P0340 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to
EC-1471, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

Trouble diagnosis name

DTC detecting condition

●

P0340
0340

Camshaft position sensor
(PHASE) circuit

The cylinder No. signal is not sent to ECM
for the first few seconds during engine
cranking.

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Camshaft position sensor (PHASE)

●

Camshaft (Intake)

●

The cylinder No. signal is not set to ECM
during engine running.

●

Starter motor (Refer to SC-45, «STARTING SYSTEM» .)

●

The cylinder No. signal is not in the normal
pattern during engine running.

●

Starting system circuit (Refer to SC-45,
«STARTING SYSTEM» .)

●

Dead (Weak) battery

EC-1413

J

K

L

M

DTC P0340 CMP SENSOR (PHASE)
[HR (WITHOUT EURO-OBD)]

DTC Confirmation Procedure

BBS004NY

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON.

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

5.
6.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed.
If 1st trip DTC is detected, go to EC-1416, «Diagnostic Procedure» .
If 1st trip DTC is not detected, go to next step.
Maintain engine speed at more than 800 rpm for at least 5 seconds.
If 1st trip DTC is detected, go to EC-1416, «Diagnostic Procedure» .

WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.
7.
8.

Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-1416, «Diagnostic Procedure» .
If 1st trip DTC is not detected, go to next step.
Start engine and maintaining engine speed at more than 800 rpm for at least 5 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-1416, «Diagnostic Procedure» .

EC-1414

SEF058Y

DTC P0340 CMP SENSOR (PHASE)
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004NZ

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1469E

EC-1415

DTC P0340 CMP SENSOR (PHASE)
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

63

WIRE
COLOR

B

ITEM

Sensor ground
[Camshaft position sensor
(PHASE)]

CONDITION

DATA (DC Voltage)

[Engine is running]
●

Warm-up condition

●

Idle speed

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0V

0 — 1.0V

NOTE:
The pulse cycle changes depending on rpm
at idle
65

R

MBIB1455E

Camshaft position sensor
(PHASE)

0 — 1.0V

[Engine is running]
●

Engine speed: 2,000 rpm

MBIB1456E

78

O

Sensor power supply
[Camshaft position sensor
(PHASE)]

[Ignition switch: ON]

Approximately 5V

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004O0

1. CHECK STARTING SYSTEM
Turn ignition switch to START position.
Does the engine turn over?
Does the starter motor operate?
Yes or No
Yes
>> GO TO 2.
No
>> Check starting system. (Refer to SC-45, «STARTING SYSTEM» .)

EC-1416

DTC P0340 CMP SENSOR (PHASE)
[HR (WITHOUT EURO-OBD)]

2. CHECK GROUND CONNECTIONS
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

EC

C

D

E
MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

Body ground

F

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace ground connections.

G

3. CHECK CAMSHAFT POSITION (CMP) SENSOR (PHASE) POWER SUPPLY CIRCUIT
1.

Disconnect camshaft position (CMP) sensor (PHASE) (1) harness connector.

–

: Vehicle front
Turn ignition switch ON.

2.

H

I

J

PBIB2971E

3.

Check voltage between CMP sensor (PHASE) terminal 1 and
ground with CONSULT-II or tester.

K

L

Voltage: Battery voltage
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

M

PBIB2609E

EC-1417

DTC P0340 CMP SENSOR (PHASE)
[HR (WITHOUT EURO-OBD)]

4. CHECK CMP SENSOR (PHASE) GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between CMP sensor (PHASE) terminal 2 and ECM terminal 63.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK CMP SENSOR (PHASE) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between CMP sensor (PHASE) terminal 3 and ECM terminal 65.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK CAMSHAFT POSITION SENSOR (PHASE)
Refer to EC-1418, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace camshaft position sensor (PHASE).

7. CHECK CAMSHAFT (INTAKE)
Check the following.
Accumulation of debris to the signal plate of camshaft (1) rear
end
●
Chipping signal plate of camshaft rear end
OK or NG
OK
>> GO TO 8.
NG
>> Remove debris and clean the signal plate of camshaft
rear end or replace camshaft.
●

PBIA9557J

8. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004O1

CAMSHAFT POSITION SENSOR (PHASE)
1.
2.
3.

Loosen the fixing bolt of the sensor.
Disconnect camshaft position sensor (PHASE) harness connector.
Remove the sensor.

EC-1418

DTC P0340 CMP SENSOR (PHASE)
[HR (WITHOUT EURO-OBD)]
4.

Visually check the sensor for chipping.
A

EC

C
PBIA9210J

D

5.

Check resistance as shown in the figure.
Terminal No. (Polarity)

Resistance Ω [at 25°C (77°F)]

E

1 (+) — 2 (-)
1 (+) — 3 (-)

Except 0 or ∞

2 (+) — 3 (-)

F

G
PBIA9584J

Removal and Installation

BBS004O2

H

CAMSHAFT POSITION SENSOR (PHASE)
Refer to EM-151, «CAMSHAFT» .

I

J

K

L

M

EC-1419

DTC P0605 ECM
[HR (WITHOUT EURO-OBD)]

DTC P0605 ECM
Component Description

PFP:23710
BBS004O3

The ECM consists of a microcomputer and connectors for signal
input and output and for power supply. The ECM controls the engine.

PBIA9222J

On Board Diagnosis Logic

BBS004O4

This self-diagnosis has one or two trip detection logic.
DTC No.
P0605
0605

Trouble diagnosis name

Engine control module

DTC detecting condition
A)

ECM calculation function is malfunctioning.

B)

ECM EEP-ROM system is malfunctioning.

C)

ECM self shut-off function is malfunctioning.

Possible cause

●

ECM

FAIL-SAFE MODE
ECM enters fail-safe mode when malfunction A is detected.
Detected items
Malfunction A

Engine operation condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5
degrees) by the return spring.

DTC Confirmation Procedure

BBS004O5

Perform PROCEDURE FOR MALFUNCTION A first. If the 1st trip DTC cannot be confirmed, perform
PROCEDURE FOR MALFUNCTION B. If there is no malfunction on PROCEDURE FOR MALFUNCTION
B, perform PROCEDURE FOR MALFUNCTION C.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

PROCEDURE FOR MALFUNCTION A
With CONSULT-II
1.
2.
3.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
If 1st trip DTC is detected, go to EC-1422, «Diagnostic Procedure» .

SEF058Y

Without CONSULT-II
1.
2.
3.

Turn ignition switch ON.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.

EC-1420

DTC P0605 ECM
[HR (WITHOUT EURO-OBD)]
4.

If 1st trip DTC is detected, go to EC-1422, «Diagnostic Procedure» .
A

PROCEDURE FOR MALFUNCTION B
With CONSULT-II
1.
2.
3.
4.

Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch OFF, wait at least 10 seconds and then turn
ON.
If 1st trip DTC is detected, go to EC-1422, «Diagnostic Procedure» .

EC

C

D

E
SEF058Y

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

F

Turn ignition switch ON and wait at least 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-1422, «Diagnostic Procedure»

G

PROCEDURE FOR MALFUNCTION C
With CONSULT-II

H

1.
2.
3.

I

4.
5.

Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch OFF, wait at least 10 seconds and then turn
ON.
Repeat step 3 for 32 times.
If 1st trip DTC is detected, go to EC-1422, «Diagnostic Procedure» .

J

K
SEF058Y

L

Without CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch ON and wait at least 1 second.
Turn ignition switch OFF and wait at least 10 seconds.
Repeat step 1 to 2 for 32 times.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-1422, «Diagnostic Procedure» .

EC-1421

M

DTC P0605 ECM
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004O6

1. INSPECTION START
1.
2.
3.
4.
5.

With CONSULT-II
Turn ignition switch ON.
Select “SELF DIAG RESULTS” mode with CONSULT-II.
Touch “ERASE”.
Perform DTC Confirmation Procedure.
See EC-1420, «DTC Confirmation Procedure» .
Is the 1st trip DTC P0605 displayed again?

Without CONSULT-II
1. Turn ignition switch ON.
2. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory.
Refer to EC-1269, «How to Erase Diagnostic Test Mode II (Self-diagnostic Results)» .
3. Perform DTC Confirmation Procedure.
See EC-1420, «DTC Confirmation Procedure» .
4. Is the 1st trip DTC 0605 displayed again?
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END

2. REPLACE ECM
1.
2.
3.
4.
5.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
Perform EC-1278, «Accelerator Pedal Released Position Learning» .
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .
>> INSPECTION END

EC-1422

DTC P1065 ECM
[HR (WITHOUT EURO-OBD)]

DTC P1065 ECM
Component Description

PFP:23710

A
BBS004O7

ECM has the memory function of the DTC memory, the air-fuel ratio
feedback compensation value memory, the Idle Air Volume Learning
value memory, etc. even when the ignition switch is turned OFF.

EC

C

D
PBIA9222J

E

On Board Diagnosis Logic
DTC No.
P1065*
1065

Trouble diagnosis name
Engine control module

BBS004O8

DTC detecting condition
ECM back-up RAM system does not function
properly.

Possible cause

F
●

ECM

*: This self-diagnosis is not for ECM power supply circuit, even though “ECM BACK UP/CIRCUIT” is displayed on CONSULT-II screen.

DTC Confirmation Procedure

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

G

BBS004O9

H

I

Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn
ON.
Repeat steps 3 and 4 for 4 times.
If 1st trip DTC is detected, go to EC-1424, «Diagnostic Procedure» .

J

K

L
SEF058Y

WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.

M

Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Repeat steps 1 to 2 for 4 times.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-1424, «Diagnostic Procedure» .

EC-1423

DTC P1065 ECM
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004OA

1. INSPECTION START
1.
2.
3.
4.
5.

With CONSULT-II
Turn ignition switch ON.
Select “SELF-DIAG RESULTS” mode with CONSULT-II.
Touch “ERASE”.
Perform DTC Confirmation Procedure.
See EC-1423, «DTC Confirmation Procedure» .
Is the 1st trip DTC P1065 displayed again?

Without CONSULT-II
1. Turn ignition switch ON.
2. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory.
Refer to EC-1269, «How to Erase Diagnostic Test Mode II (Self-diagnostic Results)»
3. Perform DTC Confirmation Procedure.
See EC-1423, «DTC Confirmation Procedure» .
4. Is the 1st trip DTC 1065 displayed again?
Yes or No
Yes
>> GO TO 2.
No
>> INSPECTION END

2. REPLACE ECM
1.
2.
3.
4.
5.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
Perform EC-1278, «Accelerator Pedal Released Position Learning» .
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .
>> INSPECTION END

EC-1424

DTC P1111 IVT CONTROL SOLENOID VALVE
[HR (WITHOUT EURO-OBD)]

DTC P1111 IVT CONTROL SOLENOID VALVE
Component Description

PFP:23796

A
BBS004OB

Intake valve timing control solenoid valve is activated by ON/OFF
pulse duty (ratio) signals from the ECM.
The intake valve timing control solenoid valve changes the oil
amount and direction of flow through intake valve timing control unit
or stops oil flow.
The longer pulse width advances valve angle.
The shorter pulse width retards valve angle.
When ON and OFF pulse widths become equal, the solenoid valve
stops oil pressure flow to fix the intake valve angle at the control
position.

EC

C

D
PBIB1842E

E

CONSULT-II Reference Value in Data Monitor Mode

BBS004OC

Specification data are reference values.
MONITOR ITEM

INT/V SOL (B1)

CONDITION
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

0% — 2%

2,500 rpm

Approx. 0% — 90%

G

H

On Board Diagnosis Logic
DTC No.
P1111
1111

Trouble diagnosis name
Intake valve timing control
solenoid valve circuit

F

SPECIFICATION

Idle

BBS004OD

DTC detecting condition
An improper voltage is sent to the ECM
through intake valve timing control solenoid
valve.

Possible cause

I

●

Harness or connectors
(Solenoid valve circuit is open or shorted.)

●

Intake valve timing control solenoid valve

DTC Confirmation Procedure

BBS004OE

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.

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

WITHOUT CONSULT-II
Start engine and wait at least 5 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-1428, «Diagnostic Procedure» .

EC-1425

K

L

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If 1st trip DTC is detected, go to EC-1428, «Diagnostic Procedure» .

M

SEF058Y

1.
2.
3.
4.

J

DTC P1111 IVT CONTROL SOLENOID VALVE
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004OF

MBWA1471E

EC-1426

DTC P1111 IVT CONTROL SOLENOID VALVE
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

C
[Engine is running]
[Ignition switch: OFF]
●

32

DATA (DC Voltage)

P

ECM relay
(Self shut-off)

For a few seconds after turning ignition switch
OFF

[Ignition switch: OFF]
●

More than a few seconds after turning ignition
switch OFF

0 — 1.0V

D
BATTERY VOLTAGE
(11 — 14V)

E

BATTERY VOLTAGE
(11 — 14V)

F

[Engine is running]
●

Warm-up condition

●

Idle speed
7 — 10V

73

LG

Intake valve timing control
solenoid valve

G
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

H
PBIA4937J

105

G

Power supply for ECM

[Ignition switch: ON]

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

BATTERY VOLTAGE
(11 — 14V)

I

J

K

L

M

EC-1427

DTC P1111 IVT CONTROL SOLENOID VALVE
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004OG

1. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect intake valve timing control solenoid valve (1) harness connector.
Turn ignition switch ON.

MBIB1546E

4.

Check voltage between intake valve timing control solenoid
valve terminal 2 and ground with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

PBIB0192E

2. DETECT MALFUNCTION PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between intake valve timing control solenoid valve and IPDM E/R
>> Repair or replace harness or connectors.

3. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR
OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 73 and intake valve timing control solenoid valve terminal 1. Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE
Refer to EC-1429, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace intake valve timing control solenoid valve.

EC-1428

DTC P1111 IVT CONTROL SOLENOID VALVE
[HR (WITHOUT EURO-OBD)]

5. CHECK INTERMITTENT INCIDENT

A

Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
EC

>> INSPECTION END

Component Inspection

BBS004OH

INTAKE VALVE TIMING CONTROL SOLENOID VALVE
1.
2.

3.
4.

C

Disconnect intake valve timing control solenoid valve harness connector.
Check resistance between intake valve timing control solenoid
valve as follows.
Terminal

Resistance

1 and 2

6.7 — 7.7Ω [at 20°C (68°F)]

1 or 2 and ground

∞Ω
(Continuity should not exist.)

If NG, replace intake valve timing control solenoid valve.
If OK, go to next step.
Remove intake valve timing control solenoid valve.
Provide 12V DC between intake valve timing control solenoid
valve terminals and then interrupt it. Make sure that the plunger
moves as shown in the figure.
CAUTION:
Do not apply 12V DC continuously for 5 seconds or more.
Doing so may result in damage to the coil in intake valve
timing control solenoid valve.
If NG, replace intake valve timing control solenoid valve.
NOTE:
Always replace O-ring when intake valve timing control
solenoid valve is removed.

Removal and Installation

D

E

F
PBIB0193E

G

H

I

J
PBIB2275E

BBS004OI

INTAKE VALVE TIMING CONTROL SOLENOID VALVE

K

Refer to EM-142, «TIMING CHAIN» .
L

M

EC-1429

DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR
[HR (WITHOUT EURO-OBD)]

DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR
Component Description

PFP:16119
BBS004OJ

Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc.
The throttle control motor is operated by the ECM and it opens and closes the throttle valve.
The throttle position sensor detects the throttle valve position, and the opening and closing speed of the throttle valve and feeds the voltage signals to the ECM. The ECM judges the current opening angle of the throttle
valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening
angle properly in response to driving condition.

On Board Diagnosis Logic

BBS004OK

This self-diagnosis has the one trip detection logic.
DTC No.

P1121
1121

Trouble diagnosis name

Electric throttle control
actuator

DTC detecting condition
A)

Electric throttle control actuator does not function
properly due to the return spring malfunction.

B)

Throttle valve opening angle in fail-safe mode is
not in specified range.

C)

ECM detect the throttle valve is stuck open.

Possible cause

●

Electric throttle control actuator

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Detected items

Engine operating condition in fail-safe mode

Malfunction A

The ECM controls the electric throttle actuator by regulating the throttle opening around the idle position.
The engine speed will not rise more than 2,000 rpm.

Malfunction B

ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less.

Malfunction C

While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls.
The engine can restart in N or P position (A/T), Neutral position (M/T) and engine speed will not exceed
1,000 rpm or more.

DTC Confirmation Procedure

BBS004OL

NOTE:
●
Perform PROCEDURE FOR MALFUNCTION A AND B first. If the DTC cannot be confirmed, perform
PROCEDURE FOR MALFUNCTION C.
●
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait
at least 10 seconds before conducting the next test.

PROCEDURE FOR MALFUNCTION A AND B
With CONSULT-II
1.
2.
3.

Turn ignition witch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Set shift lever to D position (A/T), 1st position (M/T) and wait at
least 3 seconds.
4. Set shift lever to P position (A/T), Neutral position (M/T).
5. Turn ignition switch OFF and wait at least 10 seconds.
6. Turn ignition switch ON and wait at least 1 second.
7. Set shift lever to D position (A/T), 1st position (M/T) and wait at
least 3 seconds.
8. Set shift lever to P position (A/T), Neutral position (M/T).
9. Turn ignition switch OFF, wait at least 10 seconds and then turn
ON.
10. If DTC is detected, go to EC-1431, «Diagnostic Procedure» .

EC-1430

SEF058Y

DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR
[HR (WITHOUT EURO-OBD)]
Without CONSULT-II
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

A

Turn ignition witch ON and wait at least 1 second.
Set shift lever to D position (A/T), 1st position (M/T) and wait at least 3 seconds.
Set shift lever to P position (A/T), Neutral position (M/T).
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON and wait at least 1 second.
Set shift lever to D position (A/T), 1st position (M/T) and wait at least 3 seconds.
Set shift lever to P position (A/T), Neutral position (M/T).
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1431, «Diagnostic Procedure» .

EC

C

D

PROCEDURE FOR MALFUNCTION C
With CONSULT-II
1.
2.
3.
4.
5.
6.

E

Turn ignition switch ON and wait at least 1 second.
Select “DATA MONITOR” mode with CONSULT-II.
Set shift lever to D position (A/T), 1st position (M/T) and wait at
least 3 seconds.
Set shift lever to P position (A/T), Neutral position (M/T).
Start engine and let it idle for 3 seconds.
If DTC is detected, go to EC-1431, «Diagnostic Procedure» .

F

G

H

SEF058Y

I

Without CONSULT-II
1.
2.
3.
4.
5.
6.
7.

Turn ignition witch ON and wait at least 1 second.
Set shift lever to D position (A/T), 1st position (M/T) and wait at least 3 seconds.
Set shift lever to P position (A/T), Neutral position (M/T).
Start engine and let it idle for 3 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1431, «Diagnostic Procedure» .

Diagnostic Procedure

J

K

L
BBS004OM

1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY
1.
2.

M

Remove the intake air duct.
Check if a foreign matter is caught between the throttle valve (1)
and the housing.

–
: Vehicle front
OK or NG
OK
>> GO TO 2.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.

PBIB2974E

EC-1431

DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR
[HR (WITHOUT EURO-OBD)]

2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .
>> INSPECTION END

Removal and Installation

BBS004ON

Refer to EM-120, «INTAKE MANIFOLD» .

EC-1432

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[HR (WITHOUT EURO-OBD)]

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
Description

PFP:16119

A
BBS004OO

NOTE:
If DTC P1122 is displayed with DTC P1121 or P1126, first perform the trouble diagnosis for DTC P1121 EC
or P1126. Refer to EC-1430, «DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR» or EC-1439,
«DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY» .
Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc.
C
The throttle control motor is operated by the ECM and it opens and closes the throttle valve.
The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feedback to the ECM to control the throttle control motor to make the throttle valve opening angle properly in
response to driving condition.
D

On Board Diagnosis Logic

BBS004OP

This self-diagnosis has the one trip detection logic.
DTC No.

Trouble diagnosis name

E

DTC detecting condition

Possible cause
●

P1122
1122

Electric throttle control
performance

Electric throttle control function does not operate properly.
●

Harness or connectors
(Throttle control motor circuit is open or
shorted)

F

Electric throttle control actuator

G

FAIL-SAFE MODE
When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
H

Engine operating condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.

DTC Confirmation Procedure

I

BBS004OQ

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 11V when engine
is running.

J

K

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

Turn ignition switch ON and wait at least 2 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If DTC is detected, go to EC-1435, «Diagnostic Procedure» .

L

M

SEF058Y

WITHOUT CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and wait at least 2 seconds.
Start engine and let it idle for 5 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1435, «Diagnostic Procedure» .

EC-1433

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004OR

MBWA1472E

EC-1434

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
0 — 14V
[Ignition switch: ON]

1

P

Throttle control motor
(Open)

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

D

E
PBIB1105E

2

LG

Throttle control motor relay
power supply

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

F

0 — 14V
[Ignition switch: ON]
4

L

Throttle control motor
(Close)

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Released

G

H
PBIB1104E

15

G

Throttle control motor relay

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 1.0V

I

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

J

Diagnostic Procedure

BBS004OS

1. CHECK GROUND CONNECTIONS
1.
2.

K

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

L

M

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1435

3.

Body ground

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[HR (WITHOUT EURO-OBD)]

2. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-I
Check voltage between ECM terminal 2 and ground under the following conditions with CONSULT-II or tester.
Ignition switch

Voltage

OFF

Approximately 0V

ON

Battery voltage
(11 — 14V)

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 3.

PBIA9568J

3. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-I
1.
2.

Turn ignition switch OFF.
Check voltage between ECM terminal 15 and ground with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 4.

PBIA9569J

4. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-II
1.
2.
3.

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E5.
Check harness continuity between ECM terminal 15 and IPDM E/R terminal 70.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors E59, F1
●
Harness for open or short between ECM and IPDM E/R
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK FUSE
1. Disconnect 20A fuse.
2. Check 20A fuse for blown.
OK or NG
OK
>> GO TO 9.
NG
>> Replace 20A fuse.

EC-1436

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[HR (WITHOUT EURO-OBD)]

7. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-II
1.
2.
3.

A

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between ECM terminal 2 and IPDM E/R terminal 28.
Refer to Wiring Diagram.

EC

Continuity should exist.

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.

D

8. DETECT MALFUNCTIONING PART

E

Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between ECM and IPDM E/R

F

>> Repair open circuit or short to ground or short to power in harness or connectors.

G

9. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connectors.

10. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT
1.
2.

Turn ignition switch OFF.
Disconnect electric throttle control actuator (1) harness connector.

–

: Vehicle front
Disconnect ECM harness connector.
Check harness continuity between the following terminals.
Refer to Wiring Diagram.

3.
4.

Electric throttle control
actuator terminal
5

6

ECM terminal

Should not exist

4

Should exist

1

Should exist

4

Should not exist

K

L

M

PBIB2965E

5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 11.
NG
>> Repair or replace.

EC-1437

I

J

Continuity

1

H

DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION
[HR (WITHOUT EURO-OBD)]

11. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY
1.
2.

Remove the intake air duct.
Check if foreign matter is caught between the throttle valve (1)
and the housing.

: Vehicle front
–
Illustration shows the view with intake air duct removed.
OK or NG
OK
>> GO TO 12.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.
–

PBIB2974E

12. CHECK THROTTLE CONTROL MOTOR
Refer to EC-1438, «Component Inspection» .
OK or NG
OK
>> GO TO 13.
NG
>> GO TO 14.

13. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> GO TO 14.
NG
>> Repair or replace harness or connectors.

14. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .
>> INSPECTION END

Component Inspection

BBS004OT

THROTTLE CONTROL MOTOR
1.
2.

Disconnect electric throttle control actuator harness connector.
Check resistance between terminals 5 and 6.
Resistance: Approximately 1 — 15 Ω [at 25 °C (77°F)]

3.
4.
5.

If NG, replace electric throttle control actuator and go to next
step.
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .

PBIB2909E

Removal and Installation

BBS004OU

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-120, «INTAKE MANIFOLD» .

EC-1438

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[HR (WITHOUT EURO-OBD)]

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
Component Description

PFP:16119

A
BBS004OV

Power supply for the throttle control motor is provided to the ECM via throttle control motor relay. The throttle
control motor relay is ON/OFF controlled by the ECM. When the ignition switch is turned ON, the ECM sends EC
an ON signal to throttle control motor relay and battery voltage is provided to the ECM. When the ignition
switch is turned OFF, the ECM sends an OFF signal to throttle control motor relay and battery voltage is not
provided to the ECM.
C

CONSULT-II Reference Value in Data Monitor Mode

BBS004OW

Specification data are reference values.
MONITOR ITEM
THRTL RELAY

CONDITION
●

SPECIFICATION

Ignition switch: ON

D

ON

On Board Diagnosis Logic

BBS004OX

E

These self-diagnoses have the one trip detection logic.
DTC No.
P1124
1124

P1126
1126

Trouble diagnosis name
Throttle control motor
relay circuit short

Throttle control motor
relay circuit open

DTC detecting condition

F

Possible cause
●

Harness or connectors
(Throttle control motor relay circuit is
shorted)

●

Throttle control motor relay

●

Harness or connectors
(Throttle control motor relay circuit is
open)

ECM detect the throttle control motor relay is
stuck ON.

ECM detects a voltage of power source for
throttle control motor is excessively low.
●

G

H

Throttle control motor relay

I

FAIL-SAFE MODE
When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.

J

Engine operating condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.

DTC Confirmation Procedure

K

BBS004OY

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

L

PROCEDURE FOR DTC P1124
With CONSULT-II

M

1.
2.
3.

Turn ignition switch ON and wait at least 1 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
If DTC is detected, go to EC-1442, «Diagnostic Procedure» .

SEF058Y

Without CONSULT-II
1.
2.

Turn ignition switch ON and wait at least 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.

EC-1439

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[HR (WITHOUT EURO-OBD)]
3.
4.

Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1442, «Diagnostic Procedure» .

PROCEDURE FOR DTC P1126
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 8V.

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

Turn ignition switch ON and wait at least 2 second.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If DTC is detected, go to EC-1442, «Diagnostic Procedure» .

SEF058Y

Without CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and wait at least 2 seconds.
Start engine and let it idle for 5 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1442, «Diagnostic Procedure» .

EC-1440

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004OZ

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1473E

EC-1441

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

0 — 14V
[Ignition switch: ON]
1

P

Throttle control motor
(Open)

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed
PBIB1105E

2

LG

Throttle control motor relay
power supply

[Ignition switch: ON]

BATTERY VOLTAGE
(11 — 14V)
0 — 14V

[Ignition switch: ON]
4

L

Throttle control motor
(Close)

●

Engine stopped

●

Shift lever: D D (A/T), 1st (M/T)

●

Accelerator pedal: Released
PBIB1104E

15

G

Throttle control motor relay

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 1.0V

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004P0

1. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-I
1.
2.

Turn ignition switch OFF.
Check voltage between ECM terminal 15 and ground with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.

PBIA9569J

EC-1442

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[HR (WITHOUT EURO-OBD)]

2. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-II
1.
2.
3.

A

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E5.
Check continuity between ECM terminal 15 and IPDM E/R terminal 70.
Refer to Wiring Diagram.

EC

Continuity should exist.

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

D

3. DETECT MALFUNCTIONING PART

E

Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between ECM and IPDM E/R

F

>> Repair open circuit or short to ground or short to power in harness or connectors.

G

4. CHECK FUSE
H

1. Disconnect 20A fuse.
2. Check 20A fuse for blown.
OK or NG
OK
>> GO TO 8.
NG
>> Replace 20A fuse.

I

5. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-I
1.

Check voltage between ECM terminal 2 and ground under the
following conditions with CONSULT-II or tester.
Ignition switch

Voltage

OFF

Approximately 0V

ON

Battery voltage
(11 — 14V)

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 6.

K

L

M
PBIA9568J

6. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-II
1.
2.
3.
4.

J

Turn ignition switch OFF.
Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E7.
Check continuity between ECM terminal 2 and IPDM E/R terminal 28.
Refer to Wiring Diagram.
Continuity should exist.

5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

EC-1443

DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY
[HR (WITHOUT EURO-OBD)]

7. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between ECM and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connectors.

EC-1444

DTC P1128 THROTTLE CONTROL MOTOR
[HR (WITHOUT EURO-OBD)]

DTC P1128 THROTTLE CONTROL MOTOR
Component Description

PFP:16119

A
BBS004P1

The throttle control motor is operated by the ECM and it opens and closes the throttle valve.
The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feed- EC
back to the ECM to control the throttle control motor to make the throttle valve opening angle properly in
response to driving condition.

On Board Diagnosis Logic

BBS004P2

C

This self-diagnosis has the one trip detection logic.
DTC No.
P1128
1128

Trouble diagnosis name
Throttle control motor
circuit short

DTC detecting condition
ECM detects short in both circuits between
ECM and throttle control motor.

Possible cause

D

●

Harness or connectors
(Throttle control motor circuit is shorted.)

●

Electric throttle control actuator
(Throttle control motor)

E

FAIL-SAFE MODE

F

When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.

DTC Confirmation Procedure

BBS004P3

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.

G

H

I

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

Turn ignition switch ON and wait at least 2 seconds.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 5 seconds.
If DTC is detected, go to EC-1447, «Diagnostic Procedure» .

J

K

L

SEF058Y

WITHOUT CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and wait at least 2 seconds.
Start engine and let it idle for 5 seconds.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1447, «Diagnostic Procedure» .

EC-1445

M

DTC P1128 THROTTLE CONTROL MOTOR
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004P4

MBWA1474E

EC-1446

DTC P1128 THROTTLE CONTROL MOTOR
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
0 — 14V
[Ignition switch: ON]

1

P

Throttle control motor
(Open)

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

D

E
PBIB1105E

2

LG

Throttle control motor relay
power supply

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

F

0 — 14V
[Ignition switch: ON]
4

L

Throttle control motor
(Close)

●

Engine stopped

●

Shift lever: D D (A/T), 1st (M/T)

●

Accelerator pedal: Released

G

H
PBIB1104E

15

G

Throttle control motor relay

[Ignition switch: OFF]

BATTERY VOLTAGE
(11 — 14V)

[Ignition switch: ON]

0 — 1.0V

I

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

J

Diagnostic Procedure

BBS004P5

1. CHECK GROUND CONNECTIONS
1.
2.

K

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

L

M

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1447

3.

Body ground

DTC P1128 THROTTLE CONTROL MOTOR
[HR (WITHOUT EURO-OBD)]

2. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Disconnect electric throttle control actuator (1) harness connector.

–

: Vehicle front
Disconnect ECM harness connector.
Check harness continuity between the following terminals.
Refer to Wiring Diagram.

2.
3.

Electric throttle control
actuator terminal
5

6

ECM terminal

Continuity

1

Should not exist

4

Should exist

1

Should exist

4

Should not exist

PBIB2965E

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

3. CHECK THROTTLE CONTROL MOTOR
Refer to EC-1449, «Component Inspection» .
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 5.

4. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace harness or connectors.

5. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .
>> INSPECTION END

EC-1448

DTC P1128 THROTTLE CONTROL MOTOR
[HR (WITHOUT EURO-OBD)]

Component Inspection

BBS004P6

A

THROTTLE CONTROL MOTOR
1.
2.

Disconnect electric throttle control actuator harness connector.
Check resistance between terminals 5 and 6.
EC

Resistance: Approximately 1 — 15 Ω [at 25 °C (77°F)]
3.
4.
5.

If NG, replace electric throttle control actuator and go to next
step.
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .

C

D

PBIB2909E

E

Removal and Installation

BBS004P7

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-120, «INTAKE MANIFOLD» .

F

G

H

I

J

K

L

M

EC-1449

DTC P1212 TCS COMMUNICATION LINE
[HR (WITHOUT EURO-OBD)]

DTC P1212 TCS COMMUNICATION LINE
Description

PFP:47850
BBS004PC

NOTE:
●
If DTC P1212 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC
U1000, U1001. Refer to EC-1344, «DTC U1000, U1001 CAN COMMUNICATION LINE» .
●
If DTC P1212 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010.
Refer to EC-1347, «DTC U1010 CAN COMMUNICATION» .
This CAN communication line is used to control the smooth engine operation during the TCS operation. Pulse
signals are exchanged between ECM and “ABS actuator and electric unit (control unit)”.
Be sure to erase the malfunction information such as DTC not only for “ABS actuator and electric unit
(control unit)” but also for ECM after TCS related repair.

On Board Diagnosis Logic

BBS004PD

The MI will not light up for this self-diagnosis.
Freeze frame data is not stored in the ECM for this self-diagnosis.
DTC No.

P1212
1212

Trouble diagnosis name

TCS communication
line

DTC detecting condition

ECM can not receive the information
from “ABS actuator and electric unit (control unit)” continuously.

Possible cause
●

Harness or connectors
(The CAN communication line is open or
shorted.)

●

ABS actuator and electric unit (control unit)

●

Dead (Weak) battery

DTC Confirmation Procedure

BBS004PE

TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for at least 10 seconds.
If 1st trip DTC is detected, go to EC-1450, «Diagnostic Procedure» .

SEF058Y

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

Start engine and let it idle for at least 10 seconds.
Turn ignition switch OFF and wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-1450, «Diagnostic Procedure» .

Diagnostic Procedure

BBS004PF

Refer to BRC-49, «TROUBLE DIAGNOSIS» .

EC-1450

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITHOUT EURO-OBD)]

DTC P1217 ENGINE OVER TEMPERATURE
System Description

PFP:00000

A
BBS004UV

SYSTEM DESCRIPTION
NOTE:
EC
●
If DTC P1217 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC
U1000, U1001. Refer to EC-1344, «DTC U1000, U1001 CAN COMMUNICATION LINE» .
●
If DTC P1217 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010.
C
Refer to EC-1347, «DTC U1010 CAN COMMUNICATION» .

Cooling Fan Control
Sensor

Input Signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*1

Battery

Battery voltage*1

Wheel sensor

Vehicle speed*2

Engine coolant temperature sensor
Air conditioner switch*

3

Refrigerant pressure sensor*3

ECM function

Actuator

D

E
Cooling fan
control

IPDM E/R
(Cooling fan relays)

Engine coolant temperature

F

Air conditioner ON signal*2
Refrigerant pressure

G

*1: The ECM determines the start signal status by the signals of engine speed and battery voltage.
*2: This signal is sent to ECM through CAN communication line.
*3: Models with air conditioner

H

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, refrigerant
pressure, and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF] (Models with
A/C) or 2-step control [ON/OFF] (Models without A/C).

I

Cooling Fan Operation
Models with A/C
J

K

L

M

MBIB1451E

EC-1451

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITHOUT EURO-OBD)]
Models without A/C

MBIB1393E

Cooling Fan Relay Operation
The ECM controls cooling fan relays in the IPDM E/R through CAN communication line.
Cooling fan relay

Cooling fan speed
LO

HI

Stop (OFF)

OFF

OFF

Low (LOW)

ON

OFF

High (HI)

OFF

ON

CONSULT-II Reference Value in Data Monitor Mode

BBS004UW

Specification data are reference values.
MONITOR ITEM
AIR COND SIG

CONDITION
●

Engine: After warming up, idle
the engine

●

Engine: After warming up, idle
the engine

●

Air conditioner switch: OFF

COOLING FAN

SPECIFICATION

Air conditioner switch: OFF

OFF

Air conditioner switch: ON
(Compressor operates.)

ON

Engine coolant temperature is 97°C
(207°F) or less

OFF

Engine coolant temperature is
between 98°C (208°F) and 99°C
(210°F) or more

LOW*

Engine coolant temperature is 100°C
(212°F) or more

HIGH*

*: Models without air conditioner, cooling fan operates only ON and OFF operation, but CONSULT-II display will change OFF, LOW and
HI depends on engine coolant temperature.

On Board Diagnosis Logic

BBS004UX

If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise. When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction
is indicated.
This self-diagnosis has the one trip detection logic.

EC-1452

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITHOUT EURO-OBD)]
DTC No.

Trouble diagnosis name

DTC detecting condition

●

P1217
1217

Engine over temperature
(Overheat)

Cooling fan does not operate properly (Overheat).

Possible cause

A

●

Harness or connectors
(The cooling fan circuit is open or
shorted.)

●

Cooling fan

●

IPDM E/R (Cooling fan relays)

●

Radiator hose
Radiator

C

●

Cooling fan system does not operate properly
(Overheat).

●
●

Reservoir tank (M/T models with A/C)

●

Engine coolant was not added to the system
using the proper filling method.

●

Reservoir tank cap (M/T models with
A/C)

●

Engine coolant is not within the specified
range.

●

Radiator cap (M/T models without A/C
and A/T models)

●

Water pump

●

Thermostat

For more information, refer to EC-1465,
«Main 12 Causes of Overheating» .

CAUTION:
When a malfunction is indicated, be sure to replace the coolant. Refer to MA-39, «Changing Engine
Coolant» . Also, replace the engine oil. Refer to MA-45, «Changing Engine Oil» .
1. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to
use coolant with the proper mixture ratio. Refer to MA-26, «Engine Coolant Mixture Ratio» .
2. After refilling coolant, run engine to ensure that no water-flow noise is emitted.

Overall Function Check

BBS004UY

Use this procedure to check the overall function of the cooling fan. During this check, a DTC might not be confirmed.
WARNING:
Never remove the reservoir tank cap (M/T models with A/C) or the radiator cap (M/T models without A/
C and A/T models) when the engine is hot. Serious burns could be caused by high pressure fluid
escaping from the reservoir tank or the radiator.
Wrap a thick cloth around cap. Carefully remove the cap by turning it a quarter turn to allow built-up
pressure to escape. Then turn the cap all the way off.

WITH CONSULT-II
1.

2.

3.

Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to EC-1458,
«PROCEDURE FOR MODELS WITH AIR CONDITIONER» or
EC-1462, «PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER» .
Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to EC-1458,
«PROCEDURE FOR MODELS WITH AIR CONDITIONER» or
EC-1462, «PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER» .
Turn ignition switch ON.

EC-1453

EC

D

E

F

G

H

I

J

K

L

M

SEF621W

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITHOUT EURO-OBD)]
4.
5.

Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II.
If the results are NG, go to EC-1458, «PROCEDURE FOR MODELS WITH AIR CONDITIONER» or EC-1462, «PROCEDURE
FOR MODELS WITHOUT AIR CONDITIONER» .

SEF646X

WITH GST
Models with Air Conditioner
1.

Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to EC-1458,
«PROCEDURE FOR MODELS WITH AIR CONDITIONER» .
2. Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to EC-1458,
«PROCEDURE FOR MODELS WITH AIR CONDITIONER» .
3. Start engine.
CAUTION:
Be careful not to overheat engine.
4. Set temperature control switch to full cold position.
5. Turn air conditioner switch ON.
6. Turn blower fan switch ON.
7. Run engine at idle for a few minutes with air conditioner operating.
CAUTION:
Be careful not to overheat engine.
8. Make sure that cooling fans operates at low speed.
If NG, go to EC-1458, «PROCEDURE FOR MODELS WITH AIR
CONDITIONER» .
If OK, go to the following step.
9. Turn ignition switch OFF.
10. Turn air conditioner switch and blower fan switch OFF.
11. Disconnect engine coolant temperature sensor harness connector.
12. Connect 150Ω resistor to engine coolant temperature sensor
harness connector.

SEF621W

MBIB0651E

13. Restart engine and make sure that cooling fan operates at
higher speed than low speed.
CAUTION:
Be careful not to overheat engine.
14. If NG, go to EC-1458, «PROCEDURE FOR MODELS WITH AIR
CONDITIONER» .

SEF023R

EC-1454

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITHOUT EURO-OBD)]
Models without Air Conditioner
1.

2.

3.
4.
5.
6.

Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to EC-1462,
«PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER»
.
Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to EC-1462,
«PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER»
.
Disconnect engine coolant temperature sensor harness connector.
Connect 150Ω resistor to engine coolant temperature sensor harness connector.
Start engine and make that cooling fan operates. Be careful not
to overheat engine.
If NG, go to EC-1462, «PROCEDURE FOR MODELS WITHOUT
AIR CONDITIONER» .

A

EC

C

SEF621W

D

E

F

G

H
SEF023R

I

J

K

L

M

EC-1455

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004UZ

MODELS WITH AIR CONDITIONER

MBWA1475E

EC-1456

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITHOUT EURO-OBD)]
MODELS WITHOUT AIR CONDITIONER
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1476E

EC-1457

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004V0

PROCEDURE FOR MODELS WITH AIR CONDITIONER

1. INSPECTION START
Do you have CONSULT-II?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 4.

2. CHECK COOLING FAN LOW SPEED OPERATION
With CONSULT-II
Turn ignition switch ON.
Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II and touch “LOW” on the CONSULT-II screen.
3. Make sure that cooling fan operates at low speed.
OK or NG
OK
>> GO TO 3.
NG
>> Check cooling fan control circuit. (Go to EC-1460,
«PROCEDURE A» .)
1.
2.

SEF784Z

3. CHECK COOLING FAN HIGH SPEED OPERATION
With CONSULT-II
1. Touch “HIGH” on the CONSULT-II screen.
2. Make sure that cooling fan operates at higher speed than low
speed.
OK or NG
OK
>> GO TO 6.
NG
>> Check cooling fan control circuit. (Go to EC-1460,
«PROCEDURE A» .)

SEF785Z

EC-1458

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITHOUT EURO-OBD)]

4. CHECK COOLING FAN LOW SPEED OPERATION

A

Without CONSULT-II
1. Start engine and let it idle.
2. Turn air conditioner switch ON.
3. Turn blower fan switch ON.
4. Make sure that cooling fan operates at low speed.
OK or NG
OK
>> GO TO 5.
NG
>> Check cooling fan low speed control circuit. (Go to EC1460, «PROCEDURE A» .)

EC

C

D

E

MBIB0651E

F

5. CHECK COOLING FAN HIGH SPEED OPERATION
G

Without CONSULT-II
1. Turn ignition switch OFF.
2. Turn air conditioner switch and blower fan switch OFF.
3. Disconnect engine coolant temperature sensor harness connector.
4. Connect 150Ω resistor to engine coolant temperature sensor harness connector.
5. Restart engine and make sure that cooling fan operates at
higher speed than low speed.
OK or NG
OK
>> GO TO 6.
NG
>> Check cooling fan high speed control circuit. (Go to EC1460, «PROCEDURE A» .)

H

I

J

K

SEF023R

L

6. CHECK COOLING SYSTEM FOR LEAK
Refer to CO-27, «ENGINE COOLANT» .
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

M

7. DETECT MALFUNCTIONING PART
Check the following for leak.
●
Hose
●
Radiator
●
Water pump (Refer to CO-36, «WATER PUMP» .)
●
Reservoir tank
>> Repair or replace.

EC-1459

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITHOUT EURO-OBD)]

8. CHECK RESERVOIR TANK CAP (M/T MODELS) OR RADIATOR CAP (A/T MODELS)
Refer to CO-35, «Checking Reservoir Tank Cap (M/T with A/C Models)» or CO-34, «Checking Radiator Cap
(All Models Except M/T with A/C)» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace reservoir tank cap (M/T models) or radiator cap (A/T models).

9. CHECK THERMOSTAT
Refer to CO-38, «THERMOSTAT» .
OK or NG
OK
>> GO TO 10.
NG
>> Replace thermostat.

10. CHECK ENGINE COOLANT TEMPERATURE SENSOR
Refer to EC-1365, «Component Inspection» .
OK or NG
OK
>> GO TO 11.
NG
>> Replace engine coolant temperature sensor.

11. CHECK MAIN 12 CAUSES
If the cause cannot be isolated, go to EC-1465, «Main 12 Causes of Overheating» .
>> INSPECTION END

PROCEDURE A

1. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E6.
Check voltage between IPDM E/R terminal 14 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

MBIB1307E

2. DETECT MALFUNCTIONING PART
Check the following.
●
40A fusible link
●
Harness for open or short between IPDM E/R and battery
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1460

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITHOUT EURO-OBD)]

3. CHECK COOLING FAN MOTOR CIRCUIT

A

1.

Disconnect cooling fan motor harness connector (1).

–

: Vehicle front
Disconnect IPDM E/R harness connectors E11 and E12.
Check harness continuity between cooling fan motor terminal 1
and IPDM E/R terminal 10, cooling fan motor terminal 2 and
ground.
Refer to wiring diagram.

2.
3.

EC

C

Continuity should exist.
4.
5.

D

Also check harness for short to ground and short to power.
Check harness continuity between IPDM E/R terminal 12 and
cooling fan motor terminal 1.
Refer to wiring diagram.

MBIB1549E

E

Continuity should exist.
6.
7.

Also check harness for short to ground and short to power.
Check harness continuity between IPDM E/R terminals 3, 53 and ground.
Refer to Wiring Diagram.

F

G

Continuity should exist.
8. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness for open or short between cooling fan motor and IPDM E/R
●
Harness for open or short between cooling fan motor and ground
●
Harness for open or short between resistor and IPDM E/R
●
Harness for open or short between resistor and cooling fan motor
●
Resistor E62

H

I

J

K

L

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK COOLING FAN MOTOR

M

Refer to EC-1466, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace cooling fan motor.

6. CHECK INTERMITTENT INCIDENT
Perform EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connector.

EC-1461

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITHOUT EURO-OBD)]
PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER

1. INSPECTION START
Do you have CONSULT-II?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.

2. CHECK COOLING FAN OPERATION
With CONSULT-II
1. Turn ignition switch ON.
2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II and touch “LOW” on the CONSULT-II screen.
3. Make sure that cooling fan operates.
OK or NG
OK
>> GO TO4.
NG
>> Check cooling fan control circuit. (Go to EC-1463,
«PROCEDURE B» .)

SEF784Z

3. CHECK COOLING FAN OPERATION
Without CONSULT-II
1. Turn ignition switch OFF.
2. Disconnect engine coolant temperature sensor harness connector.
3. Connect 150Ω resistor to engine coolant temperature sensor harness connector.
4. Restart engine and make sure that cooling fan operates.
OK or NG
OK
>> GO TO 4.
NG
>> Check cooling fan speed control circuit. (Go to EC-1463,
«PROCEDURE B» .)

SEF023R

4. CHECK COOLING SYSTEM FOR LEAK
Refer to CO-27, «ENGINE COOLANT» .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

EC-1462

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITHOUT EURO-OBD)]

5. DETECT MALFUNCTIONING PART

A

Check the following for leak.
●
Hose
●
Radiator
●
Water pump (Refer to CO-36, «WATER PUMP» .)

EC

C

>> Repair or replace.

6. CHECK RADIATOR CAP

D

Refer to CO-34, «Checking Radiator Cap (All Models Except M/T with A/C)» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace radiator cap.

E

7. CHECK THERMOSTAT

F

Refer to CO-38, «THERMOSTAT» .
OK or NG
OK
>> GO TO 8.
NG
>> Replace thermostat.

G

8. CHECK ENGINE COOLANT TEMPERATURE SENSOR

H

Refer to EC-1365, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace engine coolant temperature sensor.

I

9. CHECK MAIN 12 CAUSES

J

If the cause cannot be isolated, go to EC-1465, «Main 12 Causes of Overheating» .
K

>> INSPECTION END

PROCEDURE B

L

1. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E6.
Check voltage between IPDM E/R terminal 14 and ground with
CONSULT-II or tester.

M

Voltage: Battery voltage
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

MBIB1307E

EC-1463

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITHOUT EURO-OBD)]

2. DETECT MALFUNCTIONING PART
Check the following.
●
40A fusible link
●
Harness for open or short between IPDM E/R and battery
>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK COOLING FAN MOTORS CIRCUIT
1.

Disconnect cooling fan motor harness connector (1).

–

: Vehicle front
Disconnect IPDM E/R harness connectors E11 and E12.
Check harness continuity between cooling fan motor terminal 1
and IPDM E/R terminal 10, cooling fan motor terminal 2 and
ground.
Refer to wiring diagram.

2.
3.

Continuity should exist.
4.
5.

Also check harness for short to ground and short to power.
Check harness continuity between IPDM E/R terminals 3, 53
and ground.
Refer to Wiring Diagram.

MBIB1549E

Continuity should exist.
6. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness for open or short between cooling fan motor and IPDM E/R
●
Harness for open or short between cooling fan motor and ground
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK COOLING FAN MOTOR
Refer to EC-1466, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace cooling fan motor.

6. CHECK INTERMITTENT INCIDENT
Perform EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connector.

EC-1464

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITHOUT EURO-OBD)]

Main 12 Causes of Overheating

BBS004V1

A
Engine

Step

OFF

1

Inspection item

Equipment

Blocked radiator

●

Blocked condenser

●

Blocked radiator grille

●

Blocked bumper

2

●

Coolant mixture

●

Coolant tester

50 — 50% coolant mixture

See MA-26, «Engine
Coolant Mixture Ratio» .

3

●

Coolant level

●

Visual

Coolant up to MAX level
in reservoir tank and radiator filler neck

See CO-27, «LEVEL
CHECK» .

59 — 98 kPa
(0.59 — 0.98 bar, 0.6 — 1.0

See CO-34, «Checking
Radiator Cap (All Models
Except M/T with A/C)» .

4*5

●

Radiator cap

No blocking

Reference page

●

●

Visual

Standard

—

EC

●

Pressure tester

kg/cm2 , 9 — 14 psi) (Limit)
88 kPa (0.88 bar, 0.90 kg/

See CO-35, «Checking
Reservoir Tank Cap (M/T
with A/C Models)» .

4*6

●

Reservoir tank cap

●

Pressure tester

ON*2

5

●

Coolant leaks

●

Visual

No leaks

See CO-27, «LEAK
CHECK» .

ON*2

6

●

Thermostat

●

Touch the upper and
lower radiator hoses

Both hoses should be hot

See CO-38, «THERMOSTAT» , and CO-31,
«RADIATOR» .

ON*1

7

●

Cooling fan

●

CONSULT-II

Operating

See trouble diagnosis for
DTC P1217 (EC-1458,
«Diagnostic Procedure» ).

OFF

8

●

Combustion gas leak

●

Color checker chemical
tester 4 Gas analyzer

Negative

—

ON*3

9

●

Coolant temperature
gauge

●

Visual

Gauge less than 3/4
when driving

—

●

Coolant overflow to
reservoir tank

●

Visual

No overflow during driving
and idling

See MA-39, «Changing
Engine Coolant» .

cm2 , 12.8psi)

C

D

E

F

G

H

I

J

OFF*4

10

●

Coolant return from
reservoir tank to radiator

●

Visual

Should be initial level in
reservoir tank

See CO-27, «LEVEL
CHECK» .

K

OFF

11

●

Cylinder head

●

Straight gauge feeler
gauge

0.1 mm (0.004 in) Maximum distortion (warping)

See EM-173, «CYLINDER HEAD» .

L

12

●

Cylinder block and pistons

●

Visual

No scuffing on cylinder
walls or piston

See EM-189, «CYLINDER BLOCK» .

*1: Turn the ignition switch ON.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
*5: M/T models without A/C and A/T models.
*6: M/T models with A/C.
For more information, refer to CO-24, «OVERHEATING CAUSE ANALYSIS» .

EC-1465

M

DTC P1217 ENGINE OVER TEMPERATURE
[HR (WITHOUT EURO-OBD)]

Component Inspection

BBS004V2

COOLING FAN MOTOR
1.
2.

Disconnect cooling fan motor harness connectors.
Supply cooling fan motor terminals with battery voltage and
check operation.
Terminals

Cooling fan motor

(+)

(-)

1

2

MBIB0607E

EC-1466

DTC P1225 TP SENSOR
[HR (WITHOUT EURO-OBD)]

DTC P1225 TP SENSOR
Component Description

PFP:16119

A
BBS004PO

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

EC

C

D
PBIB0145E

E

On Board Diagnosis Logic

BBS004PP

The MI will not light up for this diagnosis.
F
DTC No.
P1225
1225

Trouble diagnosis name

DTC detecting condition

Closed throttle position
learning performance

Closed throttle position learning value is excessively low.

DTC Confirmation Procedure

Possible cause
●

Electric throttle control actuator
(TP sensor 1 and 2)

G
BBS004PQ

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

H

I

WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON.
If 1st trip DTC is detected, go to EC-1468, «Diagnostic Procedure» .

J

K

L

M
SEF058Y

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

Turn ignition switch ON.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-1468, «Diagnostic Procedure» .

EC-1467

DTC P1225 TP SENSOR
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004PR

1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY
1.
2.
3.

Turn ignition switch OFF.
Remove the intake air duct.
Check if foreign matter is caught between the throttle valve (1)
and the housing.

: Vehicle front
Illustration shows the view with intake air duct removed.
OK or NG
OK
>> GO TO 2.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.
–
–

PBIB2974E

2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .
>> INSPECTION END

Removal and Installation

BBS004PS

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-120, «INTAKE MANIFOLD» .

EC-1468

DTC P1226 TP SENSOR
[HR (WITHOUT EURO-OBD)]

DTC P1226 TP SENSOR
Component Description

PFP:16119

A
BBS004PT

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

EC

C

D
PBIB0145E

E

On Board Diagnosis Logic

BBS004PU

The MI will not light up for this diagnosis.
F
DTC No.
P1226
1226

Trouble diagnosis name
Closed throttle position
learning performance

DTC detecting condition
Closed throttle position learning is not performed successfully, repeatedly.

DTC Confirmation Procedure

Possible cause
●

Electric throttle control actuator
(TP sensor 1 and 2)

G
BBS004PV

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

H

I

WITH CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON.
Repeat step 3 and 4 for 32 times.
If 1st trip DTC is detected, go to EC-1470, «Diagnostic Procedure» .

J

K

L

M
SEF058Y

WITHOUT CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Repeat step 2 for 32 times.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If 1st trip DTC is detected, go to EC-1470, «Diagnostic Procedure» .

EC-1469

DTC P1226 TP SENSOR
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004PW

1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY
1.
2.
3.

Turn ignition switch OFF.
Remove the intake air duct.
Check if foreign matter is caught between the throttle valve (1)
and the housing.

: Vehicle front
Illustration shows the view with intake air duct removed.
OK or NG
OK
>> GO TO 2.
NG
>> Remove the foreign matter and clean the electric throttle
control actuator inside.
–
–

PBIB2974E

2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .
>> INSPECTION END

Removal and Installation

BBS004PX

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-120, «INTAKE MANIFOLD» .

EC-1470

DTC P1229 SENSOR POWER SUPPLY
[HR (WITHOUT EURO-OBD)]

DTC P1229 SENSOR POWER SUPPLY
On Board Diagnosis Logic

PFP:16119

A
BBS004PY

This self-diagnosis has the one trip detection logic.
DTC No.

P1229
1229

EC

Trouble diagnosis
name

Sensor power supply
circuit short

DTC detecting condition

Possible cause
●

Harness or connectors
(APP sensor 1 circuit is shorted.)
(Throttle position sensor circuit is shorted.)
[Camshaft position sensor (PHASE) circuit is
shorted.]

●

Accelerator pedal position sensor

●

Throttle position sensor

●

Camshaft position sensor (PHASE)

ECM detects a voltage of power source for
sensor is excessively low or high.

C

D

E

FAIL-SAFE MODE
When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.

F

Engine operation condition in fail-safe mode
ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return
spring.

DTC Confirmation Procedure

G

BBS004PZ

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

H

I

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

J

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-1476, «Diagnostic Procedure» .

K

L

M
SEF058Y

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

Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1476, «Diagnostic Procedure» .

EC-1471

DTC P1229 SENSOR POWER SUPPLY
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004Q0

LHD MODELS

MBWA1477E

EC-1472

DTC P1229 SENSOR POWER SUPPLY
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

EC
ITEM

CONDITION

DATA (DC Voltage)

72

L

Sensor power supply
(Throttle position sensor)

[Ignition switch: ON]

Approximately 5V

78

O

Sensor power supply
[Camshaft position sensor
(PHASE)]

[Ignition switch: ON]

Approximately 5V

102

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

C

D

E

[Ignition switch: ON]

103

A

0.3 — 0.6V

F

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

G

[Engine is running]
104

106

B

O

Sensor ground
(APP sensor 2)
Sensor power supply
(APP sensor 1)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]

Approximately 0V

H
Approximately 5V

I

[Ignition switch: ON]

110

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

J

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

K

[Engine is running]
111

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

Approximately 0V

L

M

EC-1473

DTC P1229 SENSOR POWER SUPPLY
[HR (WITHOUT EURO-OBD)]
RHD MODELS

MBWA1478E

EC-1474

DTC P1229 SENSOR POWER SUPPLY
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

EC
ITEM

CONDITION

DATA (DC Voltage)

72

L

Sensor power supply
(Throttle position sensor)

[Ignition switch: ON]

Approximately 5V

78

O

Sensor power supply
[Camshaft position sensor
(PHASE)]

[Ignition switch: ON]

Approximately 5V

102

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

C

D

E

[Ignition switch: ON]

103

A

0.3 — 0.6V

F

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

G

[Engine is running]
104

106

B

O

Sensor ground
(APP sensor 2)
Sensor power supply
(APP sensor 1)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]

Approximately 0V

H
Approximately 5V

I

[Ignition switch: ON]

110

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

J

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

K

[Engine is running]
111

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

Approximately 0V

L

M

EC-1475

DTC P1229 SENSOR POWER SUPPLY
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004Q1

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

2. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT
1.
–
–

2.

Disconnect accelerator pedal position (APP) sensor harness
connector (1).
Accelerator pedal position sensor (2)
Accelerator pedal (3)
Turn ignition switch ON.

PBIB2975E

3.

Check voltage between APP sensor terminal 4 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.

PBIA9606J

EC-1476

DTC P1229 SENSOR POWER SUPPLY
[HR (WITHOUT EURO-OBD)]

3. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between APP sensor terminal 4 and ECM terminal 106.
Refer to Wiring Diagram.
Continuity should exist.

A

EC

C

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

D

4. DETECT MALFUNCTIONING PART
E

Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM

F

>> Repair open circuit.

G

5. CHECK SENSOR POWER SUPPLY CIRCUITS
Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

72

Throttle position sensor terminal 1

EC-1397, «Wiring Diagram»

78

Camshaft position sensor (PHASE) terminal 1

EC-1415, «Wiring Diagram»

106

APP sensor terminal 4

EC-1494, «Wiring Diagram»

OK or NG
OK
>> GO TO 6.
NG
>> Repair short to ground or short to power in harness or connectors.

6. CHECK COMPONENTS
Check the following.
●
Throttle position sensor (Refer to EC-1400, «Component Inspection» .)
●
Camshaft position sensor (PHASE) (Refer to EC-1418, «Component Inspection» .)
OK or NG
OK
>> GO TO 7.
NG
>> Replace malfunctioning component.

7. CHECK APP SENSOR
Refer to EC-1206, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.

EC-1477

H

I

J

K

L

M

DTC P1229 SENSOR POWER SUPPLY
[HR (WITHOUT EURO-OBD)]

8. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace accelerator pedal assembly.
Perform EC-1278, «Accelerator Pedal Released Position Learning» .
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .
>> INSPECTION END

9. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1478

DTC P1706 PNP SWITCH
[HR (WITHOUT EURO-OBD)]

DTC P1706 PNP SWITCH
Component Description

PFP:32006

A
BBS004Q2

When the shift lever position is P or N (A/T), Neutral (M/T), park/neutral position (PNP) switch is ON.
ECM detects the position because the continuity of the line (the ON signal) exists.

EC

CONSULT-II Reference Value in Data Monitor Mode

BBS004Q3

Specification data are reference values.
MONITOR ITEM
P/N POSI SW

C
CONDITION

●

Ignition switch: ON

SPECIFICATION

Shift lever: P or N (A/T), Neutral (M/T)

ON

Shift lever: Except above

OFF

D

On Board Diagnosis Logic
DTC No.
P1706
1706

BBS004Q4

Trouble diagnosis name

DTC detecting condition

Park/neutral position switch

The signal of the park/neutral position (PNP)
switch is not changed in the process of
engine starting and driving.

Overall Function Check

E

Possible cause
●

Harness or connectors
(PNP switch circuit is open or shorted.)

●

Park/neutral position (PNP) switch
BBS004Q6

Use this procedure to check the overall function of the park/neutral position (PNP) switch circuit. During this
check, a 1st trip DTC might not be confirmed.

WITH CONSULT-II
1.
2.

G

H

Turn ignition switch ON.
Select “P/N POSI SW” in “DATA MONITOR” mode with CONSULT-II. Then check the “P/N POSI SW” signal under the following conditions.
Position (Shift lever)

F

I

Known-good signal

J

N or P position (A/T)
Neutral position (M/T)

ON

Except above position

OFF

K

If NG, go to EC-1483, «Diagnostic Procedure» .
SEF212Y

L

WITHOUT CONSULT-II
1.
2.

Turn ignition switch ON.
Check voltage between ECM terminal 70 (PNP switch signal)
and ground under the following conditions.
Condition (Gear position)

Voltage (Known-good data)

P or N position (A/T)
Neutral position (M/T)

Approx. 0

Except above position

BATTERY VOLTAGE
(11 — 14V)

3.

M

If NG, go to EC-1483, «Diagnostic Procedure» .
MBIB1397E

EC-1479

DTC P1706 PNP SWITCH
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004Q7

A/T MODELS

MBWA1479E

EC-1480

DTC P1706 PNP SWITCH
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

EC
ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch: ON]
70

GR

A

Park/Neutral position
(PNP) switch

●

Shift lever: P or N (A/T models)

●

Shift lever: Neutral (M/T models)

[Ignition switch: ON]
●

Except above position

C
Approximately 0V

BATTERY VOLTAGE
(11 — 14V)

D

E

F

G

H

I

J

K

L

M

EC-1481

DTC P1706 PNP SWITCH
[HR (WITHOUT EURO-OBD)]
M/T MODELS

MBWA1480E

EC-1482

DTC P1706 PNP SWITCH
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

EC

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch: ON]
70

GR

Park/Neutral position
(PNP) switch

●

Shift lever: P or N (A/T models)

●

Shift lever: Neutral (M/T models)

[Ignition switch: ON]
●

Except above position

Diagnostic Procedure

C
Approximately 0V

D

BATTERY VOLTAGE
(11 — 14V)
BBS004Q8

1. CHECK PNP SWITCH CIRCUIT
1.
2.

A

Turn ignition switch ON.
Check voltage between IPDM E/R terminal 31 and ground under
following condition.
Shift lever position

F

G

Voltage

P or N (A/T models)
Neutral (M/T models)

Battery voltage (11- 14V)

Except above position

Approximately 0V

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 2.

E

H

I
MBIB0652E

J

K

L

M

EC-1483

DTC P1706 PNP SWITCH
[HR (WITHOUT EURO-OBD)]

2. CHECK PNP SWITCH POWER SUPPLY CIRCUIT
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect PNP switch harness connector.
Turn ignition switch ON.
Check voltage between PNP switch terminal 1 (A/T models), 2
(M/T models) and ground with CONSULT-II or tester.

MBIB0654E

MBIB0653E

Voltage: Battery voltage
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

3. DETECT MALFUNCTIONING PARTS
Check the following.
●
10A fuse
●
Harness connectors E59, F1
●
IPDM E/R connector E7
●
Harness for short or open between PNP switch and fuse
>> Repair or replace harness or connectors.

EC-1484

DTC P1706 PNP SWITCH
[HR (WITHOUT EURO-OBD)]

4. CHECK HARNESS CONTINUTY BETWEEN PNP SWITCH AND IPDM E/R
1.
2.
3.

A
Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between IPDM E/R terminal 31 and PNP switch terminal 2 (A/T models), 3 (M/T EC
models). Refer to Wiring Diagram.

Continuity should exist.

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. DETECT MALFUNCTIONING PART

D

E

Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between IPDM E/R and PNP switch
>> Repair open circuit or short to ground or short to power in harness or connectors.

F

G

6. CHECK PNP SWITCH
Refer to AT-109, «Component Inspection» (A/T models) or MT-16, «Park/Neutral Position Switch» (M/T models).
OK or NG
OK
>> GO TO 7.
NG
>> Replace PNP switch.

7. CHECK INTERMITTENT INCIDENT

H

I

J

Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
K

>> INSPECTION END

8. CHECK PNP SWITCH GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connectors E11 and E12.
Check harness continuity between IPDM E/R terminal 3, 54 and ground.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to power.
OK or NG
OK
>> GO TO 9.
NG
>> Repair open circuit or short to power in harness or connectors.

EC-1485

L

M

DTC P1706 PNP SWITCH
[HR (WITHOUT EURO-OBD)]

9. CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Disconnect IPDM E/R harness connector E5
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 70 and IPDM E/R terminal 64.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 10.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

10. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace.

EC-1486

DTC P1805 BRAKE SWITCH
[HR (WITHOUT EURO-OBD)]

DTC P1805 BRAKE SWITCH
Description

PFP:25320

A
BBS004Q9

Brake switch signal is applied to the ECM through the stop lamp switch when the brake pedal is depressed.
This signal is used mainly to decrease the engine speed when the vehicle is driving.
EC

CONSULT-II Reference Value in Data Monitor Mode

BBS004QA

Specification data are reference values.

C

MONITOR ITEM
BRAKE SW

CONDITION
●

Ignition switch: ON

SPECIFICATION

Brake pedal: Fully released

OFF

Brake pedal: Slightly depressed

ON

On Board Diagnosis Logic

D
BBS004QB

E

This self-diagnosis has the one trip detection logic.
DTC No.

Trouble diagnosis name

P1805
1805

Brake switch

DTC detecting condition
A brake switch signal is not sent to ECM for
extremely long time while the vehicle is driving.

Possible cause
●

Harness or connectors
(Stop lamp switch circuit is open or shorted.)

●

Stop lamp switch

FAIL-SAFE MODE

BBS004QC

F

G

When the malfunction is detected, ECM enters fail-safe mode and MI light up.
H

Engine operation condition in fail-fail safe mode
ECM controls the electric throttle control actuator by regulating the throttle opening to a small range.
Therefore, acceleration will be poor.
Vehicle condition

Driving condition

When engine is idling

Normal

When accelerating

Poor acceleration

DTC Confirmation Procedure

I

J
BBS004QD

WITH CONSULT-II
1.
2.
3.
4.
5.

K

Turn ignition switch ON.
Fully depress the brake pedal for at least 5 seconds.
Erase the DTC with CONSULT-II.
Select “DATA MONITOR” mode with CONSULT-II.
If DTC is detected, go to EC-1489, «Diagnostic Procedure» .

L

M

PBIB1952E

WITHOUT CONSULT-II
1.
2.
3.
4.
5.
6.

Turn ignition switch ON.
Fully depress the brake pedal for at least 5 seconds.
Erase the Diagnostic Test Mode II (Self-diagnostic results) memory.
Refer to EC-1269, «How to Erase Diagnostic Test Mode II (Self-diagnostic Results)» .
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1489, «Diagnostic Procedure» .

EC-1487

DTC P1805 BRAKE SWITCH
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004QE

MBWA1481E

EC-1488

DTC P1805 BRAKE SWITCH
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

EC

WIRE
COLOR

ITEM

CONDITION
[Ignition switch: OFF]
●

99

R

Stop lamp switch

Brake pedal: Fully released

[Ignition switch: OFF]
●

Brake pedal: Slightly depressed

DATA (DC Voltage)

C

Approximately 0V
BATTERY VOLTAGE
(11 — 14V)

Diagnostic Procedure

D
BBS004QF

1. CHECK STOP LAMP SWITCH CIRCUIT
1.
2.

E

Turn ignition switch OFF.
Check the stop lamp when depressing and releasing the brake pedal.
Brake pedal

Stop lamp

Fully released

Not illuminated

Slightly depressed

Illuminated

F

G

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 2.

H

2. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT
1.
–

A

I

Disconnect stop lamp switch (1) harness connector.
Brake pedal (2)
J

K

L
PBIB2976E

2.

M

Check voltage between stop lamp switch terminal 1 and ground with CONSULT-II or tester.

PBIB2284E

Voltage: Battery voltage
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

EC-1489

DTC P1805 BRAKE SWITCH
[HR (WITHOUT EURO-OBD)]

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M1, E101 (LHD models)
●
Harness connectors M8, M201 (RHD models)
●
10A fuse
●
Harness for open and short between stop lamp switch and battery
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
–

2.
3.

Disconnect stop lamp switch (1) harness connector.
Brake pedal (2)
Disconnect ECM harness connector.
Check harness continuity between stop lamp switch terminal 2
and ECM terminal 99.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M8, M201 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open and short between stop lamp switch and ECM
>> Repair open circuit or short to ground or short to power in harness connectors.

6. CHECK STOP LAMP SWITCH
Refer to EC-1491, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace stop lamp switch.

7. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1490

PBIB2976E

DTC P1805 BRAKE SWITCH
[HR (WITHOUT EURO-OBD)]

Component Inspection

BBS004QG

A

STOP LAMP SWITCH
1.
2.
3.

Turn ignition switch OFF.
Disconnect stop lamp switch harness connector.
Check continuity between stop lamp switch terminals 1 and 2 under the following conditions.

EC

C

D

E
PBIB2285E

Condition
Brake pedal: Fully released.
Brake pedal: Slightly depressed.

Continuity

F

Should not exist.
Should exist.

G

If NG, adjust stop lamp switch installation, refer to BR-6, «BRAKE PEDAL» , and perform step 3 again.
H

I

J

K

L

M

EC-1491

DTC P2122, P2123 APP SENSOR
[HR (WITHOUT EURO-OBD)]

DTC P2122, P2123 APP SENSOR
Component Description

PFP:18002
BBS004QH

The accelerator pedal position sensor is installed on the upper end
of the accelerator pedal assembly. The sensor detects the accelerator position and sends a signal to the ECM.
Accelerator pedal position sensor has two sensors. These sensors
are a kind of potentiometers which transform the accelerator pedal
position into output voltage, and emit the voltage signal to the ECM.
In addition, these sensors detect the opening and closing speed of
the accelerator pedal and feed the voltage signals to the ECM. The
ECM judges the current opening angle of the accelerator pedal from
these signals and controls the throttle control motor based on these
signals.
PBIB1741E
Idle position of the accelerator pedal is determined by the ECM
receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut.

CONSULT-II Reference Value in Data Monitor Mode

BBS004QI

Specification data are reference values.
MONITOR ITEM
ACCEL SEN 1

ACCEL SEN 2*

CLSD THL POS

CONDITION
●

●

●

SPECIFICATION

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

4.0 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

3.9 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage.

On Board Diagnosis Logic

BBS004QJ

These self-diagnoses have the one trip detection logic.
NOTE:
If DTC P2122 or P2123 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229.
Refer to EC-1471, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

Trouble diagnosis name

DTC detecting condition

P2122
2122

Accelerator pedal position
sensor 1 circuit low input

An excessively low voltage from the APP
sensor 1 is sent to ECM.

P2123
2123

Accelerator pedal position
sensor 1 circuit high input

An excessively high voltage from the APP
sensor 1 is sent to ECM.

Possible cause
●

Harness or connectors
(APP sensor 1 circuit is open or
shorted.)

●

Accelerator pedal position sensor
(APP sensor 1)

FAIL-SAFE MODE
When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-1492

DTC P2122, P2123 APP SENSOR
[HR (WITHOUT EURO-OBD)]

DTC Confirmation Procedure

BBS004QK

A
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
EC
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

C

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-1497, «Diagnostic Procedure» .

D

E

F
SEF058Y

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

G

Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1497, «Diagnostic Procedure» .

H

I

J

K

L

M

EC-1493

DTC P2122, P2123 APP SENSOR
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004QL

LHD MODELS

MBWA1482E

EC-1494

DTC P2122, P2123 APP SENSOR
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
102

WIRE
COLOR
BR

A

EC
ITEM
Sensor power supply
(APP sensor 2)

CONDITION

[Ignition switch: ON]

DATA (DC Voltage)

Approximately 5V

C

0.3 — 0.6V

D

1.95 — 2.4V

E

Approximately 0V

F

Approximately 5V

G

[Ignition switch: ON]

103

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

[Engine is running]
104

106

B

O

Sensor ground
(APP sensor 2)
Sensor power supply
(APP sensor 1)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]
[Ignition switch: ON]

110

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

H

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

I

Approximately 0V

J

[Engine is running]
111

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

K

L

M

EC-1495

DTC P2122, P2123 APP SENSOR
[HR (WITHOUT EURO-OBD)]
RHD MODELS

MBWA1483E

EC-1496

DTC P2122, P2123 APP SENSOR
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
102

WIRE
COLOR
BR

A

EC
ITEM

CONDITION

Sensor power supply
(APP sensor 2)

DATA (DC Voltage)

[Ignition switch: ON]

Approximately 5V

C

0.3 — 0.6V

D

1.95 — 2.4V

E

Approximately 0V

F

Approximately 5V

G

[Ignition switch: ON]

103

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

[Engine is running]
104

106

B

O

Sensor ground
(APP sensor 2)
Sensor power supply
(APP sensor 1)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]
[Ignition switch: ON]

110

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

H

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

I

Approximately 0V

J

[Engine is running]
111

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

Diagnostic Procedure

BBS004QM

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

K

L

M

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1497

3.

Body ground

DTC P2122, P2123 APP SENSOR
[HR (WITHOUT EURO-OBD)]

2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT
1.
–
–

2.

Disconnect accelerator pedal position (APP) sensor harness
connector (1).
Accelerator pedal position sensor (2)
Accelerator pedal (3)
Turn ignition switch ON.

PBIB2975E

3.

Check voltage between APP sensor terminal 4 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

PBIA9606J

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK APP SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 111 and APP sensor terminal 2.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1498

DTC P2122, P2123 APP SENSOR
[HR (WITHOUT EURO-OBD)]

6. CHECK APP SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

A

Check harness continuity between ECM terminal 110 and APP sensor terminal 3.
Refer to Wiring Diagram.
EC

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

C

7. DETECT MALFUNCTIONING PART

D

Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM

E

F

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK APP SENSOR

G

Refer to EC-1499, «Component Inspection» .
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 9.

H

I

9. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace accelerator pedal assembly.
Perform EC-1278, «Accelerator Pedal Released Position Learning» .
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .

J

K

>> INSPECTION END
L

10. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

M

>> INSPECTION END

Component Inspection

BBS004QN

ACCELERATOR PEDAL POSITION SENSOR
1.
2.

Reconnect all harness connectors disconnected.
Turn ignition switch ON.

EC-1499

DTC P2122, P2123 APP SENSOR
[HR (WITHOUT EURO-OBD)]
3.

Check voltage between ECM terminals 110 (APP sensor 1 signal), 103 (APP sensor 2 signal) and ground under the following
conditions.
Terminal

Accelerator pedal

Voltage

110
(Accelerator pedal position
sensor 1)

Fully released

0.6 — 0.9V

Fully depressed

3.9 — 4.7V

Fully released

0.3 — 0.6V

Fully depressed

1.95 — 2.4V

103
(Accelerator pedal position
sensor 2)

4.
5.
6.
7.

PBIA9572J

If NG, replace accelerator pedal assembly and go to next step.
Perform EC-1278, «Accelerator Pedal Released Position Learning» .
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .

Removal and Installation

BBS004QO

ACCELERATOR PEDAL
Refer to ACC-2, «ACCELERATOR CONTROL SYSTEM» .

EC-1500

DTC P2127, P2128 APP SENSOR
[HR (WITHOUT EURO-OBD)]

DTC P2127, P2128 APP SENSOR
Component Description

PFP:18002

A
BBS004QP

The accelerator pedal position sensor is installed on the upper end
of the accelerator pedal assembly. The sensor detects the acceleraEC
tor position and sends a signal to the ECM.
Accelerator pedal position sensor has two sensors. These sensors
are a kind of potentiometers which transform the accelerator pedal
C
position into output voltage, and emit the voltage signal to the ECM.
In addition, these sensors detect the opening and closing speed of
the accelerator pedal and feed the voltage signals to the ECM. The
ECM judges the current opening angle of the accelerator pedal from
D
these signals and controls the throttle control motor based on these
signals.
PBIB1741E
Idle position of the accelerator pedal is determined by the ECM
E
receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut.

CONSULT-II Reference Value in Data Monitor Mode

BBS004QQ

F

Specification data are reference values.
MONITOR ITEM
ACCEL SEN 1

ACCEL SEN 2*

CLSD THL POS

CONDITION
●

●

●

SPECIFICATION

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

4.0 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

3.9 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

G

H

I

*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage.

On Board Diagnosis Logic

BBS004QR

J

These self-diagnoses have the one trip detection logic.
DTC No.
P2127
2127

P2128
2128

Trouble diagnosis name
Accelerator pedal position
sensor 2 circuit low input

Accelerator pedal position
sensor 2 circuit high input

DTC detecting condition
An excessively low voltage from the APP
sensor 2 is sent to ECM.

An excessively high voltage from the APP
sensor 2 is sent to ECM.

Possible cause
●

Harness or connectors
(APP sensor 2 circuit is open or
shorted.)
[Crankshaft position sensor (POS) circuit
is shorted.]
(Refrigerant pressure sensor circuit is
shorted.)

●

Accelerator pedal position sensor
(APP sensor 2)

●

Crankshaft position sensor (POS)

●

Refrigerant pressure sensor

FAIL-SAFE MODE
When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-1501

K

L

M

DTC P2127, P2128 APP SENSOR
[HR (WITHOUT EURO-OBD)]

DTC Confirmation Procedure

BBS004QS

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-1507, «Diagnostic Procedure» .

SEF058Y

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

Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1507, «Diagnostic Procedure» .

EC-1502

DTC P2127, P2128 APP SENSOR
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004QT

A

LHD MODELS

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1484E

EC-1503

DTC P2127, P2128 APP SENSOR
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

74

W

Sensor power supply
(Refrigerant pressure sensor)

[Ignition switch: ON]

Approximately 5V

75

G

Sensor power supply
[Crankshaft position sensor
(POS)]

[Ignition switch: ON]

Approximately 5V

102

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

103

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Engine is running]
104

106

B

O

Sensor ground
(APP sensor 2)
Sensor power supply
(APP sensor 1)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]

Approximately 0V

Approximately 5V

[Ignition switch: ON]

110

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

[Engine is running]
111

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

EC-1504

Approximately 0V

DTC P2127, P2128 APP SENSOR
[HR (WITHOUT EURO-OBD)]
RHD MODELS
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1485E

EC-1505

DTC P2127, P2128 APP SENSOR
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

74

W

Sensor power supply
(Refrigerant pressure sensor)

[Ignition switch: ON]

Approximately 5V

75

G

Sensor power supply
[Crankshaft position sensor
(POS)]

[Ignition switch: ON]

Approximately 5V

102

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

103

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Engine is running]
104

106

B

O

Sensor ground
(APP sensor 2)
Sensor power supply
(APP sensor 1)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]

Approximately 0V

Approximately 5V

[Ignition switch: ON]

110

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

[Engine is running]
111

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

EC-1506

Approximately 0V

DTC P2127, P2128 APP SENSOR
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004QU

1. CHECK GROUND CONNECTIONS
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

EC

C

D

E
MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

F

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

G

2. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I
1.
–
–

2.

H

Disconnect accelerator pedal position (APP) sensor harness
connector (1).
Accelerator pedal position sensor (2)
Accelerator pedal (3)
Turn ignition switch ON.

I

J

K
PBIB2975E

3.

Check voltage between APP sensor terminal 5 and ground with
CONSULT-II or tester.

L

Voltage: Approximately 5V
M

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.

PBIA9607J

EC-1507

DTC P2127, P2128 APP SENSOR
[HR (WITHOUT EURO-OBD)]

3. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between APP sensor terminal 5 and ECM terminal 102.
Refer to Wiring Diagram.
Continuity should exist.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
>> Repair open circuit in harness or connectors.

5. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III
Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

74

Refrigerant pressure sensor terminal 3

EC-1591, «Wiring Diagram»

75

Crankshaft position sensor (POS) terminal 1

EC-1407, «Wiring Diagram»

102

APP sensor terminal 5

EC-1503, «Wiring Diagram»

OK or NG
OK
>> GO TO 6.
NG
>> Repair short to ground or short to power in harness or connectors.

6. CHECK COMPONENTS
Check the following.
●
Crankshaft position sensor (POS) (Refer to EC-1412, «Component Inspection» .)
●
Refrigerant pressure sensor (Refer to ATC-85, «Refrigerant Pressure Sensor» .)
OK or NG
OK
>> GO TO 13.
NG
>> Replace malfunctioning component.

7. CHECK APP SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 104 and APP sensor terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.

EC-1508

DTC P2127, P2128 APP SENSOR
[HR (WITHOUT EURO-OBD)]

8. DETECT MALFUNCTIONING PART

A

Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM

EC

C

>> Repair open circuit or short to ground or short to power in harness or connectors.

9. CHECK APP SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

D

Check harness continuity between ECM terminal 103 and APP sensor terminal 6.
Refer to Wiring Diagram.
E

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

F

10. DETECT MALFUNCTIONING PART

G

Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM

H

I

>> Repair open circuit or short to ground or short to power in harness or connectors.

11. CHECK APP SENSOR

J

Refer to EC-1509, «Component Inspection» .
OK or NG
OK
>> GO TO 13.
NG
>> GO TO 12.

K

L

12. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace accelerator pedal assembly.
Perform EC-1278, «Accelerator Pedal Released Position Learning» .
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .

M

>> INSPECTION END

13. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004QV

ACCELERATOR PEDAL POSITION SENSOR
1.
2.

Reconnect all harness connectors disconnected.
Turn ignition switch ON.

EC-1509

DTC P2127, P2128 APP SENSOR
[HR (WITHOUT EURO-OBD)]
3.

Check voltage between ECM terminals 110 (APP sensor 1 signal), 103 (APP sensor 2 signal) and ground under the following
conditions.
Terminal

Accelerator pedal

Voltage

110
(Accelerator pedal position
sensor 1)

Fully released

0.6 — 0.9V

Fully depressed

3.9 — 4.7V

Fully released

0.3 — 0.6V

Fully depressed

1.95 — 2.4V

103
(Accelerator pedal position
sensor 2)

4.
5.
6.
7.

PBIA9572J

If NG, replace accelerator pedal assembly and go to next step.
Perform EC-1278, «Accelerator Pedal Released Position Learning» .
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .

Removal and Installation

BBS004QW

ACCELERATOR PEDAL
Refer to ACC-2, «ACCELERATOR CONTROL SYSTEM» .

EC-1510

DTC P2135 TP SENSOR
[HR (WITHOUT EURO-OBD)]

DTC P2135 TP SENSOR
Component Description

PFP:16119

A
BBS004QX

Electric throttle control actuator consists of throttle control motor,
throttle position sensor, etc. The throttle position sensor responds to
the throttle valve movement.
The throttle position sensor has the two sensors. These sensors are
a kind of potentiometers which transform the throttle valve position
into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the
throttle valve and feed the voltage signals to the ECM. The ECM
judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the
throttle valve opening angle properly in response to driving condition.

EC

C

D
PBIB0145E

E

CONSULT-II Reference Value in Data Monitor Mode

BBS004QY

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

More than 0.36V

●

Shift lever: D (A/T), 1st (M/T)

Accelerator pedal: Fully depressed

Less than 4.75V

THRTL SEN 1
THRTL SEN 2*

F

SPECIFICATION

G

*: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal.

On Board Diagnosis Logic

BBS004QZ

This self-diagnosis has the one trip detection logic.
NOTE:
If DTC P2135 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to
EC-1471, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

P2135
2135

Trouble diagnosis name

DTC detecting condition

Throttle position sensor
circuit range/performance

Rationally incorrect voltage is sent to ECM
compared with the signals from TP sensor 1
and TP sensor 2.

Possible cause
●

Harness or connector
(TP sensor 1 and 2 circuit is open or
shorted.)

●

Electric throttle control actuator
(TP sensor 1 and 2)

H

I

J

K

L

FAIL-SAFE MODE
When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up.
Engine operation condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

EC-1511

M

DTC P2135 TP SENSOR
[HR (WITHOUT EURO-OBD)]

DTC Confirmation Procedure

BBS004R0

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-1514, «Diagnostic Procedure» .

SEF058Y

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

Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1514, «Diagnostic Procedure» .

EC-1512

DTC P2135 TP SENSOR
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004R1

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1486E

EC-1513

DTC P2135 TP SENSOR
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch: ON]

33

Y

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

Throttle position sensor 1

More than 0.36V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

Less than 4.75V

[Ignition switch: ON]

34

R

Throttle position sensor 2

●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully released

Less than 4.75V

[Ignition switch: ON]
●

Engine stopped

●

Shift lever: D (A/T), 1st (M/T)

●

Accelerator pedal: Fully depressed

More than 0.36V

[Engine is running]
36

72

BR

L

Sensor ground
(Throttle position sensor)
Sensor power supply
(Throttle position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Ignition switch: ON]

Approximately 5V

Diagnostic Procedure

BBS004R2

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC-1514

3.

Body ground

DTC P2135 TP SENSOR
[HR (WITHOUT EURO-OBD)]

2. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT
1.

2.

A

Disconnect electric throttle control actuator (1) harness connector.
: Vehicle front
Turn ignition switch ON.

EC

C

D
PBIB2965E

3.

Check voltage between electric throttle control actuator terminal
1 and ground with CONSULT-II or tester.

E

Voltage: Approximately 5V
F

OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

G

PBIA9580J

H

3. CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 36.
Refer to Wiring Diagram.

I

J

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

K

L

4. CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between electric throttle control actuator terminal 2 and ECM terminal 33, electric throttle control actuator terminal 3 and ECM terminal 34.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK THROTTLE POSITION SENSOR
Refer to EC-1516, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

EC-1515

M

DTC P2135 TP SENSOR
[HR (WITHOUT EURO-OBD)]

6. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
1.
2.
3.

Replace the electric throttle control actuator.
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .
>> INSPECTION END

7. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004R3

THROTTLE POSITION SENSOR
1.
2.
3.
4.
5.

Reconnect all harness connectors disconnected.
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Turn ignition switch ON.
Set shift lever to D position (A/T) or 1st position (M/T).
Check voltage between ECM terminals 33 (TP sensor 1 signal),
34 (TP sensor 2 signal) and ground under the following conditions.
Terminal

Accelerator pedal

Voltage

33
(Throttle position sensor 1)

Fully released

More than 0.36V

Fully depressed

Less than 4.75V

Fully released

Less than 4.75V

Fully depressed

More than 0.36V

34
(Throttle position sensor 2)

6.
7.
8.

If NG, replace electric throttle control actuator and go to the next
step.
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .

Removal and Installation

PBIB3038E

BBS004R4

ELECTRIC THROTTLE CONTROL ACTUATOR
Refer to EM-120, «INTAKE MANIFOLD» .

EC-1516

DTC P2138 APP SENSOR
[HR (WITHOUT EURO-OBD)]

DTC P2138 APP SENSOR
Component Description

PFP:18002

A
BBS004R5

The accelerator pedal position sensor is installed on the upper end
of the accelerator pedal assembly. The sensor detects the acceleraEC
tor position and sends a signal to the ECM.
Accelerator pedal position sensor has two sensors. These sensors
are a kind of potentiometers which transform the accelerator pedal
C
position into output voltage, and emit the voltage signal to the ECM.
In addition, these sensors detect the opening and closing speed of
the accelerator pedal and feed the voltage signals to the ECM. The
ECM judges the current opening angle of the accelerator pedal from
D
these signals and controls the throttle control motor based on these
signals.
PBIB1741E
Idle position of the accelerator pedal is determined by the ECM
E
receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut.

CONSULT-II Reference Value in Data Monitor Mode

BBS004R6

F

Specification data are reference values.
MONITOR ITEM
ACCEL SEN 1

ACCEL SEN 2*

CLSD THL POS

CONDITION
●

●

●

SPECIFICATION

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

4.0 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

0.6 — 0.9V

Accelerator pedal: Fully depressed

3.9 — 4.8V

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

G

H

I

*: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage.

On Board Diagnosis Logic

BBS004R7

This self-diagnosis has the one trip detection logic.
NOTE:
If DTC P2138 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to
EC-1471, «DTC P1229 SENSOR POWER SUPPLY» .
DTC No.

Trouble diagnosis name

DTC detecting condition

Possible cause
●

P2138
2138

Accelerator pedal position sensor circuit
range/performance

Rationally incorrect voltage is sent to ECM
compared with the signals from APP sensor 1
and APP sensor 2.

EC-1517

Harness or connector
(APP sensor 1 and 2 circuit is open or
shorted.)
[Crankshaft position sensor (POS) circuit
is shorted.]
(Refrigerant pressure sensor circuit is
shorted.)

●

Accelerator pedal position sensor
(APP sensor 1 and 2)

●

Crankshaft position sensor (POS)

●

Refrigerant pressure sensor

J

K

L

M

DTC P2138 APP SENSOR
[HR (WITHOUT EURO-OBD)]
FAIL-SAFE MODE
When the malfunction is detected, ECM enters fail-safe mode and the MI lights up.
Engine operating condition in fail-safe mode
The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10
degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal condition.
So, the acceleration will be poor.

DTC Confirmation Procedure

BBS004R8

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
TESTING CONDITION:
Before performing the following procedure, confirm that battery voltage is more than 10V at idle.

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

Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-II.
Start engine and let it idle for 1 second.
If DTC is detected, go to EC-1523, «Diagnostic Procedure» .

SEF058Y

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

Start engine and let it idle for 1 second.
Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM.
If DTC is detected, go to EC-1523, «Diagnostic Procedure» .

EC-1518

DTC P2138 APP SENSOR
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004R9

A

LHD MODELS

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1487E

EC-1519

DTC P2138 APP SENSOR
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

74

W

Sensor power supply
(Refrigerant pressure sensor)

[Ignition switch: ON]

Approximately 5V

75

G

Sensor power supply
[Crankshaft position sensor
(POS)]

[Ignition switch: ON]

Approximately 5V

102

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

103

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Engine is running]
104

106

B

O

Sensor ground
(APP sensor 2)
Sensor power supply
(APP sensor 1)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]

Approximately 0V

Approximately 5V

[Ignition switch: ON]

110

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

[Engine is running]
111

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

EC-1520

Approximately 0V

DTC P2138 APP SENSOR
[HR (WITHOUT EURO-OBD)]
RHD MODELS
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1488E

EC-1521

DTC P2138 APP SENSOR
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

74

W

Sensor power supply
(Refrigerant pressure sensor)

[Ignition switch: ON]

Approximately 5V

75

G

Sensor power supply
[Crankshaft position sensor
(POS)]

[Ignition switch: ON]

Approximately 5V

102

BR

Sensor power supply
(APP sensor 2)

[Ignition switch: ON]

Approximately 5V

[Ignition switch: ON]

103

G

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

0.3 — 0.6V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

1.95 — 2.4V

[Engine is running]
104

106

B

O

Sensor ground
(APP sensor 2)
Sensor power supply
(APP sensor 1)

●

Warm-up condition

●

Idle speed

[Ignition switch: ON]

Approximately 0V

Approximately 5V

[Ignition switch: ON]

110

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

0.6 — 0.9V

[Ignition switch: ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

3.9 — 4.7V

[Engine is running]
111

B

Sensor ground
(APP sensor 1)

●

Warm-up condition

●

Idle speed

EC-1522

Approximately 0V

DTC P2138 APP SENSOR
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004RA

1. CHECK GROUND CONNECTIONS
1.
2.

A

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

EC

C

D

E
MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

F

Body ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

G

2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT
1.
–
–

2.

H

Disconnect accelerator pedal position (APP) sensor harness
connector (1).
Accelerator pedal position sensor (2)
Accelerator pedal (3)
Turn ignition switch ON.

I

J

K
PBIB2975E

3.

Check voltage between APP sensor terminal 4 and ground with
CONSULT-II or tester.

L

Voltage: Approximately 5V
M

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

PBIA9606J

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1523

DTC P2138 APP SENSOR
[HR (WITHOUT EURO-OBD)]

4. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I
1.
2.

Turn ignition switch ON.
Check voltage between APP sensor terminal 5 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 5.

PBIA9607J

5. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between APP sensor terminal 5 and ECM terminal 102.
Refer to Wiring Diagram.
Continuity should exist.

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

6. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open between APP sensor and ECM
>> Repair open circuit in harness or connectors.

7. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III
Check harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

74

Refrigerant pressure sensor terminal 3

EC-1591, «Wiring Diagram»

75

Crankshaft position sensor (POS) terminal 1

EC-1407, «Wiring Diagram»

102

APP sensor terminal 5

EC-1519, «Wiring Diagram»

OK or NG
OK
>> GO TO 8.
NG
>> Repair short to ground or short to power in harness or connectors.

8. CHECK COMPONENTS
Check the following.
Crankshaft position sensor (POS) (Refer to EC-1412, «Component Inspection» .)
●
Refrigerant pressure sensor (Refer to ATC-85, «Refrigerant Pressure Sensor» .)
OK or NG
OK
>> GO TO 15.
NG
>> Replace malfunctioning component.
●

EC-1524

DTC P2138 APP SENSOR
[HR (WITHOUT EURO-OBD)]

9. CHECK APP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

A
Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 111 and APP sensor terminal 2, ECM terminal 104 and EC
APP sensor terminal 1.
Refer to Wiring Diagram.
C
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 10.

D

E

10. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open between APP sensor and ECM
●

F

G

>> Repair open circuit in harness or connectors.

11. CHECK APP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 110 and APP sensor terminal 3, ECM terminal 103 and
APP sensor terminal 6.
Refer to Wiring Diagram.

H

I

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 13.
NG
>> GO TO 12.

12. DETECT MALFUNCTIONING PART

J

K

L

Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open between APP sensor and ECM
>> Repair open circuit in harness or connectors.

13. CHECK APP SENSOR
Refer to EC-1527, «Component Inspection» .
OK or NG
OK
>> GO TO 15.
NG
>> GO TO 14.

EC-1525

M

DTC P2138 APP SENSOR
[HR (WITHOUT EURO-OBD)]

14. REPLACE ACCELERATOR PEDAL ASSEMBLY
1.
2.
3.
4.

Replace accelerator pedal assembly.
Perform EC-1278, «Accelerator Pedal Released Position Learning» .
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1277, «Idle Speed and Ignition Timing Check» .
>> INSPECTION END

15. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1526

DTC P2138 APP SENSOR
[HR (WITHOUT EURO-OBD)]

Component Inspection

BBS004RB

A

ACCELERATOR PEDAL POSITION SENSOR
1.
2.
3.

Reconnect all harness connectors disconnected.
Turn ignition switch ON.
Check voltage between ECM terminals 110 (APP sensor 1 signal), 103 (APP sensor 2 signal) and ground under the following
conditions.
Terminal

Accelerator pedal

Voltage

110
(Accelerator pedal position
sensor 1)

Fully released

0.6 — 0.9V

Fully depressed

3.9 — 4.7V

Fully released

0.3 — 0.6V

Fully depressed

1.95 — 2.4V

103
(Accelerator pedal position
sensor 2)

4.
5.
6.
7.

EC

C

D

E
PBIA9572J

If NG, replace accelerator pedal assembly and go to next step.
Perform EC-1278, «Accelerator Pedal Released Position Learning» .
Perform EC-1279, «Throttle Valve Closed Position Learning» .
Perform EC-1279, «Idle Air Volume Learning» .

Removal and Installation

F

BBS004RC

G

ACCELERATOR PEDAL
Refer to ACC-2, «ACCELERATOR CONTROL SYSTEM» .
H

I

J

K

L

M

EC-1527

ELECTRICAL LOAD SIGNAL
[HR (WITHOUT EURO-OBD)]

ELECTRICAL LOAD SIGNAL
CONSULT-II Reference Value in Data Monitor Mode

PFP:25350
BBS004RG

Specification data are reference values.
MONITOR ITEM

LOAD SIGNAL

CONDITION

●

HEATER FAN SW

●

Ignition switch: ON

Ignition switch: ON

SPECIFICATION

Rear window defogger switch is ON and/or lighting
switch is in 2nd position.

ON

Rear window defogger switch is OFF and lighting switch
is OFF.

OFF

Heater fan is operating.

ON

Heater fan is not operating.

OFF

Diagnostic Procedure

BBS004RH

1. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCITION-I
1.
2.

Turn ignition switch ON.
Check “LOAD SIGNAL” in “DATA MONITOR” mode with CONSULT-II under the following conditions.
Condition

LOAD SIGNAL

Lighting switch: ON at 2nd position

ON

Lighting switch: OFF

OFF

OK or NG
OK
>> GO TO 2.
NG
>> GO TO 4.
PBIB0103E

2. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-II
Check “LOAD SIGNAL” in “DATA MONITOR” mode with CONSULTII under the following conditions.
Condition

LOAD SIGNAL

Rear window defogger switch: ON

ON

Rear window defogger switch: OFF

OFF

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 5.
PBIB0103E

3. CHECK HEATER FAN SIGNAL CIRCUIT OVERALL FUNCTION
Check “HEATER FAN SW” in “DATA MONITOR” mode with CONSULT-II under the following conditions.
Condition

HEATER FAN SW

Heater fan control switch: ON

ON

Heater fan control switch: OFF

OFF

OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 6.
PBIB1995E

EC-1528

ELECTRICAL LOAD SIGNAL
[HR (WITHOUT EURO-OBD)]

4. CHECK HEADLAMP SYSTEM

A

Refer to LT-7, «HEADLAMP -CONVENTIONAL TYPE-» or LT-35, «HEADLAMP — DAYTIME LIGHT SYSTEM «.
EC

>> INSPECTION END

5. CHECK REAR WINDOW DEFOGGER SYSTEM

C

Refer to GW-12, «REAR WINDOW DEFOGGER» .
D

>> INSPECTION END

6. CHECK HEATER FAN CONTROL SYSTEM

E

Refer to ATC-26, «TROUBLE DIAGNOSIS» (models with automatic air conditioner) or MTC-23, «TROUBLE
DIAGNOSIS» (models with manual air conditioner).
F

>> INSPECTION END
G

H

I

J

K

L

M

EC-1529

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[HR (WITHOUT EURO-OBD)]

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
Description

PFP:14920
BBS004RI

SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*1

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Battery

Battery voltage*1

Throttle position sensor

Throttle position

Accelerator pedal position sensor

Accelerator pedal position

Heated oxygen sensor 1

Density of oxygen in exhaust gas
(Mixture ratio feedback signal)

Wheel sensor

Vehicle speed*2

ECM function

Actuator

EVAP canister
purge flow control

EVAP canister purge volume
control solenoid valve

*1: ECM determines the start signal status by the signals of engine speed and battery voltage.
*2: This signal is sent to the ECM through CAN communication line.

This system controls flow rate of fuel vapor from the EVAP canister. The opening of the vapor by-pass passage in the EVAP canister purge volume control solenoid valve changes to control the flow rate. The EVAP
canister purge volume control solenoid valve repeats ON/OFF operation according to the signal sent from the
ECM. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is
determined by considering various engine conditions. When the engine is operating, the flow rate of fuel vapor
from the EVAP canister is regulated as the air flow changes.

COMPONENT DESCRIPTION
The EVAP canister purge volume control solenoid valve uses a ON/
OFF duty to control the flow rate of fuel vapor from the EVAP canister. The EVAP canister purge volume control solenoid valve is
moved by ON/OFF pulses from the ECM. The longer the ON pulse,
the greater the amount of fuel vapor that will flow through the valve.

PBIA9215J

CONSULT-II Reference Value in Data Monitor Mode

BBS004RJ

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

Air conditioner switch: OFF

●

No load

PURG VOL C/V

SPECIFICATION

Idle

0%

2,000 rpm

0 — 50%

EC-1530

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004RK

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1496E

EC-1531

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)
BATTERY VOLTAGE
(11 — 14V)

[Engine is running]
●

9

LG

Idle speed

EVAP canister purge volume control solenoid valve

PBIB0050E

Approximately 10V
[Engine is running]
●

Engine speed: About 2,000 rpm (More than
100 seconds after starting engine)

NOTE:
Voltage and Duty percent may vary.
PBIB0520E

[Engine is running]
[Ignition switch: OFF]
●

32

P

ECM relay
(Self shut-off)

[Ignition switch: OFF]
●

105

G

Power supply for ECM

For a few seconds after turning ignition switch
OFF

More than a few seconds after turning ignition
switch OFF

[Ignition switch: ON]

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-1532

0 — 1.0V

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004RL

1. CHECK OVERALL FUNCTION

A

With CONSULT-II
1. Turn ignition switch OFF.
2. Disconnect the EVAP purge hose (2) connected to the EVAP
canister (1).
–
–

3.

EC

C

: Vehicle front
Illustration shows the view from under the vehicle.
Turn ignition switch ON.

D

E
MBIB1497E

4.
5.
6.

F

Select “PURG VOL CONT/V” in “ACTIVE TEST” mode with
CONSULT-II.
Start engine and let it idle.
Change the valve opening percentage with touching “Qu” or
“Qd” on CONSULT-II screen, and check for vacuum existence at
the EVAP purge hose under the following conditions.
Conditions
(PURG VOL CONT/V)

Vacuum

0%

Should not exist.

100%

Should exist.

G

H

I
PBIB0569E

J

Without CONSULT-II
1. Turn ignition switch OFF.
2. Disconnect the EVAP purge hose (2) connected to the EVAP
canister (1).
–
–

3.
4.

K

: Vehicle front
Illustration shows the view from under the vehicle.
Start engine and let it idle for at least 100 seconds.
Check for vacuum existence at the EVAP purge hose under the
following conditions.
Conditions

At idle
Engine speed: About 2,000 rpm

L

M

Vacuum
Should not exist.
Should exist.

OK or NG
OK
>> GO TO 2.
NG
>> GO TO 3.

2. CHECK EVAP CANISTER
Refer to EC-1260, «EVAP CANISTER» .
OK or NG
OK
>> INSPECTION END
NG
>> Replace EVAP canister.

EC-1533

MBIB1497E

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[HR (WITHOUT EURO-OBD)]

3. CHECK EVAP PURGE LINE
Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks or improper connection.
Refer to EC-1258, «EVAPORATIVE EMISSION LINE DRAWING» .
OK or NG
OK
>> GO TO 4.
NG
>> Repair or reconnect the hose.

4. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT
1.
2.

Turn ignition switch OFF.
Disconnect EVAP canister purge volume control solenoid valve
(1) harness connector.

–

: Vehicle front
Turn ignition switch ON.

3.

PBIB2972E

4.

Check voltage between EVAP canister purge volume control
solenoid valve terminal 1 and ground with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

PBIB0148E

5. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between EVAP canister purge volume control solenoid valve and IPDM E/R
●
Harness for open or short between EVAP canister purge volume control solenoid valve and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1534

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[HR (WITHOUT EURO-OBD)]

6. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

A

Turn ignition switch OFF.
EC
Disconnect ECM harness connector.
Check harness continuity between EVAP canister purge volume control solenoid valve terminal 2 and
ECM terminal 9.
Refer to Wiring Diagram.
C
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK (With CONSULT-II)>>GO TO 7.
OK (Without CONSULT-II)>>GO TO 8.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D

E

7. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION

F

With CONSULT-II
1. Reconnect all harness connectors disconnected.
2. Start engine.
3. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with
CONSULT-II. Check that engine speed varies according to the
valve opening.
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.

G

H

I

J
PBIB0569E

8. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

K

Refer to EC-1536, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace EVAP canister purge volume control solenoid valve.

L

M

9. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1535

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
[HR (WITHOUT EURO-OBD)]

Component Inspection

BBS004RM

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
With CONSULT-II
Check air passage continuity of EVAP canister purge volume control
solenoid valve under the following conditions.
Condition
(PURG VOL CONT/V value)

Air passage continuity
between A and B

100%

Yes

0%

No

PBIA9668J

Without CONSULT-II
Check air passage continuity of EVAP canister purge volume control
solenoid valve under the following conditions.
Condition

Air passage continuity
between A and B

12V direct current supply between terminals 1 and 2

Yes

No supply

No

PBIA9560J

Removal and Installation

BBS004RN

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE
Refer to EM-120, «INTAKE MANIFOLD» .

EC-1536

FUEL INJECTOR
[HR (WITHOUT EURO-OBD)]

FUEL INJECTOR
Component Description

PFP:16600

A
BBS004RO

The fuel injector is a small, precise solenoid valve. When the ECM
supplies a ground to the fuel injector circuit, the coil in the fuel injector is energized. The energized coil pulls the ball valve back and
allows fuel to flow through the fuel injector into the intake manifold.
The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the fuel injector remains
open. The ECM controls the injection pulse duration based on
engine fuel needs.

EC

C

D
SEF375Z

E

CONSULT-II Reference Value in Data Monitor Mode

BBS004RP

Specification data are reference values.
MONITOR ITEM
B/FUEL SCHDL

INJ PULSE-B1

CONDITION

SPECIFICATION

F

See EC-1326, «TROUBLE DIAGNOSIS — SPECIFICATION VALUE» .
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: P or N (A/T), Neutral
(M/T)

●

No load

Idle

2.0 — 3.0 msec

2,000 rpm

1.9 — 2.9 msec

G

H

I

J

K

L

M

EC-1537

FUEL INJECTOR
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004RQ

MBWA1489E

EC-1538

FUEL INJECTOR
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
BATTERY VOLTAGE
[Engine is running]

25
29
30
31

R
O
GR
L

●

Warm-up condition

●

Idle speed

(11 — 14V)

D

NOTE:
The pulse cycle changes depending on rpm
at idle

Fuel injector No. 4
Fuel injector No. 3
Fuel injector No. 2
Fuel injector No. 1

E
PBIB0529E

BATTERY VOLTAGE

F

(11 — 14V)
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

G

H
PBIA4943J

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

I

Diagnostic Procedure

BBS004RR

1. INSPECTION START
J

Turn ignition switch to START.
Is any cylinder ignited?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.

K

L

M

EC-1539

FUEL INJECTOR
[HR (WITHOUT EURO-OBD)]

2. CHECK OVERALL FUNCTION
With CONSULT-II
Start engine.
Perform “POWER BALANCE” in “ACTIVE TEST” mode with
CONSULT-II.
3. Make sure that each circuit produces a momentary engine
speed drop.
1.
2.

PBIB0133E

Without CONSULT-II
1. Start engine.
2. Listen to each fuel injector operating sound.
Clicking noise should be heard.

PBIB1986E

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 3.

EC-1540

FUEL INJECTOR
[HR (WITHOUT EURO-OBD)]

3. CHECK FUEL INJECTOR POWER SUPPLY CIRCUIT
1.
2.
–

3.

A

Turn ignition switch OFF.
Disconnect fuel injector (2) harness connector.
Ignition coil (1)
Turn ignition switch ON.

EC

C

D
PBIB2968E

E

4.

Check voltage between fuel injector terminal 1 and ground with
CONSULT-II or tester.
F

Voltage: Battery voltage
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

G

H
PBIB0582E

4. DETECT MALFUNCTIONING PART

I

Check the following.
●
Harness connectors E59, F1
●
IPDM E/R harness connector E10
●
10A fuse
●
Harness for open or short between fuel injector and fuse

J

K

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK FUEL INJECTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between fuel injector terminal 2 and ECM terminals 25, 29, 30, 31.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK FUEL INJECTOR
Refer to EC-1542, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace fuel injector.

EC-1541

L

M

FUEL INJECTOR
[HR (WITHOUT EURO-OBD)]

7. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004RS

FUEL INJECTOR
1.
2.

Disconnect fuel injector harness connector.
Check resistance between terminals as shown in the figure.
Resistance: 11.1 — 14.5Ω [at 10 — 60°C (50 — 140°F)]

PBIB1727E

Removal and Installation

BBS004RT

FUEL INJECTOR
Refer to EM-135, «FUEL INJECTOR AND FUEL TUBE» .

EC-1542

FUEL PUMP
[HR (WITHOUT EURO-OBD)]

FUEL PUMP
Description

PFP:17042

A
BBS004RU

SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed*

Battery

Battery voltage*

ECM Function

Actuator

Fuel pump control

EC

Fuel pump relay

C

*: ECM determines the start signal status by the signals of engine speed and battery voltage.

The ECM activates the fuel pump for several seconds after the ignition switch is turned ON to improve engine
startability. If the ECM receives a engine speed signal from the crankshaft position sensor (POS) and camshaft position sensor (PHASE), it knows that the engine is rotating, and causes the pump to operate. If the
engine speed signal is not received when the ignition switch is ON, the engine stalls. The ECM stops pump
operation and prevents battery discharging, thereby improving safety. The ECM does not directly drive the fuel
pump. It controls the ON/OFF fuel pump relay, which in turn controls the fuel pump.
Condition

D

E

Fuel pump operation

Ignition switch is turned to ON

Operates for 1 second

Engine running and cranking

Operates

When engine is stopped

Stops in 1.5 seconds

Except as shown above

Stops

F

G

COMPONENT DESCRIPTION

H

A turbine type design fuel pump is used in the fuel tank.

I

J

K
MBIB0291E

CONSULT-II Reference Value in Data Monitor Mode

BBS004RV

L

Specification data are reference values.
MONITOR ITEM

FUEL PUMP RLY

CONDITION
●

For 1 second after turning ignition switch ON

●

Engine running or cranking

●

Except above conditions

SPECIFICATION
ON
OFF

EC-1543

M

FUEL PUMP
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004RW

MBWA1490E

EC-1544

FUEL PUMP
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

EC

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch: ON]
●

23

R

A

Fuel pump relay

For 1 second after turning ignition switch ON

C
0 — 1.0V

[Engine is running]
[Ignition switch: ON]
●

More than 1 second after turning ignition
switch ON

D
BATTERY VOLTAGE
(11 — 14V)

E

Diagnostic Procedure

BBS004RX

1. CHECK OVERALL FUNCTION
1.
2.
–

F

Turn ignition switch ON.
Pinch fuel feed hose (1) with two fingers.
Illustration shows the view with intake air duct removed.

G

Fuel pressure pulsation should be felt on the fuel
feed hose for 1 second after ignition switch is turned
ON.

H

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

I
PBIB2978E

2. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-I
1.
2.
3.
4.

J

Turn ignition switch OFF.
Disconnect ECM harness connector.
Turn ignition switch ON.
Check voltage between ECM terminal 23 and ground with CONSULT-II or tester.

K

L

Voltage: Battery voltage
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.

M

PBIA9573J

EC-1545

FUEL PUMP
[HR (WITHOUT EURO-OBD)]

3. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E5.
Check harness continuity between ECM terminal 23 and IPDM E/R terminal 69.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 4.

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness or connectors E59, F1
●
Harness for open or short between IPDM E/R and ECM
>> Repair harness or connectors.

5. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-III
1.
2.
3.
4.

Turn ignition switch OFF.
Reconnect all harness connectors disconnected.
Disconnect “fuel level sensor unit and fuel pump” harness connector.
Turn ignition switch ON.

MBIB0288E

5.

Check voltage between “fuel level sensor unit and fuel pump”
terminal 1 and ground with CONSULT-II or tester.
Voltage:

Battery voltage should exist for 1 second
after ignition switch is turned ON.

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 6.

PBIB3004E

EC-1546

FUEL PUMP
[HR (WITHOUT EURO-OBD)]

6. CHECK 15A FUSE

A

1. Turn ignition switch OFF.
2. Disconnect 15A fuse.
3. Check 15A fuse.
OK or NG
OK
>> GO TO 7.
NG
>> Replace fuse.

EC

C

7. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-IV
1.
2.

Disconnect IPDM E/R harness connector E10.
Check harness continuity between IPDM E/R terminal 20 and “fuel level sensor unit and fuel pump” terminal 1.
Refer to Wiring Diagram.

D

E

Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 11.
NG
>> GO TO 8.

F

G

8. DETECT MALFUNCTIONING PART
H

Check the following.
●
Harness or connectors M1, E101
●
Harness or connectors M72, B21
●
Harness for open or short between IPDM E/R and “fuel level sensor unit and fuel pump”

I

J

>> Repair harness or connectors.

9. CHECK FUEL PUMP GROUND CIRCUIT
1.

Check harness continuity between “fuel level sensor unit and fuel pump” terminal 3 and ground.
Refer to Wiring Diagram.
Continuity should exist.

K

L

2. Also check harness for short to power.
OK or NG
OK
>> GO TO 10.
NG
>> Repair or replace harness or connectors.

10. CHECK FUEL PUMP
Refer to EC-1548, «Component Inspection» .
OK or NG
OK
>> GO TO 11.
NG
>> Replace “fuel level sensor unit and fuel pump”.

11. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connectors.

EC-1547

M

FUEL PUMP
[HR (WITHOUT EURO-OBD)]

Component Inspection

BBS004RY

FUEL PUMP
1.
2.

Disconnect “fuel level sensor unit and fuel pump” harness connector.
Check resistance between “fuel level sensor unit and fuel pump”
terminals 1 and 3.
Resistance: Approximately 0.2 — 5.0Ω [at 25°C (77°F)]

MBIB0311E

Removal and Installation

BBS004RZ

FUEL PUMP
Refer to FL-15, «FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY» .

EC-1548

HO2S1
[HR (WITHOUT EURO-OBD)]

HO2S1
Component Description

PFP:22690

A
BBS004S0

The heated oxygen sensor 1 is placed into the exhaust manifold. It
detects the amount of oxygen in the exhaust gas compared to the
outside air. The heated oxygen sensor 1 has a closed-end tube
made of ceramic zirconia. The zirconia generates voltage from
approximately 1V in richer conditions to 0V in leaner conditions. The
heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts
the injection pulse duration to achieve the ideal air-fuel ratio. The
ideal air-fuel ratio occurs near the radical change from 1V to 0V.

EC

C

D
SEF463R

E

F

G

H
SEF288D

CONSULT-II Reference Value in Data Monitor Mode

BBS004S1

I

Specification data are reference values.
MONITOR ITEM

CONDITION

J

0 — 0.3V ←→ Approx. 0.6 — 1.0V

HO2S1 (B1)
●

HO2S1 MNTR (B1)

SPECIFICATION

Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN ←→ RICH
Changes more than 5 times during
10 seconds.

K

L

M

EC-1549

HO2S1
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004S2

MBWA1497E

EC-1550

HO2S1
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
Approximately 10V
[Engine is running]

3

Y

●

Warm-up condition

●

Engine speed: Below 3,600 rpm

D

Heated oxygen sensor 1
heater

E
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

[Engine is running]
●

BATTERY VOLTAGE
(11 — 14V)

Engine speed: Above 3,600 rpm

G

[Engine is running]
49

56

BR

R

Heated oxygen sensor 1

Sensor ground
(Heated oxygen sensor 1)

●

Warm-up condition

●

Engine speed: 2,000 rpm

[Engine is running]
●

F

Idle speed

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

0 — Approximately 1.0V
(Periodically change)

H
Approximately 0V

I

J

K

L

M

EC-1551

HO2S1
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004S3

1. CHECK OVERALL FUNCTION
With CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Select “HO2S1 MNTR (B1)” in “DATA MONITOR” mode with
CONSULT-II.
3. Keep the engine speed at 2,000 rpm under no load, and make
sure that the monitors fluctuates between LEAN and RICH more
than five times in 10 seconds.
1 time: RICH → LEAN → RICH
2 times: RICH → LEAN → RICH → LEAN →RICH

SEF820Y

Without CONSULT-II
Start engine and warm it up to normal operating temperature.
Stop engine and wait at least 10 seconds.
Set ECM in Diagnostic test mode — II (Heated oxygen sensor 1 monitor).
Refer to EC-1269, «HOW TO SWITCH DIAGNOSTIC TEST MODE» .
4. Keep the engine speed at 2,000 rpm under no load, and make
sure that the MI comes ON more than five times in 10 seconds.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
1.
2.
3.

SAT652J

2. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace ground connections.

EC-1552

3.

Body ground

HO2S1
[HR (WITHOUT EURO-OBD)]

3. RETIGHTEN HEATED OXYGEN SENSOR 1

A

Loosen and retighten heated oxygen sensor 1.
●
●

: Vehicle front
Exhaust manifold (2)

EC

Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb)
C

>> GO TO 4.
D
PBIB2966E

4. CHECK FOR EXHAUST GAS LEAK
1.
2.

E

Start engine and run it at idle.
Listen for an exhaust gas leak before three way catalyst (Manifold).

F

G

H

I
SEC502D

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace.

J

5. CHECK FOR INTAKE AIR LEAK

K

Listen for an intake air leak after the mass air flow sensor.
OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace.

L

6. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT

M

1.
2.

Turn ignition switch OFF.
Disconnect heated oxygen sensor 1 harness connector (1).

–

: Vehicle front
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 56 and HO2S1
terminal 1.
Refer to Wiring Diagram.

3.
4.

Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1553

PBIB2967E

HO2S1
[HR (WITHOUT EURO-OBD)]

7. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 49 and HO2S1 terminal 4.
Refer to Wiring Diagram.
Continuity should exist.

2.

Check harness continuity between ECM terminal 49 or HO2S1 terminal 4 and ground.
Refer to Wiring Diagram.
Continuity should not exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 8.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK MASS AIR FLOW SENSOR
Refer to EC-1359, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace mass air flow sensor.

9. CHECK PCV VALVE
Refer to EC-1262, «Component Inspection» .
OK or NG
OK
>> GO TO 10.
NG
>> Replace PCV valve.

10. CHECK HEATED OXYGEN SENSOR 1
Refer to EC-1555, «Component Inspection» .
OK or NG
OK
>> GO TO 11.
NG
>> Replace heated oxygen sensor 1.

11. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1554

HO2S1
[HR (WITHOUT EURO-OBD)]

Component Inspection

BBS004S4

A

HEATED OXYGEN SENSOR 1
With CONSULT-II
1.
2.
3.
4.
5.

Start engine and warm it up to normal operating temperature.
Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC
II.
Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”.
C
Hold engine speed at 2,000 rpm under no load during the following steps.
Touch “RECORD” on CONSULT-II screen.
D

E

SEF646Y

F

6.

Check the following.
● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes
from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds.
5 times (cycles) are counted as shown at right.
● “HO2S1 (B1)” voltage goes above 0.6V at least once.
● “HO2S1 (B1)” voltage goes below 0.3V at least once.
● “HO2S1 (B1)” voltage never exceeds 1.0V.

G

H

I
SEF217YA

J

K

L

SEF648Y

CAUTION:
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.
●

Without CONSULT-II
1.
2.

Start engine and warm it up to normal operating temperature.
Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground.

EC-1555

M

HO2S1
[HR (WITHOUT EURO-OBD)]
3.

Check the following with engine speed held at 2,000 rpm constant under no load.
● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V
more than 5 times within 10 seconds.
● The maximum voltage is over 0.6V at least 1 time.
● The minimum voltage is below 0.3V at least 1 time.
● The voltage never exceeds 1.0V.
1 time: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V
2 times: 0 — 0.3V → 0.6 — 1.0V → 0 — 0.3V → 0.6 — 1.0V → 0 0.3V
PBIA9566J
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Removal and Installation

BBS004S5

HEATED OXYGEN SENSOR 1
Refer to EM-124, «EXHAUST MANIFOLD» .

EC-1556

HO2S1 HEATER
[HR (WITHOUT EURO-OBD)]

HO2S1 HEATER
Description

PFP:22690

A
BBS004S6

SYSTEM DESCRIPTION
Sensor

Input Signal to ECM

Camshaft position sensor (PHASE)
Crankshaft position sensor (POS)

Engine speed

Engine coolant temperature sensor

Engine coolant temperature

ECM function
Heated oxygen sensor 1
heater control

Actuator

EC

Heated oxygen sensor 1 heater

The ECM performs ON/OFF duty control of the heated oxygen sensor 1 heater corresponding to the engine
speed and engine coolant temperature. The duty percent varies with engine coolant temperature when engine
is started.

OPERATION

D

E
Engine speed

Heated oxygen sensor 1 heater

Above 3,600 rpm

OFF

Below 3,600 rpm after warming up

ON

F

CONSULT-II Reference Value in Data Monitor Mode

BBS004S7

Specification data are reference values.
MONITOR ITEM

HO2S1 HTR (B1)

C

G
CONDITION

●

Engine: After warming up

●

Engine speed: Below 3,600 rpm

●

Engine speed: Above 3,600 rpm

●

Engine coolant temperature when engine started: More than 80°C (176°F)

●

Engine speed: Below 3,600 rpm

O2SEN HTR DTY

SPECIFICATION
ON

H

OFF
Approx. 30%

I

J

K

L

M

EC-1557

HO2S1 HEATER
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004S8

MBWA1497E

EC-1558

HO2S1 HEATER
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

C
Approximately 10V
[Engine is running]

3

Y

●

Warm-up condition

●

Engine speed: Below 3,600 rpm.

D

Heated oxygen sensor 1
heater

E
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

[Engine is running]
●

BATTERY VOLTAGE
(11 — 14V)

Engine speed: Above 3,600 rpm.

G

[Engine is running]
49

56

BR

R

Heated oxygen sensor 1

Sensor ground
(Heated oxygen sensor 1)

●

Warm-up condition

●

Engine speed: 2,000 rpm

[Engine is running]
●

F

Idle speed

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

0 — Approximately 1.0V
(Periodically change)

H
Approximately 0V

I

J

K

L

M

EC-1559

HO2S1 HEATER
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004S9

1. CHECK OVERALL FUNCTION
1.
2.
3.
4.
5.
6.

Start engine and warm it up to normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON.
Set tester prove between ECM terminal 3 (HO2S1 heater signal) and ground.
Start engine and let it idle.
Check the voltage under the following conditions.
Verify that the oscilloscope screen shows the signal waves as
shown below.
Conditions

Voltage
Approximately 7.0V

At idle

MBIB1394E
PBIB0519E

Engine speed is above 3,600 rpm

BATTERY VOLTAGE
(11 — 14V)

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

2. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace ground connections.

EC-1560

3.

Body ground

HO2S1 HEATER
[HR (WITHOUT EURO-OBD)]

3. CHECK HO2S1 POWER SUPPLY CIRCUIT

A

1.

Disconnect heated oxygen sensor 1 harness connector (1).

–

: Vehicle front
Turn ignition switch ON.

2.

EC

C

D
MBIB1340E

3.

E

Check voltage between HO2S1 terminal 2 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

F

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

G

PBIA9576J

H

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
IPDM E/R connector E10
●
10A fuse
●
Harness for open or short between heated oxygen sensor 1 and fuse

I

J

K

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK HO2S1 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

L

1.
2.
3.

M

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between HO2S1 terminal 3 and ECM terminal 3.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK HEATED OXYGEN SENSOR 1 HEATER
Refer to EC-1562, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace heated oxygen sensor 1.

EC-1561

HO2S1 HEATER
[HR (WITHOUT EURO-OBD)]

7. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004SA

HEATED OXYGEN SENSOR 1 HEATER
1.

Check resistance between HO2S1 terminals as follows.
Terminal No.

Resistance

2 and 3

3.4 — 4.4 Ω [at 25°C (77°F)]

1 and 2, 3, 4

∞Ω
(Continuity should not exist)

4 and 1, 2, 3

2. If NG, replace heated oxygen sensor 1.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped
from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system
threads using Oxygen Sensor Thread Cleaner tool and
approved anti-seize lubricant.

PBIA9577J

Removal and Installation

BBS004SB

HEATED OXYGEN SENSOR 1
Refer to EM-124, «EXHAUST MANIFOLD» .

EC-1562

HO2S2
[HR (WITHOUT EURO-OBD)]

HO2S2
Component Description

PFP:226A0

A
BBS004SC

The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas on each bank.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.

EC

C

D
SEF327R

E

CONSULT-II Reference Value in Data Monitor Mode

BBS004SD

Specification data are reference values.
MONITOR ITEM
HO2S2 (B1)

HO2S2 MNTR (B1)

CONDITION
●

Revving engine from idle to 3,000 rpm quickly after the following conditions are met.

–

Engine: After warming up.

–

Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute
and idle for 1 minute under no load.

SPECIFICATION

F

0 — 0.3V ←→ Approx. 0.6 1.0V

G
LEAN ←→ RICH

H

I

J

K

L

M

EC-1563

HO2S2
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004SE

MBWA1498E

EC-1564

HO2S2
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

C
[Engine is running]

5

DATA (DC Voltage)

GR

●

Below 3,600 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load

Heated oxygen sensor 2
heater

Approximately 10V

D

E
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

[Engine is running]
●

F

BATTERY VOLTAGE
(11 — 14V)

Engine speed: Above 3,600 rpm

G

[Engine is running]

50

B

Heated oxygen sensor 2

●

Revving engine from idle to 3,000 rpm quickly
after the following conditions are met.

–

Engine: After warming up.

–

Keep the engine speed between 3,500 rpm
and 4,000 rpm for 1 minute and at idle for 1
minute under no load.

H

0 — Approximately 1.0V

I

[Engine is running]
59

LG

Sensor ground
(Heated oxygen sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

J

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004SF

K

1. CHECK OVERALL FUNCTION — I
1.
2.
3.
4.
5.
6.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground.
Check the voltage while revving engine up to 4,000 rpm under
no load at least 10 times.
(Depress and release the accelerator pedal as quickly as possible.)
The voltage does not remain in the range of 0.2 — 0.4V

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.
PBIB3000E

EC-1565

L

M

HO2S2
[HR (WITHOUT EURO-OBD)]

2. CHECK OVERALL FUNCTION — II
Keep engine at idle for 10 minutes, then check the voltage between ECM terminal 50 (HO2S2 signal) and
ground, or check the voltage when coasting at 80 km/h (50 MPH) in D position with OD “OFF” (A/T), 3rd gear
position (M/T).
The voltage does not remain in the range of 0.2 — 0.4V
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 3.

3. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

3.

Body ground

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace ground connections.

4. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT
1.
–

2.
3.

Disconnect heated oxygen sensor 2 harness connector (2).
Heated oxygen sensor 2 (1)
Disconnect ECM harness connector.
Check harness continuity between HO2S2 terminal 1 and ECM
terminal 59.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1566

PBIB2949E

HO2S2
[HR (WITHOUT EURO-OBD)]

5. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

A

Check harness continuity between HO2S2 terminal 4 ECM terminal 50.
Refer to Wiring Diagram.
EC

Continuity should exist.
2.

Check harness continuity between ECM terminal 50 or HO2S2 terminal 4 and ground.
Refer to Wiring Diagram.

C

Continuity should not exist.
3. Also check harness for short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D

E

6. CHECK HEATED OXYGEN SENSOR 2
Refer to EC-1567, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace heated oxygen sensor 2.

F

G

7. CHECK INTERMITTENT INCIDENT
H

Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

I

Component Inspection

BBS004SG

HEATED OXYGEN SENSOR 2
With CONSULT-II
1.
2.
3.
4.
5.

J

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select
“HO2S2 (B1)” as the monitor item with CONSULT-II.

K

L

M

SEF662Y

EC-1567

HO2S2
[HR (WITHOUT EURO-OBD)]
6.

Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%.

PBIB0551E

“HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%.
“HO2S2 (B1)” should be below 0.50V at least once when the “FUEL INJECTION” is −25%.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Without CONSULT-II
1.
2.
3.
4.
5.
6.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground.
Check the voltage when revving up to 4,000 rpm under no load
at least 10 times.
(Depress and release accelerator pedal as soon as possible.)
The voltage should be above 0.68V at least once during this
procedure.
If the voltage is above 0.68V at step 6, step 7 is not necessary.
7. Keep vehicle idling for 10 minutes, then check voltage. Or check
the voltage when coasting from 80 km/h (50 MPH) in D position
with “OD” OFF (A/T), 3rd gear position (M/T).
The voltage should be below 0.50V at least once during this
PBIB2996E
procedure.
8. If NG, replace heated oxygen sensor 2.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7
in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner tool and approved anti-seize lubricant.

Removal and Installation

BBS004SH

HEATED OXYGEN SENSOR 2
Refer to EX-3, «EXHAUST SYSTEM» .

EC-1568

HO2S2 HEATER
[HR (WITHOUT EURO-OBD)]

HO2S2 HEATER
Description

PFP:226A0

A
BBS004SI

SYSTEM DESCRIPTION
Sensor
Camshaft position sensor (PHASE)

Input Signal to ECM

ECM Function

Actuator

EC

Heated oxygen sensor 2
heater control

Heated oxygen sensor 2 heater

C

Engine speed

Crankshaft position sensor (POS)
Engine coolant temperature sensor

Engine coolant temperature

Mass air flow sensor

Amount of intake air

D

The ECM performs ON/OFF control of the heated oxygen sensor 2 heater corresponding to the engine speed,
amount of intake air and engine coolant temperature.

OPERATION

E
Engine speed

Heated oxygen sensor 2 heater

Above 3,600 rpm

OFF

●

Below 3,600 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1
minute and at idle for 1 minute under no load

F

ON

G

CONSULT-II Reference Value in Data Monitor Mode

BBS004SJ

H

Specification data are reference values.
MONITOR ITEM

HO2S2 HTR (B1)

CONDITION
●

Engine speed: Above 3,600 rpm

●

Below 3,600 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute
and at idle for 1 minute under no load

SPECIFICATION
OFF

ON

I

J

K

L

M

EC-1569

HO2S2 HEATER
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004SK

MBWA1498E

EC-1570

HO2S2 HEATER
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

C
[Engine is running]

5

DATA (DC Voltage)

GR

●

Engine speed: Below 3,600 rpm after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load

Heated oxygen sensor 2
heater

Approximately 10V

D

E
PBIA8148J

[Ignition switch: ON]
●

Engine stopped

[Engine is running]
●

BATTERY VOLTAGE
(11 — 14V)

Engine speed: Above 3,600 rpm.

G

[Engine is running]

50

B

Heated oxygen sensor 2

F

●

Revving engine from idle to 3,000 rpm quickly
after the following conditions are met.

–

Engine: After warming up

–

Keeping the engine speed between 3,500
and 4,000 rpm for 1 minute and at idle for 1
minute under no load

0 — Approximately 1.0V

H

I

[Engine is running]
59

LG

Sensor ground
(Heated oxygen sensor 2)

●

Warm-up condition

●

Idle speed

Approximately 0V

J

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

K

L

M

EC-1571

HO2S2 HEATER
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004SL

1. CHECK OVERALL FUNCTION
1.
2.
3.
4.
5.
6.

Start engine and warm it up to the normal operating temperature.
Turn ignition switch OFF and wait at least 10 seconds.
Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load.
Let engine idle for 1 minute.
Set tester proves between ECM terminal 5 (HO2S2 heater signal) and ground.
Check the voltage under the following conditions.
Verify that the oscilloscope screen shows the signal waves as
shown below.
Conditions

Voltage
Approximately 10V

At idle

MBIB1395E
PBIA8148J

Engine speed is above 3,600 rpm

BATTERY VOLTAGE
(11 — 14V)

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

2. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace ground connections.

EC-1572

3.

Body ground

HO2S2 HEATER
[HR (WITHOUT EURO-OBD)]

3. CHECK HO2S2 POWER SUPPLY CIRCUIT
1.
–

2.

A

Disconnect heated oxygen sensor 2 harness connector (2).
Heated oxygen sensor 2 (1).
Turn ignition switch ON.

EC

C

D
PBIB2949E

3.

E

Check voltage between HO2S2 terminal 2 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

F

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

G

PBIA9576J

H

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
IPDM E/R connector E10
●
10A fuse
●
Harness for open or short between heated oxygen sensor 2 and fuse

I

J

K

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK HO2S2 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

L

1.
2.
3.

M

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between HO2S2 terminal 3 and ECM terminal 5.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK HEATED OXYGEN SENSOR 2 HEATER
Refer to EC-1574, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace heated oxygen sensor 2.

EC-1573

HO2S2 HEATER
[HR (WITHOUT EURO-OBD)]

7. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004SM

HEATED OXYGEN SENSOR 2 HEATER
1.

Check resistance between HO2S2 terminals as follows.
Terminal No.

Resistance

2 and 3

3.4 — 4.4 Ω [at 25°C (77°F)]

1 and 2, 3, 4

∞Ω
(Continuity should not exist)

4 and 1, 2, 3

2. If NG, replace heated oxygen sensor 2.
CAUTION:
●
Discard any heated oxygen sensor which has been dropped
from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.
●
Before installing new oxygen sensor, clean exhaust system
threads using Oxygen Sensor Thread Cleaner tool and
approved anti-seize lubricant.

PBIA9577J

Removal and Installation

BBS004SN

HEATED OXYGEN SENSOR 2
Refer to EX-3, «EXHAUST SYSTEM» .

EC-1574

IAT SENSOR
[HR (WITHOUT EURO-OBD)]

IAT SENSOR
Component Description

PFP:22630

A
BBS004SO

The intake air temperature sensor is built-into mass air flow sensor
(1). The sensor detects intake air temperature and transmits a signal
to the ECM.
The temperature sensing unit uses a thermistor which is sensitive to
the change in temperature. Electrical resistance of the thermistor
decreases in response to the temperature rise.

EC

C

D
PBIA9559J

E

Intake air temperature
°C (°F)

Voltage*

V

Resistance

F

kΩ

25 (77)

3.3

1.800 — 2.200

80 (176)

1.2

0.283 — 0.359

G

*: This data is reference value and is measured between ECM terminal 46 (Intake air
temperature sensor) and ground.

CAUTION:
Do not use ECM ground terminals when measuring input/output
voltage. Doing so may result in damage to the ECM’s transistor.
Use a ground other than ECM terminals, such as the ground.

H
SEF012P

I

J

K

L

M

EC-1575

IAT SENSOR
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004SP

MBWA1499E

EC-1576

IAT SENSOR
[HR (WITHOUT EURO-OBD)]

Diagnostic Procedure

BBS004SQ

1. CHECK OVERALL FUNCTION
1.
2.

A

Turn ignition switch ON.
Check voltage between ECM terminal 46 and ground with CONSULT-II or tester.

EC

Voltage: Approximately 0 — 4.8V

C

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

D

MBIB1396E

E

2. CHECK GROUND CONNECTIONS
1.
2.

F

Turn ignition switch OFF.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

G

H

I

J
MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace ground connections.

3.

Body ground

K

L

M

EC-1577

IAT SENSOR
[HR (WITHOUT EURO-OBD)]

3. CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT
1.
2.

Turn ignition switch OFF.
Disconnect mass air flow sensor (intake air temperature sensor
is built-into) (1) harness connector.

–

: Vehicle front
Turn ignition switch ON.

3.

PBIB2948E

4.

Check voltage between mass air flow sensor terminal 5 and
ground with CONSULT-II or tester.
Voltage: Approximately 5V

OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

PBIB1169E

4. CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between mass air flow sensor terminal 6 and ECM terminal 55.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK INTAKE AIR TEMPERATURE SENSOR
Refer to EC-1579, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace mass air flow sensor (with intake air temperature sensor).

6. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1578

IAT SENSOR
[HR (WITHOUT EURO-OBD)]

Component Inspection

BBS004SR

A

INTAKE AIR TEMPERATURE SENSOR
1.

2.

Check resistance between mass air flow sensor (1) terminals 5
and 6 under the following conditions.
Intake air temperature °C (°F)

Resistance kΩ

25 (77)

1.800 — 2.200

EC

If NG, replace mass air flow sensor (with intake air temperature
sensor).

C

D
PBIA9559J

E

F

G

SEF012P

Removal and Installation

H

BBS004SS

MASS AIR FLOW SENSOR
Refer to EM-118, «AIR CLEANER AND AIR DUCT» .

I

J

K

L

M

EC-1579

IGNITION SIGNAL
[HR (WITHOUT EURO-OBD)]

IGNITION SIGNAL
Component Description

PFP:22448
BBS004ST

IGNITION COIL & POWER TRANSISTOR
The ignition signal from the ECM is sent to and amplified by the
power transistor. The power transistor turns ON and OFF the ignition
coil (1) primary circuit. This ON/OFF operation induces the proper
high voltage in the coil secondary circuit.
●
Fuel injector (2)

PBIB2968E

EC-1580

IGNITION SIGNAL
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004SU

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1491E

EC-1581

IGNITION SIGNAL
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION
[Engine is running]
[Ignition switch: OFF]
●

32

P

ECM relay
(Self shut-off)

[Ignition switch: OFF]
●

105

G

Power supply for ECM

For a few seconds after turning ignition
switch OFF

More than a few seconds after turning ignition switch OFF

[Ignition switch: ON]

EC-1582

DATA (DC Voltage)

0 — 1.0V

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

IGNITION SIGNAL
[HR (WITHOUT EURO-OBD)]
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1492E

EC-1583

IGNITION SIGNAL
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

[Engine is running]

17
18
21
22

V
BR
G
Y

●

Warm-up condition

●

Idle speed

DATA (DC Voltage)

0 — 0.3V

NOTE:
The pulse cycle changes depending on rpm
at idle

Ignition signal No. 1
Ignition signal No. 2
Ignition signal No. 4
Ignition signal No. 3

PBIA9265J

0.2 — 0.5V
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

PBIA9266J

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS004SV

1. CHECK ENGINE START
Turn ignition switch OFF, and restart engine.
Is engine running?
Yes or No
Yes (With CONSULT-II)>>GO TO 2.
Yes (Without CONSULT-II)>>GO TO 3.
No
>> GO TO 4.

2. CHECK OVERALL FUNCTION
With CONSULT-II
Perform “POWER BALANCE” in “ACTIVE TEST” mode with
CONSULT-II.
2. Make sure that each circuit produces a momentary engine
speed drop.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 10.
1.

PBIB0133E

EC-1584

IGNITION SIGNAL
[HR (WITHOUT EURO-OBD)]

3. CHECK OVERALL FUNCTION

A

Without CONSULT-II
Let engine idle.
Read the voltage signal between ECM terminals 17, 18, 21, 22
and ground with an oscilloscope.
3. Verify that the oscilloscope screen shows the signal wave as
shown below.
NOTE:
The pulse cycle changes depending on rpm at idle.
1.
2.

EC

C

D

E
PBIA9567J

PBIA9265J

F

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 10.

G

4. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-I
1.
2.

Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
Check voltage between ECM terminal 105 and ground with
CONSULT-II or tester.

H

Voltage: Battery voltage

I

OK or NG
OK
>> GO TO 5.
NG
>> Go to EC-1337, «POWER SUPPLY AND GROUND CIRCUIT» .

J

K
PBIA9575J

L

M

EC-1585

IGNITION SIGNAL
[HR (WITHOUT EURO-OBD)]

5. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-II
1.
2.

Turn ignition switch OFF.
Disconnect condenser (1) harness connector.

–

: Vehicle front
Turn ignition switch ON.

3.

MBIB1548E

4.

Check voltage between condenser terminal 1 and ground with
CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 6.

PBIB0624E

6. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-III
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between IPDM E/R terminal 33 and condenser terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> Go to EC-1337, «POWER SUPPLY AND GROUND CIRCUIT» .
NG
>> GO TO 7.

7. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between IPDM E/R and condenser
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1586

IGNITION SIGNAL
[HR (WITHOUT EURO-OBD)]

8. CHECK CONDENSER GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.

A

Turn ignition switch OFF.
Check harness continuity between condenser terminal 2 and ground.
Refer to Wiring Diagram.

EC

Continuity should exist.
3. Also check harness for short to power.
OK or NG
OK
>> GO TO 9.
NG
>> Repair open circuit or short to power in harness or connectors.

C

D

9. CHECK CONDENSER
E

Refer to EC-1588, «Component Inspection»
OK or NG
OK
>> GO TO 10.
NG
>> Replace condenser.

F

10. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-IV
1.
2.
3.
–

4.

G

Turn ignition switch OFF.
Reconnect all harness connectors disconnected.
Disconnect ignition coil (1) harness connector.
Fuel injector (2)
Turn ignition switch ON.

H

I

J

PBIB2968E

5.

Check voltage between ignition coil terminal 1 and ground with
CONSULT-II or tester.

K

L

Voltage: Battery voltage
OK or NG
OK
>> GO TO 12.
NG
>> GO TO 11.

M

SEF107S

11. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connector F1
●
Harness for open or short between ignition coil and harness connector F1
>> Repair or replace harness or connectors.

EC-1587

IGNITION SIGNAL
[HR (WITHOUT EURO-OBD)]

12. CHECK IGNITION COIL GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.

Turn ignition switch OFF.
Check harness continuity between ignition coil terminal 2 and ground.
Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 13.
NG
>> Repair open circuit or short to power in harness or connectors.

13. CHECK IGNITION COIL OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

Disconnect ECM harness connector.
Check harness continuity between ECM terminals 17, 18, 21, 22 and ignition coil terminal 3.
Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 14.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

14. CHECK IGNITION COIL WITH POWER TRANSISTOR
Refer to EC-1588, «Component Inspection» .
OK or NG
OK
>> GO TO 15.
NG
>> Replace ignition coil with power transistor.

15. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS004SW

IGNITION COIL WITH POWER TRANSISTOR
CAUTION:
Do the following procedure in the place where ventilation is good without the combustible.
1. Turn ignition switch OFF.
2. Disconnect ignition coil harness connector.
3. Check resistance between ignition coil terminals as follows.
Terminal No. (Polarity)

Resistance Ω [at 25°C (77°F)]

1 and 2

Except 0 or ∞

1 and 3
2 and 3

4.
5.
6.

Except 0

If NG, replace ignition coil with power transistor.
If OK, go to next step.
Turn ignition switch OFF.
Reconnect all harness connectors disconnected.

EC-1588

MBIB0032E

IGNITION SIGNAL
[HR (WITHOUT EURO-OBD)]
7.

8.
9.
10.
11.
12.
13.
14.
15.

16.

Remove fuel pump fuse in IPDM E/R to release fuel pressure.
NOTE:
Do not use CONSULT-II to release fuel pressure, or fuel pressure applies again during the following procedure.
Start engine.
After engine stalls, crank it two or three times to release all fuel
pressure.
Turn ignition switch OFF.
Remove all ignition coil harness connectors to avoid the electrical discharge from the ignition coils.
Remove ignition coil and spark plug of the cylinder to be
checked.
Crank engine for 5 seconds or more to remove combustion gas in the cylinder.
Connect spark plug and harness connector to ignition coil.
Fix ignition coil using a rope etc. with gap of 13 — 17 mm
between the edge of the spark plug and grounded metal portion
as shown in the figure.
Crank engine for about three seconds, and check whether spark
is generated between the spark plug and the grounded metal
portion.

A

EC

C
MBIB0277E

D

E

F

G

Spark should be generated.
CAUTION:
● Do not approach to the spark plug and the ignition coil
within 50cm. Be careful not to get an electrical shock
PBIB2325E
while checking, because the electrical discharge voltage
becomes 20kV or more.
● It might cause to damage the ignition coil if the gap of more than 17 mm is taken.
NOTE:
When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning.
17. If NG, replace ignition coil with power transistor.

CONDENSER
1.
2.
3.

I

J

K

Turn ignition switch OFF.
Disconnect condenser harness connector.
Check resistance between condenser terminals 1 and 2.
Resistance:

H

L

Above 1 MΩ at 25°C (77°F)
M

PBIB0794E

Removal and Installation

BBS004SX

IGNITION COIL WITH POWER TRANSISTOR
Refer to EM-132, «IGNITION COIL» .

EC-1589

REFRIGERANT PRESSURE SENSOR
[HR (WITHOUT EURO-OBD)]

REFRIGERANT PRESSURE SENSOR
Component Description

PFP:92136
BBS004SY

The refrigerant pressure sensor (1) is installed at the condenser of
the air conditioner system. The sensor uses an electrostatic volume
pressure transducer to convert refrigerant pressure to voltage. The
voltage signal is sent to ECM, and ECM controls cooling fan system.
●

: Vehicle front

PBIB2980E

PBIB2657E

EC-1590

REFRIGERANT PRESSURE SENSOR
[HR (WITHOUT EURO-OBD)]

Wiring Diagram

BBS004SZ

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1493E

EC-1591

REFRIGERANT PRESSURE SENSOR
[HR (WITHOUT EURO-OBD)]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running]
41

BR

●

Warm-up condition

●

Both A/C switch and blower fan switch: ON

Refrigerant pressure sensor

1.0 — 4.0V

(Compressor operates)
[Engine is running]
48

74

Y

W

Sensor ground
(Refrigerant pressure sensor)
Sensor power supply
(Refrigerant pressure sensor)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Ignition switch: ON]

Approximately 5V

Diagnostic Procedure

BBS004T0

1. CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION
1.
2.
3.

Start engine and warm it up to normal operating temperature.
Turn A/C switch and blower fan switch ON.
Check voltage between ECM terminal 41 and ground with CONSULT-II or tester.
Voltage: 1.0 — 4.0V

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

PBIA9574J

2. CHECK GROUND CONNECTIONS
1.
2.
3.

Turn A/C switch and blower fan switch OFF.
Stop engine.
Loosen and retighten ground screws on the body.
Refer to EC-1342, «Ground Inspection» .

MBIB1550E

1.

IPDM E/R

2.

Body ground

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace ground connections.

EC-1592

3.

Body ground

REFRIGERANT PRESSURE SENSOR
[HR (WITHOUT EURO-OBD)]

3. CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT
1.

Disconnect refrigerant pressure sensor (1) harness connector.

–

: Vehicle front
Turn ignition switch ON.

2.

A

EC

C

D
PBIB2980E

3.

E

Check voltage between refrigerant pressure sensor terminal 3
and ground with CONSULT-II or tester.
Voltage: Approximately 5V

F

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

G

SEF479Y

H

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between refrigerant pressure sensor and ECM

I

J

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between refrigerant pressure sensor terminal 1 and ECM terminal 48.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

6. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E59, F1
●
Harness for open or short between refrigerant pressure sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1593

K

L

M

REFRIGERANT PRESSURE SENSOR
[HR (WITHOUT EURO-OBD)]

7. CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between refrigerant pressure sensor terminal 2 and ECM terminal 41.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 8.

8. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors E59, F1
●
Harness for open or short between refrigerant pressure sensor and ECM
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

9. CHECK INTERMITTENT INCIDENT
Refer to EC-1336, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace refrigerant pressure sensor.
NG
>> Repair or replace.

Removal and Installation

BBS004T1

REFRIGERANT PRESSURE SENSOR
Refer to ATC-135, «REFRIGERANT LINES» or MTC-81, «REFRIGERANT LINES» .

EC-1594

VSS
[HR (WITHOUT EURO-OBD)]

VSS
Description

PFP:32702

A
BBS004T2

The vehicle speed signal is sent to the combination meter from the “ABS actuator and electric unit (control
unit)” by CAN communication line. The combination meter then sends a signal to the ECM by CAN communi- EC
cation line.

Diagnostic Procedure

BBS004T3

1. INSPECTION START

C

Do you have CONSULT-II?
Yes or No
Yes
>> GO TO 2.
No
>> GO TO 3.

D

E

2. CHECK OVERALL FUNCTION
1.
2.
3.
4.
5.

Turn ignition switch OFF.
Lift up the vehicle.
Start engine and let it idle.
Select “VHCL SPEED SE” in “DATA MONITOR” mode with
CONSULT-II.
Select “VHCL SPEED SE” indication when rotating wheels with
suitable gear position.

F

G

H

“VHCL SPEED SE” indication should
exceed 10 km/h (6 MPH).
I

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 3.
PBIB0164E

J

3. CHECK DTC WITH “ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)”
Refer to BRC-8, «TROUBLE DIAGNOSIS» or BRC-49, «TROUBLE DIAGNOSIS» .
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace.

K

L

4. CHECK COMBINATION METER FUNCTION
M

Refer to DI-4, «COMBINATION METERS» .
>> INSPECTION END

EC-1595

MI & DATA LINK CONNECTORS
[HR (WITHOUT EURO-OBD)]

MI & DATA LINK CONNECTORS
Wiring Diagram

PFP:24814
BBS004T4

MBWA1494E

EC-1596

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR (WITHOUT EURO-OBD)]

SERVICE DATA AND SPECIFICATIONS (SDS)
Fuel Pressure

PFP:00030

A
BBS004T5

Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi)

Fuel pressure at idle

EC

Idle Speed and Ignition Timing
Target idle speed

Air conditioner: ON

Ignition timing

BBS004T6

A/T

No load* (in P or N position)

700 ± 50 rpm

M/T

No load* (in Neutral position)

650 ± 50 rpm

A/T

In P or N position

700 rpm or more

M/T

In Neutral position

750 rpm or more

A/T

In P or N position

M/T

In Neutral position

C

D

6 ± 5° BTDC

E

*: Under the following conditions:
●

Air conditioner switch: OFF

●

Electric load: OFF (Lights, heater fan & rear window defogger)

●

Steering wheel: Kept in straight-ahead position

F

Mass Air Flow Sensor

BBS004T7

Supply voltage

G

Battery voltage (11 — 14V)

Output voltage at idle

1.0 — 1.3*V

*: Engine is warmed up to normal operating temperature and running under no load.

H

Intake Air Temperature Sensor

BBS004T8

Temperature °C (°F)

Resistance kΩ

25 (77)

1.800 — 2.200

80 (176)

0.283 — 0.359

J

Engine Coolant Temperature Sensor
Temperature °C (°F)

I

BBS004T9

Resistance kΩ

20 (68)

2.1 — 2.9

50 (122)

0.68 — 1.00

90 (194)

0.236 — 0.260

Knock Sensor

K

L
BBS00587

Resistance [at 20°C (68°F)]

Approximately 530 – 590kΩ

Heated Oxygen Sensor 1 Heater

M
BBS004TA

Resistance [at 25°C (77°F)]

3.4 — 4.4Ω

Heated Oxygen sensor 2 Heater

BBS004TB

Resistance [at 25°C (77°F)]

3.4 — 4.4Ω

Crankshaft Position Sensor (POS)

BBS004TC

Refer to EC-1412, «Component Inspection» .

Camshaft Position Sensor (PHASE)

BBS004TD

Refer to EC-1418, «Component Inspection» .

Intake Valve Timing Control Solenoid Valve
Resistance [at 20°C (68°F)]

BBS00588

6.7 – 7.7Ω

EC-1597

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR (WITHOUT EURO-OBD)]

Throttle Control Motor

BBS004TE

Resistance [at 25°C (77°F)]

Approximately 1 — 15Ω

Fuel Injector

BBS004TF

Resistance [at 10 — 60°C (50 — 140°F)]

11.1 — 14.5Ω

Fuel Pump

BBS004TG

Resistance [at 25°C (77°F)]

Approximately 0.2 — 5.0Ω

EC-1598

INDEX FOR DTC
[K9K]

INDEX FOR DTC
DTC No. Index
[K9K]

PFP:00024

A
BBS003ZX

X: Applicable —: Not applicable
DTC*1 *2

Items
(CONSULT-II screen item)

MI lighting up

Trip

Red

PC001

MULTIPLXD NETWORK

3

P0016

COHERENCE CMSFT/SN

3

P0045

TURBO ACT CIRC

3

Reference page

×

EC-1705
EC-1708

×

C

EC-1710

P0070

AIR TEMP SEN CIRC

3

P0087

FLOW CAPACITY

3

×

EC-1719

P0089

RAIL PRESS REGULTN

3

×

EC-1721

P0100

AIR FLOW SEN CIRC

3

EC-1722

P0115

WATER TMP SEN CIRC

3

EC-1727

P0170

INJECTOR CODE PROG

3

EC-1731

P0180

FUEL TEMP SEN CIRC

3

EC-1732

P0190

RAIL/PRESS SEN CIR

3

×

EC-1736

P0200

INJECTOR CTRL CIRC

3

×

EC-1740

P0201

CYL 1 INJ CTRL CIR

3

×

×

EC-1745

P0202

CYL 2 INJ CTRL CIR

3

×

×

EC-1745

P0203

CYL 3 INJ CTRL CIR

3

×

×

EC-1745

P0204

CYL 4 INJ CTRL CIR

3

×

×

EC-1745

P0225

PDL POTEN CIRC TK1

3

×

EC-1751

P0231

L/PR ACTR CTRL CIR

3

×

EC-1759

P0235

IN-MANI PRES CIRC

3

×

EC-1763

P0263

MISFIRE ON CYL 1

3

×

EC-1768

P0266

MISFIRE ON CYL 2

3

×

EC-1768

P0269

MISFIRE ON CYL 3

3

×

EC-1768

P0272

MISFIRE ON CYL 4

3

×

EC-1768

P0325

ACCELEROMETER CIRC

3

P0335

ENGNE SPD SEN CIRC

3

P0340

CAMSHAFT SEN CIRC

3

EC-1778

P0380

PRHT DGNSTC CNECT

3

EC-1784

P0382

PRHT UNIT CTRL CIR

3

EC-1788

P0400

EGR SOL/VLV CIRC

3

×

×

EC-1791

P0403

EGR COMMAND CIRC

3

×

×

EC-1795

P0409

EGR POIFTN SEN CIR

3

P0487

EGR POSITN OFFSET

3

P0500

VEHL/SPD INF CIRC

3

EC-1810

P0513

ENGINE IMMOBILIZER

3

BL-215

P0530

REFRIGERNT SEN CIR

3

P0560

CPU SUPPLY VOLTAGE

3

P0571

BRAKE SWITCH CIRC

3

P0604

ECU MEMORY

3

×

EC-1825

P0606

COMPUTER(C/U)

3

×

EC-1826

P062F

MEMORY SAVED

3

×

EC-1599

EC

Yellow

EC-1715

D

E

F

G

H

I

J

K

EC-1770
×

EC-1774

EC-1800
×

EC-1805

EC-1811
×

EC-1816
EC-1820

×

EC-1828

L

M

INDEX FOR DTC
[K9K]
DTC*1 *2

MI lighting up

Items
(CONSULT-II screen item)

Trip

Red

Yellow

Reference page

P0641

SEN SUPPLY N-1 VOL

3

×

EC-1830

P0651

SEN SUPPLY N-2 VOL

3

×

EC-1837

P0685

MAIN RLY CTRL CIRC

3

EC-1845

P0703

BRAKE INFORMATION

3

EC-1850

P2120

PDL POTEN CIRC TK2

3

P2226

ATMOS PRES ASE CIR

3

*1: 1st trip DTC No. and 2nd trip DTC No. are the same as DTC No.
*2: This number is prescribed by ISO 15031-6.

EC-1600

×

EC-1855
EC-1863

INDEX FOR DTC
[K9K]

Alphabetical Index

BBS003ZW

X: Applicable —: Not applicable
Items
(CONSULT-II screen item)

MI lighting up

Reference page

DTC*1 *2

Trip

ACCELEROMETER CIRC

P0325

3

EC-1770

AIR FLOW SEN CIRC

P0100

3

EC-1722

AIR TEMP SEN CIRC

P0070

3

EC-1715

ATMOS PRES ASE CIR

P2226

3

EC-1863

BRAKE INFORMATION

P0703

3

EC-1850

BRAKE SWITCH CIRC

P0571

3

EC-1820

CAMSHAFT SEN CIRC

P0340

3

EC-1778

COHERENCE CMSFT/SN

P0016

3

EC-1708

COMPUTER(C/U)

P0606

3

×

EC-1826

CPU SUPPLY VOLTAGE

P0560

3

×

EC-1816

CYL 1 INJ CTRL CIR

P0201

3

×

×

EC-1745

CYL 2 INJ CTRL CIR

P0202

3

×

×

EC-1745

CYL 3 INJ CTRL CIR

P0203

3

×

×

EC-1745

×

EC-1745

Red

Yellow

EC

CYL 4 INJ CTRL CIR

P0204

3

×

ECU MEMORY

P0604

3

×

EGR COMMAND CIRC

P0403

3

×

EGR POIFTN SEN CIR

P0409

3

EGR POSITN OFFSET

P0487

3

EGR SOL/VLV CIRC

P0400

3

ENGINE IMMOBILIZER

P0513

3

ENGNE SPD SEN CIRC

P0335

3

×

EC-1774

FLOW CAPACITY

P0087

3

×

EC-1719

FUEL TEMP SEN CIRC

P0180

3

EC-1732

INJECTOR CODE PROG

P0170

3

EC-1731

INJECTOR CTRL CIRC

P0200

3

×

EC-1740

IN-MANI PRES CIRC

P0235

3

×

EC-1763

L/PR ACTR CTRL CIR

P0231

3

×

EC-1759

MAIN RLY CTRL CIRC

P0685

3

MEMORY SAVED

P062F

3

×

MISFIRE ON CYL 1

P0263

3

×

EC-1768

MISFIRE ON CYL 2

P0266

3

×

EC-1768

MISFIRE ON CYL 3

P0269

3

×

EC-1768

MISFIRE ON CYL 4

P0272

3

×

EC-1768

MULTIPLXD NETWORK

PC001

3

×

EC-1705

PDL POTEN CIRC TK1

P0225

3

×

EC-1751

PDL POTEN CIRC TK2

P2120

3

×

EC-1855

C

D

E

F

G

EC-1825
×

EC-1795

H

EC-1800
×

×

EC-1805

×

EC-1791

I

BL-215

EC-1845
×

EC-1828

PRHT DGNSTC CNECT

P0380

3

EC-1784

PRHT UNIT CTRL CIR

P0382

3

EC-1788

RAIL PRESS REGULTN

P0089

3

×

EC-1721

RAIL/PRESS SEN CIR

P0190

3

×

EC-1736

REFRIGERNT SEN CIR

P0530

3

×

EC-1811

EC-1601

A

J

K

L

M

INDEX FOR DTC
[K9K]
Items
(CONSULT-II screen item)

MI lighting up

Reference page

DTC*1 *2

Trip

SEN SUPPLY N-1 VOL

P0641

3

×

EC-1830

SEN SUPPLY N-2 VOL

P0651

3

×

EC-1837

TURBO ACT CIRC

P0045

3

×

EC-1710

VEHL/SPD INF CIRC

P0500

3

×

EC-1810

WATER TMP SEN CIRC

P0115

3

×

EC-1727

*1: 1st trip DTC No. and 2nd trip DTC No. are the same as DTC No.
*2: This number is prescribed by ISO 15031-6.

EC-1602

Red

Yellow

PRECAUTIONS
[K9K]

PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

A

BBS003ZY

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along EC
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
C
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be perD
formed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
E
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
F

Maintenance Information

BBS005AU

If any of following part is replaced, always replace with new* one.
If it’s not (or fail to do so), the electrical system may not be operated properly.
*: New one means a virgin control unit that has never been energized on-board.

G

RHD MODELS

H

●
●
●
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM
IPDM E/R
Combination meter
EPS control unit

I

J

LHD MODELS
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM

Precautions for Procedures without Cowl Top Cover

K

L
BBS00589

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

M

PIIB3706J

On Board Diagnostic (OBD) System of Engine

BBS003ZZ

The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of
a malfunction causing emission deterioration.
CAUTION:
●
Be sure to turn the ignition switch OFF and disconnect the battery negative cable before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves,
etc. will cause the MI to light up.

EC-1603

PRECAUTIONS
[K9K]
●

●

●

●

●

Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)
Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to PG-88, «HARNESS CONNECTOR» .
Be sure to route and secure the harnesses properly after work. The interference of the harness
with a bracket, etc. may cause the MI to light up due to the short circuit.
Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MI to light up due to the malfunction of the fuel system, etc.
Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM
before returning the vehicle to the customer.

Precautions
●
●

●

●

BBS00400

Always use a 12 volt battery as power source.
Do not attempt to disconnect battery cables while engine is
running.
Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect battery
negative cable. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned OFF.
Before removing parts, turn ignition switch OFF and then
disconnect battery negative cable.
SEF289H

●

Do not disassemble ECM.

MBIB1517E

●

–
–

When connecting ECM harness connector, fasten (A) it
securely with levers (1) as far as they will go as shown in
the figure.
ECM (2)
Loosen (B)

MBIB1518E

EC-1604

PRECAUTIONS
[K9K]
●

●

●

●
●
●
●
●
●
●

●

●

●

When connecting or disconnecting pin connectors into or
from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.
Securely connect ECM harness connectors.
A poor connection can cause an extremely high (surge)
voltage to develop in coil and condenser, thus resulting in
damage to IC’s.
Keep engine control system harness at least 10cm (4 in)
away from adjacent harness, to prevent engine control system malfunctions due to receiving external noise, degraded
operation of IC’s, etc.
Keep engine control system parts and harness dry.
Handle mass air flow sensor carefully to avoid damage.
Do not disassemble mass air flow sensor.
Do not clean mass air flow sensor with any type of detergent.
Even a slight leak in the air intake system can cause serious incidents.
Do not shock or jar the camshaft position sensor, crankshaft position sensor.
When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact.
Accidental contact of probes will cause a short circuit and
damage the ECM power transistor.
Do not use ECM ground terminals when measuring input/
output voltage. Doing so may result in damage to the ECM’s
transistor. Use a ground other than ECM terminals, such as
the ground.
Do not disassemble fuel pump.
If NG, take proper action.
Do not disassemble fuel injector.
If NG, replace fuel injector.

A

EC

C
SEF291H

D

E

F

G

H

I

J

K

L

M
SEF348N

●
●

●

Do not depress accelerator pedal when staring.
Immediately after staring, do not rev up engine unnecessarily.
Do not rev up engine just prior to shutdown.

SEF709Y

EC-1605

PRECAUTIONS
[K9K]
●

–

–

–

–

When installing C.B. ham radio or a mobile phone, be sure
to observe the following as it may adversely affect electronic control systems depending on installation location.
Keep the antenna as far as possible from the electronic
control units.
Keep the antenna feeder line more than 20 cm (8 in) away
from the harness of electronic controls.
Do not let them run parallel for a long distance.
Adjust the antenna and feeder line so that the standingwave
radio can be kept smaller.
Be sure to ground the radio to vehicle body.

SEF708Y

Cleanliness

BBS004TI

CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE
HIGH PRESSURE DIRECT INJECTION SYSTEM
Risks Relating to Contamination
The system is very sensitive to contamination. The risks caused by the introduction of contamination are:
●
Damage or destruction of the high pressure injection system and the engine
●
Seizing or leaking of a component
All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a few microns in size) get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness principle must be applied from the filter to the fuel injectors.

WHAT ARE THE SOURCES OF CONTAMINATION?
Contamination is caused by:
●
Metal or plastic chips
●
Paint
●
fibres:
–
Boxes
–
Brushes
–
Paper
–
Clothing
–
Cloths
●
Foreign bodies such as hair
●
Ambient air
●
etc
IMPORTANT: It is not possible to clean the engine using a high pressure washer because of the risk of damaging connections. In addition, moisture may collect in the connectors and create electrical connection malfunctions.

INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM
●

●

●

Ensure that you have the plugs for the unions to be opened (bag of plugs sold at the Parts Store — Nissan
part No.: 16830 BN700, Renault part No.: 77 01 206 804). Plugs are to be used once only. After use, they
must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable).
Unused plugs must be thrown away.
Ensure that you have hermetically resealable plastic bags for storing removed parts. Stored parts will
therefore be less subject to the risk of impurities. The bags must be used only once, and after use they
must be thrown away.
Lint-free towelettes to be used for injection pump related service purpose. The use of a normal cloth or
paper for cleaning purposes is forbidden. These are not lint-free and may contaminate the fuel circuit of
the system. Each lint-free cloth should only be used once.

INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
●
●

For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.
For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).

EC-1606

PRECAUTIONS
[K9K]
●
●

●
●

Use a brush and thinners to clean the connections to be opened.
Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and A
injection system zone). Check that no bristles remain adhered.
Wash your hands before and during the operation if necessary.
EC
When wearing leather protective gloves, cover these with latex gloves.

INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
●

●

●

●

●

As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The plugs to be used are available from the Parts Stores — Nissan part No.: 16830 BN700, Renault
part No.: 77 01 206 804. They must not, under any circumstances, be reused.
Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries
contamination.
All components of the injection system that are removed must be stored in a hermetically sealed plastic
bag once the plugs have been inserted.
The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been
opened. These items are likely to allow impurities to enter the system.
A new component replacing an old one must not be removed from its packaging until it is to be fitted to the
vehicle.

C

D

E

F

G

H

I

J

K

L

M

EC-1607

PRECAUTIONS
[K9K]
Instructions for Fitting The Plugs
Nissan part number: 16830 BN700
(Renault part number: 77 01 206 804)

MBIB0321E

CAUTION:
●
The engine must not run with:
–
Diesel containing more than 10% diester
–
Gasoline, even in very small amounts.
●
The system can inject the fuel into the engine at a pressure of up to 140,000 kPa (1,400 bar, 1,428
kg/cm2 , 20,300 psi). Before carrying out any work, check that the fuel rail is no longer pressurized
and that the fuel temperature is not too high.
●
You must respect the cleaning and safety advice specified in this document for any work on the
high pressure injection system.

EC-1608

ENGINE CONTROL SYSTEM
[K9K]

ENGINE CONTROL SYSTEM
System Diagram

PFP:23710

A
BBS00403

EC

C

D

E

F

G

H

I

J

K

L

M

MBIB1473E

EC-1609

ENGINE CONTROL SYSTEM
[K9K]
1.

ECM

2.

EGR volume control valve

3.

Fuel rail pressure sensor

4.

Fuel rail

5.

Fuel pump temperature sensor

6.

Fuel flow actuator (Fuel pressure
regulator)

7.

Turbocharger boost sensor (63 kW
engine models only)

8.

Charge air cooler

9.

Fuel pump

10. Engine coolant temperature sensor

11. Crankshaft position sensor

12. Mass air flow sensor and intake air
temperature sensor

13. Air cleaner

14. Stop lamp switch

15. Accelerator pedal position sensor

16. Turbocharger

17. Turbocharger boost control actuator 18. Turbocharger boost control solenoid valve (63 kW engine models
only)

19. Vacuum side

20. Ambient side

21. Glow control unit

22. Exhaust gas

23. Catalyst

24. Camshaft position sensor

25. Battery

26. Ignition switch

27. Mlfunction indicator

28. Glow lamp

29. Glow plug

30. Fuel injector

31. Fuel return

32. EGR cooler

33. CAN communication

34. Intake mamifold

EC-1610

ENGINE CONTROL SYSTEM
[K9K]

Vacuum Hose Drawing

BBS00404

A

EC

C

D

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MBIB1474E

1.

Cylinder head

2.

Turbocharger boost control
solenoid valve

4.

Turbocharger

5.

Turbocharger boost control actuator

3.

NOTE: Do not use soapy water or any type of solvent while installing vacuum hose.

Refer to EC-1609, «System Diagram» for Vacuum Control System.

EC-1611

Vacuum pump

ENGINE CONTROL SYSTEM
[K9K]

System Overview

BBS004TJ

The DCM1.2 injection system used on the K9K engine is an electronically-controlled high-pressure injection
system. The fuel is compressed by a high-pressure pump and then stored in a fuel rail that feeds the fuel injectors. Injection takes place when a current pulse applied to the fuel injector holder. The injection delivery is proportional to the fuel rail pressure and the length of pulse applied, and the start of injection is synchronised with
the start of the pulse.
The circuit comprises two sub-systems that can be distinguished from one another by the pressure level of the
fuel:
●
The low-pressure circuit comprises the reservoir, the fuel filter, the transfer pump and the fuel injector
holder return pipes
●
The high-pressure circuit consists of the high-pressure pump, the fuel rail, the fuel injector holders and the
high-pressure tubes
Finally, there are a certain number of regulation sensors and actuators that allow command and control of the
system as a whole.

Fuel Injection Control

BBS004TL

The high pressure injection system is intended to deliver a specific quantity of fuel to the engine at a specific
time.
●
DELPHI DCM1.2 Common Rail injection system
Refer to EC-1609, «System Diagram» for details.
●
The system consists of:
–
Priming pump on the low pressure circuit
–
Fuel filter
–
High pressure pump incorporating a low pressure pump (transfer pump)
–
Flow actuator (fuel pressure regulator) attached to the fuel pump
–
Fuel rail
–
Fuel rail pressure sensor located in the fuel rail
–
Four fuel injectors
–
Fuel pump temperature sensor
–
Engine coolant temperature sensor
–
Intake air temperature sensor
–
Camshaft position sensor (cylinder reference sensor)
–
Turbocharger boost sensor
–
Knock sensor
–
EGR volume control valve
–
Accelerator pedal position sensor
–
ECM
●
The “common rail” direct high pressure injection system works sequentially.
●
This new injection system reduces operating noise, reduces the volume of pollutant gases and particles
and produces high engine torque at low engine speeds thanks to a pre-injection procedure.
●
The high pressure pump generates the high pressure sent to the fuel rail. The flow actuator on the pump
controls the quantity of fuel supplied according to the demand determined by the ECM. The fuel rail supplies each fuel injector through a steel pipe.
●
The ECM:
–
Determines the value of injection pressure necessary for the engine to operate well and then controls the
pressure regulator. It checks that the pressure value is correct by analyzing the value transmitted by the
fuel rail pressure sensor located on the fuel rail.
–
Determines the injection time necessary to deliver the right quantity of fuel and the moment when injection
should be started.
–
Controls each fuel injector electrically and individually after determining these two values.
●
The injected flow to the engine is determined by:
–
The duration of fuel injector control

EC-1612

ENGINE CONTROL SYSTEM
[K9K]
–
–
–
–
●
–
–
–
–
–
●

–
–
●

The fuel injector opening and closing speed
A
The needle travel (determined by a constant for the type of fuel injector)
The nominal hydraulic flow of the fuel injector (unique to each fuel injector)
The fuel rail pressure controlled by the ECM
EC
The ECM controls:
The idle speed adjustment
The exhaust gas flow reinjected into the intake manifold
C
The fuel supply control (advance, flow and fuel rail pressure)
The cooling fan control
The glow plug (pre/post heating) control
D
The high pressure pump is supplied at low pressure by an integrated low pressure pump (transfer pump).
It supplies the fuel rail whose pressure is controlled for charge by the flow actuator and for discharging by
the fuel injector valves. Falls in pressure can be compensated for in this way. The flow actuator allows the E
high pressure pump to provide just the amount of fuel necessary to maintain the pressure in the fuel rail.
Thanks to this element, heat generation is minimized and engine output improved.
In order to discharge the fuel rail using the fuel injector valves, the valves are controlled by short electrical
F
impulses:
Short enough not to open the fuel injector, (through the return circuit from the fuel injectors)
Long enough to open the valves and discharge the fuel rail
G
The ECM controls the cooling fans and the engine coolant temperature warning light on the instrument
panel.

IMPORTANT
●
–
–
●

●

●

●

●

●

●

●
●
●
●
●

H

The engine must not operate with:
Fuel containing more than 10% diester
Gasoline, even in tiny quantities
The system can inject the fuel into the engine at a pressure up to 1400 bars. Before carrying out any work,
check that the fuel rail is not under pressure and that the fuel temperature is not too high.
You must respect the cleaning and safety advice specified in this document for any work on the high pressure injection system.
Removal of the interior of the pump and fuel injectors is prohibited. Only the flow actuator, the fuel pump
temperature sensor and the venturi can be replaced.
For safety reasons, it is strictly forbidden to slacken a high pressure pipe union when the engine is running.
It is not possible to remove the fuel rail pressure sensor from the fuel rail because this may cause circuit
contamination malfunctions. If the fuel rail pressure sensor fails, the fuel rail pressure sensor, the fuel rail
and the five high pressure pipes must be replaced.
It is strictly forbidden to remove any injection pump pulley marked number 070 575. If the pump is being
replaced, the pulley must be replaced.
It is forbidden to repair the wiring connecting the knock sensor and the crankshaft positon sensor. If the
wiring should malfunction, it has to be replaced with new wiring.
Applying 12V directly to any component in the system is prohibited.
Ultrasonic carbon removal and cleaning are prohibited.
Never start the engine without the battery being connected correctly.
Disconnect the injection system ECM when carrying out any welding work on the vehicle.
It is essential to replace all the disconnected air intake plastic pipes.

Functions Performed

BBS004TK

Function: Fuel supply management (advance, delivery and pressure).
Quantity of fuel injected and regulation of injection advance.
The injection control parameters are the quantities to be injected and their respective advances.
These are calculated by the ECM on the basis of information from the following signals:
●
Engine speed (crankshaft + cam for synchronisation)
●
Accelerator pedal position

EC-1613

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ENGINE CONTROL SYSTEM
[K9K]
Charge air pressure
Intake air temperature
●
Charge air pressure
●
Engine coolant temperature
●
Fuel rail pressure
●
Ambient barometric pressure
The quantities to be injected and their respective advances are converted into:
●
Reference tooth
●
Time between this tooth and the start of the pulse
●
Time for which the fuel injector holder is fed
An electrical current (pulse) is sent to each fuel injector holder as a function of the previously calculated data.
The system performs between one and four injections (a pilot injection, a pre-injection, a main injection and a
post-injection). The general principle is to calculate a total delivery injected which will then be distributed
across the deliveries of the various injections to promote efficient combustion and a reduction in pollutant
emissions.
●
●

A knock sensor is used to control some of the deviations when the fuel is injected. This plays a number of
roles:
●
Protection of the engine by detecting injection losses (disabled on the basic version)
●
Checking of the pilot quantity by measurement of the deviations and dispersions
By modifying the duration on the one hand and the injection advance on the other, it is possible to readjust the
quantity of fuel injected and the instant of ignition of the mixture.

FUEL RAIL PRESSURE CONTROL
The quality of combustion is influenced by the size of the droplets atomised in the cylinder. In the combustion
chamber, smaller drops of fuel will have time to burn completely and not produce smoke or nonburned particles. To meet anti-pollution requirements it is necessary to reduce the size of the droplets and thus the injection holes.
The smaller these holes are, the less fuel can be introduced at a given pressure which limits the power. To
overcome this malfunction it is necessary to increase the quantity of fuel injected which in practice means
increasing the pressure (and the number of openings of the fuel injector nozzles). In the case of the Delphi
Common Rail, the pressure can reach 1600 bar in the fuel rail and must be permanently controlled. The measurement circuit is comprised an active fuel rail pressure sensor on the fuel rail linked to an analogue port of
the ECM.
The high-pressure pump is fed at low pressure (5 bar) by an integral transfer pump. This feeds the fuel rail, the
pressure of which is controlled for the charging by the fuel flow actuator (fuel pressure regulator) and for discharge by the fuel injector. This allows drops in pressure to be compensated. The fuel flow actuator (fuel pressure regulator) allows the high-pressure pump to only supply the quantity of fuel necessary to maintain the
pressure in the fuel rail. Thanks to this device, the generation of heat is minimised and the efficiency of the
engine is improved.
In order to discharge the fuel rail using the fuel injectors, the fuel injectors are operated by means of small
electrical pulses:
●
Sufficiently small not to open the fuel injector (the fuel passes through the return circuit from the fuel injectors)
●
Sufficiently long to open the valves and discharge the fuel rail
Surplus fuel is fed back to the fuel filter or to the reservoir according to its delivery. In the event of non-actuation of the fuel flow actuator (fuel pressure regulator), the pressure in the fuel rail is limited by a pressure relief
valve fitted on the pump.

IDLING CONTROL
The ECM is responsible for idling control. In practice it has to take into account the instantaneous power level
to be delivered as a function of the following elements:
●
Engine coolant temperature

EC-1614

ENGINE CONTROL SYSTEM
[K9K]
●
●
●

●

Gear ratio selected
A
Battery charge
Whether electrical loads (additional heating, climate control, engine ventilator set, rear window defogger,
etc.) are on or off
EC
System malfunctions detected

INDIVIDUAL FUEL INJECTOR CORRECTION
The fuel injectors of the DCM1.2 system must be calibrated with fuel injector adjusting values in order to accurately set their delivery. Calibration of each fuel injector is performed for various pressures on a test bed and
the characteristics are shown on a label attached to the fuel injector holder body. These fuel injector adjusting
values are then entered in the ECM memory thereby allowing it to operate the fuel injectors taking into account
their manufacturing variance.

C

D

MEASUREMENT OF THE ANGULAR POSITION
Crankshaft position sensor (CKPS):
Measurement of the angular position is performed by means of a magneto-inductive sensor that is excited by
machined into the flywheel of the crankshaft. This flywheel comprises sixty teeth with a spacing of six degrees,
less two missing teeth to form a notch.
Camshaft position sensor (CMPS):
A second sensor (Hall effect) excited by a tooth machined in the drive pulley of the high-pressure pump (in
synch with the camshaft), rotates at half the speed of the engine and provides information on the operation of
the injection cycle.
By comparing the signals from these two sensors, the angular position subsystem (APS) of the ECM is capable of providing the system as a whole with the following synchronisation information: the angular position of
the flywheel, the speed, the number of the active fuel injector and the advance in the injection cycle.
This module also provides the system with information on the speed of rotation.

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NEW PUMP HOUSING FUEL FLOW STRATEGY (PUMP FUEL FLOW)
Lubrication of the pump is by means of a fuel flow cycle during which the pump is filled and comes up to pressure before transferring the fuel to the fuel rail.
This lubrication is performed using a strategy known as “new pump housing fuel flow” which prevents starting
for around 10 seconds, which is the time needed for filling of the pump and starting.
For vehicles equipped with keys, if the key is released before this “first start-up” phase it is not necessary to
perform a power latch before proceeding to restart the vehicle.
This strategy applies following an initial start-up in the factory and then whenever there is a change of ECM if
the fuel rail pressure parameters are not copied over to the new ECM, or also following reprogramming of the
ECM.

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VARIABLE LOW CAPACITY (VLC) FUNCTION
Due to the combination of a number of parameters such as the temperature of the fuel, wear of parts, clogging
of the fuel filter, and so on, the system′s limit may be reached during its lifetime. In this case, the pressure in
the fuel rail cannot be maintained because of a lack of capacity of the pump. In the event of a lack of pump
capacity, therefore, this strategy will reduce the delivery required to a value that allows the pressure controller
to re-check the pressure.

EGR VOLUME CONTROL VALVE OPERATION
The EGR system (exhaust gas recirculation) is comprised a direct current proportional EGR volume control
valve with integral potentiometer to read the position of the valve. The EGR volume control position is controlled in a closed circuit via the potentiometer and/or the change in the estimated air deliver

AIR DELIVERY CALCULATION
The delivery of fresh air that enters the engine is indicated by a mass air flow sensor. This mass air flow sensor allows management of the quantity of exhaust gas to be recirculated in order to guarantee the best recirculation rates. An intake air temperature sensor is incorporated in the mass air flow sensor.
Measurement of the air delivery allows closed-circuit control via the EGR volume control valve.

TURBO CONTROL
K9K 63kw Engine:
The turbo system is comprised a solenoid valve that allows control of the waste gate in order to create a boost
pressure or a depression in the admission circuit.

EC-1615

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ENGINE CONTROL SYSTEM
[K9K]
K9K 50kw Engine:
The turbo system is self-regulating and does not need to be controlled by the ECM.

FUNCTION: STORED FUNCTIONS
Climate Control Management Assistance
With climate controlled models, the DCM1.2 system offers the possibility of deactivating the air conditioning
under certain usage conditions:
●
Intentional interruption by the driver
●
During the start-up phases
●
In the event of overheating (in order to reduce the power to be supplied by the engine)
●
When the speed is maintained at a very high level (protection of the compressor)
●
For temporary periods (such as strong acceleration demands during overtaking, anti-stalling and moving
off). These conditions are only taken into account where they occur repeatedly, in order to avoid instability
of the system (untimely deactivations)
●
When certain malfunctions arise

Cold Loop Climate Control
The climate control is the cold loop type and its management shared between a number of control units. The
ECM is responsible for:
●
Managing the demand for cold as a function of the controls in the passenger compartment and the pressure value
●
Determining the power absorbed by the compressor from the pressure
●
Determining the engine ventilator set commands as a function of the speed of the vehicle and the pressure
The driver turns on the climate control from the instrument panel. The information is sent to the ECM via the
CAN system. This demand for cold is authorised or declined as a function of the measured pressure. If this
pressure is outside the operational limits, the cold loop strategy is not activated.
NOTE:
These demands for operation of the air cooling set can be made from the ECM but they pass via the CAN.
These demands are a function of the climate control, but also the engine coolant temperature and the speed
of the vehicle.

Passenger Compartment Climate Control
A direct injection engine is characterised by injection of the fuel directly into the combustion chamber. The
result is a reduction in heat losses from the upper part of the engine and consequently a smaller cylinder head
cooling circuit is needed.
The effect of this reduction is that the temperature of the water passing through is increased more slowly. This
water is then used by the passenger compartment heating system. During severe cold spells, therefore, it
becomes difficult to quickly reach a comfortable temperature in the passenger compartment.
In order to limit the heating delay, air heating resistors are incorporated in the passenger compartment heating
circuit. The passenger compartment heating unit determines the need to operate the heating resistors, the
IPDM E/R physically controls the heating resistors and the ECM determines on the one hand as a function of
the alternator the operational power limits of the heating resistors and on the other when to disable the heating
resistors as a function of the engine speed, the load and the speed of the vehicle.

Idle Speed Control

BBS004TM

The ECM takes over calculation of the idle speed to maintain the idle speed at the recommended level and to
compensate for any variation in the mechanical or electrical couple as regards:
●
Engine coolant temperature
●
Battery voltage
●
Gear selected on the transmission
●
Electrical loads (climate control system, cooling fan assembly etc.)
●
Any malfunctions found
At the normal operating temperature, without high electrical load, the idle speed is 800 ± 50 rpm.

EC-1616

ENGINE CONTROL SYSTEM
[K9K]
IDLE SPEED CORRECTION ACCORDING TO ENGINE COOLANT TEMPERATURE
A

EC

C

D

E

F
MBIB1475E

X.

Engine speed in rpm

Y.

Engine coolant temperature in °C

SPEED ADJUSTMENT WHEN THERE IS AN ACCELERATOR PEDAL POSITION SENSOR MALFUNCTION
●

●

●
●

If one or both terminals of the accelerator pedal position sensor are suspected, the ECM overrides the idle
speed to maintain it at 1100 rpm. This fail-safe mode limits performance. The orange malfunction indicator
lights up and flashes.
If the accelerator pedal position sensor is blocked, is no longer being supplied, or is not transmitting an
output signal, the ECM overrides the idle speed to maintain it at 1300 rpm. This mode limits performance.
The orange malfunction indicator lights up and flashes.
In both cases, when the brake pedal is depressed, the idle speed is stabilised at the recommended speed.
If the information from the accelerator pedal position sensor and the brake switch information does not
correspond, the speed is changed to 1100 rpm.

IDLE SPEED ADJUSTMENT WHEN THERE IS AN FUEL INJECTOR CODE MALFUNCTION
When there is an fuel injector code malfunction, the ECM overrides the idle speed to maintain it at 1300 rpm.
This mode limits performance. The orange malfunction indicator lights up and flashes.

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CORRECTION OF THE IDLING SPEED ACCORDING TO THE GEAR RATIOS
The idling speed is modified according to the gear selected in the transmission:
●
in neutral, 1st and 2nd gear, the speed is (at the normal operating temperature) 850 rpm (graph A),
●
for the other gears, the speed is (at the normal operating temperature) 900 rpm (graph B).

EC-1617

M

ENGINE CONTROL SYSTEM
[K9K]

MBIB1476E

X.

Engine speed in rpm

Y.

Engine coolant temperature in °C

Air Conditioning Control

BBS004TN

AIR CONDITIONING CONTROL
The compressor is a variable displacement type.
The air conditioning relay is controlled by IPDM E/R.

COMPRESSOR OPERATION PROGRAMMING
During certain stages of operation, the ECM stops the compressor from functioning.

Engine Starting Program
The compressor is prevented from operating for 4 seconds after the engine has started.

Thermal Protection Program
The compressor is not engaged when the engine coolant temperature is higher than 115 °C (239 °F) or from
110 °C (230 °F) at high speed, 4500 rpm for more than 3 seconds.

Fan Motor Control Programming
At idling speed and also when driving, with the air conditioning activated, the speed of the fan motor is determined according to the refrigerant pressure and the vehicle speed.

Recovery of Performance
When pressure is applied to the accelerator pedal above 70%, the compressor is disengaged for 5 seconds.

Recovery of Output When The Vehicle Starts Moving
In order to help the vehicle move off, the air conditioning compressor is disengaged if the position of the accelerator pedal is above 35% and the idling speed less than 1250 rpm.

Anti-Stall Protection
The compressor is disengaged if the engine speed is lower than 750 rpm.

Engine Overspeed Timed Protection Program
The compressor is disengaged when the engine speed reaches 4500 rpm for more than 3 seconds.
NOTE:
The time between the compressor being disengaged twice is always greater than 10 seconds.

EC-1618

ENGINE CONTROL SYSTEM
[K9K]

Pre/Postheating (Glow Plug) Control

BBS004TO

A

The pre/postheating function is controlled by the glow control unit.

PRE/POSTHEATING (GLOW PLUG) OPERATING PRINCIPLE
“Preheating” at Ignition Switch ON
1.

EC

Variable preheating
The time period for the glow lamp to light up and the feed to heater plugs depends on the engine coolant
temperature and the battery voltage.

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MBIB1477E

X.

2.

Time in seconds

Y.

Temperature in °C

Whatever the situation, the preheating glow lamp cannot be lit for more than 10 seconds (except in the
event of an engine coolant temperature sensor malfunction).
Fixed preheating
After the glow lamp goes out the plugs remain supplied for a fixed period of 5 seconds.

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“Post Heating” With The Engine Running
During this phase the plugs are supplied continuously according to engine coolant temperature.
For idle speed without depressing the accelerator pedal.

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M

MBIB1478E

X.

Time in seconds

Y.

Engine coolant temperature in °C

EC-1619

ENGINE CONTROL SYSTEM
[K9K]

Glow Plugs

BBS004TP

The resistance of a glow plug is 0.6Ω.
TIGHTENING TORQUE
Glow plug: 1.5 N·m, 15 kg/cm, 13 in/lb
Plugs may be removed without having to open the high pressure circuit.

REMOVAL
1.
2.
3.
4.

Disconnect the battery.
Unclip the plug connector.
Clean the outside of the plug to avoid any dirt entering the cylinder.
Loosen and remove the plugs.

MBIB1479E

To undo the plug on cylinder 4 use a 10 mm long radio socket attached to a universal joint. Once the plug is
loosened use a hose to unscrew it completely.

REFITTING
Proceed in the reverse order of removal.

Cooling Fan Control

BBS004TQ

The cooling fan motor is controlled by the ECM.

COOLING FAN OPERATION WITH THE ENGINE RUNNING
The cooling fan motor is controlled:
●
At slow speed if the engine coolant temperature exceeds 96 °C (205 °F) or if there is an engine coolant
temperature sensor malfunction, and is switched off when the temperature falls below 93 °C (199 °F).
●
at high speed if the engine coolant temperature exceeds 99 °C (210 °F) or if there is a low speed malfunction, and is switched off when the temperature falls below 96 °C (205 °F).
The cooling fan motor low and high speeds are controlled when the air conditioning function is selected on the
instrument panel.
If the low speed setting is suspected, the high speed setting operates under the low speed conditions.

EC-1620

ENGINE CONTROL SYSTEM
[K9K]
A

EC

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MBIB1472E

OPERATION OF THE ENGINE COOLANT TEMPERATURE WARNING LIGHT
The engine coolant temperature warning light remains lit if the engine coolant temperature exceeds 114 °C
(237 °F). It goes out when the temperature falls below 111 °C (232 °F).

EC-1621

ENGINE CONTROL SYSTEM
[K9K]

Oil Vapour Rebreathing

BBS004TR

CIRCUIT DIAGRAM

MBIB1480E

●

●

1.

Cylinder head cover

2.

Oil vapour rebreathing duct

4.

Air inlet duct

5.

Turbocharger

3.

Oil vapour recirculation valve

A: When there is a low charge, the vacuum in the intake air duct is below the spring set point. The oil
vapours are extensively rebreathed by the vacuum in the intake air duct.
B: When there is a medium or high charge, the pressure in the intake air duct exhausts the valve diaphragm, the oil vapours are breathed in small quantities via a calibrated hole.

CHECKING
To ensure the correct operation of the anti-pollution system, the oil vapour rebreathing circuit must be kept
clean and in good condition.

Exhaust Gas Recirculation (EGR)

BBS004TS

CIRCUIT DIAGRAM

MBIB1481E

1.

Engine

2.

Air filter unit

3.

Air distributor

4.

Exhaust manifold

5.

EGR volume control valve

6.

Turbocharger

7.

ECM

A.

Air inlet

B.

Exhaust gas outlet

EC-1622

ENGINE CONTROL SYSTEM
[K9K]
PURPOSE OF THE EGR SYSTEM
A

Exhaust gas recirculation is used to reduce the nitrogen oxide (NOx) content of the exhaust gases.
The ECM authorises gas to pass by controlling an EGR volume control valve.

OPERATING PRINCIPLE
The valve is controlled by an RCO (Opening Cyclic Ratio) signal sent by the ECM. The RCO signal modulates
the opening of the valve and consequently the quantity of exhaust gas directed back to the intake manifold.
The ECM continuously carries out a test to detect the position of the EGR volume control valve.
NOTE:
The position of the EGR volume control valve is determined by the calculation of the amount of air taken in by
the engine.

EC

C

D

OPERATING CONDITIONS
The parameters which determine the activation of the EGR volume control valve are as follows:
●
Engine coolant temperature
●
Intake air temperature
●
Ambient barometric pressure
●
Accelerator pedal position
●
Injected fuel flow
●
Engine speed
Operating point for the EGR volume control valve test:
The EGR volume control valve is activated when:
●
Intake air temperature is > 15 °C (59 °F) and engine coolant temperature is > 70 °C (158 °F)
●
Intake air temperature is > 50 °C (122 °F) and engine coolant temperature is > 40 °C (104 °F)
●
Engine speed is between 850 and 1,000 rpm
●
Injected fuel flow is between 2 and 5 mg/stroke
●
Ambient barometric pressure is between 980 and 1,000 mbar
In this case, the CONSULT-II can read an RCO value of the EGR volume control valve equals to 16%.
EGR function is disabled if:
●
Battery voltage is less than 9 V
●
Engine speed is below 500 rpm
●
Mapping (engine speed/load) exceeds a given threshold
●
Air conditioning compressor is activated
The EGR volume control valve is not supplied for 2 seconds after the engine starts.
If there is a malfunction in:
●
EGR volume control valve
●
Turbocharger boost sensor
the operation of the EGR volume control valve is cut.

MBIB1482E

1.

Position sensor signal
(sensor signal)

2.

Position sensor earth
(sensor ground)

3.

Position sensor feed
(sensor power)

4.

Valve earth control
(ground control)

5.

Not used

6.

Valve feed
(power supply)

EC-1623

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ENGINE CONTROL SYSTEM
[K9K]

CAN Communication

BBS0040B

SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
Refer to LAN-27, «CAN Communication Unit» , about CAN communication for detail.

EC-1624

BASIC SERVICE PROCEDURE
[K9K]

BASIC SERVICE PROCEDURE
Fuel Filter

PFP:00018

A
BBS0040C

DESCRIPTION
A water draining cock is on the lower side and a priming pump for bleeding air is on the upper side.

EC

AIR BLEEDING
After fuel filter is replaced and after fuel system components are removed/installed, bleed air from fuel line as
follows:
1. Prime the circuit using the priming pump.
2. Perform engine cranking with repeating several times until engine starting.
CAUTION:
●
Crank engine until it starts. Do not crank engine for more than 30 seconds.
●
Prepare a tray to collect fuel. Prevent fuel from adhering to rubber parts, especially the engine
mounting insulator.

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WATER DRAINING
1.
2.

3.

4.
5.

Prepare a tray at the drain plug open end.
Loosen drain plug, and operate priming pump to drain water from fuel filter.
CAUTION:
● Water in filter is drained with fuel. Prepare larger capacity pan than fuel filter volume.
● Drained water is mixed with fuel. Prevent fuel from adhering to rubber parts such as engine
mounting insulator.
After draining, close drain plug by hand.
CAUTION:
If drain plug is tightened excessively, it may be damaged and fuel will leak. Do not use tools to
tighten drain cock.
Bleed air in fuel piping. Refer to EC-1625, «AIR BLEEDING» .
Start engine and make sure there is no fuel leakage.

Injector Adjustment Value Registration

BBS0040E

There is a 16 digit code on the fuel injectors called injector adjustment value. This code is specific to each fuel
injector, and takes into account differences in manufacture and specifies the flow injected by each of them.
When a fuel injector is replaced, it is necessary to program the injector adjustment value of the new fuel injector into the ECM.
When an ECM is replaced, it is necessary to program the injector adjustment values of the four fuel injectors.
There are two possibilities:
●
If it is possible to communicate with the ECM:
–
Read out the data from the ECM using the “SAVE DATA FOR REPLACE” in “WORK SUPPORT” mode
with CONSULT-II.
–
Turn ignition switch OFF.
–
Remove battery negative cable.
–
Change the ECM.
–
Reprogram the data from the “WRITE DATA AFTER REPLACE” in “WORK SUPPORT” mode with CONSULT-II to the replaced ECM.
–
After replacement, ensure that the ECM has not detected malfunctions relating to the injector adjustment
value and check that the MI is turned OFF.
●
If it is not possible to communicate with the ECM:
–
Turn ignition switch OFF.
–
Remove battery negative cable.
–
Change the ECM.
–
Read the data on the fuel injectors.
–
Enter the data in the ECM using the “ENTER INJCTR CALIB DATA” in “WORK SUPPORT” mode with
CONSULT-II manually.

EC-1625

F

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BASIC SERVICE PROCEDURE
[K9K]
–

–

Reconfigure the different elements such as the power-assisted steering pump assembly and the thermoplungers etc.
Using CONSULT-II, ensure that the ECM has not detected malfunctions relating to the injector adjustment
value and check that the MI is turned OFF.

Tightening The High Pressure Pipes

BBS004TX

All the high pressure pipe removed must be systematically replaced along with the clips.
NOTE:
Fit the pump/rail pipe before the rail/injector pipes.

RAIL-PUMP PIPE
●
●
●
●
●
●
●

Undo the rail,
Grease the threads of the high pressure pipe nuts,
Insert the high pressure pipe olive into the taper of the high pressure pump outlet,
Insert the high pressure pipe olive into the taper of the high pressure rail inlet.
Move the nut into position by hand, on the rail side then the pump side,
Tighten the rail,
Tighten the high pressure pipe nuts on the rail side then on the
pump side.

MBIB1483E

RAIL/INJECTOR PIPES
Undo the rail,
Grease the threads of the high pressure pipe nuts,
●
Insert the high pressure pipe olive into the taper of the high pressure injector inlet,
●
Insert the high pressure pipe olive into the taper of the high pressure rail outlet,
●
Move the nuts into position by hand, on the injector side then the rail side,
●
Tighten the rail,
●
Ensure that the new clip, supplied with the new high pressure pipe, is fitted,
●
Tighten the nuts of the high pressure pipes on the injector side first and then on the fuel rail side.
NOTE:
Before fitting a new high pressure pipe, move back the nuts on the pipe then lightly lubricate the nut
threads with the oil from the sachet (1) provided in the parts kit.
●
●

Checking Sealing After Repair

BBS004TY

After any operation, check that there are no fuel leaks.
Reprime the circuit using the priming pump.
Start the engine and allow to warm up at idle speed, visually inspecting for any fuel leaks.
Apply tracing fluid around the high pressure connections of the pipe that has been replaced.
Once the engine coolant temperature is above 50 °C and provided there are no malfunctions present, carry
out a road test, taking the engine speed up to 4,000 rpm at least once to check that there are no leaks.
Perform a visual inspection after the road test to make sure that there are no high pressure leaks.
Clean off the tracing fluid.

Replacing ECM

BBS004TZ

The system can be reprogrammed using CONSULT-II.
Before an ECM is replaced in after-sales, the following must be done.

EC-1626

BASIC SERVICE PROCEDURE
[K9K]
●
●

●

Check the injector adjustment value using “WORK SUPPORT” mode with CONSULT-II.
After replacing ECM, enter each injector adjustment value using “WORK SUPPORT” mode with CONSULT-II.
Also set the system configuration using “CONFIGURATION” mode with CONSULT-II.

A

EC

Replacing Fuel Injectors

BBS004U0

NOTE:
Injector adjustment value is a factory calibration carried out on each fuel injector to adjust the flow of
each one precisely, taking into account differences in manufacture.
The injector adjustment values are written on a label affixed to each fuel injector then entered in the ECM
which can then control each fuel injector by taking account of their differences in manufacture.
The system can be programmed “WORK SUPPORT” mode with CONSULT-II.
The injector adjustment values (16 digit code) must be replaced after replacing a fuel injector.
●
Entering each injector adjustment value, when replacing the ECM.

C

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EC-1627

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[K9K]

ON BOARD DIAGNOSTIC (OBD) SYSTEM
Introduction

PFP:00028
BBS0040I

The ECM controls the display on the instrument panel of certain information relating to the operation of the
engine.
Four functions are involved here: The OBD malfunction indicator [MI(Yellow)] for the EOBD (European On
Board Diagnostics), the pre/post heating, the engine coolant temperature and engine malfunction [MI(Red)].
These four functions are represented by four lights given out by the ECM

PRE/POST HEATING LAMP
This lamp indicates that the pre-heating has been activated.

ENGINE COOLANT TEMPERATURE LIGHT
This light is used as an indicator of engine overheating.
●
In the event of overheating, it is up to the driver whether to stop the vehicle or not.

OBD LIGHT
The OBD malfunction indicator [MI(Yellow)] is used to alert the driver to the existence of engine control system
malfunctions involving excessive pollution or if the EOBD system is deactivated.
The ECM makes a request for lighting of the MI(Yellow) only where there is a malfunction present at the end of
three consecutive cycles.
The 3-second visual check upon powering up (automatic test procedure controlled by the IPDM E/R) is performed by the ECM.
In the event of a confirmed OBD malfunction by lighting of the OBD light, no flashing of the light must be
observed following the lighting test.

DTCs Causing MI to Light
DTC

Description

Characterization

Reference page

P0201

Cylinder 1 injector control circuit
(Open circuit)
(Short circuit)

CC
CO

EC-1745, «DTC P0201 — P0204
FUEL INJECTOR»

P0202

Cylinder 2 injector control circuit
(Open circuit)
(Short circuit)

CC
CO

EC-1745, «DTC P0201 — P0204
FUEL INJECTOR»

P0203

Cylinder 3 injector control circuit
(Open circuit)
(Short circuit)

CC
CO

EC-1745, «DTC P0201 — P0204
FUEL INJECTOR»

P0204

Cylinder 4 injector control circuit
(Open circuit)
(Short circuit)

CC
CO

EC-1745, «DTC P0201 — P0204
FUEL INJECTOR»

P0400

EGR volume control valve
(EGR volume control valve blocked open)

4.DEF

EC-1791, «DTC P0400 EGR
FUNCTION»

P0403

EGR volume control valve
(Open circuit or short circuit to ground)

CO.0

EC-1795, «DTC P0403 EGR
VOLUME CONTROL VALVE»

P0487

EGR volume control valve control position sensor circuit
(Open circuit or short circuit to ground)
(Short circuit to +12V)

CO.0
CC.1

EC-1805, «DTC P0487 EGR
VOLUME CONTROL VALVE
CONTROL POSITION SENSOR»

P062F

ECM
(Reading to EEPROM memory)

2.DEF

EC-1828, «DTC P062F ECM»

ENGINE WARNING LIGHT
In the event of an engine malfunction, the ECM may request the display of an engine warning light [MI(Red)].

How to Erase DTC

BBS004UN

With CONSULT-II
The DTC in the ECM can be erased by selecting “ERASE” in the “SELF-DIAG RESULTS” mode with CONSULT-II.

EC-1628

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[K9K]
1.
2.
3.
4.

If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 5
seconds and then turn it ON (engine stopped) again.
A
Touch “ENGINE”.
Touch “SELF-DIAG RESULTS”.
EC
Touch “ERASE”. (The DTC in the ECM will be erased.)

C

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PBIB2452E

NATS (Nissan Anti-Theft System)
●

●

●

H

BBS0040L

If the security indicator lights up with the ignition switch in
the ON position or “NATS MALFUNCTION””is displayed on
“SELF-DIAG RESULTS” screen, perform self-diagnostic
results mode with CONSULT-II using NATS program card.
Refer to BL-215, «NATS (Nissan Anti-Theft System)» .
Confirm no self-diagnostic results of NATS is displayed
before touching “ERASE” in “SELF-DAIG RESULTS” mode
with CONSULT-II.
When replacing ECM, initialization of NATS system and registration of all NATS ignition key IDs must be carried out
SEF543X
with CONSULT-II using NATS program card.
Therefore, be sure to receive all keys from vehicle owner.
Regarding the procedure of NATS initialization and all NATS ignition key ID registration, refer to
CONSULT-II operation manual, NATS.

REPLACING THE ECM
This vehicle is fitted with an engine immobilizer system which is controlled by a key recognition system.
The ECM is supplied without a code but they must all be programmed with one.
If an ECM is replaced, it must be programmed with the code of the vehicle and the correct operation of the
engine immobilizer function must be checked.
WARNING:
These vehicles have a special ECM which does not function unless it is coded.
Consequently, it is strongly recommended that you do not carry out tests using ECMs borrowed from
the warehouse or on another vehicle to prevent coding and uncoding malfunctions which may leave
the ECM useless.

UNCODING PROCEDURE
If the ECM has learnt a code and must be returned to the workshop, it is imperative that you uncode it before
removing it.

EC-1629

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TROUBLE DIAGNOSIS
[K9K]

TROUBLE DIAGNOSIS
Trouble Diagnosis Introduction

PFP:00004
BBS0040O

SCOPE OF THIS DOCUMENT
This document presents the trouble diagnosis method applicable to all ECMs with the following specifications:
Vehicle(s):

E11 with K9K

Function concerned:

DELPHI, DIRECT DIESEL INJECTION,
COMMON RAIL MULTI INJECTION

Name of ECM:

INJECTION DCM1.2

Program No.:

4D

VDIAG No.:

48

PREREQUISITES FOR TROUBLE DIAGNOSIS
To begin trouble diagnosis, it is essential to have the following items available:

Documentation Type
Diagnostic procedures:
●
Assisted with CONSULT-II, Service Manual.
●
Wiring diagrams.
Special tool required PLUGGED RAIL tools

REMINDERS
Trouble Diagnosis:
There are present DTCs and stored DTCs (which appeared in a certain context and have since disappeared
or which are still present but have not had trouble diagnosis performed on them in the current context).
The “present” or “stored” status of DTCs must be considered when activating the diagnostic tool after power is
supplied to the ECM (without activating the system components).
Deal with present DTCs according to the procedure specified in the corresponding DTC trouble diagnosis.
For stored DTCs, note the DTCs displayed and follow the instructions in the Notes section.
If the DTC is confirmed when the instructions in the Notes section are applied, the malfunction is present. Deal
with the DTC.
If the DTC is not confirmed, check:
●
Electrical lines which correspond to the malfunction
●
Connectors for these lines (for oxidation, bent pins, etc.)
●
Resistance of the malfunction component
●
Condition of the wires (melted or cut insulation, wear)

Conformity Check
The conformity check is designed to check the states and data monitor items which do not display any DTCs
on the diagnostic tool when inconsistent. This phase therefore allows:
●
Diagnoses malfunctions that do not have a DTC display, and which may correspond to a customer complaint.
●
Checks that the system is operating correctly and that there is no risk of a DTC reappearing after repairs.
This section gives the trouble diagnosis procedures for states and parameters and the conditions for checking
them.
If a state is not operating normally or a data monitor value is outside permitted tolerance values, you should
consult the corresponding trouble diagnosis page.

Customer Complaints — Trouble Diagnosis
If the test with the CONSULT-II is OK, but the customer complaint still present, the malfunction should be
treated by customer complaints.
A synopsis of the general procedure to follow is provided on the next page in the form of a flow chart.

EC-1630

TROUBLE DIAGNOSIS
[K9K]
DIAGNOSTIC PROCEDURE
A

EC

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MBIB1484E

EC-1631

TROUBLE DIAGNOSIS
[K9K]
Wiring Control
Diagnostics malfunctions
Removing the connectors and/or handling the wirings may temporarily remove the origin of a DTC. The measurements of the electrical voltages, resistance and insulation are generally correct, especially when the DTC
is not present at the time of the analysis (stored DTC).
Visual Check
Look for impacts under the bonnet and in the passenger compartment.
Perform a careful check of the protections, insulation and correct running of wirings.
Look for traces of oxidation.
Tactile Check
While manipulating the wirings, use the diagnostic tool to detect a change in DTC states from “stored” to
“present”.
Ensure that the connectors are correctly engaged.
Apply light stresses to the connectors.
Gently manipulate the wiring harness.
If a change of state occurs, try to isolate the origin of the incident.
Examination of Each Element
Disconnect the connectors and check the appearance of the clips and blades and their crimping (no crimping
on the insulating part).
Check that the clips and blades are properly engaged in the receptacles.
Ensure that there is no rebounding of clips or blades at the time of connection.
Check the contact pressure of the clips using a suitable model blade.
Resistance Control
Test the continuity of the lines in their entirety, then section by section.
Try to create a short-circuit to earth, on the + 12 V or with another wire.
If a DTC is detected, repair or replace the wiring.

SAFETY INSTRUCTIONS
All work on components requires that the safety rules be obeyed to prevent damage or injury:
●
Make sure the battery is properly charged to avoid damaging the ECM with a low charge.
●
Use the proper tools.
Cleanliness instructions which must be followed when working on the high-pressure direct injection system:

Risks Relating to Contamination:
The system is very sensitive to contamination. The risks caused by the introduction of contamination are damage to or destruction of the high-pressure injection system and the engine, seizing or incorrect sealing of a
component.
All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a few microns in size) get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness guidelines must be applied from the filter through to the injectors.
●
What are the sources of contamination?
Contamination is caused by:
–
Metal or plastic chips
–
Paint
–
Fibres from cardboard, brushes, paper, clothing, cloths
–
Foreign bodies such as hair
–
Ambient atmosphere, etc.
WARNING:
Before working on the injection system, ensure that the system pressure is nearing 0 bar.
CAUTION:
it is not possible to clean the engine using a high-pressure washer because of the risk of damaging
the connections. In addition, moisture may collect in the connectors and cause electrical connection
malfunctions.

Instructions to Be Followed before Any Work is Carried Out on The Injection System:
●

Ensure that you have the plugs for the unions to be opened (bag of plugs available from the Parts Stores,
NISSAN part No:16830 BN700, Renault part No: 77 01 206 804). Plugs are to be used once only. After

EC-1632

TROUBLE DIAGNOSIS
[K9K]

●

●

use, they must be thrown away (once used they are soiled and cleaning is not sufficient to make them
reusable). Unused plugs must be thrown away.
A
Ensure that you have hermetically resealable plastic bags for storing removed parts. There is less risk of
parts stored in this way being exposed to contamination. The bags must be used only once, and after use
they must be thrown away.
EC
Ensure that lint-free towelettes are used for injection pump related service purposes. The use of a normal
cloth or paper for cleaning purposes is prohibited. They are not lint-free and may contaminate the fuel circuit of the system. A lint-free cloth should only be used once.
C

Instructions to Be Followed before Opening The Fuel Circuit:
Use new thinner for each operation (used thinner contains impurities). Pour it into a clean receptacle.
For each operation, use a clean brush in good condition (the brush must not shed its bristles).
Use a brush and thinners to clean the connections to be opened.
Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and injection system zone). Check that no bristles remain adhering.
Wash your hands before and during the operation if necessary.
When wearing leather protective gloves, cover them with latex gloves.

Instructions to Be Followed During The Operation:
As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system.
The plugs to be used are available from the Parts Stores. They must not, under any circumstances, be reused.
Close the resealable bag, even if it has to be reopened shortly afterwards. The ambient atmosphere carries
impurities.
All components removed from the injection system must be stored in a hermetically sealed plastic bag once
the plugs have been inserted.
The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been
opened.
These items are likely to allow contaminants to enter the system.
A new component replacing an old one must not be removed from its packaging until it is to be fitted to the
vehicle.

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ECM REPLACEMENT, PROGRAMMING OR REPROGRAMMING OPERATION
Following items can be (re)programmed via the DLC using the CONSULT-II.
●
System configuration
●
Injector adjustment value
Before replacing the ECM in after-sales operations, the following data must be readout using CONSULT-II:
●
The injector adjustment values to be noted to appropriate paper or CONSULT-II copying function.
NOTE:
The injector adjustment value for each fuel injector must be entered manually after the ECM has been
replaced or (re)programmed by reading the injector adjustment value on each fuel injector.
IMPORTANT: It is not possible to test an ECM from the parts stores because it cannot be fitted to any other
vehicle.
REPLACING THE INJECTORS
NOTE:
The injector adjustment value is a calibration made on each fuel injector in the factory in order to adjust its flow
precisely.
These injector adjustment values are written on a label affixed to each fuel injector then entered into the ECM
which then controls each fuel injector taking into account its individual manufacturing variations.
When replacing one or more fuel injectors, the parameters of the fuel injector output concerned must be modified. The system can be configured using the CONSULT-II.

EC-1633

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TROUBLE DIAGNOSIS
[K9K]

Trouble Diagnosis — Symptom

BBS004U2

NOTE:
Only consult this customer complaint after a complete check using the CONSULT-II.
Symptom

Trouble diagnosis

Reference page

CHART 1

EC-1635

The engine does not start

CHART 2

EC-1636

The engine starts with difficulty or starts then stalls

CHART 3

EC-1638

Starting difficult with warm engine

CHART 4

EC-1640

Rough idle speed (pumping)

CHART 5

EC-1641

Idle speed too high or too low

CHART 6

EC-1642

Unexpected acceleration/deceleration and engine stalling

CHART 7

EC-1642

Response malfunction

CHART 8

EC-1643

Engine stop (timing)

CHART 9

EC-1644

Engine jerking

CHART 10

EC-1646

Lack of power

CHART 11

EC-1647

Too much power

CHART 12

EC-1648

Excessive consumption

CHART 13

EC-1649

Overspeed when lifting off accelerator or changing gear

CHART 14

EC-1650

Engine dies when pulling away

CHART 15

EC-1651

The engine does not stop

CHART 16

EC-1652

Clanking engine, noisy engine

CHART 17

EC-1653

Squalling noise

CHART 18

EC-1654

General mechanical noises

CHART 19

EC-1654

Blue, white or black smoke

CHART 20

EC-1656

Exhaust odors

CHART 21

EC-1657

Diesel odors

CHART 22

EC-1657

Smoke (blue, white or black) on acceleration

CHART 23

EC-1658

No communication with the ECM

Starting malfunction

Idle speed malfunction

Behavior while driving

Road holding (continued)

Noise, odors or smoke

EC-1634

TROUBLE DIAGNOSIS
[K9K]
CHART 1: NO COMMUNICATION WITH THE ECM
A

1. INSPECTION START

Ensure that CONSULT-II is not causing the malfunction by trying to establish dialogue with an ECM on another
vehicle. If the CONSULT-II is not at malfunction, and dialogue cannot be established with any other ECM on EC
the same vehicle, the cause could be a suspected ECM interfering on the CAN communication line.
Check the voltage of the battery and carry out the operations necessary to obtain a voltage which is to specification (9.5 V < U battery < 17.5 V).
C
>> GO TO 2.
D

2. CHECK CAN COMMUNICATION
Perform trouble diagnosis on the CAN communication line using CONSULT-II.

E

>> GO TO 3.

3. CHECK ECM GROUND

F

Check the ECM earth (ground) point on the side strut tower.
G

>> GO TO 4.

4. CHECK DLC CONNECTOR CIRCUIT

H

Check the followings:
●
Connection between the CONSULT-II and the DLC (wiring in good condition)
●
Engine and passenger compartment fuses
>> GO TO 5.

I

J

5. CHECK DLC CONNECTOR CIRCUIT
Check for the presence of 12 V on terminal 16 with ignition switch OFF, 12 V on terminal 8 with ignition switch
ON and an earth (ground) on terminals 4 and 5 of the data link connector.
Repair if necessary.

K

L

>> GO TO 6.
M

EC-1635

TROUBLE DIAGNOSIS
[K9K]

6. CHECK ECM POWER SUPPLY AND GROUND CIRCUIT
Connect the CONSULT-II and check the insulation, continuity and absence of interference resistance of the
connections:
●
ECM terminal 104 and IPDM E/R harness connector terminal 29
●
ECM terminal 109 and IPDM E/R harness connector terminal 32
●
ECM terminal 110 and IPDM E/R harness connector terminal 32
●
ECM terminal 22 and fuse block M7
●
ECM terminal 25 and ground
●
ECM terminal 26 and ground
●
ECM terminal 27 and ground
●
ECM terminal 32 and ground
●
ECM terminal 2 and DLC terminal 7
(Refer to EC-1698, «Wiring Diagram» .)
Repair if necessary.
>> INSPECTION END

CHART 2: THE ENGINE DOES NOT START

1. CHECK FUEL
Check that the fuel reservoir is correctly filled and with the right fuel.
>> GO TO 2.

2. CHECK ENGINE OIL AND ENGINE COOLANT LEVEL
Check the engine oil and coolant levels.
>> GO TO 3.

3. CHECK INLET AIR CIRCUIT
Check the inlet air circuit using TEST 5. Refer to EC-1663, «TEST 5: AIR INLET CIRCUIT CHECK» .
>> GO TO 4.

4. CHECK CATALYTIC CONVERTER
Is the catalytic converter clogged or deteriorated?
Yes or No
Yes
>> Replace the catalytic converter.
No
>> GO TO 5.

5. CHECK ELECTRICAL CIRCUIT
Check the electrical circuit using TEST 2. Refer to EC-1661, «TEST 2: ELECTRICAL CIRCUIT CHECK» .
>> GO TO 6.

EC-1636

TROUBLE DIAGNOSIS
[K9K]

6. CHECK DISTRIBUTION

A

Is the distribution properly adjusted?
Yes or No
Yes
>> GO TO 7.
No
>> Perform the required repairs.

EC

7. CHECK WIRING HARNESS

C

Visually check the condition of the engine wiring harness.
D

>> GO TO 8.

8. CHECK STARTER

E

Is the starter working properly (minimum engine speed of 200 rpm)?
Yes or No
Yes
>> GO TO 9.
No
>> Perform the required repairs.

9. CHECK COMPRESSION PRESSURE

F

G

Are the compressions correct?
Yes or No
Yes
>> GO TO 10.
No
>> Perform the required repairs.

H

10. CHECK GLOW PLUG

I

Check the condition of the glow plugs.
J

>> GO TO 11.

11. CHECK ENGINE PARAMETERS

K

Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
L

>> GO TO 12.

12. CHECK FUEL RAIL PRESSURE

M

Does “RAIL PRESSURE” indicate less than 50 bar under + following contact?
Yes or No
Yes
>> GO TO 13.
No
>> Perform the trouble diagnosis for FRP sensor. Refer to EC-1736, «DTC P0190 FRP SENSOR» .

13. CHECK LOW PRESSURE CIRCUIT
Check the low pressure circuit using TEST 1. Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT
CHECK» .
>> GO TO 14.

EC-1637

TROUBLE DIAGNOSIS
[K9K]

14. CHECK HIGH PRESSURE CIRCUIT
Visually check the high pressure circuit for leaks using TEST 8. Refer to EC-1665, «TEST 8: HIGH-PRESSURE CIRCUIT LEAK CHECK» .
>> GO TO 15.

15. CHECK HIGH PRESSURE SYSTEM
Check the high pressure system using TEST 7. Refer to EC-1664, «TEST 7: HIGH PRESSURE SYSTEM
CHECK» .
>> GO TO 16.

16. CEHCK ECM
Check the ECM using TEST 6. Refer to EC-1664, «TEST 6: ECM CHECK» .
>> INSPECTION END

CHART 3: THE ENGINE STARTS WITH DIFFICULTY OR STARTS THEN STALLS

1. CHECK FUEL
Check that the fuel reservoir is correctly filled and with the right fuel.
>> GO TO 2.

2. CHECK ENGINE OIL AND ENGINE COOLANT LEVEL
Check the engine oil and coolant levels.
>> GO TO 3.

3. CHECK INLET AIR CIRCUIT
Check the inlet air circuit using TEST 5. Refer to EC-1663, «TEST 5: AIR INLET CIRCUIT CHECK» .
>> GO TO 4.

4. CHECK CATALYTIC CONVERTER
Is the catalytic converter clogged or deteriorated?
Yes or No
Yes
>> Replace the catalytic converter.
No
>> GO TO 5.

5. CHECK DISTRIBUTION
Is the distribution properly adjusted?
Yes or No
Yes
>> GO TO 6.
No
>> Perform the required repairs.

EC-1638

TROUBLE DIAGNOSIS
[K9K]

6. CHECK COMPRESSION PRESSURE

A

Are the compressions correct?
Yes or No
Yes
>> GO TO 7.
No
>> Perform the required repairs.

EC

7. CHECK GLOW PLUG

C

Check the condition of the glow plugs.
D

>> GO TO 8.

8. CHECK WIRING HARNESS

E

Visually check the condition of the engine wiring harness.
F

>> GO TO 9.

9. CHECK ELECTRICAL CIRCUIT
Check the electrical circuit using TEST 2. Refer to EC-1661, «TEST 2: ELECTRICAL CIRCUIT CHECK» .
>> GO TO 10.

G

H

10. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 11.

I

J

11. CHECK LOW PRESSURE CIRCUIT
Check the low pressure circuit using TEST 1. Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT
CHECK» .
>> GO TO 12.

K

L

12. CHECK HIGH PRESSURE CIRCUIT
Visually check the high pressure circuit for leaks using TEST 8. Refer to EC-1665, «TEST 8: HIGH-PRESSURE CIRCUIT LEAK CHECK» .
>> GO TO 13.

13. CHECK HIGH PRESSURE SYSTEM
Check the high pressure system using TEST 7. Refer to EC-1664, «TEST 7: HIGH PRESSURE SYSTEM
CHECK» .
>> GO TO 14.

14. CHECK ECM
Check the ECM using TEST 6. Refer to EC-1664, «TEST 6: ECM CHECK» .
>> INSPECTION END

EC-1639

M

TROUBLE DIAGNOSIS
[K9K]
CHART 4: STARTING DIFFICULT WITH WARM ENGINE

1. CHECK FUEL
Check that the fuel reservoir is correctly filled and with the right fuel.
>> GO TO 2.

2. CHECK INLET AIR CIRCUIT
Check the inlet air circuit using TEST 5. Refer to EC-1663, «TEST 5: AIR INLET CIRCUIT CHECK» .
>> GO TO 3.

3. CHECK COMPRESSION PRESSURE
Are the compressions correct?
Yes or No
Yes
>> GO TO 4.
No
>> Perform the required repairs.

4. CHECK CATALYTIC CONVERTER
Is the catalytic converter clogged or deteriorated?
Yes or No
Yes
>> Replace the catalytic converter.
No
>> GO TO 5.

5. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 6.

6. CHECK WIRING HARNESS
Visually check the condition of the engine wiring harness.
>> GO TO 7.

7. CHECK LOW PRESSURE CIRCUIT
Check the low pressure circuit using TEST 1. Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT
CHECK» .
>> GO TO 8.

8. CHECK FUEL INJECTORS
Operate the fuel injectors via ACTIVE TEST with CONSULT-II.
>> GO TO 9.

EC-1640

TROUBLE DIAGNOSIS
[K9K]

9. CHECK FUEL INECTORS

A
Is movement of the valve audible 1 m away from the vehicle?
Yes or No
EC
Yes
>> GO TO 10.
No
>> Perform TEST 11. Refer to EC-1666, «TEST 11: FUEL FILTER CHECK» . If TEST 11 is in order,
replace the malfunctioning fuel injector(s).
C
CHECK ECM

10.

Check the ECM using TEST 6. Refer to EC-1664, «TEST 6: ECM CHECK» .

D

>> INSPECTION END

CHART 5: ROUGH IDLE SPEED (PUMPING)

E

1. CHECK LOW PRESSURE CIRCUIT
Check the low pressure circuit using TEST 1. Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT
CHECK» .

F

G

>> GO TO 2.

2. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 3.

H

I

3. CHECK WIRING HARNESS
Is the engine wiring harness cut off or jammed?
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 4.

J

K

4. CHECK FUEL PUMP
L

Is the high pressure actuator blocked?
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 5.

M

5. CHECK HIGH PRESSURE CIRCUIT
Check for leaks in the high pressure circuit using TEST 8. Refer to EC-1665, «TEST 8: HIGH-PRESSURE
CIRCUIT LEAK CHECK» .
>> GO TO 6.

6. CHECK GLOW PLUG
Check that the glow plugs are working properly.
Is the glow plug resistance above 1Ω?
Yes or No
Yes
>> Replace the glow plugs.
No
>> GO TO 7.

EC-1641

TROUBLE DIAGNOSIS
[K9K]

7. CHECK COMPRESSION PRESSURE
Are the compressions correct?
Yes or No
Yes
>> GO TO 8.
No
>> Carry out the required repairs.

8. CHECEK FUEL INJECTORS
Check the fuel injectors using TEST 3. Refer to EC-1662, «TEST 3: FUEL INJECTOR CHECK» .
>> GO TO 9.

9. CHECK FUEL PUMP
Check the high pressure pump using TEST 7. Refer to EC-1664, «TEST 7: HIGH PRESSURE SYSTEM
CHECK» .
>> INSPECTION END

CHART 6: IDLE SPEED TOO HIGH/TOO LOW

1. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 2.

2. CHECK ELECTRICAL CIRCUIT
Check the electrical circuit using TEST 2. Refer to EC-1661, «TEST 2: ELECTRICAL CIRCUIT CHECK» .
>> GO TO 3.

3. CHECK CLUTCH LINKAGE
Is the clutch linkage correct?
Yes or No
Yes
>> GO TO 4.
No
>> Carry out the required repairs

4. CHECK ECM
Check the ECM using TEST 6. Refer to EC-1664, «TEST 6: ECM CHECK» .
>> INSPECTION END

CHART 7: UNEXPECTED ACCELERATION/DECELERATION AND ENGINE OVERCHARGING

1. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 2.

EC-1642

TROUBLE DIAGNOSIS
[K9K]

2. CHECK INLET AIR CIRCUIT

A

Check the air inlet circuit using TEST 5. Refer to EC-1663, «TEST 5: AIR INLET CIRCUIT CHECK» .
EC

>> GO TO 3.

3. CHECK WIRING HARNESS
C

Is the engine wiring harness cut off or pinched?
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 4.

D

4. CHECK FUEL INJECTORS

E

Check the fuel injectors using TEST 3. Refer to EC-1662, «TEST 3: FUEL INJECTOR CHECK» .
F

>> GO TO 5.

5. CHECK ENGINE ASPIRATION
Check that the engine has not aspirated its oil (engine stalls).
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 6.

6. CHECK ECM

G

H

I

Check the ECM using TEST 6. Refer to EC-1664, «TEST 6: ECM CHECK» .
J

>> INSPECTION END

CHART 8: RESPONSE MALFUNCTION

1. CHECK INLET AIR CIRCUIT

K

Check the inlet air circuit using TEST 5. Refer to EC-1663, «TEST 5: AIR INLET CIRCUIT CHECK» .
L

>> GO TO 2.

2. CHECK COMPRESSION PRESSURE

M

Are the compressions correct?
Yes or No
Yes
>> GO TO 3.
No
>> Carry out the required repairs.

3. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 4.

EC-1643

TROUBLE DIAGNOSIS
[K9K]

4. CHECK TURBOCHARGER
Check that the turbocharger is working properly.
Is the turbocharger correct?
Yes or No
Yes
>> GO TO 5.
No
>> Carry out the required repairs.

5. CHECK LOW PRESSURE CIRCUIT
Check the low pressure circuit using TEST 1. Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT
CHECK» .
>> GO TO 6.

6. CHECK HIGH PRESSURE CIRCUIT
Check for leaks in the high pressure circuit using TEST 8. Refer to EC-1665, «TEST 8: HIGH-PRESSURE
CIRCUIT LEAK CHECK» .
>> GO TO 7.

7. CHECK FUEL PUMP
Is the high pressure actuator blocked?
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 8.

8. CHECK FUEL INJECTORS
Check the fuel injectors using TEST 3. Refer to EC-1662, «TEST 3: FUEL INJECTOR CHECK» .
>> GO TO 9.

9. CHECK ECM
Check the ECM using TEST 6. Refer to EC-1664, «TEST 6: ECM CHECK» .
>> INSPECTION END

CHART 9: ENGINE STOP/STALLING

1. CHECK FUEL
Check that the fuel reservoir is correctly filled and with the right fuel.
>> GO TO 2.

2. CHECK ENGINE OIL AND ENGINE COOLANT
Check the engine oil and coolant levels.
>> GO TO 3.

EC-1644

TROUBLE DIAGNOSIS
[K9K]

3. CEHCK ENGINE ASPIRATION

A

Check that the engine has not aspirated its oil (engine racing).
EC

>> GO TO 4.

4. CHECK INLET AIR CIRCUIT
Check the inlet air circuit using TEST 5. Refer to EC-1663, «TEST 5: AIR INLET CIRCUIT CHECK» .
>> GO TO 5.

C

D

5. CHECK CATALYTIC CONVERTER
Is the catalytic converter clogged or deteriorated?
Yes or No
Yes
>> Replace the catalytic converter.
No
>> GO TO 6.

E

F

6. CHECK WIRING HARNESS
Visually check the condition of the engine wiring harness.
>> GO TO 7.

G

H

7. CHECK ELECTRICAL CIRCUIT
Check the electrical circuit using TEST 2. Refer to EC-1661, «TEST 2: ELECTRICAL CIRCUIT CHECK» .
>> GO TO 8.

I

J

8. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .

K

>> GO TO 9.
L

9. CHECK LOW PRESSURE CIRCUIT
Check the low pressure circuit using TEST 1. Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT
CHECK» .
>> GO TO 10.

10. CHECK HIGH PRESSURE CURCUIT
Visually check the high pressure circuit for leaks using TEST 8. Refer to EC-1665, «TEST 8: HIGH-PRESSURE CIRCUIT LEAK CHECK» .
>> GO TO 11.

11. CHECK HIGH PRESSURE SYSTEM
Check the high pressure system using TEST 7. Refer to EC-1660, «Trouble Diagnosis — Basic Test Procedure»
.
>> GO TO 12.

EC-1645

M

TROUBLE DIAGNOSIS
[K9K]

12. CHECK ECM
Check the ECM using TEST 6. Refer to EC-1664, «TEST 6: ECM CHECK» .
>> INSPECTION END

CHART 10: ENGINE JERKING

1. CHECK FUEL
Check that the fuel tank is correctly filled and that the fuel type is suitable.
Is the fuel type suitable and the tank correctly filled?
Yes or No
Yes
>> GO TO 2.
No
>> Refill the fuel tank correctly.

2. CHECK LOW PRESSURE CIRCUIT
Check the low pressure circuit using TEST 1. Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT
CHECK» .
>> GO TO 3.

3. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 4.

4. CHECK WIRING HARNESS
Is the engine wiring harness cut off or pinched?
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 5.

5. CEHCK GLOW PLUG
Check that the glow plugs are working properly.
Is the glow plug resistance above 1Ω?
Yes or No
Yes
>> Replace the glow plugs.
No
>> GO TO 6.

6. CHECK COMPRESSION PRESSURE
Are the compressions correct?
Yes or No
Yes
>> GO TO 7.
No
>> Carry out the required repairs.

7. CHECK VALVE CLEARANCE
Is the valve clearance properly adjusted?
Yes or No
Yes
>> GO TO 8.
No
>> Make the necessary adjustments.

EC-1646

TROUBLE DIAGNOSIS
[K9K]

8. CHECK FUEL PUMP

A

Check the high pressure pump using TEST 7. Refer to EC-1664, «TEST 7: HIGH PRESSURE SYSTEM
CHECK» .
EC

>> GO TO 9.

9. CHECK ECM

C

Check the ECM using TEST 6. Refer to EC-1664, «TEST 6: ECM CHECK» .
D

>> INSPECTION END

CHART 11: LACK OF POWER
E

1. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .

F

>> GO TO 2.

2. CHECK INLET AIR CIRCUIT

G

Check the inlet air circuit using TEST 5. Refer to EC-1663, «TEST 5: AIR INLET CIRCUIT CHECK» .
H

>> GO TO 3.

3. CHECK ENGINE OIL LEVEL

I

Is the engine oil level correct?
Yes or No
Yes
>> GO TO 4.
No
>> Top up the oil.

J

4. CEHCK CATALYTIC CONVERTER

K

Is the catalytic converter sealed off or damaged?
Yes or No
Yes
>> Replace the catalytic converter.
No
>> GO TO 5.

L

5. CHECK TURBOCHARGER

M

Check that the turbocharger is working properly.
Is the turbocharger correct?
Yes or No
Yes
>> GO TO 6.
No
>> Carry out the required repairs.

6. CHECK LOW PRESSURE CURCUIT
Check the low pressure circuit using TEST 1. Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT
CHECK» .
>> GO TO 7.

EC-1647

TROUBLE DIAGNOSIS
[K9K]

7. CHECK FUEL INJECTORS
Check the fuel injectors using TEST 3. Refer to EC-1662, «TEST 3: FUEL INJECTOR CHECK» .
>> GO TO 8.

8. CEHCK COMPRESSION PRESSURE
Are the compressions correct?
Yes or No
Yes
>> GO TO 9.
No
>> Carry out the required repairs.

9. CEHCK VALVE CLEARANCE
Is the valve clearance properly adjusted?
Yes or No
Yes
>> INSPECTION END
No
>> Make the necessary adjustments.

CHART 12: TOO MUCH POWER

1. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 2.

2. CEHCK INLET AIR CIRCUIT
Check the inlet air circuit using TEST 5. Refer to EC-1663, «TEST 5: AIR INLET CIRCUIT CHECK» .
>> GO TO 3.

3. CHECK ENGINE ASPIRATION
Check that the engine has not aspirated its oil (engine stalls).
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 4.

4. CHECK FUEL INJECTORS
Check the fuel injectors using TEST 3. Refer to EC-1662, «TEST 3: FUEL INJECTOR CHECK» .
>> GO TO 5.

5. CHECK ECM
Check the ECM using TEST 6. Refer to EC-1664, «TEST 6: ECM CHECK» .
>> INSPECTION END

EC-1648

TROUBLE DIAGNOSIS
[K9K]
CHART 13: EXCESSIVE CONSUMPTION
A

1. CHECK LOW PRESSURE CIRCUIT

Check the low pressure circuit using TEST 1. Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT
EC
CHECK» .
>> GO TO 2.
C

2. CHECK FUEL PUMP
Is the high pressure actuator leaking?
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 3.

D

E

3. CHECK FUEL PUMP TEMPERATURE SENSOR
Is the fuel pump temperature sensor leaking?
Yes or No
Yes
>> Replace the fuel pump temperature sensor.
No
>> GO TO 4.

F

G

4. CHECK LOW PRESSURE CIRCUIT
Check the low pressure circuit using TEST 1. Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT
CHECK» .

H

I

>> GO TO 5.

5. CHECK FUEL INJECTORS

J

Check the fuel injectors using TEST 3. Refer to EC-1662, «TEST 3: FUEL INJECTOR CHECK» .
K

>> GO TO 6.

6. CHECK HIGH PRESSURE CIRCUIT
Check for leaks in the high pressure circuit using TEST 8. Refer to EC-1665, «TEST 8: HIGH-PRESSURE
CIRCUIT LEAK CHECK» .

L

M

>> GO TO 7.

7. CHECK INLET AIR CIRCUIT
Check the inlet air circuit using TEST 5. Refer to EC-1663, «TEST 5: AIR INLET CIRCUIT CHECK» .
>> GO TO 8.

8. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 9.

EC-1649

TROUBLE DIAGNOSIS
[K9K]

9. CHECK ENGINE OIL LEVEL
Is the engine oil level correct?
Yes or No
Yes
>> GO TO 10.
No
>> Top up the oil.

10. CHECK CATALYTIC CONVERTER
Is the catalytic converter clogged or damaged?
Yes or No
Yes
>> Replace the catalytic converter.
No
>> GO TO 11.

11. CHECK TURBOCHARGER
Check that the turbocharger is working properly.
Is the turbocharger correct?
Yes or No
Yes
>> GO TO 12.
No
>> Carry out the required repairs.

12. CHECK COMPRESSION PRESSURE
Are the compressions correct?
Yes or No
Yes
>> GO TO 13.
No
>> Carry out the required repairs.

13. CHECK ECM
Check the ECM using TEST 6. Refer to EC-1664, «TEST 6: ECM CHECK» .
>> INSPECTION END

CHART 14: OVERSPEED WHEN LIFTING OFF ACCELERATOR OR CHANGING GEAR

1. CHECK ACCELERATOR PEDAL
Check that there is no obstacle obstructing the accelerator pedal travel (carpet, hard spot, etc.).
>> GO TO 2.

2. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 3.

3. CHECK WIRING HARNESS
Is the engine wiring harness cut or pinched?
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 4.

EC-1650

TROUBLE DIAGNOSIS
[K9K]

4. CHECK CLUTCH LINKAGE

A

Is the clutch linkage properly adjusted?
Yes or No
Yes
>> GO TO 5.
No
>> Carry out the required repairs.

EC

5. CHECK ENGINE ASPIRATION

C

Check that the engine has not aspirated its oil (engine stalls).
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 6.

D

6. CHECK TURBOCHARGER

E

Check that the turbocharger is working properly.
Is the turbocharger correct?
Yes or No
Yes
>> GO TO 7.
No
>> Carry out the required repairs.

F

G

7. CHECK INJECTORS
Check the injectors using TEST 3. Refer to EC-1662, «TEST 3: FUEL INJECTOR CHECK» .
>> GO TO 8.

H

I

8. CHECK ECM
Check the ECM using TEST 6. Refer to EC-1664, «TEST 6: ECM CHECK» .

J

>> INSPECTION END

CHART 15: ENGINE DIES ON PULLING AWAY

K

1. CHECK CLUTCH PEDAL
L

Is the clutch pedal free travel correctly adjusted?
Yes or No
Yes
>> GO TO 2.
No
>> Carry out the required repairs.

M

2. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 3.

3. CHECK INLET AIR CIRCUIT
Check the inlet air circuit using TEST 5. Refer to EC-1663, «TEST 5: AIR INLET CIRCUIT CHECK» .
>> GO TO 4.

EC-1651

TROUBLE DIAGNOSIS
[K9K]

4. CHECK CTALYTIC CONVETER
Is the catalytic converter clogged or damaged?
Yes or No
Yes
>> Replace the catalytic converter.
No
>> GO TO 5.

5. CHECK LOW PRESSURE CIRCUIT
Check the low pressure circuit using TEST 1. Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT
CHECK» .
>> GO TO 6.

6. CHECK CLUTCH LINKAGE
Is the clutch linkage properly adjusted?
Yes or No
Yes
>> GO TO 7.
No
>> Carry out the required repairs.

7. CHECK WIRING HARNESS
Is the engine wiring harness cut or pinched?
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 8.

8. CHECK ECM
Check the ECM using TEST 6. Refer to EC-1664, «TEST 6: ECM CHECK» .
>> INSPECTION END

CHART 16: ENGINE BACKFIRES, ENGINE NOISE

1. CHECK FUEL
Check that the fuel reservoir is correctly filled and with the right fuel.
>> GO TO 2.

2. CHECK ENGINE OIL AND ENGINE COOLANT LEVEL
Check the engine oil and coolant levels.
>> GO TO 3.

3. CHECK COMPRESSION PRESSURE
Are the compressions correct?
Yes or No
Yes
>> GO TO 4.
No
>> Perform the required repairs.

EC-1652

TROUBLE DIAGNOSIS
[K9K]

4. CHECK GLOW PLUG

A

Check the condition of the glow plugs.
EC

>> GO TO 5.

5. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 6.

C

D

6. CHECK INLET AIR CIRCUIT
Check the inlet air circuit using TEST 5. Refer to EC-1663, «TEST 5: AIR INLET CIRCUIT CHECK» .
>> GO TO 7.

E

F

7. CHECK LOW PRESSURE CURCUIT
Check the low pressure circuit using TEST 1. Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT
CHECK» .
>> GO TO 8.

G

H

8. CHECK INJECTORS
Check the injectors using TEST 3. Refer to EC-1662, «TEST 3: FUEL INJECTOR CHECK» .
>> INSPECTION END

CHART 17: CLANKING ENGINE, NOISY ENGINE

I

J

1. CHECK ENGINE PARAMETERS
K

Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 2.

L

2. CHECK INLET AIR CIRCUIT
Check the inlet air circuit using TEST 5. Refer to EC-1663, «TEST 5: AIR INLET CIRCUIT CHECK» .
>> GO TO 3.

3. CHECK GLOW PLUG
Check that the glow plugs are working properly.
Is the glow plug resistance above 1Ω?
Yes or No
Yes
>> Replace the glow plugs.
No
>> GO TO 4.

EC-1653

M

TROUBLE DIAGNOSIS
[K9K]

4. CHECK COMPRESSION PRESSURE
Are the compressions correct?
Yes or No
Yes
>> GO TO 5.
No
>> Carry out the required repairs.

5. CHECK LOW PRESSURE CIRCUIT
Check the low pressure circuit using TEST 1. Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT
CHECK» .
>> GO TO 6.

6. CHECK FUEL INECTORS
Check the fuel injectors using TEST 3. Refer to EC-1662, «TEST 3: FUEL INJECTOR CHECK» .
>> INSPECTION END

CHART 18: SQUALLING NOISE

1. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 2.

2. CHECK WIRING HARNESS
Is the engine wiring harness cut or pinched?
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 3.

3. CHECK FUEL PUMP
Is the high pressure actuator blocked?
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 4.

4. CHECK ECM
Check the ECM using TEST 6. Refer to EC-1664, «TEST 6: ECM CHECK» .
>> INSPECTION END

CHART 19: VARIOUS MECHANICAL NOISES

1. CHECK FUEL INJECOTR OPERATION
Check that the fuel injectors are not making a buzzing noise (injector discharge).
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 2.

EC-1654

TROUBLE DIAGNOSIS
[K9K]

2. CHECK FUEL INJECTOR INSTALLATION

A

Are the mounting clips on the fuel injector pipes broken or missing?
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 3.

3. CHECK ENGINE PARAMETERS

EC

C

Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
D

>> GO TO 4.

4. CHECK CATALYTIC CONVERTER

E

Is the catalytic converter clogged or damaged?
Yes or No
Yes
>> Replace the catalytic converter.
No
>> GO TO 5.

F

5. CHECK INLET AIR CIRCUIT

G

Check the inlet air circuit using TEST 5. Refer to EC-1663, «TEST 5: AIR INLET CIRCUIT CHECK» .
H

>> GO TO 6.

6. CHECK FUEL INJECTORS

I

Check the fuel injectors using TEST 3. Refer to EC-1662, «TEST 3: FUEL INJECTOR CHECK» .
J

>> GO TO 7.

7. CHECK CLUTCH LINKAGE
K

Is the clutch linkage properly adjusted?
Yes or No
Yes
>> GO TO 8.
No
>> Carry out the required repairs.

L

8. CHECK TURBOCHARGER

M

Check that the turbocharger is working properly.
Is the turbocharger correct?
Yes or No
Yes
>> GO TO 9.
No
>> Carry out the required repairs.

9. CHECK VALVE CLEARANCE
Is the valve clearance properly adjusted?
Yes or No
Yes
>> INSPECTION END
No
>> Make the necessary adjustments.

EC-1655

TROUBLE DIAGNOSIS
[K9K]
CHART 20: EXHAUST ODOURS

1. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 2.

2. CHECK INLET AIR CIRCUIT
Check the inlet air circuit using TEST 5. Refer to EC-1663, «TEST 5: AIR INLET CIRCUIT CHECK» .
>> GO TO 3.

3. CHECK ENGINE ASPIRATION
Check that the engine has not aspirated its oil (engine stalls).
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 4.

4. CHECK TURBOCHARGER
Check that the turbocharger is working properly.
Is the turbocharger correct?
Yes or No
Yes
>> GO TO 5.
No
>> Carry out the required repairs.

5. CHECK ENGINE OIL
Is the engine oil level correct?
Yes or No
Yes
>> GO TO 6.
No
>> Top up the oil.

6. CHECK CATALYTIC CONVETER
Is the catalytic converter clogged or damaged?
Yes or No
Yes
>> Replace the catalytic converter.
No
>> GO TO 7.

7. CHECK FUEL INJECTORS
Check the fuel injectors using TEST 3. Refer to EC-1662, «TEST 3: FUEL INJECTOR CHECK» .
>> GO TO 8.

8. CHECK ECM
Check the ECM using TEST 6. Refer to EC-1664, «TEST 6: ECM CHECK» .
>> INSPECTION END

EC-1656

TROUBLE DIAGNOSIS
[K9K]
CHART 21: DIESEL ODOURS
A

1. CHECK LOW PRESSURE CIRCUIT

Check the low pressure circuit using TEST 1. Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT
EC
CHECK» .
>> GO TO 2.
C

2. CHECK FUEL PUMP
Is the high pressure actuator leaking?
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 3.

D

E

3. CHECK FUEL PUMP TEMPERATURE SENSOR
Is the fuel pump temperature sensor leaking?
Yes or No
Yes
>> Replace the fuel temperature sensor.
No
>> GO TO 4.

F

G

4. CHECK FUEL INJECTORS
Check the fuel injectors using TEST 3. Refer to EC-1662, «TEST 3: FUEL INJECTOR CHECK» .
>> GO TO 5.

H

I

5. CHECK HIGH PRESSURE CIRCUIT
Check for leaks in the high pressure circuit using TEST 8. Refer to EC-1665, «TEST 8: HIGH-PRESSURE
CIRCUIT LEAK CHECK» .

J

K

>> INSPECTION END

CHART 22: BLUE, WHITE OR BLACK SMOKE

1. CHECK FUEL

L

Check that the fuel reservoir is correctly filled and with the right fuel.
M

>> GO TO 2.

2. CHECK ENGINE OIL AND ENGINE COOLANT LEVEL
Check the engine oil and coolant levels.
>> GO TO 3.

3. CHECK ENGINE ASPIRATION
Check that the engine has not aspirated its oil (engine racing).
>> GO TO 4.

EC-1657

TROUBLE DIAGNOSIS
[K9K]

4. CHECK COMPRESSION PRESSURE
Are the compressions correct?
Yes or No
Yes
>> GO TO 5.
No
>> Perform the required repairs.

5. CHECK GLOW PLUG
Check the condition of the glow plugs.
>> GO TO 6.

6. CHECK CATALYTIC CONVERTER
Is the catalytic converter clogged or deteriorated?
Yes or No
Yes
>> Replace the catalytic converter.
No
>> GO TO 7.

7. CHECK INLET AIR CIRCUIT
Check the inlet air circuit using TEST 5. Refer to EC-1663, «TEST 5: AIR INLET CIRCUIT CHECK» .
>> GO TO 8.

8. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 9.

9. CHECK LOW PRESSURE CIRCUIT
Check the low pressure circuit using TEST 1. Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT
CHECK» .
>> GO TO 10.

10. CHECK FUEL INJECTORS
Check the fuel injectors using TEST 3. Refer to EC-1662, «TEST 3: FUEL INJECTOR CHECK» .
>> INSPECTION END

CHART 23: SMOKE (BLUE, BLACK OR WHITE) ON ACCELERATING

1. CHECK FUEL
Check that the fuel reservoir is correctly filled and with the right fuel.
>> GO TO 2.

2. CHECK ENGINE OIL AND ENGINE COOLANT LEVEL
Check the engine oil and coolant levels.
>> GO TO 3.

EC-1658

TROUBLE DIAGNOSIS
[K9K]

3. CHECK ENGINE ASPIRATION

A

Check that the engine has not aspirated its oil (engine racing).
EC

>> GO TO 4.

4. CHECK COMPRESSION PRESSURE
C

Are the compressions correct?
Yes or No
Yes
>> GO TO 5.
No
>> Perform the required repairs.

D

5. CHECK GLOW PLUG

E

Check the condition of the glow plugs.
F

>> GO TO 6.

6. CHECK CATALYTIC CONVERTER
Is the catalytic converter clogged or deteriorated?
Yes or No
Yes
>> Replace the catalytic converter.
No
>> GO TO 7.

7. CHECK INLET AIR CIRCUIT

G

H

I

Check the inlet air circuit using TEST 5. Refer to EC-1663, «TEST 5: AIR INLET CIRCUIT CHECK» .
J

>> GO TO 8.

8. CHECK TURBOCHARGER
Ensure that the turbo compressor is working correctly.
Is the turbo compressor in order?
Yes or No
Yes
>> GO TO 9.
No
>> Perform the required repairs.

9. CHECK WIRING HARNESS

K

L

M

Visually check the condition of the engine wiring harness.
>> GO TO 9.

10. CHECK ENGINE PARAMETERS
Check the engine parameters using TEST 4. Refer to EC-1663, «TEST 4: PARAMETER CHECK» .
>> GO TO 11.

EC-1659

TROUBLE DIAGNOSIS
[K9K]

11. CHECK LOW PRESSURE CIRCUIT
Check the low pressure circuit using TEST 1. Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT
CHECK» .
>> GO TO 12.

12. CHECK FUEL INJECTORS
Check the fuel injectors using TEST 3. Refer to EC-1662, «TEST 3: FUEL INJECTOR CHECK» .
>> GO TO 13.

13. CHECK ECM
Check the ECM using TEST 6. Refer to EC-1664, «TEST 6: ECM CHECK» .
>> INSPECTION END

Trouble Diagnosis — Basic Test Procedure

BBS004U3

DESCRIPTION
NOTE:
Only consult the tests after following the diagnostic procedure chart.
Some specific checks are grouped under the “tests” heading and are used as required in different diagnostic
charts.
Basic test

Trouble diagnosis

Reference page

Low pressure circuit check

TEST 1

EC-1660

Electrical circuit check

TEST 2

EC-1661

Fuel injector check

TEST 3

EC-1662

Parameter check

TEST 4

EC-1663

Air inlet circuit check

TEST 5

EC-1663

ECM check

TEST 6

EC-1664

High pressure pump check

TEST 7

EC-1664

High pressure circuit leak check

TEST 8

EC-1665

Fuel injector leak check

TEST 9

EC-1665

Fuel injector return flow in starting phase

TEST 10

EC-1666

Fuel filter check

TEST 11

EC-1666

TEST 1: LOW PRESSURE CIRCUIT CHECK

1. CHECK CONFORMITY
Check the conformity of the low pressure connections.
Is the low pressure circuit connection correct?
Yes or No
Yes
>> GO TO 2.
No
>> Carry out the required repairs.

2. CHECK FOR LEAK
Look for leaks on the unions.
Are there leaks in the hoses and unions?
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 3.

EC-1660

TROUBLE DIAGNOSIS
[K9K]

3. CHECK FUEL FILTER

A

Check the correctness of the fuel filter.
Is the fuel filter correct?
Yes or No
Yes
>> GO TO 4.
No
>> Replace the fuel filter with an original part.

EC

C

4. CHECK FOR WATER
Check for water in the fuel filter.
Is there water in the fuel filter?
Yes or No
Yes
>> Drain the fuel filter.
No
>> GO TO 5.

D

E

5. CHECK FOR AIR BUBBLES
Check for air bubbles in the fuel filter.
Are there any air bubbles in the low pressure circuit?
Yes or No
Yes
>> GO TO 6.
No
>> GO TO 7.

6. BLEED AIR

F

G

H

Bleed the low pressure circuit.
Place a container under the fuel filter:
●
Disconnect the return hose at the fuel filter and block the fuel filter.
●
Pump using the vacuum pump until there is no air left.
●
Reconnect the return hose immediately.

I

J

>> INSPECTION END
K

7. INSPECTION END
Low pressure circuit OK.

L

>> INSPECTION END
M

TEST 2: ELECTRICAL CIRCUIT CHECK

1. CHECK BATTERY AND ALTERNATOR
Check the battery charge and ensure that the alternator is working properly.
Is the charge circuit correct?
Yes or No
Yes
>> GO TO 2.
No
>> Carry out the required repairs.

2. CHECK FUSE
Check the fuses.
Are the fuses correct?
Yes or No
Yes
>> GO TO 3.
No
>> Carry out the required repairs.

EC-1661

TROUBLE DIAGNOSIS
[K9K]

3. CHECK ECM RELAY
Check that the ECM relay is in working order.
Is the ECM relay working properly?
Yes or No
Yes
>> GO TO 4.
No
>> Replace the relay.

4. CHECK ENGINE GROUND
Test the engine ground.
Is the engine ground correct?
Yes or No
Yes
>> GO TO 5.
No
>> Carry out the required repairs.

5. INSPECTION END
The electrical circuit is OK.
>> INSPECTION END

TEST 3: FUEL INJECTOR CHECK

1. VISUALLY CHECK
Visually inspect the fuel injector wells.
Is there fuel in the fuel injector wells?
Yes or No
Yes
>> Fuel injector ice leak, replace the fuel injector.
No
>> GO TO 2.

2. PERFORM ACTIVE TEST
Perform “ACTIVE TEST”.
Can you hear the fuel injector valve moving?
Yes or No
Yes
>> GO TO 3.
No
>> Carry out test 11. If test 11 is OK, replace the fuel injector.

3. CHECK RETURN FLOW
Compare the return flow of the four fuel injectors when hot using a measuring cylinder. See TEST 9.
Does one of the four fuel injectors have a greater return flow than the others?
Yes or No
Yes
>> Replace the fuel injector with an unusually high return flow (leak at the valve).
No
>> GO TO 4.

4. CHECK NO.1 CYLINDER
Disconnect cylinder No. 1 fuel injector.
Is there a noticeable change in engine noise?
Yes or No
Yes
>> GO TO 5.
No
>> Replace fuel injector No.1 with a new part.

EC-1662

TROUBLE DIAGNOSIS
[K9K]

5. CHECK ANOTHER CYLINDER

A

Reconnect cylinder No. 1 fuel injector.
Carry out the same test on the other cylinders to identify a possible suspected fuel injector.
The injector is sound.

EC

>> INSPECTION END
C

TEST 4: PARAMETER CHECK

1. CHECK INJECTOR ADJUSTMENT VALUE
Use the CONSULT-II to check that injector adjustment value corresponds to the fuel injectors.
Is injector adjustment value correctly filled in?
Yes or No
Yes
>> GO TO 3.
No
>> GO TO 2.

2. ENTER INJECTOR ADJUSTMENT VALUE

D

E

F

Use the CONSULT-II to program injector adjustment value into the memory, paying attention to the cylinder
numbers.

G

>> INSPECTION END
H

3. INSPECTION END
Check that the “DATA MONITOR” value (parameter) are consistent.

I

>> INSPECTION END
J

TEST 5: AIR INLET CIRCUIT CHECK

1. CHECK AIR LEAK
K

Check for the presence of a leak/intake of air.
Presence of a leak/intake of air.
Yes or No
Yes
>> Carry out the required repairs.
No
>> GO TO 2.

L

2. CHECK AIR FILTER

M

Check the condition of the air filter.
Air filter OK.
Yes or No
Yes
>> GO TO 3.
No
>> Replace the air filter with a new part.

3. CHECK INTAKE MANIFOLD
Check that the intake manifold is not obstructed (dirty).
Is the intake manifold blocked?
Yes or No
Yes
>> Clean the intake manifold.
No
>> Air circuit OK.

EC-1663

TROUBLE DIAGNOSIS
[K9K]
TEST 6: ECM CHECK

1. CHECK ECM CONNECTOR
Check that the ECM connectors are locked correctly.
Are the connectors poorly locked?
Yes or No
Yes
>> Lock the connectors correctly.
No
>> Replace the ECM.

TEST 7: HIGH PRESSURE SYSTEM CHECK
NOTE:
Certain malfunctions make it impossible to carry out this test, deal with them first.
It is useless and dangerous to engage the starter motor for more than 5 seconds.

1. CHECK FUEL PUMP
It is possible to check the high pressure supply pump capacity by carrying out the following procedure:
Turn the ignition switch OFF, disconnect the low pressure actuator from the fuel pump (IMV brown connector) and connect a test adaptor (test IMV).
●
Disconnect the 4 fuel injectors.
●
Turn the ignition switch ON, connect CONSULT-II and select “RAIL PRESSURE” in DATA MONITOR
mode.
●
Apply brake and start engine. The starter will cut out automatically after 5 seconds.
●
Read “RAIL PRESSURE” indication and confirm that maximum value during the test.
Is the rail pressure greater than 1050 bar?
Yes or No
Yes
>> GO TO 4.
No
>> GO TO 2.
●

2. CHECK FUEL RAIL PRESSURE
Is the rail pressure greater than 900 bar?
Yes or No
Yes
>> GO TO 3.
No
>> GO TO 5.

3. CHECK FUEL RAIL PRESSURE
Repeat the test when cold. Engine coolant temperature = Intake air temperature.
Is the rail pressure greater than 1050 bar?
Yes or No
Yes
>> GO TO 4.
No
>> GO TO 5.

4. CHECK FUEL INJECTOR SEALING
The pump can supply the operating pressure.
Turn the ignition switch OFF and reconnect the 4 fuel injectors and low pressure actuator electrically.
Turn the ignition switch ON, and erase DTCs using the CONSULT-II.
Carry out the trouble diagnosis on the fuel injectors by checking the return volume of the 4 fuel injectors (See
TEST 9 fuel injector sealing check).
>> Repair or replace.

EC-1664

TROUBLE DIAGNOSIS
[K9K]

5. CHECK STARTING CIRCUIT

A

Make sure that the starting circuit is working correctly (minimum engine speed 200 rpm).
Turn the ignition switch OFF and reconnect the 4 fuel injectors and low pressure actuator electrically.
Turn the ignition switch ON, and erase the DTCs using CONSULT-II.

EC

>> GO TO 6.
C

6. CHECK FUEL FILTER
Carry out TEST 11.

D

>> GO TO 7.

7. CHECK FUEL INJECTOR RETURN VOLUME
Carry out the trouble diagnosis on the fuel injectors by checking the return volume of the 4 fuel injectors.
See TEST 9 or TEST 10 if the engine does not start.
Is TEST 9 or TEST 10 correct?
Yes or No
Yes
>> Replace the high pressure pump.
No
>> Replace the suspected fuel injector(s).

E

F

G

TEST 8: HIGH-PRESSURE CIRCUIT LEAK CHECK
NOTE:
Certain malfunctions make it impossible to carry out this test, deal with them first.
There is a command that performs a leak test on the high-pressure circuit when the engine is running.
This command can detect a leak on the high-pressure circuit if a union is improperly fitted or bolted, but cannot
detect a small leak if a union is not torque tightened.
This command can only be used if the engine temperature is above 60°C.
Perform “HIGH PRESS CIRC LEAK T” in ACTIVE TEST mode, the engine will automatically carry out one
cycle of 4 accelerations to raise the pressure in the fuel rail and check whether there are leaks in the high
pressure circuit.
Watch out for any objects (tools, etc.) on the sides of the engine housing during the four accelerations (vibrations possible).

H

I

J

K

TEST 9: FUEL INJECTOR LEAK CHECK
NOTE:
Certain malfunctions make it impossible to carry out this test, deal with them first.
“HIGH PRESS CIRC LEAK T” in ACTIVE TEST mode also allows you to check the return volume of each fuel
injector to detect a leak inside the fuel injectors.
Tooling required:
●
It is essential to use 4 transparent pipes with an internal diameter of 4 mm and a length of approximately
50 cm.
●
4 graduated measuring cylinders.
PROCEDURE
●
Check that the engine coolant temperature is above 60°C.
●
Turn ignition switch OFF.
●
Disconnect the return pipes from the 4 fuel injectors.
●
Fit a plug in the pump venturi tube to prevent the low-pressure circuit from depriming.
●
Connect the 4 transparent pipes with an internal diameter of 4 mm and a length of 50 cm in place of the
return pipes.
●
Immerse these 4 pipes into 4 graduated measuring cylinders.
Having carried out these preparations, start the engine, then let it run for 2 minutes at idle speed.
●
Perform “HIGH PRESS CIRC LEAK T” in ACTIVE TEST mode: the engine will automatically perform one
cycle of 4 accelerations to raise the pressure in the fuel rail and measure the leaks inside the fuel injectors
in these conditions.

EC-1665

L

M

TROUBLE DIAGNOSIS
[K9K]
Once the cycle is complete, perform “HIGH PRESS CIRC LEAK T” in ACTIVE TEST mode again for the
correct reading of the return volume of each fuel injector.
At the end of both cycles, the return volume of each fuel injector should be 35 ml at maximum. If the return
volume of one of the fuel injectors is above 35 ml, replace the suspected fuel injector.
●
Disconnect the 4 transparent pipes and reconnect the fuel injector return circuit.
Watch out for any objects (tools, etc.) at the sides of the engine housing during the four cycles (vibrations possible).
●

TEST 10: FUEL INJECTOR RETURN FLOW IN STARTING PHASE
NOTE:
Certain malfunctions make it impossible to carry out this test, deal with them first.
It is useless and dangerous to engage the starter motor for more that 5 seconds.
In the event the engine does not start, only the static leak can be measured, that is the leak with the fuel injector closed, inactive and not subject to any high pressure.
Make sure that the starting circuit is working correctly (minimum speed 200 rpm).
Tooling required:
●
It is essential to use four transparent pipes with an internal diameter of 4 mm and approximately 50 cm
long.
●
A test adapter (TEST IMV)
PROCEDURE:
1. Turn ignition switch OFF.
2. Disconnect the four fuel injector return pipes.
3. Fit a plug in the pump venturi tube to prevent the low-pressure circuit from depriming.
4. Connect the four transparent pipes with an internal diameter of 4 mm and a length of approximately 50
cm.
5. Disconnect the low pressure actuator from the pressure (brown IMV connector) and connect the test
adapter (test IMV).
6. Electrically disconnect the 4 fuel injectors.
7. Turn ignition switch ON, apply brake and start engine. The starter cuts in automatically after 5 seconds.
8. Measure the amount of fuel in each pipe.
Replace the fuel injector(s) whose leak return is greater than 10 cm.
Disconnect the four transparent fuel pipes and reconnect the fuel injector return circuit.
Disconnect the test IMV and reconnect the low pressure actuator to the pump.

TEST 11: FUEL FILTER CHECK

1. CEHCK FUEL FILTER
Check the conformity of the fuel filter.
Is the fuel filter correct?
Yes or No
Yes
>> GO TO 2.
No
>> Replace the fuel filter with an original part.

2. CHECK FUEL FILTER
Turn ignition switch OFF, analyses the fuel in the fuel filter.
●
Disconnect the fuel supply and return hoses from the fuel filter.
●
Block the fuel filter inlets and outlets straight away with appropriate plugs.
●
Remove the fuel filter from its holder and shake it well, keeping the caps in place and empty the contents
of the fuel filter into a glass container by lifting up a protective cap and undoing the bleed screw.
Can you see at the bottom of the container a deposit of black particles?
Yes or No
Yes
>> GO TO 3.
No
>> Fuel filter correct.

EC-1666

TROUBLE DIAGNOSIS
[K9K]

3. CHECK METAL PARTICLES

A
Pass a magnet beneath the container to collect only all the metal particles. Take the magnet away from the
container.
EC
Do the particles collected using the magnet cover a surface area greater than 1 cm2 ?
Yes or No
Yes
>> Replace the entire injection system.
C
No
>> Fuel filter correct.

D

E

F

G

H

I

J

K

L

M

EC-1667

TROUBLE DIAGNOSIS
[K9K]

Engine Control Component Parts Location

BBS0040T

MBIB1516E

1. Fuel filter (LHD models)

2. Camshaft position sensor

3. Fuel pump

4. Knock sensor (Accelerometer)

5. Turbocharger boost control solenoid
valve

6. Turbocharger boost sensor
(63kw engine models only)

7. Crankshaft position sensor

8. Engine coolant temperature sensor

9. Glow control unit

10. ECM

11. Mass air flow sensor

12. EGR volume control valve

13. Fuel injector

14. Fuel rail

15. Primimg pump

EC-1668

TROUBLE DIAGNOSIS
[K9K]
A

EC

C

D

E

F

G

H

I

J

K

L

M
MBIB1537E

: Vehicle front
1. Turbocharger boost sensor
(63kw engine models only)

2. Mass air flow sensor

3. EGR volume control valve

4. Engine coolant temperature sensor

5. Fuel injector

6. Crankshaft position sensor

7. Camshaft position sensor

8. Battery

9. ECM

EC-1669

TROUBLE DIAGNOSIS
[K9K]

MBIB1538E

: Vehicle front
1. Turbocharger boost control solenoid
valve
(63kw engine models only)

2. Turbocharger boost sensor
(63kw engine models only)

3. EGR volume control valve

4. Engine oil filler cap

5. Accelerator pedal

6. Accelerator pedal position sensor

7. Refrigerant pressure sensor

8. Knock sensor (Accelerometer)

9. Fuel rail

EC-1670

TROUBLE DIAGNOSIS
[K9K]

Wiring Diagram — ECM —

BBS0040U

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1546E

EC-1671

TROUBLE DIAGNOSIS
[K9K]

MBWA1570E

Refer to EC-21, «How to Check Vehicle Type» to confirm the engine type.

EC-1672

TROUBLE DIAGNOSIS
[K9K]

ECM Harness Connector Terminal Layout

BBS0040V

A

EC

C

MBIB1485E

ECM Terminals And Reference Value

BBS0040W

PREPARATION
1.

D

E

ECM (1) is located in the engine room left side near battery (2).

F

G

H
MBIB1519E

2.

3.

Disconnect ECM harness connectors.
● When disconnecting ECM harness connectors, loosen (B) it
with levers (1) as far as they will go as shown in the figure.
– ECM (2)
– Fasten (A)
Connect a break-out box (SST) and Y-cable adapter (SST)
between the ECM and ECM harness connector.
● Use extreme care not to touch 2 pins at one time.
● Data is for comparison and may not be exact.

I

J

K

MBIB1518E

L

M

EC-1673

TROUBLE DIAGNOSIS
[K9K]
ECM INSPECTION TABLE
Remarks: Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

1

L

CAN communication line

2

LG

Data link connector

CONDITION

[Ignition switch ON]
[Ignition switch ON]
●

CONSULT-II is disconnected.

[Ignition switch OFF]
●

5

R

Stop lamp switch

Brake pedal: Fully released

[Ignition switch OFF]
●

6

7

L/R

Y

Brake pedal: Slightly depressed

Sensor ground
(Accelerator pedal position
sensor 2)

[Engine is running]

CAN communication line

[Ignition switch ON]

●

Warm-up condition

●

Idle speed

DATA
(DC Voltage and Pulse Signal)
Approximately 2.6V
Output voltage varies with the
communication status.
Approximately 2.6V

Approximately 0V
BATTERY VOLTAGE
(11 — 14V)

Approximately 0.3V

Approximately 2.4V
Output voltage varies with the
communication status.

[Ignition switch ON]

12

L/W

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

Approximately 0.4V

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

Approximately 2.0V

18

L

Sensor power supply
(Accelerator pedal position
sensor 2)

[Ignition switch ON]

Approximately 4.6V

22

O

Ignition switch

[Ignition switch ON]

BATTERY VOLTAGE
(11 — 14V)

25
26
27

B
B
B

ECM ground

28

29

B

R

[Engine is running]

Sensor ground
(Accelerator pedal position
sensor 1)
Sensor power supply
(Accelerator pedal position
sensor 1)

●

Warm-up condition

●

Idle speed

Approximately 0V

[Engine is running]
●

Warm-up condition

●

Idle speed

[Ignition switch ON]

Approximately 0.24V

Approximately 5.0V

[Ignition switch ON]

30

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

Approximately 0.76V

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

EC-1674

Approximately 4.2V

TROUBLE DIAGNOSIS
[K9K]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse Signal)

A

[Engine is running]
32

B

ECM ground

●

Warm-up condition

●

Idle speed

EC

Approximately 0V

0 — 12.5V

C

[Ignition switch ON]

35

R

●

Warm-up condition

●

Idle speed

D

MBIB1504E

Turbocharger boost control
solenoid valve

E

0 — 12.5V
[Ignition switch ON]
●

Warm-up condition

●

Engine speed: 2,000 rpm

F

G
MBIB1505E

[Engine is running]

37

B

●

Warm-up condition

●

Idle speed

EGR volume control valve

Approximately 1.1V

H

Approximately 0.78V

I

0 — 12.5V

J

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

[Engine is running]
●

Warm-up condition

●

Idle speed

K

MBIB1506E

39

P

Fuel pump

L

0 — 12.5V

M

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

MBIB1507E

[Engine is running]

40

W

●

Warm-up condition

●

Idle speed

EGR volume control valve

Approximately 0.7 — 1.9

[Engine is running]

41

44

—

W

Sensor ground
(Knock sensor shield circuit)
Knock sensor

●

Warm-up condition

●

Engine speed: 2,000 rpm

[Engine is running]
●

Idle speed

[Engine is running]
●

Idle speed

EC-1675

Approximately 1.5 — 1.9V

Approximately 0.2V

Approximately 0.3V

TROUBLE DIAGNOSIS
[K9K]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse Signal)

45

O

Sensor ground
(Knock sensor)

[Engine is running]

Approximately 0.3V

47

L

Sensor power supply
(Fuel rail pressure sensor)

[Ignition switch ON]

Approximately 5.0V

48

V

Sensor power supply
(Turbocharger boost sensor)

[Ignition switch ON]

Approximately 5.0V

49

SB

Sensor power supply
(EGR volume control valve
control position sensor)

[Ignition switch ON]

Approximately 5.0V

50

L

Sensor power supply
(Mass air flow sensor)

[Ignition switch ON]

Approximately 5.0V

51

R

Intake air temperature sensor

[Engine is running]

Approximately 0.3 — 5.0V
Output voltage varies with intake
air temperature

●

53

54

P

P

Warm-up condition

Engine coolant temperature
sensor

[Engine is running]

Fuel pump temperature sensor

[Engine is running]

●

●

Warm-up condition

Warm-up condition

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0.3 — 5.0V
Output voltage varies with engine
coolant temperature
Approximately 0.3 — 5.0V
Output voltage varies with fuel
pump temperature
0 — 12.5V

NOTE:
The pulse cycle changes depending on
rpm at idle.
MBIB1508E

55

R

Crankshaft position sensor
0 — 12.5V
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

MBIB1509E

[Engine is running]
●

Warm-up condition

●

Idle speed

0 — 1V

NOTE:
The pulse cycle changes depending on
rpm at idle.
MBIB1510E

56

Y

Camshaft position sensor
0 — 1V
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

MBIB1511E

EC-1676

TROUBLE DIAGNOSIS
[K9K]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse Signal)

A

[Engine is running]

57

R

●

Warm-up condition

●

Idle speed

Fuel rail pressure sensor

Approximately 1.0V

EC

Approximately 1.5V

C

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

[Engine is running]

58

O

●

Warm-up condition

●

Idle speed

Turbocharger boost sensor

Approximately 1.6V

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

E
Approximately 2.0V

F

[Engine is running]

59

L

EGR volume control valve
control position sensor

●

Warm-up condition

●

Idle speed

Approximately 4.1V

G

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

[Ignition switch: ON]

D

Approximately 3.3V

Approximately 0.36V

H

[Engine is running]
60

Y

Mass air flow sensor

●

Warm-up condition

●

Idle speed

Approximately 1.7V

I

Approximately 2.2V

J

Approximately 0.25V

K

[Engine is running]

63

64

B

G

●

Warm-up condition

●

Engine speed: 2,500 rpm

Sensor ground
(Engine coolant temperature
sensor)

[Engine is running]

Sensor ground
(Fuel pump temperature sensor)

[Engine is running]

●

Warm-up condition

●

Idle speed

●

Warm-up condition

●

Idle speed

Approximately 0.3V

[Engine is running]
65

B

Sensor ground
(Crankshaft position sensor)

●

Warm-up condition

●

Idle speed

M
Approximately 0.3V

[Engine is running]
66

L

Sensor ground
(Camshaft position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0.3V

[Engine is running]
67

B

Sensor ground
(Fuel rail pressure sensor)

●

Warm-up condition

●

Idle speed

Approximately 0.45V

[Engine is running]
68

69

G

P

Sensor ground
(Turbocharger boost sensor)
Sensor ground
(EGR volume control valve
control position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0.3V

[Engine is running]
●

Warm-up condition

●

Idle speed

EC-1677

L

Approximately 0.5V

TROUBLE DIAGNOSIS
[K9K]
TERMINAL
NO.

70

WIRE
COLOR

G

ITEM

Sensor ground
(Mass air flow sensor/ Intake
air temperature sensor)

CONDITION
[Engine is running]
●

Warm-up condition

●

Idle speed

[Engine is running]

73
75
77
79

B/P
P/L
G
L

Fuel injector No. 2
Fuel injector No. 4
Fuel injector No. 3
Fuel injector No. 1

DATA
(DC Voltage and Pulse Signal)

●

Warm-up condition

●

Idle speed

Approximately 0.5V

0 — 9V

NOTE:
The pulse cycle changes depending on
rpm at idle.
MBIB1512E

0 — 9V
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

MBIB1513E

[Engine is running]

74

O

76

V

78

R

80

P

Fuel injector power supply
No. 2
Fuel injector power supply
No. 4
Fuel injector power supply
No. 3
Fuel injector power supply
No. 1

●

Warm-up condition

●

Idle speed

5 — 10V

NOTE:
The pulse cycle changes depending on
rpm at idle.
MBIB1514E

5 — 10V
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

MBIB1515E

83

W

Sensor power supply
(Refrigerant pressure sensor)

[Ignition switch ON]

Approximately 5.0V

[Engine is running]
89

BR

Refrigerant pressure sensor

●

Warm-up condition

●

Both A/C switch and blower fan switch:
ON (Compressor operates)

[Ignition switch ON]
[Ignition switch OFF]
●

104

P

ECM relay (self-shutoff)

For a few seconds after turning ignition
switch OFF

[Ignition switch OFF]
●

More than a few seconds after turning
ignition switch OFF

EC-1678

Approximately 2.3V

Approximately 1.4V

BATTERY VOLTAGE
(11 — 14V)

TROUBLE DIAGNOSIS
[K9K]
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse Signal)

A

[Engine is running]
107

109
110

Y

G
G

Sensor ground
(Refrigerant pressure sensor)

Power supply for ECM

●

Warm-up condition

●

Idle speed

[Ignition switch ON]

Approximately 0.3V

BATTERY VOLTAGE
(11 — 14V)

EC

C

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

D

E

F

G

H

I

J

K

L

M

EC-1679

TROUBLE DIAGNOSIS
[K9K]

Conformity Check

BBS004TH

ECM STATUS AND PARAMETERS
Test Condition: Engine Stopped and Ignition Switch ON
Order

Function

Parameter or status
check or action

Display and notes

Trouble diagnosis

1

Battery voltage

PR074:

BATTERY VOL

12 V < BATTERY VOL < 14.4 V

In the event of a malfunction,
perform the trouble diagnosis for
CHARGING SYSTEM.

2

Engine speed

PR055:

ENGINE SPEED

Indicates the engine’s rotational
speed in rpm.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0335 CKP SENSOR.

3

Accelerator pedal
position

PR030:

ACCEL/PDL POS
0%

Indicates the position of the
accelerator pedal as a%.
ACCEL/PDL POS = 0%

In the event of a malfunction,
perform the trouble diagnosis for
APP SENSOR (DTC P0225,
P0651 and P2120) and DTC
P0641 SENSOR POWER SUPPLY.

4

Enginr coolant temperature

PR064:

WATER TEMP
Warm: 90°C

Indicates the engine coolant
temperature in °C.
Default value: 80°C

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0115 ETC SENSOR.

5

Fuel tank temperature

PR063:

FUEL TEMP
Cold = WATER
TEMP
Warm: 50C

Indicates the fuel tank temperature in °C. This value is given by
the fuel tank temperature sensor.
Default value: 30°C.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0180 FTT SENSOR.

PR035:

ATOMOS PRESS

Indicates the ambient barometric pressure in mbar. The sensor
is incorporated in the ECM.

PR032:

INLET PRESS

Indicates the pressure in the turbocharger in mbar.

PR038:

RAIL PRESSURE
Warm or cold
— 90 bar < RAIL
PRESSURE > 90
bar

Indicates the fuel rail pressure in
Bar.
This pressure is supplied by the
fuel rail pressure sensor.
Default value: 2000 Bar.

6

7

Intake air pressure

Fuel rail pressure

If not consistent, check ATOMOS PRESS, INLET PRESS (in
DATA MONITOR mode) and
local ambient barometric pressure, with the engine stopped
and ignition switch ON.
In the event of a malfunction,
perform the trouble diagnosis for
DTC P0190 FRP SENSOR.

Indicates the current status of
the engine.

8

Engine

ET038:

MOTOR
Engine
+ after ignition feed

●

+ after ignition feed

●

CRANKING

●

RUNNING

●

MAINTAINED SUPPLY: Supply maintained during the
power latch phase.

●

Stalled: When the engine has
stalled.

●

PROTECTED: When a level 2
malfunction appears or when
the engine speed is limited to
a certain engine speed.

EC-1680

NONE.

TROUBLE DIAGNOSIS
[K9K]
Order

Function

Parameter or status
check or action

Display and notes

Trouble diagnosis

A

Indicates the status of the immobilizer system.
●

9

Immobilizer

ET003:

ENG IMMOBILIZ
INACTIVE
●

10

11

Code programmed

Vehicle speed

ET006:

PR089:

CODE PROGRAM
YES

VEHICLE SPEED

INACTIVE: The ECM has recognized the immobilizer code
transmitted by the Intelligent
Key unit or BCM.

EC
If ACTIVE, perform the trouble
diagnosis for NATS.

ACTIVE: The ECM does not
recognize the immobilizer
code transmitted by the Intelligent Key unit or BCM.

D

States whether the immobilizer
code has been programmed by
the ECM or not.
●

YES: Code programmed

●

NO: Code not programmed by
the ECM.

Indicates the vehicle speed in
kph. This parameter is transmitted by the “ABS actuator and
electric unit (control unit)” or
combination meter via CAN communication line.

If NO, replace ECM.

1

2

Function

Battery voltage

Engine speed

BATTERY VOL

12V < BATTERY VOL < 14.4V

PR055:

ENGINE SPEED
Cold: 900 rpm
Warm: 805 rpm

Indicates the engine’s rotational speed in rpm.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0335 CKP SENSOR.

ACCEL/PDL POS
0%

Indicates the position of the
accelerator pedal as a%.
ACCEL/PDL POS = 0%

In the event of a malfunction,
perform the trouble diagnosis for
APP SENSOR (DTC P0225,
P0651 and P2120) and DTC
P0641 SENSOR POWER SUPPLY.

WATER TEMP
Warm: 90°C

Indicates the engine coolant
temperature in °C.
Default value: 80°C.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0115 ETC SENSOR.

PR061:

EXT AIR TEMP

Indicates the ambient air temperature in °C. This information is provided by BCM via
CAN communication line.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0100 MAF SENSOR.

PR059:

INLET AIR TEMP
Cold = EXT AIR
TEMP
Warm: 30°C

Indicates the intake air temperature in °C. This information is provided by the IAT
sensor.
Default value: 20°C.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0070 IAT SENSOR.

PR063:

FUEL TEMP
Cold = WATER
TEMP
Warm: 50°C

Indicates the fuel tank temperature in °C. This value is given
by the fuel tank temperature
sensor.
Default value: 30°C.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0180 FTT SENSOR.

Engine coolant temperature

PR064:

5

External air
temperature

7

Inlet air temperature

Fuel tank temperature

Trouble diagnosis

PR074:

4

6

Display and notes

In the event of a malfunction,
perform the trouble diagnosis for
CHARGING SYSTEM.

PR030:

G

H

Parameter or status
check or action

Accelerator pedal
position

3

E

F
Perform the trouble diagnosis for
CAN communication line. Perform the trouble diagnosis for
“ABS actuator and electric unit
(control unit)” or combination
meter.

Test Condition: Engine at Idle
Order

C

EC-1681

I

J

K

L

M

TROUBLE DIAGNOSIS
[K9K]
Order

Parameter or status
check or action

Function

ATOMOS PRESS

Indicates the ambient barometric pressure in mbar. The
sensor is incorporated in the
ECM.
600 mbar < Cold < 1050 mbar
600 mbar < Warm < 1050
mbar

PR032:

INLET PRESS

Indicates the pressure in the
turbocharger in mbar.
INLET PRESS = local ambient
barometric pressure

PR038:

RAIL PRESSURE
Cold: 260 Bar
Warm: 230 Bar

Indicates the fuel rail pressure
in Bar.
This pressure is supplied by
the fuel rail pressure sensor.
Default value: 2000 Bar.

PR035:
8

9

Display and notes

Intake air pressure

Fuel rail pressure

Trouble diagnosis

If not consistent, check ATOMOS
PRESS, INLET PRESS (in DATA
MONITOR mode) and local
ambient barometric pressure,
with the engine stopped and ignition switch ON.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0190 FRP SENSOR.

START SUBFUNCTION
Test Condition: Engine Stopped and Ignition Switch ON
Order

1

2

Function

ECM + after ignition feed

Starting

Parameter or status
check or action

ET001:

ET076:

C/U+AFTR IGN
PRESENT

STARTING
AUTHORISED

Display and notes

Trouble diagnosis

Indicates that the ECM is supplied with a + after ignition feed.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0560 BATTERY VOLTAGE or P0685 ECM RELAY.

●

Present

●

Absent

Indicates whether or not starting
has been authorized by the
ECM.
AUTHORISED: The ECM has
given starting authorisation.
PROHIBITED: The ECM has not
given starting authorisation.

If PROHIBITED perform the trouble diagnosis for preheating system.

Indicates the current status of
the engine.

3

4

Engine

Battery voltage

ET038:

PR074:

MOTOR
Engine
+ after ignition
feed

BATTERY VOL

●

+ after ignition feed

●

CRANKING

●

RUNNING

●

MAINTAINEDSUPPLY: Supply maintained during the
power latch phase.

●

Stalled: When the engine has
stalled.

●

Protected: When a malfunction
appears or when the engine
speed is limited to a certain
engine speed.

12V < BATTERY VOL < 13.5V

EC-1682

NONE.

In the event of a malfunction,
perform the trouble diagnosis for
CHARGING SYSTEM.

TROUBLE DIAGNOSIS
[K9K]
Test Condition: Engine at Idle
Order

1

2

Computer + after
ignition feed

Starting

A

Parameter or status
check or action

Function

ET001:

ET076:

Display and notes
Indicates that the ECM is supplied with a + after ignition
feed.

C/U+ AFTR IGN
PRESENT

●

Present

●

Absent

Indicates whether or not starting has been authorized by
the ECM.
AUTHORISED: The ECM has
given starting authorisation.
PROHIBITED: The ECM has
not given starting authorisation.

STARTING
AUTHORISED

Trouble diagnosis

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0560 BATTERY VOLTAGE or P0685 ECM RELAY.

C

If PROHIBITED perform the
trouble diagnosis for preheating
system.

3

4

Engine

Battery voltage

ET038:

PR074:

+ after ignition feed

●

CRANKING

●

RUNNING

●

MAINTAINED
SUPPLY: Supply maintained during the power
latch phase.

MOTOR
Engine
+ after ignition feed

BATTERY VOL

●

Stalled: When the engine
has stalled.

●

Protected: When a malfunction appears or when the
engine speed is limited to a
certain engine speed.

13V < BATTERY VOL < 14V

D

E

Indicates the current status of
the engine.
●

EC

F

G
NONE.

H

I

J
In the event of a malfunction,
perform the trouble diagnosis for
CHARGING SYSTEM.

K

PROTECTION SUBFUNCTION
Test Condition: Engine Stopped and Ignition Switch ON
Order

Function

L

Parameter or status
check or action

Display and notes

Trouble diagnosis

Indicates the status of the immobilizer system.
●

1

Immobilizer

ET003:

ENG IMMOBILIZ
INACTIVE
●

2

3

Code programmed

Battery voltage

ET006:

PR074:

CODE PROGRAM
YES

BATTERY VOL

INACTIVE: The ECM has recognized the immobilizer code
transmitted by the Intelligent
Key unit or BCM.

M

If ACTIVE, perform the trouble
diagnosis for NATS.

ACTIVE: The ECM does not
recognize the immobilizer
code transmitted by the Intelligent Key unit or BCM.

States whether the immobilizer
code has been programmed by
the ECM or not.
●

YES: Code programmed

●

NO: Code not programmed by
the ECM.

12V < BATTERY VOL < 13.5V

EC-1683

If NO, replace ECM.

In the event of a malfunction,
perform the trouble diagnosis for
CHARGING SYSTEM.

TROUBLE DIAGNOSIS
[K9K]
Test Condition: Engine at Idle
Order

Parameter or status
check or action

Function

Display and notes

Trouble diagnosis

Indicates the status of the
immobilizer system.
●

1

Immobilizer

ET003:

ENG IMMOBLIZ
INACTIVE
●

2

3

Code programmed

Battery voltage

ET006:

PR074:

CODE PROGRAM
YES

BATTERY VOL

INACTIVE: The ECM has
recognized the immobilizer
code transmitted by the
Intelligent Key unit or BCM.

If ACTIVE, perform the trouble
diagnosis for NATS.

ACTIVE: The ECM does
not recognize the immobilizer code transmitted by
the Intelligent Key unit or
BCM.

States whether the immobilizer code has been programmed by the computer or
not.
●

YES: Code programmed

●

NO: Code not programmed
by the ECM.

13V < BATTERY VOL < 14V

If NO, replace ECM.

In the event of a malfunction,
perform the trouble diagnosis for
CHARGING SYSTEM.

SUB SYSTEM COLD LOOP
Test Condition: Engine Stopped and Ignition Switch ON
Order

Function

Parameter or status
check or action

Display and notes
States whether the vehicle is fitted with air conditioning or not.

1

Air conditioning
present

ET079:

PRSNC CLMTSTN
YES

●

YES: Air conditioning is
detected by the ECM.

●

NO: Air conditioning is not
detected by the ECM.

Trouble diagnosis

If not consistent with the vehicle
equipment, perform the trouble
diagnosis for CAN communication line.

The ECM requests the IPDM E/
R (via CAN communication) to
start the compressor
●

2

Compressor
engagement request

ET088:

DMND LNK COMP
INACTIVE

●

ACTIVE: The CAN communication should not be suspected on the Automatic
Transmission, IPDM E/R or
Intelligent Key unit or BCM
system.
The Intelligent Key unit or
BCM should request the ECM
to be engaged.
The refrigerant pressure sensor should not be suspected.
Satisfactory engine operating
conditions (engine coolant
temperature, engine load
etc.).
INACTIVE: One of the above
conditions has not been fulfilled.

EC-1684

NONE.

TROUBLE DIAGNOSIS
[K9K]
Order

Function

Parameter or status
check or action

Display and notes

Trouble diagnosis

Non operational information,
designed solely for trouble diagnosis purposes.
●

3

Air conditioning
authorization

ET004:

A/C AUTHOR
YES

●

4

5

Refrigerant pressure

Engine speed

PR037:

PR055:

RFRGERNT PRES

ENGINE SPEED

YES: Satisfactory engine
operating conditions (engine
coolant temperature, engine
load etc.). The vehicle is not
in a specific movement phase
(hill start or stop etc.).

6

7

8

9

Fast idle speed
request

Engine coolant temperature

Vehicle speed

Power used by the
AC compressor

ET023:

PR064:

PR089:

PR125:

ACCEL IDL RQ
ABSENT

EC

NONE.

Indicates the value in Bar for
the refrigerant fluid in the system.
2 Bar < RFRGERNT PRES < 27
Bar
Default value: 0 Bar

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0530 REFRIGERANT
PRESSURE SENSOR.

Indicates the engine’s rotational speed in rpm.

In the event of a malfunction,
perform the trouble diagnosis for
dtc P0335 CKP SENSOR.

●

ABSENT: The Intelligent Key
unit or BCM did not make the
request

●

PRESENT: The Intelligent
Key unit or BCM has made a
request

C

D

NO: One of the above conditions has not been fulfilled.

The Intelligent Key unit or BCM
requests fast idle speed to the
ECM.

A

E

F

G

In the event of a malfunction,
perform the trouble diagnosis for
CAN communication line. Perform the trouble diagnosis for
the Intelligent Key unit or BCM.

H

I

WATER TEMP
Warm: 90°C

Indicates the engine coolant
temperature in °C.
Default value: 80°C.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0115 ETC SENSOR.

J

Perform the trouble diagnosis for
CAN communication line.
Perform the trouble diagnosis for
“ABS actuator and electric unit
(control unit)” or combination
meter.

K

VEHICLE SPEED

Indicates the vehicle speed in
kph. This parameter is transmitted by the “ABS actuator and
electric unit (control unit)” or
combination meter via CAN
communication line.
Indicates the power used by the
compressor

NONE.

PWR ABSOB A/C
0 WATT

EC-1685

L

M

TROUBLE DIAGNOSIS
[K9K]
Order

Function

Parameter or status
check or action

Display and notes

Trouble diagnosis

The ECM requests the IPDM E/
R to start the fan.

10

Fan speed request*

ET022:

FAN UNIT LOW
INACTIVE

●

INACTIVE: Engine speed = 0
rpm.

●

ACTIVE: Engine speed = idle
speed, correct refrigerant
pressure and vehicle speed =
0 km/h or high engine coolant
temperature.

NONE.

The ECM requests the IPDM E/
R to start the fans.

11

Fan speed request*

ET021:

FAN UNIT HIGH
INACTIVE

●

INACTIVE: Engine speed = 0
rpm.

●

ACTIVE: Engine speed = idle
speed.
Refrigerant pressure > 15
Bar, vehicle speed = 0 km/h
or high coolant temperature.

NONE.

*: When climate control is requested with the engine at idle speed and vehicle speed = 0 km/h, FAN UNIT LOW will always be “ACTIVE”
and FAN UNIT HIGH “INACTIVE” (except refrigerant pressure> 15 bar, vehicle speed = 0 km/h and high engine coolant temperature).
The fan is prevented from operating under certain engine coolant temperature conditions when driving.

Test Condition: Engine at Idle
Order

Function

Parameter or status
check or action

Display and notes
States whether the vehicle is fitted with air conditioning or not.

1

Air conditioning
present

ET079:

PRSNC CLMTSTN
YES

●

YES: Air conditioning is
detected by the ECM.

●

NO: Air conditioning is not
detected by the ECM.

Trouble diagnosis

If not consistent with the vehicle
equipment, perform the trouble
diagnosis for CAN communication line.

The ECM requests the IPDM E/
R (via CAN communication line)
to start the compressor
●

2

Compressor
engagement request

ET088:

DMND LNK COMP
INACTIVE

●

ACTIVE: The CAN communication should not be suspected on the Automatic
Transmission, IPDM E/R or
Intelligent Key unit or BCM
system.
The Intelligent Key unit or
BCM should request the ECM
to be engaged.
The refrigerant pressure sensor should not be suspected.
Satisfactory engine operating
conditions (engine coolant
temperature, engine load
etc.).
INACTIVE: One of the above
conditions has not been fulfilled or no request has been
made by the driver so A/C
AUTHOR = NO.

EC-1686

NONE.

TROUBLE DIAGNOSIS
[K9K]
Order

Function

Parameter or status
check or action

Display and notes

Trouble diagnosis

Non operational information,
designed solely for trouble diagnosis purposes.
●

3

Air conditioning authorization

ET004:

A/C AUTHOR
YES
●

YES: Satisfactory engine
operating conditions (engine
coolant temperature, engine
load etc.). The vehicle is not in
a specific movement phase
(hill start or stop etc.).

4

Refrigerant pressure

PR037:

RFRGERNT PRES

5

Engine speed

PR055:

ENGINE SPEED
Cold: 900 rpm
Warm: 805 rpm

Indicates the engine’s rotational
speed in rpm.
The Intelligent Key unit or BCM
requests fast idle speed from the
ECM.

6

Fast idle speed
request

ET023:

ACCEL IDL RQ
ABSENT

●

●

7

Engine coolant temperature

PR064:

EC

C
NONE.

D

INACTIVE: One of the above
conditions has not be fulfilled
or no request has been made
by the driver so DMND LNK
COMP = INACTIVE.

Indicates the value in Bar for the
refrigerant fluid in the system.
2 Bar < RFRGERNT PRES < 27
Bar
Default value: 0 Bar.

ABSENT: The Intelligent Key
unit or BCM did not make the
request.
PRESENT: The Intelligent Key
unit or BCM has made the
request.

E
In the event of a malfunction,
perform the trouble diagnosis for
DTC P0530 REFRUGERANT
PRESSURE SENSOR.
In the event of a malfunction,
perform the trouble diagnosis for
DTC P0335 CKP SENSOR.

In the event of a malfunction,
perform the trouble diagnosis for
CAN communication line. Perform the trouble diagnosis for the
Intelligent Key unit or BCM.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0115 ECT SENSOR.
Perform the trouble diagnosis for
CAN communication line.
Perform the trouble diagnosis for
“ABS actuator and electric unit
(control unit)” or combination
meter.
NONE.

Vehicle speed

PR089:

VEHICLE SPEED

9

Power used by the AC
compressor

PR125:

PWR ABSOB A/C
0 WATT

Indicates the power used by the
compressor

EC-1687

G

I

J

Indicates the engine coolant
temperature in °C.
Default value: 80°C.

8

F

H

WATER TEMP
Warm: 90°C

Indicates the vehicle speed in
kph. This parameter is transmitted by the “ABS actuator and
electric unit (control unit)” or
combination meter via CAN
communication line.

A

K

L

M

TROUBLE DIAGNOSIS
[K9K]
Order

Parameter or status
check or action

Function

Display and notes

Trouble diagnosis

The ECM requests the IPDM E/
R to start the fan.

FAN UNIT LOW
INACTIVE

ET022:

10

●

INACTIVE: The request is not
made by theECM because
DMND LNK COMP = INACTIVE and A/C AUTHOR = NO.

●

ACTIVE: The request is made
by the ECM.
DMND LNK COMP = ACTIVE
and A/C AUTHOR = YES.
(correct refrigerant pressure
and vehicle speed = 0 km/h or
high engine coolant temperature).

Fan speed request*

NONE.

The ECM requests the IPDM E/
R to start the fan.

FAN UNIT HIGH
INACTIVE

ET021:

●

INACTIVE: The request is not
made by the ECM because
DMND LNK COMP = INACTIVE and A/C AUTHOR = NO.

●

ACTIVE: The request is made
by the ECM.
DMND LNK COMP = ACTIVE
and A/C AUTHOR = YES.
Refrigerant pressure > 15 Bar,
vehicle speed = 0 km/h or high
engine coolant temperature.

*: When climate control is requested with the engine at idle speed and vehicle speed = 0 km/h, FAN UNIT LOW will always be “ACTIVE”
and FAN UNIT HIGH “INACTIVE” (except refrigerant pressure > 15 bar, vehicle speed = 0 km/ h and high engine coolant temperature).
The fan is prevented from operating under certain engine coolant temperature conditions when driving.

HEATING SUBFUNCTION
Test Condition: Engine Stopped and Ignition Switch ON
Order

Function

1

Engine coolant temperature

Parameter or status
check or action
PR064:

WATER TEMP
Warm: 90°C

Display and notes
Indicates the engine coolant
temperature in °C.
Default value: 80°C.

Trouble diagnosis
In the event of a malfunction,
perform the trouble diagnosis for
DTC P0115 ECT SENSOR.

Test Condition: Engine at Idle
Order

Function

1

Engine coolant temperature

Parameter or status
check or action

PR064:

WATER TEMP
Warm: 90°C

Display and notes
Indicates the engine coolant
temperature in °C.
Default value: 80°C.

EC-1688

Trouble diagnosis
In the event of a malfunction,
perform the trouble diagnosis
for DTC P0115 ECT SENSOR.

TROUBLE DIAGNOSIS
[K9K]
FUEL CIRCUIT SUB FUNCTION
Test Condition: Engine Stopped and Ignition Switch ON
Order

1

2

3

Function

Fuel tank temperature

Fuel flow

Fuel rail pressure

4

Fuel rail pressure set
point

5

Fuel rail pressure sensor voltage

6

Engine speed

Parameter or status
check or action

A

Display and notes

Trouble diagnosis

FUEL TEMP
Cold = WATER
TEMP
Warm: 50°C

Indicates the fuel tank temperature in °C.
Default value: 30°C.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0180 FTT SENSOR.

PR017:

FUEL FLOW
0.0 mg/piston
stroke

Indicates the fuel flow injected
in mg/piston stroke for each
injector.
FUEL FLOW = 0 mg/piston
stroke

NONE.

PR038:

RAIL PRESSURE
Cold and warm:
— 90 bar < RAIL
PRESSURE < 90
bar

Indicates the fuel rail pressure
in Bar.
This pressure is supplied by
the fuel rail pressure sensor.
Default value: 2000 Bar.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0190 FRP SENSOR.

PR008:

RAIL PRES SET
375 bar (Engine
starting pressure
instruction)
Cold: 500 Bar
Warm: 300 Bar

Indicates a theoretical pressure value for optimum engine
operation.
300 bar < RAIL PRES SET <
500 bar.

NONE.

PR080:

RAIL PRES S V
Cold: 0.5V
Cold: 4.5V

Indicates the voltage delivered
by the ECM on the fuel rail
pressure sensor.
0.5V < RAIL PRES S V < 4.5V
Default value: 4.5V

NONE.

Indicates the engine’s rotational speed in rpm.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0335 CKP SENSOR.

J

Display and notes

Trouble diagnosis

K

PR063:

FUEL TEMP
Cold = WATER
TEMP
Warm: 50°C

Indicates the fuel tank temperature in °C.
Default value: 30°C.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0180 FTT SENSOR.

PR017:

FUEL FLOW
10 < Cold < 2 mg/
piston stroke
4 < Warm < 6 mg/
piston stroke

Indicates the fuel flow injected
in mg/piston stroke for each
injector.

NONE.

PR038:

RAIL PRESSURE
Cold: 260 Bar
Warm: 230 Bar

Indicates the fuel rail pressure
in Bar.
This pressure is supplied by
the fuel rail pressure sensor.
Default value: 2000 Bar.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0190 FRP SENSOR.

PR008:

RAIL PRES SET
375 bar. (Engine
starting pressure
specification).
Cold: 260 Bar
Warm: 230 Bar

Indicates a theoretical pressure value for optimum engine
operation.

NONE.

RP063:

PR055:

ENGINE SPEED

EC

C

D

E

F

G

H

I

Test Condition: Engine at Idle
Order

1

2

3

4

Function

Fuel tank temperature

Fuel flow

Fuel rail pressure

Fuel rail pressure set
point

Parameter or status
check or action

EC-1689

L

M

TROUBLE DIAGNOSIS
[K9K]
Order

Function

Parameter or status
check or action

Display and notes

5

Fuel rail pressure sensor voltage

PR080:

RAIL PRES S V

Indicates the voltage delivered
by the ECM on the fuel rail
pressure sensor.
0.5 V (0 bar) < RAIL PRES S
V < 4.5 V (1600 bar)

6

Engine speed

PR055:

ENGINE SPEED
Cold: 900 rpm V
Warm: 805 rpm

Indicates the engine’s rotational speed in rpm.

Trouble diagnosis

NONE.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0115 ECT SENSOR.

PRE-HEATING/IGNITION SUBFUNCTION
Test Condition: Engine Stopped and Ignition Switch ON
Order

Function

1

Engine coolant temperature

Parameter or status
check or action

Display and notes

Trouble diagnosis

PR064:

WATER TEMP
Warm: 90°C

Indicates the engine coolant
temperature in °C.
Default value: 80°C.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0115 ETC SENSOR.

Indicates the intake air temperature in °C. This information is provided by the IAT
sensor.
Default value: 30°C.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0070 IAT SENSOR.

12V < BATTERY VOL < 14.4V

In the event of a malfunction,
perform the trouble diagnosis for
CHARGING SYSTEM.

Display and notes

Trouble diagnosis

2

Intake air temperature

PR059:

INLET AIR TEMP
Cold = EXT AIR
TEMP
Warm: 30°C

3

Battery voltage

PR074:

BATTERY VOL

Test Condition: Engine at Idle
Order

Function

1

Engine coolant temperature

2

External air
temperature

Parameter or status
check or action
WATER TEMP
Warm: 90°C

Indicates the engine coolant
temperature in °C.
Default value: 80°C.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0115 ETC SENSOR.

PR061:

EXT AIR TEMP

Indicates the ambient air temperature in °C. This information is provided by BCM via
CAN communication line.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0100 MAF SENSOR.

Indicates the intake air temperature in °C. This information is
provided by the IAT sensor.
Default value: 30°C.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0070 IAT SENSOR.

12 V < BATTERY VOL < 14.4V

In the event of a malfunction,
perform the trouble diagnosis for
CHARGING SYSTEM.

PR064:

3

Intake air temperature

PR059:

INLET AIR TEMP
Cold = EXT AIR
TEMP
Warm: 30°C

4

Battery voltage

PR074:

BATTERY VOL

AIR CIRC SUBFUNCTION (TURBOCHARGING/INLET.)
Test Condition: Engine Stopped and Ignition Switch ON
Order

1

Function

Intake air temperature

Parameter or status
check or action

PR059:

INLET AIR TEMP
Cold = EXT AIR
TEMP
Warm: 30°C

Display and notes
Indicates the intake air temperature in °C. This information is provided by the IAT
sensor.
Default value: 30°C.

EC-1690

Trouble diagnosis

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0070 IAT SENSOR.

TROUBLE DIAGNOSIS
[K9K]
Order

2

Function

Parameter or status
check or action

Display and notes

PR035:

ATOMOS PRESS

Indicates the ambient barometric pressure in mbar. The
sensor is incorporated in the
ECM.

PR032:

INLET PRESS

Indicates the pressure in the
turbocharger in mbar.

Intake air pressure

Trouble diagnosis
If not consistent, check ATOMOS PRESS, INLET PRESS (in
DATA MONITOR mode) and
local ambient barometric pressure, with the engine stopped
and ignition switch ON.

3

Air flow

PR132:

AIR FLOW

Mass air flow estimated by the
ECM.

NONE.

4

Intake air temperature
sensor voltage

PR081:

INLET TMP S V

Indicates the voltage delivered
by the ECM to supply the
intake air temperature sensor.

NONE.

5

Engine speed

PR055:

ENGINE SPEED

Indicates the engine’s rotational speed in rpm.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0335 CKP SENSOR.

1

Function

Intake air temperature

3

4

5

Intake temperature
sensor voltage

Engine speed

ATOMOS PRESS

Indicates the ambient barometric pressure in mbar. The
sensor is incorporated in the
ECM.

PR032:

INLET PRESS

Indicates the pressure in the
turbocharger in mbar.

PR132:

AIR FLOW
350 < Cold< 400
mg/piston stroke
300 < Warm < 350
mg/piston stroke

Air flow estimated by the
ECM.

PR081:

INLET TMP S V

Indicates the voltage delivered
by the computer to supply the
inlet temperature sensor

NONE.

PR055:

ENGINE SPEED
Cold: 900 rpm V
Warm: 805 rpm

Indicates the engine’s rotational speed in rpm.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0335 CKP SENSOR.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0070 IAT SENSOR.
If not consistent, check ATOMOS PRESS, INLET PRESS (in
DATA MONITOR mode) and
local ambient barometric pressure, with the engine stopped
and ignition switch ON.

Function

1

Engine coolant temperature

WATER TEMP
Warm: 90°C

Function

1

Engine coolant temperature

Display and notes
Indicates the engine coolant
temperature in °C.
Default value: 80°C

Parameter or status
check or action
PR064:

WATER TEMP
Warm: 90°C

I

NONE.

L

Trouble diagnosis
In the event of a malfunction,
perform the trouble diagnosis for
DTC P0115 ECT SENSOR.

Test Condition: Engine at Idle
Order

H

K

Parameter or status
check or action
PR064:

G

J

ENGINE COOLING SUB FUNCTION
Test Condition: Engine Stopped and Ignition Switch ON
Order

E

Trouble diagnosis

Indicates the intake air temperature in °C. This information is provided by the IAT
sensor. Default value: 30°C.

Air circuit pressure

Air flow

Display and notes

INLET AIR TEMP
Cold = EXT AIR
TEMP
Warm: 30°C

PR035:
2

C

F

Parameter or status
check or action

PR059:

EC

D

Test Condition: Engine at Idle
Order

A

Display and notes
Indicates theengine coolant
temperature in °C.
Default value: 80 °C.

EC-1691

Trouble diagnosis
In the event of a malfunction,
perform the trouble diagnosis for
DTC P0115 ECT SENSOR.

M

TROUBLE DIAGNOSIS
[K9K]
DRIVER PARAMETERS SUB FUNCTION
Test Condition: Engine Stopped and Ignition Switch ON
Order

1

2

Function

Accelerator pedal
position

Accelerator pedal
position sensor voltage

Parameter or status
check or action

PR030:

ACCEL/PDL POS
0%

PR086:

PL PTNMR T1 V
16%

PR088:

PL PTNMR T2 V
7%

Display and notes

Trouble diagnosis

Indicates the percentage of the
accelerator pedal position
between no load and full load
position.
0% < ACCEL/PDL POS < 100%

In the event of a malfunction,
perform the trouble diagnosis for
APP SENSOR (DTC P0225,
P0651 and P2120) and DTC
P0641 SENSOR POWER SUPPLY.

Indicates the voltage supply percentage for the accelerator
pedal position sensor 1 and 2.
10% < PL PTNMR T1 V < 20%
5% < PL PTNMR T2 V < 15%

In the event of a malfunction,
perform the trouble diagnosis for
APP SENSOR (DTC P0225,
P0651 and P2120) and DTC
P0641 SENSOR POWER SUPPLY.

Display and notes

Trouble diagnosis

Test Condition: Engine at Idle
Order

1

2

Function

Accelerator pedal
position

Accelerator pedal
position sensor voltage

Parameter or status
check or action

PR030:

ACCEL/PDL POS
0%

PR086:

PL PTNMR T1 V
16%

PR088:

PL PTNMR T2 V
7%

Indicates the percentage of the
accelerator pedal position
between no load and full load
position.
0% < ACCEL/PDL POS < 100%
Indicates the voltage supply
percentage for the accelerator
pedal position sensor 1 and 2.
10% < PL PTNMR T1 V < 20%
5% < PL PTNMR T2 V < 15%

In the event of a malfunction,
perform the trouble diagnosis for
APP SENSOR (DTC P0225,
P0651 and P2120) and DTC
P0641 SENSOR POWER SUPPLY.

ANTIPOLLUTION/OBD SUBFUNCTION
Test Condition: Engine Stopped and Ignition Switch ON
Order

Function

Parameter or status
check or action

Display and notes

Trouble diagnosis

Indicates the condition of the
EGR volume control.
1

EGR volume control

ET008:

EGR SOL/V CNT
INACTIVE

●

INACTIVE: The valve is not
controlled by the ECM.

●

ACTIVE: The valve is controlled by the ECM.

NONE.

2

Ambient barometric
pressure

PR035:

ATOMOS PRESS

Indicates the ambient barometric pressure in mbar. The sensor is incorporated in the ECM.

If not consistent, check ATOMOS PRESS, INLET PRESS (in
DATA MONITOR mode) and
local ambient barometric pressure, with the engine stopped
and ignition switch ON.

3

Mass air flow

PR132:

AIR FLOW

Air flow estimated by the ECM.

NONE.

4

Fuel flow

PR017:

FUEL FLOW
0.0 mg/piston
stroke

Indicates the fuel flow out of the
fuel pump in mg/piston stroke.

NONE.

EGR/V OPN REF
Warm or cold
= — 50

Indicates a theoretical EGR volume control valve opening
value for optimum engine operation.
EGR/V OPN REF = EGR PO
RECOPY

NOTE.

5

EGR volume control
valve control

PR005:

EC-1692

TROUBLE DIAGNOSIS
[K9K]
Order

6

Function

EGR volume control
valve position feedback

Parameter or status
check or action

PR051:

EGR PO RECOPY
Warm or cold
= — 50

Display and notes
Indicates the actual value of the
EGR volume control valve position.
EGR PO RECOPY = EGR/V
OPN REF

Trouble diagnosis

NOTE.

EC

Indicates the EGR volume control valve control position sensor voltage according to the
valve position.
7

8

9

EGR volume control
valve control position
sensor voltage

Accelerator pedal
position

Engine coolant temperature

PR077:

PR030:

PR064:

EGR POS SE VO
1.09 V

ACCEL/PDL POS
0%

WATER TEMP
Warm: 90°C

●

INACTIVE: The valve is not
controlled by the ECM

●

ACTIVE: The valve is controlled by the ECM.
0.5V < EGR POS SE VO <
4.8V

A

C

D

NOTE.

E

Indicates the percentage of the
accelerator pedal position
between no load and full load
position.
ACCEL/PDL POS = 0%

In the event of a malfunction,
perform the trouble diagnosis for
APP SENSOR (DTC P0225,
P0651 and P2120) and DTC
P0641 SENSOR POWER SUPPLY.

Indicates the engine coolant
temperature in °C.
Default value: 80°C.

In the event of a malfunction,
perform the trouble diagnosis for
DTC P0115 ECT SENSOR.

H

Trouble diagnosis

I

F

G

Test Condition: Engine at Idle
Parameter or status
check or action

Order

Display and notes
Indicates the condition of the
EGR volume control.

1

2

3

EGR volume control

Ambient barometric
pressure

Air flow

4

Fuel flow

5

EGR volume control
valve control

6

EGR volume control
valve position feedback

ET008:

EGR SOL/V CNT
INACTIVE

●

INACTIVE: The valve is not
controlled by the ECM.

●

ACTIVE: The valve is controlled by the ECM.

Indicates the ambient barometric pressure in mbar. The
sensor is incorporated in the
ECM.

J
NONE.

K
If not consistent, check ATOMOS PRESS, INLET PRESS (in
DATA MONITOR mode) and
local ambient barometric pressure, with the engine stopped
and ignition switch ON.

PR035:

ATOMOS PRESS

PR132:

AIR FLOW
350 < Cold < 400
mg/piston stroke
300 < Warm< 350
mg/piston stroke

Air flow estimated by the ECM.

NONE.

PR017:

FUEL FLOW
10 < Cold < 12
mg/piston stroke
4 < Warm < 6
mg/piston stroke

Indicates the fuel flow out of
the fuel pump in mg/piston
stroke.

NONE.

PR005:

EGR/V OPN REF
Warm: 20%

Indicates a theoretical EGR
volume control valve opening
value for optimum engine
operation.

NONE.

PR051:

EGR PO RECOPY
Warm: approx. 20%

Indicates the actual value of
the EGR volume control valve
position.
Default value: 30%

NONE.

EC-1693

L

M

TROUBLE DIAGNOSIS
[K9K]
Parameter or status
check or action

Order

Display and notes

Trouble diagnosis

Indicates the EGR volume
control valve control position
sensor voltage according to
the valve position.
7

EGR volume control
valve control position
sensor voltage

PR077:

EGR POS SE VO

●

INACTIVE: The valve is not
controlled by the ECM.

●

ACTIVE: The valve is controlled by the ECM.
0.5 V < EGR POS SE VO <
4.8 V

8

Accelerator pedal
position

PR030:

ACCEL/PDL POS
0%

Indicates the percentage of the
pedal position between no
load and full load position
0 < ACCEL/PDL POS < 100%

9

Engine coolant temperature

PR064:

WATER TEMP
Warm: 90°C

Indicates the engine coolant
temperature in °C.
Default value: 80°C.

NONE.

In the event of a malfunction,
perform the trouble diagnosis for
APP SENSOR (DTC P0225,
P0651 and P2120) and DTC
P0641 SENSOR POWER SUPPLY.
In the event of a malfunction,
perform the trouble diagnosis for
DTC P0115 ECT SENSOR.

CONSULT-II Reference Value in Data Monitor Mode

BBS0040Z

Remarks:
● Specification data are reference values.
● Specification data are output/input values which are detected or supplied by the ECM at the connector.
* Specification data may not be directly related to their components signals/values/operations.
MONITOR ITEM
CONDITION
SPECIFICATION
●

Run engine and compare CONSULT-II value with the tachometer
indication.

●

Engine speed: Idle

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Ignition switch: ON
(Engine stopped)

WATER TEMP

●

Engine: After warming up

More than 70°C (158°F)

FUEL TEMP

●

Engine: After warming up

More than 40°C (104°F)

BATTERY VOL

●

Ignition switch: ON (Engine stopped)

11 — 14V

ENGINE SPEED

IDLE REG REF

ACCEL/PDL POS

Almost the same speed as the
tachometer indication

Approximately 800 rpm

Accelerator pedal: Fully released

Approximately 0%

Altitude
Approx. 0m: Approx. 100.62 kPa
(1.0062 bar, 1.026 kg/cm2 , 14.59 psi)
Approx. 1,000 m: Approx. 88.95 kPa
ATMOS PRESS

●

(0.8895 bar, 0.907 kg/cm2 , 12.90 psi)
Approx. 1,500 m: Approx. 83.16 kPa

Ignition switch: ON

(0.8316 bar, 0.848 kg/cm2 , 12.06 psi)
Approx. 2,000 m: Approx. 78.36 kPa
(0.7836 bar, 0.799 kg/cm2 , 11.36 psi)
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

INLET PRESS

AIR FLOW

Idle

Approximately 980 mbar

2,000 rpm

Approximately 1,010 mbar

Idle

Approximately 200 mg/cp

2,000 rpm

Approximately 270 mg/cp

EC-1694

TROUBLE DIAGNOSIS
[K9K]
MONITOR ITEM
VEHICLE SPEED

CONDITION
●

Turn drive wheels and compare CONSULT-II value with the
speedometer indication

Almost the same speed as the speedometer indication

●

Engine: After warming up

Idle

Approximately 230 bar

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

2,000 rpm

Approximately 450 bar

●

No load

●

Engine: After warming up

Idle

Approximately 230 bar

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

2,000 rpm

Approximately 450 bar

●

No load

●

Engine: After warming up

Idle

Approximately 4.9 mg/cp

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

RAIL PRESSURE

RAIL PRES SET

FUEL FLOW

EGR PO RECOPY

EGR/V OPN REEF

REFGERNT PRSS

PL PTNMR T2 V

A

EC

C

D

E
2,000 rpm

Approximately 3.5 mg/cp

F
Idle

Approximately -50 %

G

Idle

Approximately -50 %

H

I
Idle

Approximately 5.7 bar

J

Idle

Approximately 0 W

K

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

Approximately 15 %

L

●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

Approximately 6 %

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

PWR ABSOB A/C

PL PTNMR T1 V

SPECIFICATION

EGR POS SE VO

INLET TMP S V

M
Idle

Approximately 3.56 V

Idle

Approximately 1.6 V

EC-1695

TROUBLE DIAGNOSIS
[K9K]
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

RAIL PRES S V

H R ATHD MX P

SPECIFICATION

Idle

Approximately 1 V

2,000 rpm

Approximately 1.5 V

Idle

Approximately 20 W

EC-1696

TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT
[K9K]

TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT
Description

PFP:00006

A
BBS00411

Intermittent incidents may occur. In many cases, the incident resolves itself (the part or circuit function returns
to normal without intervention). It is important to realize that the symptoms described in the customer’s com- EC
plaint often do not recur on DTC visits. Realize also that the most frequent cause of intermittent incidents
occurrences is poor electrical connections. Because of this, the conditions under which the incident occurred
may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may not indiC
cate the specific malfunctioning area.

Diagnostic Procedure

BBS00412

1. INSPECTION START

D

Erase DTCs. Refer to EC-1628, «How to Erase DTC» .
E

>> GO TO 2.

2. CHECK GROUND TERMINALS

F

Check ground terminals for corroding or loose connection.
Refer to EC-1703, «Ground Inspection» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

G

H

3. SEARCH FOR ELECTRICAL INCIDENT
Perform GI-25, «How to Perform Efficient Diagnosis for an Electrical Incident» , “INCIDENT SIMULATION
TESTS”.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace.

I

J

K

L

M

EC-1697

POWER SUPPLY AND GROUND CIRCUIT
[K9K]

POWER SUPPLY AND GROUND CIRCUIT
Wiring Diagram

PFP:24110
BBS00413

MBWA1564E

EC-1698

POWER SUPPLY AND GROUND CIRCUIT
[K9K]
Remarks: Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

22

O

Ignition switch

[Ignition switch ON]

25
26
27

B
B
B

ECM ground

●

Warm-up condition

●

Idle speed

DATA
(DC Voltage and Pulse Signal)

A

EC

BATTERY VOLTAGE
(11 — 14V)

C

Approximately 0V

D

Approximately 0V

E

[Engine is running]

[Engine is running]
32

B

ECM ground

●

Warm-up condition

●

Idle speed

[Ignition switch ON]
[Ignition switch OFF]
●

104

P

ECM relay (self-shutoff)

For a few seconds after turning ignition
switch OFF

[Ignition switch OFF]
●

109
110

G
G

Power supply for ECM

More than a few seconds after turning ignition switch OFF

[Ignition switch ON]

Diagnostic Procedure

F

Approximately 1.4V

G
BATTERY VOLTAGE
(11 — 14V)

H

BATTERY VOLTAGE
(11 — 14V)
BBS00414

1. INSPECTION START
Start engine.
Is engine running?
Yes or No
Yes
>> GO TO 7.
No
>> GO TO 2.

I

J

K

2. CHECK ECM POWER SUPPLY CIRCUIT-I
1.
2.

L

Turn ignition switch ON.
Check voltage between ECM terminal 22 and ground with CONSULT-II or tester.

M

Voltage: Battery voltage
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

MBIB1461E

EC-1699

POWER SUPPLY AND GROUND CIRCUIT
[K9K]

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M1, E101
●
Fuse block (J/B) connector M7
●
10A fuse
●
Harness for open or short between ECM and fuse
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screw on the body.
Refer to EC-1703, «Ground Inspection» .
–
Body ground (1)
–
Priming pump (2)
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace ground connections.

MBIB1520E

5. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHOR
1.
2.

Disconnect ECM harness connector.
Check harness continuity between ECM terminals 25, 26, 27, 32 and ground.
Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to power in harness or connectors.

6. CHECK ECM POWER SUPPLY CIRCUIT-II
1.
2.
3.

Reconnect ECM harness connector.
Turn ignition switch ON.
Check voltage between IPDM E/R terminal 33 and ground with
CONSULT-II or tester.
Voltage:

Battery voltage

OK or NG
OK
>> Go to EC-1759, «DTC P0231 FUEL PUMP» .
NG
>> GO TO 7.

MBIB1462E

EC-1700

POWER SUPPLY AND GROUND CIRCUIT
[K9K]

7. CHECK ECM POWER SUPPLY CIRCUIT-III
1.
2.
3.

A

Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON and then OFF.
Check voltage between ECM terminals 109, 110 and ground
with CONSULT-II or tester.
Voltage:

EC

After turning ignition switch OFF, battery
voltage will exist for a few seconds, then
drop to approximately 0V.

OK or NG
OK
>> GO TO 14.
NG (Battery voltage does not exist)>>GO TO 8.
NG (Battery voltage exists for more then a few seconds)>>GO TO
11.

C

D

MBIB1463E

8. CHECK ECM POWER SUPPLY CIRCUIT-IV
1.
2.

E

F

Turn ignition switch OFF and wait at least 10 seconds.
Check voltage between ECM terminal 104 and ground with
CONSULT-II or tester.

G

Voltage: Battery voltage
OK or NG
OK
>> GO TO 9.
NG
>> GO TO 11.

H

I
PBIB1171E

J

9. CHECK ECM POWER SUPPLY CIRCUIT-V
1.
2.
3.

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between ECM terminals 109, 110 and IPDM E/R terminal 32.
Refer to Wiring Diagram.

K

L

Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 16.
NG
>> GO TO 10.

10. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors E48, F101
●
Harness for open or short between ECM and IPDM E/R
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1701

M

POWER SUPPLY AND GROUND CIRCUIT
[K9K]

11. CHECK ECM POWER SUPPLY CIRCUIT-VI
1.
2.
3.

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between ECM terminal 104 and IPDM E/R terminal 29 under the following conditions.
Refer to Wiring Diagram.

MBIB1559E

CONDITION 1:
CONDITION 2:

Continuity should exist.
Continuity should not exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 13.
NG
>> GO TO 12.

12. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F101
●
Diode E64
●
Harness for open or short between ECM and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

13. CHECK 20A FUSE
1. Disconnect 20 A fuse.
2. Check 20A fuse
OK or NG
OK
>> GO TO 16.
NG
>> Replace 20A fuse.

EC-1702

POWER SUPPLY AND GROUND CIRCUIT
[K9K]

14. CHECK GROUND CONNECTIONS

A

1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screw on the body.
Refer to EC-1703, «Ground Inspection» .
–
Body ground (1)
–
Priming pump (2)
OK or NG
OK
>> GO TO 15.
NG
>> Repair or replace ground connections.

EC

C

D
MBIB1520E

E

15. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.

Disconnect ECM harness connector.
Check harness continuity between ECM terminals 25, 26, 27, 32 and ground.
Refer to Wiring Diagram.

F

Continuity should exist.

G

3. Also check harness for short to power.
OK or NG
OK
>> GO TO 16.
NG
>> Repair open circuit or short to power in harness or connectors.

H

16. CHECK INTERMITTENT INCIDENT

I

Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

Ground Inspection

J

K

BBS00416

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

EC-1703

L

M

POWER SUPPLY AND GROUND CIRCUIT
[K9K]
For detailed ground distribution information, refer to PG-38, «Ground Distribution» .

PBIB1870E

EC-1704

DTC PC001 CAN COMMUNICATION LINE
[K9K]

DTC PC001 CAN COMMUNICATION LINE
Description

PFP:22693

A
BBS0041O

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- EC
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
C
Each control unit transmits/receives data but selectively reads required data only.

On Board Diagnosis Logic
DTC No.
PC001

BBS0041P

Trouble diagnosis name
MULTIPLEX NETWORK (CAN COMMUNICATION LINE)
●

1.DEF: Carry out the multiplex network toruoble diagnosis

NOTE:
●
Special notes:
–
Malfunction indicator (Red) lights up.

Possible cause
●

Harness or connectors
(CAN communication line is open or
shorted)

D

E

F

G

H

I

J

K

L

M

EC-1705

DTC PC001 CAN COMMUNICATION LINE
[K9K]

Wiring Diagram

BBS0041R

MBWA1568E

EC-1706

DTC PC001 CAN COMMUNICATION LINE
[K9K]

Diagnostic Procedure

BBS0041S

A

Go to LAN-27, «CAN Communication Unit» .

EC

C

D

E

F

G

H

I

J

K

L

M

EC-1707

DTC P0016 CKP — CMP CORRELATION
[K9K]

DTC P0016 CKP — CMP CORRELATION
On Board Diagnosis Logic
DTC No.

P0016

PFP:10328
BBS0041T

Trouble diagnosis name

Possible cause

CRANKSHAFT POSITION — CAMSHAFT POSITION CORRELATION

●

Harness or connectors
(CMP sensor circuit is open or shorted.)

●

Harness or connectors
(CKP sensor circuit is open or shorted.)

●

Camshaft position sensor

●

Crankshaft position sensor

●

Timing belt

●

Signal plate

NOTE:
●
If DTC P0016 is displayed with DTC P0335 or P0340, first perform trouble diagnosis for DTC P0335
or P0340. Refer to EC-1774, «DTC P0335 CKP SENSOR» or EC-1778, «DTC P0340 CMP SENSOR» .
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present when cranking the engine or at idle speed.

Diagnostic Procedure

BBS0041V

1. CHECK CAMSHAFT POSITION SENSOR
Refer to EC-1783, «Component Inspection» .
OK or NG
OK
>> GO TO 2.
NG
>> Replace camshaft position sensor.

2. CHECK SPROCKET
Visually check for chipping signal plate gear tooth.
OK or NG
OK
>> GO TO 3.
NG
>> Remove debris and clean the signal plate or replace sprocket.

3. CHECK CRANKSHAFT POSITION SENSOR
Refer to EC-1777, «Component Inspection» .
OK or NG
OK
>> GO TO 4.
NG
>> Replace crankshaft position sensor.

4. CHECK GEAR TOOTH
Visually check for chipping signal plate gear tooth.
OK or NG
OK
>> GO TO 5.
NG
>> Replace the signal plate.

5. CHECK TIMING BELT
Refer to EM-272, «TIMING BELT» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace timing belt.

EC-1708

DTC P0016 CKP — CMP CORRELATION
[K9K]

6. CHECK INTERMITTENT INCIDENT

A

Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
EC

>> INSPECTION END

C

D

E

F

G

H

I

J

K

L

M

EC-1709

DTC P0045 TC BOOST CONTROL SORENOID VALVE
[K9K]

DTC P0045 TC BOOST CONTROL SORENOID VALVE
Description

PFP:14956
BBS0041W

The turbocharger boost control solenoid valve controls vacuum signal to the turbocharger boost control actuator. By changing the variable nozzle vane opening through the rods, the intake air volume is
adjusted.

MBIB1521E

The turbocharger boost control solenoid valve (1) is moved by ON/
OFF pulse from the ECM. The longer the ON pulse, the charge air
pressure rises.

MBIB1522E

On Board Diagnosis Logic
DTC No.

BBS0041X

Trouble diagnosis name

Possible cause
●

Harness or connectors
(The solenoid valve circuit is open or
shorted.)

C0.0: Open circuit oe short circuit to ground

●

Turbocharger boost control solenoid valve

CC.1: Short circuit to +12V

●

Turbocharger

●

Turbocharger boost sensor

●

Air inlet circuit

TURBOCHARGER BOOST CONTROL SOLENOID VALVE CIRCUIT
P0045

●
●

NOTE:
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present when ignition switch is in the ON position.
●
Special notes:
–
If this DTC is present, air flow regulation is cut, EGR voluime control valve is closed and turbocharger
boost pressure regulation is cut.
–
Suspected injection message displayed on the instrument panel and reduced performance.
–
Malfunction indicator (Red) lights up.

EC-1710

DTC P0045 TC BOOST CONTROL SORENOID VALVE
[K9K]

Wiring Diagram

BBS0041Z

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1567E

EC-1711

DTC P0045 TC BOOST CONTROL SORENOID VALVE
[K9K]
Specification data are reference valves, and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse Signal)
0 — 12.5V

[Ignition switch ON]

35

R

●

Warm-up condition

●

Idle speed

MBIB1504E

Turbocharger boost control
solenoid valve

0 — 12.5V
[Ignition switch ON]
●

Warm-up condition

●

Engine speed: 2,000 rpm

MBIB1505E

[Ignition switch ON]
[Ignition switch OFF]
●

104

P

ECM relay (self-shutoff)

For a few seconds after turning ignition
switch OFF

[Ignition switch OFF]
●

109
110

G
G

Power supply for ECM

More than a few seconds after turning ignition switch OFF

[Ignition switch ON]

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-1712

Approximately 1.4V

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

DTC P0045 TC BOOST CONTROL SORENOID VALVE
[K9K]

Diagnostic Procedure

BBS00420

1. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect turbocharger boost control solenoid valve (1) harness connector.
Turn ignition switch ON.

EC

C

D

MBIB1522E

4.

Check voltage between turbocharger boost control solenoid
valve terminals 2 and ground with CONSULT-II or tester.

E

F

Voltage: Battery voltage
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

G

H

MBIB1101E

2. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F101
●
Harness for open and short between turbocharger boost control solenoid valve and IPDM E/R

I

J

K

>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR

L

OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 35 and turbocharger boost control solenoid valve terminal 1. Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE
Refer to EC-1714, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace turbocharger boost control solenoid valve.

EC-1713

M

DTC P0045 TC BOOST CONTROL SORENOID VALVE
[K9K]

5. CHECK OTHER ITEMS
Check the following.
●
Turbocharger
●
Air inlet circuit (for obstructions, etc.)
●
Turbocharger boost pressure sensor signal
OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace.

6. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS00421

TURBOCHARGER BOOST CONTROL SOLENOID VALVE
1.

Disconnect turbocharger boost control solenoid valve (1) harness connector.

MBIB1522E

2.

Check harness continuity between turbocharger boost control
solenoid valve terminals under the following conditions.
Temperature °C (°F)

Resistance kΩ

-30 (-22)

18.6 ± 1.8

23 (73)

21 ± 2.1

110 (230)

18 ± 1.8

If NG, replace turbocharger boost control solenoid valve.
MBIB1486E

EC-1714

DTC P0070 IAT SENSOR
[K9K]

DTC P0070 IAT SENSOR
Component Description

PFP:22693

A
BBS00422

The intake air temperature sensor (1) is built into mass air flow sensor. The sensor detects intake air temperature and transmits a signal
to the ECM.
The temperature sensing unit uses a thermistor which is sensitive to
the change in temperature. Electrical resistance of the thermistor
decreases in response to the temperature rise.

EC

C

D
MBIB1523E

E

On Board Diagnosis Logic
DTC No.

BBS00423

Trouble diagnosis name
INTAKE AIR TEMPERATURE SENSOR CIRCUIT

P0070

●

CO.1: Open circuit or short circuit to +12V

●

CC.1: Short circuit to ground

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Intake air temperature sensor

F

G

H

I

J

K

L

M

EC-1715

DTC P0070 IAT SENSOR
[K9K]

Wiring Diagram

BBS00425

MBWA1547E

EC-1716

DTC P0070 IAT SENSOR
[K9K]

Diagnostic Procedure

BBS00426

1. CHECK GROUND CONNECTIONS

A

1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screw on the body.
Refer to EC-1703, «Ground Inspection» .
–
Body ground (1)
–
Priming pump (2)
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC

C

D

MBIB1520E

E

2. CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT
1.

Disconnect mass air flow sensor (intake air temperature sensor
is built-into) (2) harness connector.

–

: Vehicle front
Turbocharger boost sensor (1)
EGR volume control valve (3)
Turn ignition switch ON.

–
–

2.

F

G

H

I
MBIB1524E

3.

Check voltage between MAF sensor terminal 1 and ground with
CONSULT-II or tester.

J

Voltage: Approximately 5.0V
OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connectors.

K

L

MBIB1464E

3. CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between MAF sensor terminal 2 and ECM terminal 70.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1717

M

DTC P0070 IAT SENSOR
[K9K]

4. CHECK INTAKE AIR TEMPERATURE SENSOR
Refer to EC-1718, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace mass air flow sensor (with intake air temperature sensor).

5. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS00427

INTAKE AIR TEMPERATURE SENSOR
1.

2.

Check resistance between mass air flow sensor terminals 1 and
2 under the following conditions.
Temperature °C (°F)

Resistance kΩ

-40 (-40)

50,000 ± 6,800

-10 (14)

9,500 ± 900

25 (77)

2,051 ± 120

50 (122)

810 ± 47

80 (176)

310 ± 17

If NG, replace mass air flow sensor (with intake air temperature
sensor).

Removal and Installation

MBIB1487E

BBS00428

MASS AIR FLOW SENSOR
Refer to EM-245, «AIR CLEANER AND AIR DUCT» .

EC-1718

DTC P0087 FUEL SYSTEM
[K9K]

DTC P0087 FUEL SYSTEM
On Board Diagnosis Logic
DTC No.

P0087

PFP:22693

A
BBS00429

Trouble diagnosis name

FUEL FLOW CAPACITY FUNCTION

Possible cause
●

Fuel pump

●

Fuel injector

●

Fuel rail pressure sensor

●

Fuel filter

●

Air mixed with fuel

●

Lack of fuel

●

Fuel line

EC

C

D

NOTE:
●
Special notes:
–
Malfunction indicator (Red) lights up.

E

Diagnostic Procedure

BBS0042B

1. CHECK FUEL RAIL PRESSURE SENSOR
Refer to EC-1664, «TEST 7: HIGH PRESSURE SYSTEM CHECK» .
OK or NG
OK
>> GO TO 2.
NG
>> Replace fuel rail.

F

G

H

2. CHECK FUEL INJECTOR
Refer to EC-1662, «TEST 3: FUEL INJECTOR CHECK» .
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

I

J

3. REPLACE FUEL INJECOR
1.
2.

Replace fuel injector of malfunctioning cylinder.
Perform Injector Adjustment Value Registration. Refer to EC-1625, «Injector Adjustment Value Registration» .

K

L

>> INSPECTION END

4. CHECK FUEL PUMP

M

Refer to EC-1762, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace fuel pump.

5. CHECK FUEL FILTER
Refer to EC-1666, «TEST 11: FUEL FILTER CHECK» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace fuel filter.

EC-1719

DTC P0087 FUEL SYSTEM
[K9K]

6. CHECK FUEL LINE
Refer to EC-1660, «TEST 1: LOW PRESSURE CIRCUIT CHECK» .
OK or NG
OK
>> GO TO 7.
NG
>> Repair fuel line.

7. PERFORM HIGH PRESSURE SYSTEM CHECK
Refer to EC-1664, «TEST 7: HIGH PRESSURE SYSTEM CHECK» .
>> INSPECTION END

Removal and Installation

BBS0042C

FUEL INJECTOR
Refer to EM-266, «FUEL INJECTOR» .

FUEL PUMP
Refer to EM-268, «HIGH PRESSURE PUMP» .

EC-1720

DTC P0089 FUEL PUMP
[K9K]

DTC P0089 FUEL PUMP
On Board Diagnosis Logic
DTC No.

PFP:16700

A
BBS0042D

Trouble diagnosis name

Possible cause

EC

FUEL RAIL PRESSURE REGULATION FUNCTION

P0089

●

1.DEF: At minimum limit

●

2.DEF: At maximum limit

●

3.DEF: Below minimum threshold

●

4.DEF: Above maximum threshold

●

5.DEF: High flow current < minimum

●

5.DEF: High flow current > maximum

●

7.DEF: Low flow current < minimum

●

8.DEF: Low flow current > maximum

●

Fuel pump

●

Air mixed with fuel

●

Lack of fuel

●

Fuel rail pressure sensor

C

D

E

NOTE:
●
Special notes:
–
Malfunction indicator (Red) lights up.

F

Diagnostic Procedure

BBS0042F

1. CHECK FUEL RAIL PRESSURE SENSOR

G

Refer to EC-1664, «TEST 7: HIGH PRESSURE SYSTEM CHECK» .
OK or NG
OK
>> GO TO 2.
NG
>> Replace fuel rail.

H

I

2. CHECK FUEL PUMP
Perform EC-1762, «Component Inspection» .
OK or NG
OK
>> GO TO 3.
NG
>> Replace Fuel pump.

J

K

3. CHECK FUEL FILTER
Refer to EC-1666, «TEST 11: FUEL FILTER CHECK» .
OK or NG
OK
>> GO TO 4.
NG
>> Replace fuel filter.

L

M

4. CHECK FUEL LINE
Refer to EC-1665, «TEST 8: HIGH-PRESSURE CIRCUIT LEAK CHECK» .
OK or NG
OK
>> GO TO 5.
NG
>> Repair fuel line.

5. PERFORM HIGH PRESSURE SYSTEM CHECK
Refer to EC-1664, «TEST 7: HIGH PRESSURE SYSTEM CHECK» .
>> INSPECTION END

Removal and Installation

BBS0042G

FUEL PUMP
Refer to EM-268, «HIGH PRESSURE PUMP» .

EC-1721

DTC P0100 MAF SENSOR
[K9K]

DTC P0100 MAF SENSOR
Component Description

PFP:22693
BBS0042H

The mass air flow sensor is placed in the stream of intake air.
●
Intake air temperature sensor (1)

MBIB1523E

CONSULT-II Reference Value in Data Monitor Mode

BBS0042I

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

AIR FLOW

SPECIFICATION

Idle

Approximately 200 mg/cp

2,000 rpm

Approximately 270 mg/cp

On Board Diagnosis Logic
DTC No.

BBS0042J

Trouble diagnosis name

Possible cause

MASS AIR FLOW SENSOR CIRCUIT

P0100

●

1.DEF: Parmanent low lebel

●

2.DEF: Parmanent high lebel

●
●

●

Harness or connectors
(The sensor circuit is open or shorted.)

3.DEF: Below minimum threshold

●

Mass air flow sensor

4.DEF: Above maximum threshold

●

Air filter obstructed

●

5.DEF: Parmanent at minimum limit

●

Intake air duct obstructed

●

6.DEF: Parmanent at maximum limit

NOTE:
●
If DTC P0100 is displayed with DTC P0235, first perform trouble diagnosis for DTC P0235. Refer to
EC-1763, «DTC P0235 TC BOOST SENSOR» .
●
If DTC P0100 is displayed with DTC P0641, first perform trouble diagnosis for DTC P0641. Refer to
EC-1830, «DTC P0641 SENSOR POWER SUPPLY» .
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present with engine running.
●
Special notes:
–
If this DTC is present, mass air flow sensor function will stop and EGR voluime control valve is closed.

EC-1722

DTC P0100 MAF SENSOR
[K9K]

Wiring Diagram

BBS0042L

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1548E

EC-1723

DTC P0100 MAF SENSOR
[K9K]
Specification data are reference values, and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
50

WIRE
COLOR
L

ITEM
Sensor power supply
(Mass air flow sensor)

CONDITION

DATA
(DC Voltage)

[Ignition switch: ON]

Approximately 5.0V

[Ignition switch: ON]

Approximately 0.36V

[Engine is running]
60

Y

Mass air flow sensor

●

Warm-up condition

●

Idle speed

Approximately 1.7V

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,500 rpm.

Approximately 2.2V

[Engine is running]
70

G

Mass air flow sensor
ground

●

Warm-up condition

●

Idle speed

[Ignition switch ON]
[Ignition switch OFF]
●

104

P

ECM relay (self-shutoff)

For a few seconds after turning ignition
switch OFF

[Ignition switch OFF]
●

109
110

G
G

Power supply for ECM

More than a few seconds after turning ignition switch OFF

[Ignition switch ON]

Diagnostic Procedure

Approximately 0.3V

Approximately 1.4V

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)
BBS0042M

1. CHECK AIR FILTER
Check that air filter is not obsstructed.
Yes or No
Yes
>> Repair.
No
>> GO TO 2.

2. CHECK INTAKE AIR DUCT
Check that intake air duct is not obsstructed.
Yes or No
Yes
>> Repair.
No
>> GO TO 3.

EC-1724

DTC P0100 MAF SENSOR
[K9K]

3. CHECK GROUND CONNECTIONS

A

1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screw on the body.
Refer to EC-1703, «Ground Inspection» .
–
Body ground (1)
–
Priming pump (2)
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace ground connections.

EC

C

D
MBIB1520E

E

4. CHECK MAFS POWER SUPPLY CIRCUIT
1.

Disconnect mass air flow sensor (2) harness connector.

–

: Vehicle front
Turbocharger boost sensor (1)
EGR volume control valve (3)
Turn ignition switch ON.

–
–

2.

F

G

H

MBIB1524E

3.

I

Check voltage between mass air flow sensor terminals 4, 5 and
ground with CONSULT-II or tester.
J

Terminal
4:
5:

Voltage
Battery voltage
Approximately 5.0V

K

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

L
MBIB1465E

5. DETECT MALFUNCTIONING PART

M

Check the following.
●
Harness connectors E48, F101
●
Harness for open or short between mass air flow sensor and IPDM E/R
●
Harness for open or short between mass air flow sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1725

DTC P0100 MAF SENSOR
[K9K]

6. CHECK MAFS GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between mass air flow sensor terminal 2 and ECM terminal 70.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

7. CHECK MAFS INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between mass air flow sensor terminal 6 and ECM terminal 60.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK MASS AIR FLOW SENSOR
Refer to EC-1726, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace mass air flow sensor.

9. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS0042N

MASS AIR FLOW SENSOR
1.
2.
3.

Reconnect all harness connectors disconnected.
Start engine and warm it up to normal operating temperature.
Check voltage between ECM terminal 60 (Mass air flow sensor
signal) and ground.
Condition

Voltage V

Ignition switch ON (Engine stopped.)

Approx. 0.36

Engine speed: Idle

Approx. 1.7

Engine speed: 2,500 rpm

Approx. 2.2

4.

If NG, replace mass air flow sensor.
SEC915C

Removal and Installation

BBS0042O

MASS AIR FLOW SENSOR
Refer to EM-245, «AIR CLEANER AND AIR DUCT» .

EC-1726

DTC P0115 ECT SENSOR
[K9K]

DTC P0115 ECT SENSOR
Description

PFP:22693

A
BBS0042P

The engine coolant temperature sensor (1) is used to detect the
engine coolant temperature. The sensor modifies a voltage signal
from the ECM. The modified signal returns to the ECM as the engine
coolant temperature input. The sensor uses a thermistor which is
sensitive to the change in temperature. The electrical resistance of
the thermistor decreases as temperature increases.

EC

C

D
MBIB1525E

E

On Board Diagnosis Logic
DTC No.

BBS0042Q

Trouble diagnosis name
ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT

P0115

●

CC.0: Short circuit to ground

●

CO.1: Short circuit to +12V or open circuit

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Engine coolant temperature sensor

F

G

NOTE:
●
Special notes:
–
If this DTC is present, cooling fan motor is activated at low speed for vehicles fitted with air conditioning.

H

I

J

K

L

M

EC-1727

DTC P0115 ECT SENSOR
[K9K]

Wiring Diagram

BBS0042S

MBWA1549E

EC-1728

DTC P0115 ECT SENSOR
[K9K]

Diagnostic Procedure

BBS0042T

1. CHECK GROUND CONNECTIONS

A

1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screw on the body.
Refer to EC-1703, «Ground Inspection» .
–
Body ground (1)
–
Priming pump (2)
Yes or No
Yes
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC

C

D

MBIB1520E

E

2. CHECK ECT SENSOR POWER SUPPLY CIRCUIT
1.
2.

F

Disconnect engine coolant temperature sensor (1) harness connector.
Turn ignition switch ON.

G

H

I
MBIB1525E

3.

Check voltage between ECT sensor terminal 3 and ground with
CONSULT-II or tester.

J

Voltage: Approximately 5.0V
OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connectors.

K

L

MBIB1466E

3. CHECK ECT SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECT sensor terminal 2 and ECM terminal 63.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1729

M

DTC P0115 ECT SENSOR
[K9K]

4. CHECK ENGINE COOLANT TEMPERATURE SENSOR
Refer to EC-1730, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace engine coolant temperature sensor.

5. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS0042U

ENGINE COOLANT TEMPERATURE SENSOR
1.

2.

Check resistance between engine coolant temperature sensor
terminals 2 and 3 as shown in the figure.
Engine coolant temperature °C (°F)

Resistance kΩ

-40 (-40)

76,000 ± 7,000

-10 (14)

12,500 ± 1,130

25 (77)

2,252 ± 112

50 (122)

810 ± 40

80 (176)

280 ± 8

110 (230)

115 ± 3

120 (248)

88 ± 2

MBIB1488E

If NG, replace engine coolant temperature sensor.

Removal and Installation

BBS0042V

ENGINE COOLANT TEMPERATURE SENSOR
Refer to EM-276, «CYLINDER HEAD» .

EC-1730

DTC P0170 FUEL INJECTOR ADJUSTMENT VALUE
[K9K]

DTC P0170 FUEL INJECTOR ADJUSTMENT VALUE
On Board Diagnosis Logic
DTC No.
P0170

PFP:22693

A
BBS0042X

Trouble diagnosis name
INJECTOR ADJUSTMENT VALUE DATA ERROR

Possible cause
●

Injector Adjustment Value is not registered
sufficiently

NOTE:
●
If DTC P0170 is displayed with DTC P0200, P0201, P0202, P0203, P0204, first perform trouble diagnosis for other DTC. Refer to EC-1740, «DTC P0200 FUEL INJECTOR» or EC-1745, «DTC P0201 P0204 FUEL INJECTOR» .

EC

C

D

Diagnostic Procedure

BBS0042Z

1. PERFORM INJECTOR ADJUSTMENT VALUE REGISTRATION
Perform Injector Adjustment Value Registration. Refer to EC-1625, «Injector Adjustment Value Registration» .
>> INSPECTION END

E

F

G

H

I

J

K

L

M

EC-1731

DTC P0180 FUEL PUMP TEMPERATURE SENSOR
[K9K]

DTC P0180 FUEL PUMP TEMPERATURE SENSOR
Description

PFP:22693
BBS00430

Fuel pump temperature sensor is built in the fuel pump. The sensor detects the fuel temperature in the fuel
pump and calibrates the fuel injection amount change by fuel temperature.

CONSULT-II Reference Value in Data Monitor Mode

BBS00431

Specification data are reference values.
MONITOR ITEM
FUEL TEMP SEN

CONDITION
●

SPECIFICATION

Engine: After warming up

More than 40°C (104°F)

On Board Diagnosis Logic
DTC No.

BBS00432

Trouble diagnosis name
FUEL PUMP TEMPERATURE SENSOR CIRCUIT

P0180

●

CC.0: Short circuit to ground

●

CO.1: Short circuit to +12V or open circuit

EC-1732

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Fuel pump temperature sensor

DTC P0180 FUEL PUMP TEMPERATURE SENSOR
[K9K]

Wiring Diagram

BBS00434

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1550E

EC-1733

DTC P0180 FUEL PUMP TEMPERATURE SENSOR
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
54

WIRE
COLOR

P

ITEM

Fuel pump temperature
sensor

DATA
(DC Voltage and Pulse Signal)

CONDITION

[Engine is running]
●

Warm-up condition

Approximately 0.3 — 5.0V
Output voltage varies with fuel
pump temperature

[Engine is running]
64

G

Fuel pump temperature
sensor ground

●

Warm-up condition

●

Idle speed

Approximately 0.3V

Diagnostic Procedure

BBS00435

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screw on the body.
Refer to EC-1703, «Ground Inspection» .
–
Body ground (1)
–
Priming pump (2)
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

MBIB1520E

2. CHECK FUEL PUMP TEMPERATURE SENSOR POWER SUPPLY CIRCUIT
1.
2.
3.

Disconnect fuel pump temperature sensor harness connector.
Turn ignition switch ON.
Check voltage between fuel pump temperature sensor terminal
1 and ground with CONSULT-II or tester.
Voltage: Approximately 5.0V

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connectors.

PBIB2245E

EC-1734

DTC P0180 FUEL PUMP TEMPERATURE SENSOR
[K9K]

3. CHECK FUEL PUMP TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between fuel pump temperature sensor terminal 2 and ECM terminal 64.
Refer to Wiring Diagram.

EC

Continuity should exist.

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D

4. CHECK FUEL PUMP TEMPERATURE SENSOR

E

Refer to EC-1735, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace fuel pump.

F

5. CHECK INTERMITTENT INCIDENT

G

Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
H

>> INSPECTION END

Component Inspection

BBS004UO

FUEL PUMP TEMPERATURE SENSOR
1.

Check resistance between fuel pump temperature sensor terminals 1 and 2 as shown in the figure.
Resistence:

2.

I

J

2.2 kΩ at 25°C (77°F)

If NG, replace fuel pump.
K

L
PBIB0417E

Removal and Installation

BBS00436

FUEL PUMP
Refer to EM-268, «HIGH PRESSURE PUMP» .

EC-1735

M

DTC P0190 FRP SENSOR
[K9K]

DTC P0190 FRP SENSOR
CONSULT-II Reference Value in Data Monitor Mode

PFP:22693
BBS00438

Specification data are reference values.
MONITOR

CONDITION
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

RAIL PRESSURE

RAIL PRES SET

SPECIFICATOIN

Idle

Approximately 230 bar

2,000 rpm

Approximately 450 bar

Idle

Approximately 230 bar

2,000 rpm

Approximately 450 bar

On Board Diagnosis Logic
DTC No.

BBS00439

Trouble diagnosis name

Possible cause

FUEL RAIL PRESSURE SENSOR CIRCUIT

P0190

●

1.DEF: Inconsistency

●

2.DEF: Below minimum threshold

●

3.DEF: Above maximum threshold

●

4.DEF: Value outside of tolerance

●

CC.0: Short circuit to ground

●

CO.1: Short circuit to +12V or open circuit

●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Fuel rail pressure sensor

NOTE:
●
If DTC P0190 is displayed with DTC P0641, first perform trouble diagnosis for DTC P0641. Refer to
EC-1830, «DTC P0641 SENSOR POWER SUPPLY» .
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present after the engine started.
●
Special notes:
–
If this DTC is present, engine stops and is impossible to restarted.
–
Malfunction indicator (Red) lights up.

EC-1736

DTC P0190 FRP SENSOR
[K9K]

Wiring Diagram

BBS0043B

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1551E

EC-1737

DTC P0190 FRP SENSOR
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
47

WIRE
COLOR
L

ITEM
Sensor power supply
(Fuel rail pressure sensor)

CONDITION

[Ignition switch ON]

DATA
(DC Voltage)
Approximately 5.0V

[Engine is running]

57

R

Fuel rail pressure sensor

●

Warm-up condition

●

Idle speed

Approximately 1.0V

[Engine is running]
●

Warm-up condition

●

Engine speed is 2,000 rpm

Approximately 1.5V

[Engine is running]
67

B

Sensor ground
(Fuel rail pressure sensor)

●

Warm-up condition

●

Idle speed

Diagnostic Procedure

Approximately 0.45V

BBS0043C

1. CHECK GROUND CONNECTION
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screw on the body.
Refer to EC-1703, «Ground Inspection» .
–
Body ground (1)
–
Priming pump (2)
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

MBIB1520E

2. CHECK FUEL RAIL PRESSURE SENSOR POWER SUPPLY CIRCUIT
1.
2.
3.

Disconnect fuel rail pressure sensor harness connector.
Turn ignition switch ON.
Check voltage between fuel rail pressure sensor terminal 3
ground with CONSULT-II or tester.
Voltage: Approximately 5.0V

OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

MBIB1467E

EC-1738

DTC P0190 FRP SENSOR
[K9K]

3. CHECK FUEL RAIL PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between fuel rail pressure sensor terminal 2 and ECM terminal 67.
Refer to Wiring Diagram.

EC

Continuity should exist.

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D

4. CHECK FUEL RAIL PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

E

Check harness continuity between ECM terminal 57 and fuel rail pressure sensor terminal 1.
Refer to Wiring Diagram.
F

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness connectors.

G

H

5. CHECK FUEL RAIL PRESSURE SENSOR
Refer to EC-1739, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace fuel rail.

I

J

6. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

K

>> INSPECTION END
L

Component Inspection

BBS0043D

FUEL RAIL PRESSURE SENSOR
1.
2.
3.

4.

5.

Reconnect harness connector disconnected.
Start engine and warm it up to normal operating temperature.
Check voltage between ECM terminal 57 (Fuel rail pressure
sensor signal) and ground under the following conditions.
Condition

Voltage V

Idle

Approximately 1.0

2,000 rpm

Approximately 1.5

If the voltage is out of specification, disconnect fuel rail pressure
sensor harness connector and connect it again. Then repeat
above check.
If NG, replace fuel rail.

Removal and Installation

M

MBIB1539E

BBS0043E

FUEL RAIL
Refer to EM-267, «INJECTOR RAIL» .

EC-1739

DTC P0200 FUEL INJECTOR
[K9K]

DTC P0200 FUEL INJECTOR
Component Description

PFP:16600
BBS004UP

The fuel injector is a small, precise solenoid valve. When the ECM supplies a ground to the fuel injector circuit,
the coil in the fuel injector is energized. The energized coil pulls the needle valve back and allows fuel to flow
through the fuel injector into the cylinder. The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the fuel injector remains open. The ECM controls the injection pulse
duration based on engine fuel needs.

CONSULT-II Reference Value in Data Monitor Mode

BBS004UQ

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

FUEL FLOW

SPECIFICATION

Idle

Approximately 4.9 mg/cp

2,000 rpm

Approximately 3.5 mg/cp

On Board Diagnosis Logic
DTC No.

BBS0043F

Trouble diagnosis name
FUEL INJECTOR CIRCUIT

P0200

●

CC.0: Short circuit to ground

●

CC.1: Short circuit to +12V

Possible cause
●

Harness or connectors
(The fuel injector circuit is shorted.)

●

Fuel injector

NOTE:
●
If DTC P0200 is displayed with DTC P0201, P0202, P0203, P0204, first perform trouble diagnosis
for other DTC. Refer to EC-1745, «DTC P0201 — P0204 FUEL INJECTOR» .
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present with engine running.
●
Special notes:
–
If this DTC is present, the engine stops.
–
Malfunction indicator (Red) lights up.

EC-1740

DTC P0200 FUEL INJECTOR
[K9K]

Wiring Diagram

BBS004TT

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1553E

EC-1741

DTC P0200 FUEL INJECTOR
[K9K]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

[Engine is running]

73
75
77
79

B/P
P/L
G
L

Fuel injector No. 2
Fuel injector No. 4
Fuel injector No. 3
Fuel injector No. 1

●

Warm-up condition

●

Idle speed

DATA
(DC Voltage and Pulse Signal)
0 — 9V

NOTE:
The pulse cycle changes depending on rpm at
idle.
MBIB1512E

0 — 9V
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

MBIB1513E

[Engine is running]

74

O

76

V

78

R

80

P

Fuel injector power supply
No. 2
Fuel injector power supply
No. 4
Fuel injector power supply
No. 3
Fuel injector power supply
No. 1

●

Warm-up condition

●

Idle speed

5 — 10V

NOTE:
The pulse cycle changes depending on rpm at
idle.
MBIB1514E

5 — 10V
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

MBIB1515E

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-1742

DTC P0200 FUEL INJECTOR
[K9K]

Diagnostic Procedure

BBS0043H

1. CHECK FUEL INJECTOR POWER SUPPLY FOR OPEN AND SHORT CIRCUIT
1.
2.
3.
4.

A

Turn ignition switch OFF.
Disconnect fuel injector (1) harness connector.
Disconnect ECM harness connector.
Check harness continuity between the following terminals.
Refer to Wiring Diagram.
Terminal

EC

C

Cylinder

ECM

Fuel injector

74

1

No.2

76

1

No.4

78

1

No.3

80

1

No.1

D

MBIB1526E

F

Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 2.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

2. CHECK FUEL INJECOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between the following terminals.
Refer to Wiring Diagram.
Terminal

G

H

I

Cylinder

ECM

Fuel injector

73

2

No.2

75

2

No.4

77

2

No.3

79

2

No.1

J

K

L

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> GO TO 4.
NG
>> Repair or open circuit or short to ground or short to power in harness or connectors.

4. REPLACE FUEL INJECOR
1.
2.

E

Replace fuel injector of malfunctioning cylinder.
Perform Injector Adjustment Value Registration. Refer to EC-1625, «Injector Adjustment Value Registration» .
>> INSPECTION END

EC-1743

M

DTC P0200 FUEL INJECTOR
[K9K]

Removal and Installation

BBS004TV

FUEL INJECTOR
Refer to EM-266, «FUEL INJECTOR» .

EC-1744

DTC P0201 — P0204 FUEL INJECTOR
[K9K]

DTC P0201 — P0204 FUEL INJECTOR
Component Description

PFP:16600

A
BBS0043I

The fuel injector is a small, precise solenoid valve. When the ECM supplies a ground to the fuel injector circuit,
the coil in the fuel injector is energized. The energized coil pulls the needle valve back and allows fuel to flow EC
through the fuel injector into the cylinder. The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the fuel injector remains open. The ECM controls the injection pulse
duration based on engine fuel needs.
C

CONSULT-II Reference Value in Data Monitor Mode

BBS0043J

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

FUEL FLOW

Idle

Approximately 4.9 mg/cp

2,000 rpm

Approximately 3.5 mg/cp

E

On Board Diagnosis Logic
DTC No.

D

SPECIFICATION

BBS0043K

Trouble diagnosis name

Possible cause

G

NO. 1 CYLINDER FUEL INJECTOR CIRCUIT
P0201

●

CO: Open circuit

●

CC: Short circuit

●

1.DEF: At minimum stop

●

2.DEF: At maximum stop

F

H

NO. 2 CYLINDER FUEL INJECTOR CIRCUIT
P0202

●

CO: Open circuit

●

CC: Short circuit

●

1.DEF: At minimum stop

●

2.DEF: At maximum stop

I

NO. 3 CYLINDER FUEL INJECTOR CIRCUIT
P0203

●

CO: Open circuit

●

CC: Short circuit

●

1.DEF: At minimum stop

●

2.DEF: At maximum stop

●

Harness or connectors
(The fuel injector circuit is open.)

●

Fuel injector

J

K

L

NO. 4 CYLINDER FUEL INJECTOR CIRCUIT
P0204

●

CO: Open circuit

●

CC: Short circuit

●

1.DEF: At minimum stop

●

2.DEF: At maximum stop

M

NOTE:
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present with engine running.
●
Special notes:
–
If this DTC is present, the idle speed is stuck at 1,000 rpm with engine noise, unstable engine speed,
reduced engine performance.
–
Malfunction indicator (Red) lights up.
–
Malfunction indicator (Yellow) lights up.

EC-1745

DTC P0201 — P0204 FUEL INJECTOR
[K9K]

Wiring Diagram

BBS0043M

MBWA1553E

EC-1746

DTC P0201 — P0204 FUEL INJECTOR
[K9K]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

C
[Engine is running]

73
75
77
79

DATA
(DC Voltage and Pulse Signal)

B/P
P/L
G
L

Fuel injector No. 2
Fuel injector No. 4
Fuel injector No. 3
Fuel injector No. 1

●

Warm-up condition

●

Idle speed

0 — 9V

D

NOTE:
The pulse cycle changes depending on rpm at
idle.

E
MBIB1512E

0 — 9V

F
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

G
MBIB1513E

H
[Engine is running]

74

O

76

V

78

R

80

P

Fuel injector power supply
No. 2
Fuel injector power supply
No. 4
Fuel injector power supply
No. 3
Fuel injector power supply
No. 1

●

Warm-up condition

●

Idle speed

5 — 10V

I

NOTE:
The pulse cycle changes depending on rpm at
idle.

J
MBIB1514E

5 — 10V

K
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

L
MBIB1515E

M

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS0043N

1. CHECK DTC
Make sure that which malfunction (DTC second line indication) is displayed.
A

CO or CC

B

1.DEF or 2.DEF

A or B
A
B

>> GO TO 2.
>> GO TO 5.

EC-1747

DTC P0201 — P0204 FUEL INJECTOR
[K9K]

2. CHECK FUEL INJECTOR POWER SUPPLY FOR OPEN AND SHORT CIRCUIT
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect fuel injector (1) harness connector.
Disconnect ECM harness connector.
Check harness continuity between the following terminals corresponding to the malfunctioning cylinder.
Refer to Wiring Diagram.
Terminal
DTC

Cylinder

ECM

Fuel injector

P0201

80

1

No.1

P0202

74

1

No.2

P0203

78

1

No.3

P0204

76

1

No.4

MBIB1526E

Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK FUEL INJECOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between the following terminals corresponding to the malfunctioning cylinder.
Refer to Wiring Diagram.
Terminal

DTC

Cylinder

ECM

Fuel injector

P0201

79

2

No.1

P0202

73

2

No.2

P0203

77

2

No.3

P0204

75

2

No.4

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1748

DTC P0201 — P0204 FUEL INJECTOR
[K9K]

4. CHECK FUEL INJECTOR CIRCUIT FOR SHORT

A

Check harness continuity between the following terminals corresponding to the malfunctioning cylinder. Refer
to Wiring Diagram.

P0201

P0202

P0203

P0204

EC

Terminal

DTC

Cylinder

Fuel injector

ECM

2

Except 79

1

Except 80

2

Except 73

1

Except 74

2

Except 77

1

Except 78

2

Except 75

1

Except 76

No.1

No.2

C

D

No.3

E
No.4

F

Continuity should not exist.
OK or NG
OK
>> GO TO 8.
NG
>> Repair circuit short in harness or connectors.

5. CHECK INJECTOR ADJUSTMENT VALUE

G

H

Make sure that all injector adjustment values are registered correctly.
Refer to EC-1625, «Injector Adjustment Value Registration» .
OK or NG
OK
>> GO TO 6.
NG
>> Perform Injector Adjustment Value Registration. Refer to EC-1625, «Injector Adjustment Value
Registration» .

I

J

6. CHECK KNOCK SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT
Check knock sensor shield circuit for open and short.
Refer to EC-1771, «Wiring Diagram» .
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

7. CHECK KNOCK SENSOR INSTALLATION

K

L

M

Check that knock sensor is installed securely on the engine.
Refer to EM-282, «OVERHAUL» .
OK or NG
OK
>> GO TO 8.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> GO TO 9.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1749

DTC P0201 — P0204 FUEL INJECTOR
[K9K]

9. REPLACE FUEL INJECOR
1.
2.

Replace fuel injector of malfunctioning cylinder.
Perform Injector Adjustment Value Registration. Refer to EC-1625, «Injector Adjustment Value Registration» .
>> INSPECTION END

Component Inspection

BBS0043O

FUEL INJECTOR
1.
2.

Disconnect fuel injector harness connector.
Check resistance between terminals as shown in the figure.
Continuity should exist.

3.

If NG, replace fuel injector.

MBIB1253E

Removal and Installation

BBS0043P

FUEL INJECTOR
Refer to EM-266, «FUEL INJECTOR» .

EC-1750

DTC P0225 APP SENSOR
[K9K]

DTC P0225 APP SENSOR
Description

PFP:22693

A
BBS0043Q

The accelerator pedal position sensor is installed on the upper end
of the accelerator pedal assembly. The sensors detect the accelerator pedal position and sends a signal to the ECM. The ECM uses the
signal to determine the amount of fuel to be injected.

EC

C

D
PBIB1741E

E

CONSULT-II Reference Value in Data Monitor Mode

BBS0043R

Specification data are reference values.
MONITOR ITEM
PL PTNMR T1 V
PL PTNMR T2 V

CONDITION
Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

Approximately 15 %

●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

Approximately 6 %

On Board Diagnosis Logic
DTC No.

F

SPECIFICATION

●

G

BBS0043S

Trouble diagnosis name

H

Possible cause

APP SENSOR 1 CIRCUIT
●

CO.0: Open circuit or short circuit to ground

●

CC.1: Short circuit to +12V

●

1.DEF: Inconsistency between APP sensors 1 and 2

●

2.DEF: No signal

●

3.DEF: Blocked component

P0225

●

Harness or connectors
(The APP sensor 1 circuit is open or shorted.)

●

Accelerator pedal position sensor
(Accelerator pedal position sensor 1)

NOTE:
●
If DTC P0225 is displayed with DTC P0641, first perform trouble diagnosis for DTC P0641. Refer to
EC-1830, «DTC P0641 SENSOR POWER SUPPLY» .
●
Special notes:
–
If this DTC is present, the engine speed is maintained above 1,000 rpm, the engine performance is
reduced, and malfuction indicator (Red) lights up.
–
If this DTC is present with DTC P2120, the engine speed is fixed at 1,800 rpm, the engine performance is
reduced, and malfuction indicator (Red) lights up.

EC-1751

I

J

K

L

M

DTC P0225 APP SENSOR
[K9K]

Wiring Diagram

BBS0043U

LHD MODELS

MBWA1554E

EC-1752

DTC P0225 APP SENSOR
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

6

WIRE
COLOR

L/R

ITEM

Sensor ground
(Accelerator pedal position
sensor 2)

CONDITION

DATA
(DC Voltage and Pulse Signal)

[Engine is running]
●

Warm-up condition

●

Idle speed

12

18

28

29

L/W

Accelerator pedal position
sensor 2

L

Sensor power supply
(Accelerator pedal position
sensor 2)

B

Sensor ground
(Accelerator pedal position
sensor 1)

R

Sensor power supply
(Accelerator pedal position
sensor 1)

Engine stopped

●

Accelerator pedal: Fully released

C

D
Approximately 0.4V

E

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

[Ignition switch ON]

Approximately 2.0V

F
Approximately 4.6V

G

[Engine is running]
●

Warm-up condition

●

Idle speed

[Ignition switch ON]

Approximately 0.24V

H
Approximately 5.0V

I

[Ignition switch ON]

30

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

EC

Approximately 0.3V

[Ignition switch ON]
●

A

Approximately 0.76V

J

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

Approximately 4.2V

K

L

M

EC-1753

DTC P0225 APP SENSOR
[K9K]
RHD MODELS

MBWA1555E

EC-1754

DTC P0225 APP SENSOR
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

6

WIRE
COLOR

L/R

ITEM

Sensor ground
(Accelerator pedal position
sensor 2)

CONDITION

DATA
(DC Voltage and Pulse Signal)

[Engine is running]
●

Warm-up condition

●

Idle speed

12

18

28

29

L/W

Accelerator pedal position
sensor 2

L

Sensor power supply
(Accelerator pedal position
sensor 2)

B

Sensor ground
(Accelerator pedal position
sensor 1)

R

Sensor power supply
(Accelerator pedal position
sensor 1)

Engine stopped

●

Accelerator pedal: Fully released

C

D
Approximately 0.4V

E

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

[Ignition switch ON]

Approximately 2.0V

F
Approximately 4.6V

G

[Engine is running]
●

Warm-up condition

●

Idle speed

[Ignition switch ON]

Approximately 0.24V

H
Approximately 5.0V

I

[Ignition switch ON]

30

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

EC

Approximately 0.3V

[Ignition switch ON]
●

A

Approximately 0.76V

J

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

Diagnostic Procedure

Approximately 4.2V

K
BBS0043V

1. CHCEK GROUND CONNECTIONS

L

1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screw on the body.
Refer to EC-1703, «Ground Inspection» .
–
Body ground (1)
–
Priming pump (2)
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

M

MBIB1520E

EC-1755

DTC P0225 APP SENSOR
[K9K]

2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT
1.
–
–

2.

Disconnect accelerator pedal position (APP) sensor harness
connector (1).
Accelerator pedal position sensor (2)
Accelerator pedal (3)
Turn ignition switch ON.

MBIB1345E

3.

Check voltage between APP sensor terminal 4 and ground with
CONSULT-II or tester.
Voltage: Approximately 5.3V

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

MBIB1468E

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK APP SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between APP sensor terminal 2 and ECM terminal 28.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1756

DTC P0225 APP SENSOR
[K9K]

6. CHECK APP SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

A

Check harness continuity between ECM terminal 30 and APP sensor terminal 3.
Refer to Wiring Diagram.
EC

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

C

7. DETECT MALFUNCTIONING PART

D

Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM

E

F

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK APP SENSOR

G

Refer to EC-1757, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace accelerator pedal assembly.

H

I

9. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

J

>> INSPECTION END

Component Inspection

BBS0043W

K

ACCELERATOR PEDAL POSITION SENSOR
1.

Disconnect APP sensor harness connector (1).
● Accelerator pedal position sensor (2)
● Accelerator pedal (3)

L

M

MBIB1345E

EC-1757

DTC P0225 APP SENSOR
[K9K]
2.

Check resistance between the APP sensor terminals 2 and 4, 1
and 5.
Terminals
2 and 4:
1 and 5:

3.

Resistance
1.7 ± 0.9 kΩ
2.4 ± 1.2 kΩ

If NG, replace accelerator pedal assembly.

MBIB1489E

Removal and Installation

BBS0043X

ACCELERATOR PEDAL
Refer to ACC-2, «ACCELERATOR CONTROL SYSTEM» .

EC-1758

DTC P0231 FUEL PUMP
[K9K]

DTC P0231 FUEL PUMP
Description

PFP:22693

A
BBS0043Y

To control the amount of the fuel inhalation of the fuel pump, a plunger is built into the fuel pump. When the
amount of the fuel inhalation of fuel increases, the fuel pump raises the fuel exhalation pressure. As a result, EC
the fuel injection pressure is raised. When the load of the engine increases, the ECM sends a signal to the fuel
pump to raise the injection pressure.

CONSULT-II Reference Value in Data Monitor Mode

BBS0043Z

C

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

FUEL FLOW

SPECIFICATION

Idle

Approximately 4.9 mg/cp

2,000 rpm

Approximately 3.5 mg/cp

On Board Diagnosis Logic
DTC No.

E

BBS00440

Trouble diagnosis name
FUEL PUMP CONTROL CIRCUIT

P0231

D

●

●

CO.0: Open circuit or short circuit to ground

●

CC.1: Short circuit to +12V

F

Possible cause

●

Harness or connectors
(The fuel pump circuit is open or shorted.)

G

Fuel pump

NOTE:
●
Special notes:
–
If this DTC is present, the fuel pump is fully opened and the engine is stopped to prevent it from revving.
–
Malfuction indicator (Red) lights up.

H

I

J

K

L

M

EC-1759

DTC P0231 FUEL PUMP
[K9K]

Wiring Diagram

BBS00442

MBWA1556E

EC-1760

DTC P0231 FUEL PUMP
[K9K]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
A
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
EC
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse Signal)

C
0 — 12.5V
[Engine is running]
●

Warm-up condition

●

Idle speed

D

E
MBIB1506E

39

P

Fuel pump
0 — 12.5V

F
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

G
MBIB1507E

[Ignition switch ON]
[Ignition switch OFF]
●

104

P

ECM relay (self-shutoff)

For a few seconds after turning ignition
switch OFF

[Ignition switch OFF]
●

109
110

G
G

Power supply for ECM

More than a few seconds after turning ignition switch OFF

[Ignition switch ON]

H
Approximately 1.4V

I
BATTERY VOLTAGE
(11 — 14V)

J

BATTERY VOLTAGE
(11 — 14V)

K

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS00443

1. CHECK FUEL PUMP POWER SUPPLY CIRCUIT
1.
2.
3.
4.

L

Turn ignition switch OFF.
Disconnect fuel pump harness connector.
Turn ignition switch ON.
Check voltage between fuel pump terminal 2 and ground with
CONSULT-II or tester.

M

Voltage: Battery voltage
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

PBIB2605E

EC-1761

DTC P0231 FUEL PUMP
[K9K]

2. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F101
●
Harness for open or short between fuel pump and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK FUEL PUMP OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 39 and fuel pump terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK FUEL PUMP
Refer to EC-1762, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace fuel pump.

5. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS00444

FUEL PUMP
1.
2.

Disconnect fuel pump harness connector.
Check resistance between fuel pump terminals 1 and 2.
Resistance: 5.3 ± 0.5Ω [at 20°C (68°F)]

3.

If NG, replace fuel pump.

PBIB0417E

Removal and Installation

BBS00445

FUEL PUMP
Refer to EM-268, «HIGH PRESSURE PUMP» .

EC-1762

DTC P0235 TC BOOST SENSOR
[K9K]

DTC P0235 TC BOOST SENSOR
Component Description

PFP:22693

A
BBS00446

The turbocharger boost sensor detects pressure in the exit side of
the charge air cooler. The sensor output voltage to the ECM
increases as pressure increases.

EC

C

D
MBIB1527E

E

CONSULT-II Reference Value in Data Monitor Mode

BBS00447

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

INLET PRESS

Approximately 980 mbar

2,000 rpm

Approximately 1,010 mbar

On Board Diagnosis Logic
DTC No.

F

SPECIFICATION

Idle

G

BBS00448

Trouble diagnosis name

Possible cause

TURBOCHARGER BOOST SENSOR CIRCUIT
●

1.DEF: Parmanent low lebel

●

2.DEF: Parmanent high lebel

●

3.DEF: Below minimum threshold

●

4.DEF: Above maximum threshold

●

5.DEF: Inconsistency

●

6.DEF: Parmanent at maximum limit

●

7.DEF: Parmanent at minimum limit

P0235

H

I
●

●

Harness or connectors
(The sensor circuit is open or shorted.)

J

Turbocharger boost sensor

K

NOTE:
●
If DTC P0235 is displayed with DTC P0641, first perform the trouble diagnosis for DTC P0641.
Refer to EC-1830, «DTC P0641 SENSOR POWER SUPPLY» .
●
Special notes:
–
Malfunction indicator (Red) lights up.

EC-1763

L

M

DTC P0235 TC BOOST SENSOR
[K9K]

Wiring Diagram

BBS0044A

MBWA1557E

EC-1764

DTC P0235 TC BOOST SENSOR
[K9K]
Specification data are reference values, and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
48

WIRE
COLOR
V

ITEM
Sensor power supply
(Turbocharger boost sensor)

CONDITION

[Ignition switch ON]

A

EC

DATA
(DC Voltage)
Approximately 5.0V

C

Approximately 1.6V

D

Approximately 2.0V

E

Approximately 0.3V

F

[Engine is running]

58

O

Turbocharger boost sensor

●

Warm-up condition

●

Idle speed

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

[Engine is running]
68

G

Sensor ground
(Turbocharger boost sensor)

●

Warm-up condition

●

Idle speed

Diagnostic Procedure

BBS0044B

G

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screw on the body.
Refer to EC-1703, «Ground Inspection» .
–
Body ground (1)
–
Priming pump (2)
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

H

I

J

K
MBIB1520E

L

M

EC-1765

DTC P0235 TC BOOST SENSOR
[K9K]

2. CHECK TURBOCHARGER BOOST SENSOR POWER SUPPLY CIRCUIT
1.
2.

Disconnect turbocharge boost sensor (1) harness connector.
Turn ignition switch ON.

MBIB1528E

3.

Check voltage between turbocharge boost sensor terminal 1
and ground with CONSULT-II or tester.
Voltage: Approximately 5.0V

OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

MBIB1469E

3. CHECK TURBOCHAGER BOOST SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between turbocharger boost sensor terminal 2 and ECM terminal 68.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK TURBOCHAGER BOOST SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminals 58 and turbocharger boost sensor terminal 3.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness connectors.

5. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace turbocharger boost sensor.
NG
>> Repair open circuit or short to ground or short to power in harness connectors.

EC-1766

DTC P0235 TC BOOST SENSOR
[K9K]

Removal and Installation

BBS0044D

A

TURBOCHARGER BOOST SENSOR
Refer to EM-247, «CHARGE AIR COOLER» .

EC

C

D

E

F

G

H

I

J

K

L

M

EC-1767

DTC P0263, P0266, P0269, P0272 NO.1 — 4 CYLINDER MISFIRE
[K9K]

DTC P0263, P0266, P0269, P0272 NO.1 — 4 CYLINDER MISFIRE
On Board Diagnosis Logic
DTC No.

P0263
P0266
P0269
P0272

Trouble diagnosis name

PFP:22693
BBS0044T

Possible cause

NO. 1 CYLINDER MISFIRE
NO. 2 CYLINDER MISFIRE
NO. 3 CYLINDER MISFIRE
NO. 4 CYLINDER MISFIRE

●

Insufficient compression

●

Incorrect valve clearance

●

Intake air leak

●

EGR volume control valve

●

The fuel injector circuit is open or shorted

●

Fuel injector

NOTE:
●
If DTC P0263, P0266, P0269 or P0272 is displayed with DTC P0201, P0202, P0203 or P0204, first
perform the trouble diagnosis for DTC P0201, P0202, P0203 or P00204. Refer to EC-1745, «DTC
P0201 — P0204 FUEL INJECTOR» .
●
If DTC P0263, P0266, P0269 or P0272 is displayed with DTC P0089, first perform the trouble diagnosis for DTC P0089. Refer to EC-1721, «DTC P0089 FUEL PUMP» .
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present when the engine speed is at idle speed.
●
Special notes:
–
If this DTC is present, the engine is maintained at 1,000 rpm and engine performance is reduced.
–
Malfuction indicator (Red) lights up.

EC-1768

DTC P0263, P0266, P0269, P0272 NO.1 — 4 CYLINDER MISFIRE
[K9K]

Diagnostic Procedure

BBS0044V

1. CHECK FOR INTAKE AIR LEAK

A

1. Start engine and run it at idle speed.
2. Listen for the sound of the intake air leak.
OK or NG
OK
>> GO TO 2.
NG
>> Discover air leak location and repair.

EC

C

2. CHECK FOR EGR VOLUME CONTROL VALVE
D

1. Stop engine.
2. Visually check EGR volume comtrol valve.
Refer to EM-251, «EGR UNIT» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

E

F

3. CHECK FUEL INJECTOR
G

Refer to EC-1750, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

H

4. REPLACE FUEL INJECOR
1.
2.

Replace fuel injector of malfunctioning cylinder.
Perform Injector Adjustment Value Registration. Refer to EC-1625, «Injector Adjustment Value Registration» .

I

J

>> INSPECTION END
K

5. CHECK COMPRESSION PRESSURE
Check compression pressure.
OK or NG
OK
>> GO TO 6.
NG
>> Repair.

L

M

6. CHECK VALVE CLEARANCE
Check valve clearance.
Refer to EM-292, «Valve Clearance» .
OK or NG
OK
>> GO TO 7.
NG
>> Repair.

7. CHECK INTERMITTENT INCIDENT
Perform EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1769

DTC P0325 KNOCK SENSOR (KS)
[K9K]

DTC P0325 KNOCK SENSOR (KS)
Component Description

PFP:22060
BBS0044W

The knock sensor (1) is attached to the cylinder block. It senses engine knocking using a piezoelectric element. A knocking vibration from the cylinder block is sensed as vibrational pressure. This pressure is converted into a voltage signal and sent to the ECM.
●
Fuel rail (2)

MBIB1529E

On Board Diagnosis Logic

BBS0044X

The MIL will not light up for these diagnoses.
DTC No.

Trouble Diagnosis Name

Possible Cause
●

P0325

KNOCK SENSOR CIRCUIT
●

Harness or connectors
(The sensor circuit is open or shorted.)
Knock sensor

NOTE:
●
If DTC P0325 is displayed with DTC P0115, P0180 or P2226, first perform the trouble diagnosis for
DTC P0115, P0180 or P22264. Refer to EC-1727, «DTC P0115 ECT SENSOR» , EC-1732, «DTC P0180
FUEL PUMP TEMPERATURE SENSOR» or EC-1863, «DTC P2226 BARO SENSOR» .
A malfunction for these sensors could lead to an incorrect touble diagnosis on the knock sensor.
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present when the engine speed is at idle speed.

EC-1770

DTC P0325 KNOCK SENSOR (KS)
[K9K]

Wiring Diagram

BBS0044Z

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1558E

EC-1771

DTC P0325 KNOCK SENSOR (KS)
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
41

44

WIRE
COLOR
—

W

ITEM
Sensor ground
(Knock sensor shield circuit)
Knock sensor

CONDITION
[Engine is running]
●

Idle speed

[Engine is running]
●

Idle speed

DATA (DC Voltage)

Approximately 0.2V

Approximately 0.3V

[Engine is running]
45

O

Sensor ground
(Knock sensor)

●

Warm-up condition

●

Idle speed

Approximately 0.3V

Diagnostic Procedure

BBS00450

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screw on the body.
Refer to EC-1703, «Ground Inspection» .
–
Body ground (1)
–
Primimg pump (2)
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

MBIB1520E

2. CHECK KNOCK SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
–

2.
3.

Disconnect knock sensor (1) harness connector.
Fuel rail (2)
Disconnect ECM harness connector.
Check harness continuity between knock sensor terminal 1 and
ECM terminal 45. Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

3. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between knock sensor terminal 2 and ECM terminal 44.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1772

MBIB1529E

DTC P0325 KNOCK SENSOR (KS)
[K9K]

4. CHECK KNOCK SENSOR

A

Check continuity between knock sensor terminals 1 and 2.
Continuity should exist.

EC

OK or NG
OK
>> GO TO 5.
NG
>> Replace knock sensor.

C

5. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

D

>> INSPECTION END
E

Removal and Installation

BBS00452

KNOCK SENSOR
Refer to EM-282, «OVERHAUL» .

F

G

H

I

J

K

L

M

EC-1773

DTC P0335 CKP SENSOR
[K9K]

DTC P0335 CKP SENSOR
Description

PFP:23731
BBS0044E

The crankshaft position (CKP) sensor is located on the oil pan facing
the gear teeth (cogs) of the signal plate.
The ECM receives the voltage signal from crankshaft position sensor
and detects the fluctuation of the engine revolution.

MBIB1530E

CONSULT-II Reference Value in Data Monitor Mode

BBS0044F

Specification data are reference values.
MONITOR ITEM
ENGINE SPEED

CONDITION
●

SPECIFICATION

Run engine and compare CONSULT-II value with the tachometer
indication.

Almost the same speed as the
tachometer indication

On Board Diagnosis Logic
DTC No.

BBS0044G

Trouble diagnosis name

Possible cause

CRANKSHAFT POSITION SENSOR CIRCUIT

P0335

●

1.DEF: Inconsistency

●

2.DEF: No signal

●

3.DEF: Too many additional teeth

●

4.DEF: Teeth missing

●

5.DEF: Additional teeth

●

6.DEF: Too many teeth missing

●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Crankshaft position sensor

NOTE:
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present with the engine cranking or idling.
●
Special notes:
–
If this DTC (with 1.DEF, 2.DEF, 3.DEF, 6.DEF) is present, the engine stops and malfunction indicator
(Red) lights up.
–
If this DTC (with 4.DEF, 5.DEF) is present, the engine performance is reduced and malfunction indicator
(Red) will not light up.

EC-1774

DTC P0335 CKP SENSOR
[K9K]

Wiring Diagram

BBS0044I

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1559E

EC-1775

DTC P0335 CKP SENSOR
[K9K]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

[Engine is running]
●

Warm-up condition

●

Idle speed

DATA
(DC Voltage and Pulse Signal)
0 — 12.5V

NOTE:
The pulse cycle changes depending on rpm at
idle.
MBIB1508E

55

R

Crankshaft position sensor
0 — 12.5V
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

MBIB1509E

[Engine is running]
65

B

Crankshaft position sensor
ground

●

Warm-up condition

●

Idle speed

Approximately 0.3V

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS0044J

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screw on the body.
Refer to EC-1703, «Ground Inspection» .
–
Body ground (1)
–
Priming pump (2)
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

MBIB1520E

EC-1776

DTC P0335 CKP SENSOR
[K9K]

2. CHECK CKP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

A

Disconnect crankshaft position (CKP) sensor (1) harness connector.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 65 and CKP
sensor terminal 2.
Refer to Wiring Diagram.

EC

C

Continuity should exist.
4. Also check harness for and short to ground and short to power.
OK or NG
OK
>> GO TO 3.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

D
MBIB1531E

E

3. CHECK CKP SENSOR INPUT SIGNALCIRCUIT FOR OPEN AND SHORT
1.

F

Check harness continuity between ECM terminal 55 and CKP sensor terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

G

2. Also check harness for and short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

H

4. CHECK CRANKSHAFT POSITION SENSOR

I

Refer to EC-1777, «Component Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace crankshaft position sensor.

J

5. CHECK GEAR TOOTH

K

Visually check for chipping flywheel gear tooth.
OK or NG
OK
>> GO TO 6.
NG
>> Replace signal plate.

L

6. CHECK INTERMITTENT INCIDENT

M

Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

Component Inspection

BBS0044K

CRANKSHAFT POSITION SENSOR
1.
2.

Disconnect crankshaft position sensor harness connector.
Check resistance between crankshaft positon sensor terminals 1 and 2.
Resistance: 760 Ω

3.

If NG, replace crankshaft position sensor.

Removal and Installation

BBS0044L

CRANKSHAFT POSITION SENSOR
Refer to EM-257, «OIL PAN» .

EC-1777

DTC P0340 CMP SENSOR
[K9K]

DTC P0340 CMP SENSOR
Description

PFP:23731
BBS0044M

The camshaft position (CMP) sensor senses the retraction with camshaft to identify a particular cylinder. The camshaft position (CMP)
sensor senses the piston position.
The sensor consists of a permanent magnet and Hall IC.
When engine is running, the high and low parts of the teeth cause
the gap with the sensor to change.
The changing gap causes the magnetic field near the sensor to
change.
Due to the changing magnetic field, the voltage from the sensor
changes.
MBIB1532E

On Board Diagnosis Logic
DTC No.

P0340

BBS0044N

Trouble diagnosis name

CAMSHAFT POSITION SENSOR CIRCUIT
●

1.DEF: Signal absent

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Camshaft position sensor

●

Timing belt

●

Signal plate

NOTE:
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present with the engine cranking or idling.

EC-1778

DTC P0340 CMP SENSOR
[K9K]

Wiring Diagram

BBS0044P

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1560E

EC-1779

DTC P0340 CMP SENSOR
[K9K]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

[Engine is running]
●

Warm-up condition

●

Idle speed

DATA
(DC Voltage and Pulse Signal)
0 — 1V

NOTE:
The pulse cycle changes depending on rpm at
idle.
MBIB1510E

56

Y

Camshaft position sensor
0 — 1V
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

MBIB1511E

[Engine is running]
66

L

Sensor ground
(Camshaft position sensor)

●

Warm-up condition

●

Idle speed

[Ignition switch ON]
[Ignition switch OFF]
●

104

P

ECM relay (self-shutoff)

For a few seconds after turning ignition
switch OFF

[Ignition switch OFF]
●

109
110

G
G

Power supply for ECM

More than a few seconds after turning ignition switch OFF

[Ignition switch ON]

Approximately 0.3V

Approximately 1.4V

BATTERY VOLTAGE
(11 — 14V)
BATTERY VOLTAGE
(11 — 14V)

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure

BBS0044Q

1. CHECK GROUND CONNECTIONS
1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screw on the body.
Refer to EC-1703, «Ground Inspection» .
–
Body ground (1)
–
Priming pump (2)
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

MBIB1520E

EC-1780

DTC P0340 CMP SENSOR
[K9K]

2. CHECK CMP SENSOR POWER SUPPLY CIRCUIT
1.
2.

A

Disconnect camshaft position (CMP) sensor (1) harness connector.
Turn ignition switch ON.

EC

C

D
MBIB1533E

3.

E

Check voltage between CMP sensor terminal 3 and ground with
CONSULT-II or tester.
Voltage: Approximately 5.0V

F

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

G

MBIB1010E

H

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F101
●
Harness continuity between camshaft position sensor and IPDM E/R

I

J

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK CMP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 66 and CMP sensor terminal 1.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK CMP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 56 and CMP sensor terminal 2.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1781

K

L

M

DTC P0340 CMP SENSOR
[K9K]

6. CHECK CAMSHAFT POSITION SENSOR
Refer to EC-1783, «Component Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Replace camshaft position sensor.

7. CHECK SPROCKET
Visually check for chipping signal plate gear tooth.
OK or NG
OK
>> GO TO 8.
NG
>> Repair or replace sprocket.

8. CHECK TIMING BELT
Refer to EM-272, «TIMING BELT» .
OK or NG
OK
>> GO TO 8.
NG
>> Replace timing belt.

9. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1782

DTC P0340 CMP SENSOR
[K9K]

Component Inspection

BBS0044R

A

CAMSHAFT POSITION SENSOR
1.
2.
3.

Reconnect all harness connectors disconnected.
Start engine and warm it up to normal operating temperature.
Measure the voltage signal between ECM terminal 56 and
ground with CONSULT-II or tester under the followng conditions.
CONDITION

[Engine is running]
●

Warm-up condition

●

Idle speed

EC

DATA
(DC Voltage and Pulse Signal)

C

0 — 1V

D

NOTE:
The pulse cycle changes depending on
rpm at idle.

E
MBIB1540E

MBIB1510E

F

0 — 1V
[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

G

H

MBIB1511E

4.

If NG, replace camshaft position sensor.

Removal and Installation

BBS0044S

I

CAMSHAFT POSITION SENSOR
Refer to EM-272, «TIMING BELT» .
J

K

L

M

EC-1783

DTC P0380 GLOW CONTROL UNIT
[K9K]

DTC P0380 GLOW CONTROL UNIT
On Board Diagnosis Logic
DTC No.
P0380

PFP:22693
BBS00453

Trouble diagnosis name

Possible cause
●

Harness or connectors
(The glow control unit circuit is open.)

●

Glow control unit

GLOW PLUG DIAGNOSTIC CONNECTION

EC-1784

DTC P0380 GLOW CONTROL UNIT
[K9K]

Wiring Diagram

BBS00455

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1561E

EC-1785

DTC P0380 GLOW CONTROL UNIT
[K9K]

Diagnostic Procedure

BBS00456

1. CHECK GLOW CONTROL UNIT POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect glow control unit harness connecetor.
Check voltage between glow control unit terminal 3 and ground
with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

MBIB1470E

2. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E49, F103
●
60A fusible link
●
Harness for open and short between glow control unit and battery
>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK GLOW CONTROL UNIT OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

Disconnect ECM harness connector.
Check harness continuity between ECM terminal 90 and glow control unit terminal 9.
Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK GLOW CONTROL UNIT INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 98 and glow control unit terminal 8.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1786

DTC P0380 GLOW CONTROL UNIT
[K9K]

5. CHECK GLOW PLUG CIRCUIT
1.
2.

A

Disconnect glow plug harness connectors.
Check harness continuity between glow control unit terminals 1, 2, 6, 7 and glow plug teminal 1.
Refer to Wiring Diagram.

EC

Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

C

D

6. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace glow control unit
NG
>> Repair or replace.

E

F

G

H

I

J

K

L

M

EC-1787

DTC P0382 GLOW CONTROL UNIT
[K9K]

DTC P0382 GLOW CONTROL UNIT
On Board Diagnosis Logic
DTC No.

PFP:22693
BBS00458

Trouble diagnosis name
GLOW CONTROL UNIT CIRCUIT

P0382

●

CC.1: Short circuit to +12V

●

CO.0: Open circuit or short circuit to ground

Possible cause
●

Harness or connectors
(The glow control unit circuit is open or shorted.)

●

Glow control unit

NOTE:
●
Special note:
–
If this DTC is present, engine starting is difficult (or impossible when cold).
–
If this DTC (with CO.0) is present, continuous operation of the glow plugs permanently controlled with risk
of being damaged and risk of damaging the engine.

EC-1788

DTC P0382 GLOW CONTROL UNIT
[K9K]

Wiring Diagram

BBS0045A

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1561E

EC-1789

DTC P0382 GLOW CONTROL UNIT
[K9K]

Diagnostic Procedure

BBS0045B

1. CHECK GLOW CONTROL UNIT POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect glow control unit harness connecetor.
Check voltage between glow control unit terminal 3 and ground
with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

MBIB1470E

2. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E49, F103
●
60A fusible link
●
Harness for open and short between glow control unit and battery
>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK GLOW CONTROL UNIT OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.

Disconnect ECM harness connector.
Check harness continuity between ECM terminal 90 and glow control unit terminal 9.
Refer to Wiring Diagram.
Continuity should exist.

3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK GLOW CONTROL UNIT INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

Check harness continuity between ECM terminal 98 and glow control unit terminal 8.
Refer to Wiring Diagram.
Continuity should exist.

2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace glow control unit
NG
>> Repair or replace.

EC-1790

DTC P0400 EGR FUNCTION
[K9K]

DTC P0400 EGR FUNCTION
CONSULT-II Reference Value in Data Monitor Mode

PFP:14710

A
BBS0045E

Specification data are reference values.
MONITOR ITEM

CONDITION

EGR PO
RECOPY

EGR/V OPN
REEF

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

EGR POS SE VO

Idle

D
Idle

Approximately -50 %

E

Idle

Approximately 3.56 V

EGR VOLUME CONTROL VALVE CIRCUIT
●

1.DEF: Parameter at minimum level

●

2.DEF: Parameter at maximum level

●

3.DEF: Inconsistency

●

4.DEF: Valve jammed

●

5.DEF: Valve clogged

F

BBS0045F

Trouble diagnosis name

P0400

C

Approximately -50 %

On Board Diagnosis Logic
DTC No.

EC

SPECIFICATION

G

Possible cause
●

Harness or connectors
(The EGR volume control valve circuit is open
or shorted.)

●

EGR volume control valve stuck

●

EGR volume control valve control position
sensor

●

EGR passage clogged

NOTE:
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present with engine running.
●
Special notes:
–
If this DTC is present, the engine will be unsteady, with popssible stalling. Starting malfunctions, or even
impossible when cold.
–
Malfunction indicator (Red) lights up.
–
Malfunction indicator (Yellow) lights up.

H

I

J

K

L

M

EC-1791

DTC P0400 EGR FUNCTION
[K9K]

Wiring Diagram

BBS0045H

MBWA1562E

EC-1792

DTC P0400 EGR FUNCTION
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse Signal)

[Engine is running]

37

B

●

Warm-up condition

●

Idle speed

EGR volume control valve

Warm-up condition

●

Engine speed: 2,000 rpm

C

D
Approximately 0.78V

E

[Engine is running]

40

49

W

SB

EGR volume control valve

Sensor power supply
(EGR volume control valve
control position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0.7 — 1.9

F

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

[Ignition switch ON]

EC

Approximately 1.1V

[Engine is running]
●

A

Approximately 1.5 — 1.9V

G
Approximately 5.0V

H
[Engine is running]

59

69

L

P

EGR volume control valve
control position sensor

Sensor ground
(EGR volume control valve
control position sensor)

●

Warm-up condition

●

Idle speed

Approximately 4.1V

I

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

Approximately 3.3V

J

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0.5V

K

L

M

EC-1793

DTC P0400 EGR FUNCTION
[K9K]

Diagnostic Procedure

BBS0045I

1. CHECK EGR VOLUME CONTROL VALVE CONTROL CIRCUIT
1.
2.
–

3.
4.

Turn ignition switch OFF.
Disconnect EGR volume control valve (1) harness connector.
Brake fluid reservoir (2)
Disconnect ECM harness connector.
Check harness continuity between ECM terminals and EGR volume control valve terminals as follows.
Refer to Wiring Diagram.
ECM terminal

EGR volume control valve terminal

37

2

40

6

49

1

59

5

69

3

Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 2.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

2. CHECK EGR VOLUME CONTROL VALVE
Refer to EC-1799, «Component Inspection» .
OK or NG
OK
>> GO TO 3.
NG
>> Replace EGR volume control valve.

3. CHECK EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
Refer to EC-1799, «Component Inspection» .
OK or NG
OK
>> GO TO 4.
NG
>> Replace EGR volume control valve.

4. CHECK EGR PASSAGE
Check the following for clogging and cracks.
EGR tube
●
EGR hose
●
EGR cooler
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace EGR passage.
●

5. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1794

MBIB1535E

DTC P0403 EGR VOLUME CONTROL VALVE
[K9K]

DTC P0403 EGR VOLUME CONTROL VALVE
CONSULT-II Reference Value in Data Monitor Mode

PFP:14710

A
BBS0045M

Specification data are reference values.
MONITOR ITEM

CONDITION

EGR PO
RECOPY

EGR/V OPN
REEF

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

EGR POS SE VO

Idle

D
Idle

Approximately -50 %

E

Idle

Approximately 3.56 V

F

BBS0045N

Trouble diagnosis name
EGR VOLUME CONTROL VALVE CIRCUIT

P0403

C

Approximately -50 %

On Board Diagnosis Logic
DTC No.

EC

SPECIFICATION

●

CC.1: Short circuit to +12V

●

CO.0: Open circuit or short circuit to ground

●

CO: Open circuit

●

1.DEF: Overheat detection

G

Possible cause
●

Harness or connectors
(The EGR volume control valve circuit is open
or shorted.)

●

EGR volume control valve stuck closed

●

EGR volume control valve control positiom
sensor

NOTE:
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present with engine running at idle speed.
●
Special notes:
–
If this DTC is present, the engine is difficult to start, or even impossible when cold.
–
Malfunction indicator (Red) lights up.
–
Malfunction indicator (Yellow) lights up.

H

I

J

K

L

M

EC-1795

DTC P0403 EGR VOLUME CONTROL VALVE
[K9K]

Wiring Diagram

BBS0045P

MBWA1562E

EC-1796

DTC P0403 EGR VOLUME CONTROL VALVE
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse Signal)

[Engine is running]

37

B

●

Warm-up condition

●

Idle speed

EGR volume control valve

Warm-up condition

●

Engine speed: 2,000 rpm

C

D
Approximately 0.78V

E

[Engine is running]

40

49

W

SB

EGR volume control valve

Sensor power supply
(EGR volume control valve
control position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0.7 — 1.9

F

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

[Ignition switch ON]

EC

Approximately 1.1V

[Engine is running]
●

A

Approximately 1.5 — 1.9V

G
Approximately 5.0V

H
[Engine is running]

59

69

L

P

EGR volume control valve
control position sensor

Sensor ground
(EGR volume control valve
control position sensor)

●

Warm-up condition

●

Idle speed

Approximately 4.1V

I

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

Approximately 3.3V

J

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0.5V

K

L

M

EC-1797

DTC P0403 EGR VOLUME CONTROL VALVE
[K9K]

Diagnostic Procedure

BBS0045Q

1. CHECK EGR VOLUME CONTROL VALVE CONTROL CIRCUIT
1.
2.
–

3.
4.

Turn ignition switch OFF.
Disconnect EGR volume control valve (1) harness connector.
Brake fluid reservoir (2)
Disconnect ECM harness connector.
Check harness continuity between ECM terminals and EGR volume control valve terminals as follows.
Refer to Wiring Diagram.
ECM terminal

EGR volume control valve terminal

37

2

40

6

49

1

59

5

69

3

Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 2.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

2. CHECK EGR VOLUME CONTROL VALVE
Refer to EC-1799, «Component Inspection» .
OK or NG
OK
>> GO TO 3.
NG
>> Replace EGR volume control valve.

3. CHECK EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
Refer to EC-1799, «Component Inspection» .
OK or NG
OK
>> GO TO 4.
NG
>> Replace EGR volume control valve.

4. CHECK EGR PASSAGE
Check the following for clogging and cracks.
EGR tube
●
EGR hose
●
EGR cooler
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace EGR passage.
●

5. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1798

MBIB1535E

DTC P0403 EGR VOLUME CONTROL VALVE
[K9K]

Component Inspection

BBS0045R

A

EGR VOLUME CONTROL VALVE
1.
2.

Disconnect EGR volume control valve (1) harness connector.
● Brake fluid reservoir (2)
Check resistance between EGR volume control valve terminals
2 and 6.

EC

Resistance: 8 ± 2.3 Ω at 25°C (77°F)

C

If NG, replace EGR volume control valve.

D
MBIB1535E

EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
1.
2.

E

Disconnect EGR volume control valve (1) harness connector.
● Brake fluid reservoir (2)
Check resistance between EGR volume control valve terminals
1 and 3.

F

Continuity should exist.
G

If NG, replace EGR volume control valve.

H
MBIB1535E

Removal and Installation

BBS0045S

EGR VOLUME CONTROL VALVE

I

Refer to EM-251, «EGR UNIT» .
J

K

L

M

EC-1799

DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[K9K]

DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
PFP:22693

CONSULT-II Reference Value in Data Monitor Mode

BBS0047K

Specification data are reference values.
MONITOR ITEM

EGR PO
RECOPY

EGR/V OPN
REEF

CONDITION
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

EGR POS SE VO

SPECIFICATION

Idle

Approximately -50 %

Idle

Approximately -50 %

Idle

Approximately 3.56 V

On Board Diagnosis Logic
DTC No.

BBS0047L

Trouble diagnosis name
EGR VOLUME CONTROL VALVE CONTROL POSITION
SENSOR CIRCUIT

P0409

●

1.DEF: Above maximum threshold

●

1.DEF: Below minimum threshold

Possible Cause
●

Harness or connectors
(The EGR volume control valve control position
sensor circuit is open or shorted.)

●

EGR volume control valve control position sensor

●

EGR volume control valve stuck

NOTE:
●
If this DTC is displayed with DTC P0641, first perform the trouble diagnosis for DTC P0641. Refer
to EC-1830, «DTC P0641 SENSOR POWER SUPPLY» .

EC-1800

DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[K9K]

Wiring Diagram

BBS0047N

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1562E

EC-1801

DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse Signal)

[Engine is running]

37

B

●

Warm-up condition

●

Idle speed

EGR volume control valve

Approximately 1.1V

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

Approximately 0.78V

[Engine is running]

40

49

W

SB

EGR volume control valve

Sensor power supply
(EGR volume control valve
control position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0.7 — 1.9

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

[Ignition switch ON]

Approximately 1.5 — 1.9V

Approximately 5.0V

[Engine is running]

59

69

L

P

EGR volume control valve
control position sensor

Sensor ground
(EGR volume control valve
control position sensor)

●

Warm-up condition

●

Idle speed

Approximately 4.1V

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

Approximately 3.3V

[Engine is running]
●

Warm-up condition

●

Idle speed

EC-1802

Approximately 0.5V

DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[K9K]

Diagnostic Procedure

BBS0047O

1. CHECK EGR VOLUME CONTROL VALVE CONTROL CIRCUIT
1.
2.
–

3.
4.

A

Turn ignition switch OFF.
Disconnect EGR volume control valve (1) harness connector.
Brake fluid reservoir (2)
Disconnect ECM harness connector.
Check harness continuity between ECM terminals and EGR volume control valve terminals as follows.
Refer to Wiring Diagram.

EC

C

D
ECM terminal

EGR volume control valve terminal

37

2

40

6

49

1

59

5

69

3

Continuity should exist.

MBIB1535E

E

F

G

5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 2.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

2. CHECK EGR VOLUME CONTROL VALVE

H

I

Refer to EC-1804, «Component Inspection» .
OK or NG
OK
>> GO TO 3.
NG
>> Replace EGR volume control valve.

J

3. CHECK EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR

K

Refer to EC-1804, «Component Inspection» .
OK or NG
OK
>> GO TO 4.
NG
>> Replace EGR volume control valve.

L

4. CHECK EGR PASSAGE

M

Check the following for clogging and cracks.
●
EGR tube
●
EGR hose
●
EGR cooler
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace EGR passage.

5. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1803

DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[K9K]

Component Inspection

BBS004UR

EGR VOLUME CONTROL VALVE
1.
2.

Disconnect EGR volume control valve (1) harness connector.
● Brake fluid reservoir (2)
Check resistance between EGR volume control valve terminals
2 and 6.
Resistance: 8 ± 2.3 Ω at 25°C (77°F)
If NG, replace EGR volume control valve.

MBIB1535E

EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
1.
2.

Disconnect EGR volume control valve (1) harness connector.
● Brake fluid reservoir (2)
Check resistance between EGR volume control valve terminals
1 and 3.
Continuity should exist.
If NG, replace EGR volume control valve.

MBIB1535E

Removal and Installation

BBS004US

EGR VOLUME CONTROL VALVE
Refer to EM-251, «EGR UNIT» .

EC-1804

DTC P0487 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[K9K]

DTC P0487 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
PFP:22693

CONSULT-II Reference Value in Data Monitor Mode

BBS0047R

Specification data are reference values.
MONITOR ITEM

EGR PO
RECOPY

EGR/V OPN
REEF

EC
CONDITION

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

EGR POS SE VO

SPECIFICATION

Idle

D
Idle

Approximately -50 %

E

Idle

F

Approximately 3.56 V

BBS0047S

Trouble diagnosis name
EGR VOLUME CONTROL VALVE CONTROL POSITION
SENSOR CIRCUIT

P0487

C

Approximately -50 %

On Board Diagnosis Logic
DTC No.

A

●

CO.0: Short circuit to ground or open circuit

●

CC.1: Short circuit to +12V

G

Possible Cause
●

Harness or connectors
(The EGR volume control valve control position
sensor circuit is open or shorted.)

H

●

EGR volume control valve control position sensor

I

●

EGR volume control valve stuck

NOTE:
●
If this DTC is displayed with DTC P0641, first perform the trouble diagnosis for DTC P0641. Refer
to EC-1830, «DTC P0641 SENSOR POWER SUPPLY» .
●
Special notes:
–
Malfunction indicator (Yellow) lights up.

J

K

L

M

EC-1805

DTC P0487 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[K9K]

Wiring Diagram

BBS0047U

MBWA1562E

EC-1806

DTC P0487 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION

DATA
(DC Voltage and Pulse Signal)

[Engine is running]

37

B

●

Warm-up condition

●

Idle speed

EGR volume control valve

Warm-up condition

●

Engine speed: 2,000 rpm

C

D
Approximately 0.78V

E

[Engine is running]

40

49

W

SB

EGR volume control valve

Sensor power supply
(EGR volume control valve
control position sensor)

●

Warm-up condition

●

Idle speed

Approximately 0.7 — 1.9

F

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

[Ignition switch ON]

EC

Approximately 1.1V

[Engine is running]
●

A

Approximately 1.5 — 1.9V

G
Approximately 5.0V

H
[Engine is running]

59

69

L

P

EGR volume control valve
control position sensor

Sensor ground
(EGR volume control valve
control position sensor)

●

Warm-up condition

●

Idle speed

Approximately 4.1V

I

[Engine is running]
●

Warm-up condition

●

Engine speed: 2,000 rpm

Approximately 3.3V

J

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0.5V

K

L

M

EC-1807

DTC P0487 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[K9K]

Diagnostic Procedure

BBS0047V

1. CHECK EGR VOLUME CONTROL VALVE CONTROL CIRCUIT
1.
2.
–

3.
4.

Turn ignition switch OFF.
Disconnect EGR volume control valve (1) harness connector.
Brake fluid reservoir (2)
Disconnect ECM harness connector.
Check harness continuity between ECM terminals and EGR volume control valve terminals as follows.
Refer to Wiring Diagram.
ECM terminal

EGR volume control valve terminal

37

2

40

6

49

1

59

5

69

3

Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 2.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

2. CHECK EGR VOLUME CONTROL VALVE
Refer to EC-1809, «Component Inspection» .
OK or NG
OK
>> GO TO 3.
NG
>> Replace EGR volume control valve.

3. CHECK EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
Refer to EC-1809, «Component Inspection» .
OK or NG
OK
>> GO TO 4.
NG
>> Replace EGR volume control valve.

4. CHECK EGR PASSAGE
Check the following for clogging and cracks.
EGR tube
●
EGR hose
●
EGR cooler
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace EGR passage.
●

5. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1808

MBIB1535E

DTC P0487 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[K9K]

Component Inspection

BBS004UT

A

EGR VOLUME CONTROL VALVE
1.
2.

Disconnect EGR volume control valve (1) harness connector.
● Brake fluid reservoir (2)
Check resistance between EGR volume control valve terminals
2 and 6.

EC

Resistance: 8 ± 2.3 Ω at 25°C (77°F)

C

If NG, replace EGR volume control valve.

D
MBIB1535E

EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
1.
2.

E

Disconnect EGR volume control valve (1) harness connector.
● Brake fluid reservoir (2)
Check resistance between EGR volume control valve terminals
1 and 3.

F

Continuity should exist.
G

If NG, replace EGR volume control valve.

H
MBIB1535E

Removal and Installation

BBS004UU

EGR VOLUME CONTROL VALVE

I

Refer to EM-251, «EGR UNIT» .
J

K

L

M

EC-1809

DTC P0500 VSS
[K9K]

DTC P0500 VSS
Description

PFP:32702
BBS0045T

The vehicle speed signal is sent to the combination meter from the “ABS actuator and electric unit (control
unit)” by CAN communication line. The combination meter then sends a signal to the ECM by CAN communication line.

On Board Diagnosis Logic
DTC No.

P0500

BBS0045U

Trouble diagnosis name

Possible cause
●

Harness or connectors
(The CAN communication line is open or shorted)

●

Harness or connectors
(The vehicle speed signal circuit is open or shorted)

●

Wheel sensor

●

Combination meter

●

ABS actuator and electric unit (control unit)

VEHICLE SPEED INFORMATION

Diagnostic Procedure

BBS0045X

1. CHECK DTC WITH “ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)”
Refer to BRC-8, «TROUBLE DIAGNOSIS» or BRC-49, «TROUBLE DIAGNOSIS» .
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace.

2. CHECK COMBINATION METER
Refer to DI-4, «COMBINATION METERS» .
>> INSPECTION END

EC-1810

DTC P0530 REFRIGERANT PRESSURE SENSOR
[K9K]

DTC P0530 REFRIGERANT PRESSURE SENSOR
Component Description

PFP:22693

A
BBS0045Y

The refrigerant pressure sensor (1) is installed at the condenser of
the air conditioner system. The sensor uses an electrostatic volume
pressure transducer to convert refrigerant pressure to voltage. The
voltage signal is sent to ECM, and ECM controls cooling fan system.

EC

C

D
MBIB1536E

E

CONSULT-II Reference Value in Data Monitor Mode

BBS0045Z

Specification data are reference values.
MONITOR ITEM

CONDITION
●

Engine: After warming up

●

Air conditioner switch: OFF

●

Shift lever: Neutral position

●

No load

REFGERNT PRSS

Idle

Approximately 5.7 bar

On Board Diagnosis Logic
DTC No.

Trouble diagnosis name

●

CO.1: Short circuit to +12V or open circuit

●

CC.0: Short circuit to ground

G

BBS00460

REFRIGERANT PRESSURE SENSOR CIRCUIT
P0530

F

SPECIFICATION

H

Possible cause
●

Harness or connectors
(The sensor circuit is open or shorted.)

●

Refrigerant pressure sensor

NOTE:
●
If DTC P0530 is displayed with DTC P0641, first perform the trouble diagnosis for DTC P0643.1
Refer to EC-1830, «DTC P0641 SENSOR POWER SUPPLY» .

I

J

K

L

M

EC-1811

DTC P0530 REFRIGERANT PRESSURE SENSOR
[K9K]

Wiring Diagram

BBS00462

MBWA1563E

EC-1812

DTC P0530 REFRIGERANT PRESSURE SENSOR
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
83

WIRE
COLOR
W

A

EC
ITEM
Sensor power supply
(Refrigerant pressure sensor)

CONDITION

[Ignition switch: ON]

DATA (DC Voltage)

Approximately 5.0V

C

Approximately 2.3V

D

[Engine is running]
89

BR

Refrigerant pressure sensor

●

Warm-up condition

●

Both A/C switch and blower fan switch: ON
(Compressor operates.)

E

[Engine is running]
107

Y

Sensor ground
(Refrigerant pressure sensor)

●

Warm-up condition

●

Idle speed

Approximately 0.3V

F

Diagnostic Procedure

BBS00463

1. CHECK GROUND CONNECTIONS
G

1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screw on the body.
Refer to EC-1703, «Ground Inspection» .
–
Body ground (1)
–
Priming pump (2)
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

H

I

J
MBIB1520E

K

L

M

EC-1813

DTC P0530 REFRIGERANT PRESSURE SENSOR
[K9K]

2. CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT
1.
2.

Disconnect refrigerant pressure sensor (1) harness connector.
Turn ignition switch ON.

MBIB1536E

3.

Check voltage between refrigerant pressure sensor terminal 3
and ground with CONSULT-II or tester.
Voltage: Approximately 5.0V

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

MBIB1471E

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F101
●
Harness for open or short between ECM and refrigerant pressure sensor
>> Repair harness or connectors.

4. CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between refrigerant pressure sensor terminal 1 and ECM terminal 107.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F101
●
Harness for open or short between ECM and refrigerant pressure sensor
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1814

DTC P0530 REFRIGERANT PRESSURE SENSOR
[K9K]

6. CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

A

Check harness continuity between ECM terminal 89 and refrigerant pressure sensor terminal 2.
Refer to Wiring Diagram.
EC

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

C

7. DETECT MALFUNCTIONING PART

D

Check the following.
●
Harness connectors E48, F101
●
Harness for open or short between ECM and refrigerant pressure sensor

E

F

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK INTERMITTENT INCIDENT

G

Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace refrigerant pressure sensor.
NG
>> Repair or replace.

Removal and Installation

H

BBS00464

REFRIGERANT PRESSURE SENSOR

I

Refer to ATC-135, «REFRIGERANT LINES» or MTC-81, «REFRIGERANT LINES» .
J

K

L

M

EC-1815

DTC P0560 BATTERY VOLTAGE
[K9K]

DTC P0560 BATTERY VOLTAGE
On Board Diagnosis Logic
DTC No.

PFP:22693
BBS00465

Trouble diagnosis name

Possible cause
●

Battery

●

Battery terminal

●

Alternator

●

Incorrect jump starting

BATTERY VOLTAGE
P0560

●

1.DEF: Above maximum threshold

●

2.DEF: Below threshold

NOTE:
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present when the engine is running at above 1,000 rpm.
●
Special notes:
–
Malfunction indicator (Red) lights up.

EC-1816

DTC P0560 BATTERY VOLTAGE
[K9K]

Wiring Diagram

BBS004U4

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1571E

EC-1817

DTC P0560 BATTERY VOLTAGE
[K9K]
Remarks: Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.
22

WIRE
COLOR
O

ITEM

Ignition switch

CONDITION

[Ignition switch ON]

Diagnostic Procedure

DATA
(DC Voltage and Pulse Signal)
BATTERY VOLTAGE
(11 — 14V)
BBS00467

1. CHECK BATTERY VOLTAGE
1.
2.

Turn ignition switch ON.
Check battery voltage.
Voltage: Above 11V

OK or NG
OK
>> GO TO 2.
NG
>> Recharge the battery.

2. CHECK BATTERY TERMINALS
1. Turn ignition switch OFF.
2. Check battery terminals condition.
OK or NG
OK
>> GO TO 3.
NG
>> Repair the battery terminals.

3. CHECK BATTERY AND ALTERNATOR
Check that the proper type of battery and type of alternator are installed.
Refer to, SC-5, «BATTERY» and SC-15, «CHARGING SYSTEM» .
OK or NG
OK
>> GO TO 4.
NG
>> Replace with a proper one.

4. CHECK ECM POWER SUPPLY CIRCUIT
1.
2.

Turn ignition switch ON.
Check voltage between ECM terminal 22 and groound with
CONSULT-II or tester.
Voltage: Above 11V

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

MBIB1461E

EC-1818

DTC P0560 BATTERY VOLTAGE
[K9K]

5. DETECT MALFUNCTIONING PART

A

Check the following.
●
Fuse block (J/B) connector M7
●
10A fuse
●
Harness connectors M1, E101
●
Harness for open or short between ECM and fuse block (J/B)

EC

C

>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK ELECTRICAL PARTS DAMAGE

D

Check the following for damage.
●
Wiring harness and harness connectors for burn
●
Fuses for short
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace malfunctioning part.

E

F

G

H

I

J

K

L

M

EC-1819

DTC P0571 BRAKE SWITCH
[K9K]

DTC P0571 BRAKE SWITCH
Description

PFP:22693
BBS00468

Brake switch signal is applied to the ECM through the stop lamp switch when the brake pedal is depressed.
This signal is used mainly to decrease the engine speed when the vehicle is driving.

On Board Diagnosis Logic
DTC No.

BBS0046A

Trouble diagnosis name
BRAKE SWITCH CIRCUIT

P0571

●

CO.0: Open circuit or short circuit to ground

●

1.DEF: Signal absent

Possible cause
●

Harness or connectors
(Stop lamp switch circuit is open or shorted.)

●

Stop lamp switch

NOTE:
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present when the ignition switch is turned ON, when deceleratig or when the brake
pedal is depressed.

EC-1820

DTC P0571 BRAKE SWITCH
[K9K]

Wiring Diagram

BBS0046C

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1565E

EC-1821

DTC P0571 BRAKE SWITCH
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION
[Ignition switch: ON]
●

5

R

Stop lamp switch

Brake pedal: Fully released

[Ignition switch: ON]
●

Brake pedal: Slightly depressed

DATA (DC Voltage)

Approximately 0V
BATTERY VOLTAGE
(11 — 14V)

Diagnostic Procedure

BBS0046D

1. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT
1.
2.
–

3.

Turn ignition switch OFF.
Disconnect stop lamp switch (1) harness connector.
Brake pedal (2)
Turn ignition switch ON.

MBIB1346E

4.

Check voltage between stop lamp switch terminal 3 and ground
with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

MBIB1558E

2. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors M1, E101 (RHD models)
●
Harness connectors M8, M201 (RHD models)
●
10A fuse
●
Fuse block (J/B) connector E7
●
Harness for open and short between stop lamp switch and IPDM E/R
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1822

DTC P0571 BRAKE SWITCH
[K9K]

3. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 5 and stop lamp switch terminal 4.
Refer to Wiring Diagram.
Continuity should exist.

A

EC

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

4. DETECT MALFUNCTIONING PART

D

E

Check the following.
●
Harness connectors M1, E101 (RHD models)
●
Harness connectors M8, M201 (RHD models)
●
Harness for open and short between stop lamp switch and ECM

F

G

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK STOP LAMP SWITCH

H

Refer to EC-1824, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace stop lamp switch.

I

6. CHECK INTERMITTENT INCIDENT

J

Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
K

>> INSPECTION END
L

M

EC-1823

DTC P0571 BRAKE SWITCH
[K9K]

Component Inspection

BBS0046E

STOP LAMP SWITCH
1.

Disconnect stop lamp switch (1) harness connector.
● Brake pedal (2)

MBIB1346E

2.

Check continuity between stop lamp switch terminals 3 and 4
under the following conditions.
Conditions

Brake pedal: Fully released
Brake pedal: Slightly depressed

Continuity
Should not exist
Should exist

If NG, adjust stop lamp switch installation, refer to BR-6,
«BRAKE PEDAL» , and perform step 2 again.
PBIB2103E

EC-1824

DTC P0604 ECM
[K9K]

DTC P0604 ECM
Description

PFP:22693

A
BBS0046F

The ECM consists of a microcomputer and connectors for signal
input and output and for power supply. The ECM controls the engine.

EC

C

D
MBIB1517E

E

On Board Diagnosis Logic
DTC No.
P0604

BBS0046G

Trouble diagnosis name
ECM MEMORY

Possible cause
●

F

ECM

NOTE:
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present with engine running.
●
Special notes:
–
If this DTC is present, it is impossible to stop and restart the engine.
–
Malfunction indicator (Red) lights up.

Diagnostic Procedure

G

H
BBS0046I

1. CHECK INJECTOR ADJUSTMENT VALUE

I

Check that all injector adjustment values are resistered correctly.
OK or NG
OK
>> GO TO 2.
NG
>> Enter all injector adjustment values correctly. Refer to EC-1625, «Injector Adjustment Value Registration» .

J

K

2. REPLACE ECM
1.
2.
3.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
Perform Injector Adjustment Value Registration. Refer to EC-1625, «Injector Adjustment Value Registration» .
>> INSPECTION END

EC-1825

L

M

DTC P0606 ECM
[K9K]

DTC P0606 ECM
Description

PFP:23710
BBS0046J

The ECM consists of a microcomputer and connectors for signal
input and output and for power supply. The ECM controls the engine.

MBIB1517E

On Board Diagnosis Logic
DTC No.

BBS0046K

Trouble diagnosis name

Possible cause

ECM

P0606

●

1.DEF: Analogue/digital converter

●

2.DEF: Injection calibration data

●

3.DEF: Memory self-test

●

4.DEF: Non refreshed watchdog

●

5.DEF: Interference on the injector control line

●

6.DEF: Watachdog activation

●

ECM

NOTE:
●
Special note:
–
If this DTC is present, the engine speed is set to 1,300 rpm, alouder sound is heard comimg from the
engine and malfunction indiocator (Red) lights up.
–
When engine is stopped, malfunction indicator (Red) lights up.

Diagnostic Procedure

BBS0046M

1. CHECK DTC
Make sure that which malfunction (DTC second line indication) is displayed.
A

1.DEF, 3.DEF, 4.DEF or 6.DEF

B

2.DEF

C

5.DEF

A, B or C
A
>> GO TO 2.
B
>> GO TO 3.
C
>> GO TO 5.

2. REPLACE ECM
1.
2.
3.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
Perform Injector Adjustment Value Registration. Refer to EC-1625, «Injector Adjustment Value Registration» .
>> INSPECTION END

EC-1826

DTC P0606 ECM
[K9K]

3. CHECK INJECTOR ADJUSTMENT VALUE

A
Check that all injector adjustment values are resistered correctly.
OK or NG
EC
OK
>> GO TO 4.
NG
>> Enter all injector adjustment values correctly. Refer to EC-1625, «Injector Adjustment Value Registration» .
C
REPLACE ECM

4.
1.
2.
3.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
Perform Injector Adjustment Value Registration. Refer to EC-1625, «Injector Adjustment Value Registration» .
>> INSPECTION END

D

E

F

5. CHECK INJECTOR CONTROL CIRCUIT
Check injector control circuit for open and short.
Refer to EC-1741, «Wiring Diagram» .
OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace harness or connectors.

6. REPLACE ECM
1.
2.
3.

G

H

I

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
Perform Injector Adjustment Value Registration. Refer to EC-1625, «Injector Adjustment Value Registration» .

J

K

>> INSPECTION END
L

M

EC-1827

DTC P062F ECM
[K9K]

DTC P062F ECM
Description

PFP:22693
BBS004UK

The ECM consists of a microcomputer and connectors for signal
input and output and for power supply. The ECM controls the engine.

MBIB1517E

On Board Diagnosis Logic
DTC No.

BBS004UL

Trouble diagnosis name

Possible cause

ECM EEPROM MEMORY
P062F

●

1.DEF: Writing to EEPROM memory

●

1.DEF: Reading to EEPROM memory

●

ECM

NOTE:
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present with engine running.
●
Special notes:
–
If this DTC is present, it is impossible to stop and restart the engine.
–
Malfunction indicator (Red) lights up.
–
Malfunction indicator (Yellow) lights up.

Diagnostic Procedure

BBS004UM

1. CHECK BATTERY CABLE
Check the battery cable for damage.
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace.

2. CHECK BATTERY VALTAGE
Check the battery voltage.
Voltage: Above 11V
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

3. CHECK POWER SUPPLY AND GROUND CIRCUIT
Check the ECM power supply and ground circuit. Perform EC-1699, «Diagnostic Procedure» .
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace.

EC-1828

DTC P062F ECM
[K9K]

4. REPLACE ECM
1.
2.
3.

A
Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
EC
Re-communicating Function» .
Perform Injector Adjustment Value Registration. Refer to EC-1625, «Injector Adjustment Value Registration» .
C

>> INSPECTION END
D

E

F

G

H

I

J

K

L

M

EC-1829

DTC P0641 SENSOR POWER SUPPLY
[K9K]

DTC P0641 SENSOR POWER SUPPLY
On Board Diagnosis Logic
DTC No.

PFP:22693
BBS0046N

Trouble diagnosis name

Possible cause
●

Harness or connectors
(The APP sensor 1 power supply circuit is shorted.)
(Fuel rail pressure sensor circuit is shorted.)
(Turbosharger boost sensor circuit is shorted.)
(EGR volume control valve control position sensor circuit
is shorted.)
(Mass air flow sensor circuit is shorted.)
(Refrigerant pressure sensor circuit is shorted.)

●

Accelerator pedal position sensor
(Accelerator pedal position sensor 1)

●

Fuel rail pressure sensor

●

Turbosharger boost sensor

●

EGR volume control valve control position sensor

●

Mass air flow sensor

●

Refrigerant pressure sensor

SENSOR POWER SUPPLY CIRCUIT
P0641

●

1.DEF: Parameter at minimum level

●

2.DEF: Parameter at maximum level

NOTE:
●
If DTC P0641 is displayed with DTC P0100, P0190, P0225, P0235, P0409, P0487, P0530, P0651,
P2120, first perform trouble diagnosis for DTC P0641.
●
Special notes:
–
If this DTC is present, the engine stops immediately and cannnot be restarted.
–
Malfuction indicator (Red) lights up.

EC-1830

DTC P0641 SENSOR POWER SUPPLY
[K9K]

Wiring Diagram

BBS0046P

A

LHD MODELS

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1573E

EC-1831

DTC P0641 SENSOR POWER SUPPLY
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

6

WIRE
COLOR

L/R

ITEM

Sensor ground
(Accelerator pedal position
sensor 2)

CONDITION

DATA
(DC Voltage and Pulse Signal)

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0.3V

[Ignition switch ON]

12

L/W

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

18

L

Sensor power supply
(Accelerator pedal position
sensor 2)

28

B

Sensor ground
(Accelerator pedal position
sensor 1)

●

Warm-up condition

●

Idle speed

Sensor power supply
(Accelerator pedal position
sensor 1)

[Ignition switch ON]

29

R

Approximately 0.4V

[Ignition switch ON]

Approximately 2.0V

Approximately 4.6V

[Engine is running]
Approximately 0.24V

Approximately 5.0V

[Ignition switch ON]

30

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

Approximately 0.76V

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

Approximately 4.2V

47

L

Sensor power supply
(Fuel rail pressure sensor)

[Ignition switch ON]

Approximately 5.0V

48

V

Sensor power supply
(Turbocharger boost sensor)

[Ignition switch ON]

Approximately 5.0V

49

SB

Sensor power supply
(EGR volume control valve
position sensor)

[Ignition switch ON]

Approximately 5.0V

50

L

Sensor power supply
(Mass air flow sensor)

[Ignition switch ON]

Approximately 5.0V

83

W

Sensor power supply
(Refrigerant pressure sensor)

[Ignition switch ON]

Approximately 5.0V

EC-1832

DTC P0641 SENSOR POWER SUPPLY
[K9K]
RHD MODELS
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1574E

EC-1833

DTC P0641 SENSOR POWER SUPPLY
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

6

WIRE
COLOR

L/R

ITEM

Sensor ground
(Accelerator pedal position
sensor 2)

CONDITION

DATA
(DC Voltage and Pulse Signal)

[Engine is running]
●

Warm-up condition

●

Idle speed

Approximately 0.3V

[Ignition switch ON]

12

L/W

Accelerator pedal position
sensor 2

●

Engine stopped

●

Accelerator pedal: Fully released

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

18

L

Sensor power supply
(Accelerator pedal position
sensor 2)

28

B

Sensor ground
(Accelerator pedal position
sensor 1)

●

Warm-up condition

●

Idle speed

Sensor power supply
(Accelerator pedal position
sensor 1)

[Ignition switch ON]

29

R

Approximately 0.4V

[Ignition switch ON]

Approximately 2.0V

Approximately 4.6V

[Engine is running]
Approximately 0.24V

Approximately 5.0V

[Ignition switch ON]

30

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

Approximately 0.76V

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

Approximately 4.2V

47

L

Sensor power supply
(Fuel rail pressure sensor)

[Ignition switch ON]

Approximately 5.0V

48

V

Sensor power supply
(Turbocharger boost sensor)

[Ignition switch ON]

Approximately 5.0V

49

SB

Sensor power supply
(EGR volume control valve
position sensor)

[Ignition switch ON]

Approximately 5.0V

50

L

Sensor power supply
(Mass air flow sensor)

[Ignition switch ON]

Approximately 5.0V

83

W

Sensor power supply
(Refrigerant pressure sensor)

[Ignition switch ON]

Approximately 5.0V

EC-1834

DTC P0641 SENSOR POWER SUPPLY
[K9K]

Diagnostic Procedure

BBS0046Q

1. CHECK GROUND CONNECTIONS

A

1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screw on the body.
Refer to EC-1703, «Ground Inspection» .
–
Body ground (1)
–
Priming pump (2)
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

EC

C

D

MBIB1520E

E

2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT-I
1.
–
–

2.

F

Disconnect accelerator pedal position (APP) sensor harness
connector (1).
Accelerator pedal position sensor (2)
Accelerator pedal (3)
Turn ignition switch ON.

G

H

I
MBIB1345E

3.

Check voltage between APP sensor terminal 4 and ground with
CONSULT-II or tester.

J

Voltage: Approximately 5.0V
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 3.

K

L

MBIB1468E

3. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT-II
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connecor.
Check harness continuity between APP sensor terminal 4 and ECM terminal 29.
Refe to Wiring Diagram.
Continuity should exist.

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

EC-1835

M

DTC P0641 SENSOR POWER SUPPLY
[K9K]

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK SENSOR POWER SUPPLY CIRCUITS
Check the following.
Harness for short to power and short to ground, between the following terminals.
ECM terminal

Sensor terminal

Reference Wiring Diagram

29

APP sensor terminal 4

EC-1831

47

Fuel rail pressure sensor terminal 3

EC-1737

48

Turbocharger boost sensor terminal 1

EC-1764

49

EGR volume control valve control position sensor terminal 1

EC-1801

50

Mass air flow sensor terminal 5

EC-1723

83

Refrigerant pressure sensor terminal 3

EC-1812

OK or NG
OK
>> GO TO 6.
NG
>> Repair short to ground or short to power in harness or connectors.

6. CHECK COMPONENTS
Check the following.
Fuel rail pressure sensor (Refer to EC-1739, «Component Inspection» .)
●
Turbocharger boost sensor (Refer to EC-1765, «Diagnostic Procedure» .)
●
EGR volume control valve control position sensor (Refer to EC-1799, «Component Inspection» .)
●
Mass air flow sensor (Refer to EC-1726, «Component Inspection» .)
●
Refrigerant pressure sensor (Refer to ATC-85, «COMPONENT INSPECTION» or MTC-51, «COMPONENT INSPECTION» .)
OK or NG
OK
>> GO TO 7.
NG
>> Replace malfunctioning component.
●

7. CHECK APP SENSOR
Refer to EC-1757, «Component Inspection» .
OK or NG
OK
>> GO TO 8.
NG
>> Replace accelerator pedal assembly.

8. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
>> INSPECTION END

EC-1836

DTC P0651 APP SENSOR
[K9K]

DTC P0651 APP SENSOR
Description

PFP:22693

A
BBS004U5

The accelerator pedal position sensor is installed on the upper end
of the accelerator pedal assembly. The sensors detect the accelerator pedal position and sends a signal to the ECM. The ECM uses the
signal to determine the amount of fuel to be injected.

EC

C

D
PBIB1741E

E

CONSULT-II Reference Value in Data Monitor Mode

BBS004U6

Specification data are reference values.
MONITOR ITEM
PL PTNMR T1 V
PL PTNMR T2 V

CONDITION
Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

Approximately 15 %

●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

Approximately 6 %

On Board Diagnosis Logic
DTC No.

Trouble diagnosis name

●

CO.1: Open circuit or short circuit to +12V

●

CC.0: Short circuit to ground

G

BBS004U7

H

Possible cause
●

APP SENSOR 2 CIRCUIT
P0651

F

SPECIFICATION

●

●

Harness or connectors
(The APP sensor 2 circuit is open or shorted.)

I

Accelerator pedal position sensor
(Accelerator pedal position sensor 2)

NOTE:
●
If DTC P0651 is displayed with DTC P0641, first perform trouble diagnosis for DTC P0641. Refer to
EC-1830, «DTC P0641 SENSOR POWER SUPPLY» .
●
Special notes:
–
If this DTC is present, the engine idle speed is set to 1,000 rpm, the engine performance is reduced, and
–
Malfunction indicator (Red) lights up.

J

K

L

M

EC-1837

DTC P0651 APP SENSOR
[K9K]

Wiring Diagram

BBS004U8

LHD MODELS

MBWA1554E

EC-1838

DTC P0651 APP SENSOR
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

6

WIRE
COLOR

L/R

ITEM

Sensor ground
(Accelerator pedal position
sensor 2)

CONDITION

DATA
(DC Voltage and Pulse Signal)

[Engine is running]
●

Warm-up condition

●

Idle speed

12

18

28

29

L/W

Accelerator pedal position
sensor 2

L

Sensor power supply
(Accelerator pedal position
sensor 2)

B

Sensor ground
(Accelerator pedal position
sensor 1)

R

Sensor power supply
(Accelerator pedal position
sensor 1)

Engine stopped

●

Accelerator pedal: Fully released

C

D
Approximately 0.4V

E

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

[Ignition switch ON]

Approximately 2.0V

F
Approximately 4.6V

G

[Engine is running]
●

Warm-up condition

●

Idle speed

[Ignition switch ON]

Approximately 0.24V

H
Approximately 5.0V

I

[Ignition switch ON]

30

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

EC

Approximately 0.3V

[Ignition switch ON]
●

A

Approximately 0.76V

J

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

Approximately 4.2V

K

L

M

EC-1839

DTC P0651 APP SENSOR
[K9K]
RHD MODELS

MBWA1555E

EC-1840

DTC P0651 APP SENSOR
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

6

WIRE
COLOR

L/R

ITEM

Sensor ground
(Accelerator pedal position
sensor 2)

CONDITION

DATA
(DC Voltage and Pulse Signal)

[Engine is running]
●

Warm-up condition

●

Idle speed

12

18

28

29

L/W

Accelerator pedal position
sensor 2

L

Sensor power supply
(Accelerator pedal position
sensor 2)

B

Sensor ground
(Accelerator pedal position
sensor 1)

R

Sensor power supply
(Accelerator pedal position
sensor 1)

Engine stopped

●

Accelerator pedal: Fully released

C

D
Approximately 0.4V

E

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

[Ignition switch ON]

Approximately 2.0V

F
Approximately 4.6V

G

[Engine is running]
●

Warm-up condition

●

Idle speed

[Ignition switch ON]

Approximately 0.24V

H
Approximately 5.0V

I

[Ignition switch ON]

30

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

EC

Approximately 0.3V

[Ignition switch ON]
●

A

Approximately 0.76V

J

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

Diagnostic Procedure

Approximately 4.2V

K
BBS004U9

1. CHCEK GROUND CONNECTIONS

L

1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screw on the body.
Refer to EC-1703, «Ground Inspection» .
–
Body ground (1)
–
Priming pump (2)
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

M

MBIB1520E

EC-1841

DTC P0651 APP SENSOR
[K9K]

2. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT
1.
–
–

2.

Disconnect accelerator pedal position (APP) sensor harness
connector (1).
Accelerator pedal position sensor (2)
Accelerator pedal (3)
Turn ignition switch ON.

MBIB1345E

3.

Check voltage between APP sensor terminal 5 and ground with
CONSULT-II or tester.
Voltage: Approximately 5.0V

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

PBIB1597E

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK APP SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between APP sensor terminal 1 and ECM terminal 6.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1842

DTC P0651 APP SENSOR
[K9K]

6. CHECK APP SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

A

Check harness continuity between ECM terminal 12 and APP sensor terminal 6.
Refer to Wiring Diagram.
EC

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

C

7. DETECT MALFUNCTIONING PART

D

Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM

E

F

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK APP SENSOR

G

Refer to EC-1843, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace accelerator pedal assembly.

H

I

9. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

J

>> INSPECTION END

Component Inspection

BBS004UA

K

ACCELERATOR PEDAL POSITION SENSOR
1.

Disconnect APP sensor harness connector (1).
● Accelerator pedal position sensor (2)
● Accelerator pedal (3)

L

M

MBIB1345E

EC-1843

DTC P0651 APP SENSOR
[K9K]
2.

Check resistance between the APP sensor terminals 2 and 4, 1
and 5.
Terminals
2 and 4:
1 and 5:

3.

Resistance
1.7 ± 0.9 kΩ
2.4 ± 1.2 kΩ

If NG, replace accelerator pedal assembly.

MBIB1489E

Removal and Installation

BBS004UB

ACCELERATOR PEDAL
Refer to ACC-2, «ACCELERATOR CONTROL SYSTEM» .

EC-1844

DTC P0685 ECM RELAY
[K9K]

DTC P0685 ECM RELAY
On Board Diagnosis Logic
DTC No.

PFP:22693

A
BBS0046V

Trouble diagnosis name
ECM RELAY CIRCUIT

P0685

●

1.DEF: Permanent low signal

●

2.DEF: Permanent high signal

Possible cause
●

Harness or connectors
(The ECM relay circuit is shorted.)

●

ECM relay

EC

C

D

E

F

G

H

I

J

K

L

M

EC-1845

DTC P0685 ECM RELAY
[K9K]

Wiring Diagram

BBS0046X

MBWA1572E

EC-1846

DTC P0685 ECM RELAY
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION
[Ignition switch ON]
[Ignition switch OFF]
●

104

P

ECM relay (self-shutoff)

For a few seconds after turning ignition
switch OFF

[Ignition switch OFF]
●

109
110

G
G

Power supply for ECM

More than a few seconds after turning ignition switch OFF

[Ignition switch ON]

Diagnostic Procedure

A

EC

DATA
(DC Voltage)

C
Approximately 1.4V

D
BATTERY VOLTAGE
(11 — 14V)

E
BATTERY VOLTAGE
(11 — 14V)
BBS0046Y

F

1. CHECK ECM POWER SUPPLY CIRCUIT-I
1.
2.
3.

Turn ignition switch OFF and wait at least 10 seconds.
Turn ignition switch ON and then OFF.
Check voltage between ECM terminals 109, 110 and ground
with CONSULT-II or tester.
Voltage:

G

H

After turning ignition switch OFF, battery
voltage will exist for a few seconds, then
drop to approximately 0V.

OK or NG
OK
>> GO TO 9.
NG (Battery voltage does not exist)>>GO TO 2.
NG (Battery voltage exists for more then a few seconds)>>GO TO
5.

I

J
MBIB1463E

K

2. CHECK ECM POWER SUPPLY CIRCUIT-II
1.
2.

Turn ignition switch OFF and wait at least 10 seconds.
Check voltage between ECM terminal 104 and ground with
CONSULT-II or tester.

L

M

Voltage: Battery voltage
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 5.

PBIB1171E

EC-1847

DTC P0685 ECM RELAY
[K9K]

3. CHECK ECM POWER SUPPLY CIRCUIT-III
1.
2.
3.

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between ECM terminals 109, 110 and IPDM E/R terminal 32.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 4.

4. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F101
●
Harness for open or short between ECM and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK ECM POWER SUPPLY CIRCUIT-IV
1.
2.
3.

Disconnect ECM harness connector.
Disconnect IPDM E/R harness connector E7.
Check harness continuity between ECM terminal 104 and IPDM E/R terminal 29 under the following conditions.
Refer to Wiring Diagram.

MBIB1559E

CONDITION 1:
CONDITION 2:

Continuity should exist.
Continuity should not exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

6. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors E48, F101
●
Diode E64
●
Harness for open or short between ECM and IPDM E/R
>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1848

DTC P0685 ECM RELAY
[K9K]

7. CHECK 20A FUSE

A

1. Disconnect 20 A fuse.
2. Check 20A fuse
OK or NG
OK
>> GO TO 8.
NG
>> Replace 20A fuse.

EC

C

8. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

9. CHECK INTERMITTENT INCIDENT

D

E

F

Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
G

>> INSPECTION END

H

I

J

K

L

M

EC-1849

DTC P0703 BRAKE SWITCH
[K9K]

DTC P0703 BRAKE SWITCH
Description

PFP:22693
BBS00470

Brake switch signal is applied to the ECM through the stop lamp switch when the brake pedal is depressed.
This signal is used mainly to decrease the engine speed when the vehicle is driving.

On Board Diagnosis Logic
DTC No.

BBS00472

Trouble diagnosis name
BRAKE SWITCH CIRCUIT

P0703

●

1.DEF: Signal absent

●

2.DEF: Inconsistency

Possible cause
●

Harness or connectors
(Stop lamp switch circuit is open or shorted.)

●

Stop lamp switch

NOTE:
●
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present when the ignition switch is ON, when decelerating or when the brake pedal
is depressed.

EC-1850

DTC P0703 BRAKE SWITCH
[K9K]

Wiring Diagram

BBS00474

A

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1565E

EC-1851

DTC P0703 BRAKE SWITCH
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

WIRE
COLOR

ITEM

CONDITION
[Ignition switch: ON]
●

5

R

Stop lamp switch

Brake pedal: Fully released

[Ignition switch: ON]
●

Brake pedal: Slightly depressed

DATA (DC Voltage)

Approximately 0V
BATTERY VOLTAGE
(11 — 14V)

Diagnostic Procedure

BBS00475

1. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT
1.
2.
–

3.

Turn ignition switch OFF.
Disconnect stop lamp switch (1) harness connector.
Brake pedal (2)
Turn ignition switch ON.

MBIB1346E

4.

Check voltage between stop lamp switch terminal 3 and ground
with CONSULT-II or tester.
Voltage: Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

MBIB1558E

2. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors M1, E101 (RHD models)
●
Harness connectors M8, M201 (RHD models)
●
10A fuse
●
Fuse block (J/B) connector E7
●
Harness for open and short between stop lamp switch and IPDM E/R
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1852

DTC P0703 BRAKE SWITCH
[K9K]

3. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between ECM terminal 5 and stop lamp switch terminal 4.
Refer to Wiring Diagram.
Continuity should exist.

A

EC

C

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

4. DETECT MALFUNCTIONING PART

D

E

Check the following.
●
Harness connectors M1, E101 (RHD models)
●
Harness connectors M8, M201 (RHD models)
●
Harness for open and short between stop lamp switch and ECM

F

G

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK STOP LAMP SWITCH

H

Refer to EC-1854, «Component Inspection» .
OK or NG
OK
>> GO TO 6.
NG
>> Replace stop lamp switch.

I

6. CHECK INTERMITTENT INCIDENT

J

Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
K

>> INSPECTION END
L

M

EC-1853

DTC P0703 BRAKE SWITCH
[K9K]

Component Inspection

BBS00476

STOP LAMP SWITCH
1.

Disconnect stop lamp switch (1) harness connector.
● Brake pedal (2)

MBIB1346E

2.

Check continuity between stop lamp switch terminals 3 and 4
under the following conditions.
Conditions

Brake pedal: Fully released
Brake pedal: Slightly depressed

Continuity
Should not exist
Should exist

If NG, adjust stop lamp switch installation, refer to BR-6,
«BRAKE PEDAL» , and perform step 2 again.
PBIB2103E

EC-1854

DTC P2120 APP SENSOR
[K9K]

DTC P2120 APP SENSOR
Description

PFP:22693

A
BBS00477

The accelerator pedal position sensor is installed on the upper end
of the accelerator pedal assembly. The sensors detect the accelerator pedal position and sends a signal to the ECM. The ECM uses the
signal to determine the amount of fuel to be injected.

EC

C

D
PBIB1741E

E

CONSULT-II Reference Value in Data Monitor Mode

BBS00478

Specification data are reference values.
MONITOR ITEM
PL PTNMR T1 V
PL PTNMR T2 V

CONDITION
Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

Approximately 15 %

●

Ignition switch: ON
(Engine stopped)

Accelerator pedal: Fully released

Approximately 6 %

On Board Diagnosis Logic
DTC No.

Trouble diagnosis name

●

CO.0: Open circuit or short circuit to ground

●

CC.1: Short circuit to +12V

G

BBS00479

●

Harness or connectors
(The APP sensor 2 circuit is open or shorted.)

I

Accelerator pedal position sensor
(Accelerator pedal position sensor 2)

NOTE:
●
If DTC P2120 is displayed with DTC P0641, first perform trouble diagnosis for DTC P0641. Refer to
EC-1830, «DTC P0641 SENSOR POWER SUPPLY» .
●
If DTC P2120 is displayed with DTC P0651, first perform trouble diagnosis for DTC P0651. Refer to
EC-1837, «DTC P0651 APP SENSOR» .
●
Special notes:
–
If this DTC is present, the engine speed is maintained above 1,000 rpm, and malfuction indicator (Red)
lights up.
–
If this DTC is present with DTC P0225, the engine idle speed is fixed at 1,800 rpm, and malfuction indicator (Red) lights up.

EC-1855

H

Possible cause
●

APP SENSOR 2 CIRCUIT
P2120

F

SPECIFICATION

●

J

K

L

M

DTC P2120 APP SENSOR
[K9K]

Wiring Diagram

BBS0047B

LHD MODELS

MBWA1554E

EC-1856

DTC P2120 APP SENSOR
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

6

WIRE
COLOR

L/R

ITEM

Sensor ground
(Accelerator pedal position
sensor 2)

CONDITION

DATA
(DC Voltage and Pulse Signal)

[Engine is running]
●

Warm-up condition

●

Idle speed

12

18

28

29

L/W

Accelerator pedal position
sensor 2

L

Sensor power supply
(Accelerator pedal position
sensor 2)

B

Sensor ground
(Accelerator pedal position
sensor 1)

R

Sensor power supply
(Accelerator pedal position
sensor 1)

Engine stopped

●

Accelerator pedal: Fully released

C

D
Approximately 0.4V

E

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

[Ignition switch ON]

Approximately 2.0V

F
Approximately 4.6V

G

[Engine is running]
●

Warm-up condition

●

Idle speed

[Ignition switch ON]

Approximately 0.24V

H
Approximately 5.0V

I

[Ignition switch ON]

30

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

EC

Approximately 0.3V

[Ignition switch ON]
●

A

Approximately 0.76V

J

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

Approximately 4.2V

K

L

M

EC-1857

DTC P2120 APP SENSOR
[K9K]
RHD MODELS

MBWA1555E

EC-1858

DTC P2120 APP SENSOR
[K9K]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.
TERMINAL
NO.

6

WIRE
COLOR

L/R

ITEM

Sensor ground
(Accelerator pedal position
sensor 2)

CONDITION

DATA
(DC Voltage and Pulse Signal)

[Engine is running]
●

Warm-up condition

●

Idle speed

12

18

28

29

L/W

Accelerator pedal position
sensor 2

L

Sensor power supply
(Accelerator pedal position
sensor 2)

B

Sensor ground
(Accelerator pedal position
sensor 1)

R

Sensor power supply
(Accelerator pedal position
sensor 1)

Engine stopped

●

Accelerator pedal: Fully released

C

D
Approximately 0.4V

E

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

[Ignition switch ON]

Approximately 2.0V

F
Approximately 4.6V

G

[Engine is running]
●

Warm-up condition

●

Idle speed

[Ignition switch ON]

Approximately 0.24V

H
Approximately 5.0V

I

[Ignition switch ON]

30

W

Accelerator pedal position
sensor 1

●

Engine stopped

●

Accelerator pedal: Fully released

EC

Approximately 0.3V

[Ignition switch ON]
●

A

Approximately 0.76V

J

[Ignition switch ON]
●

Engine stopped

●

Accelerator pedal: Fully depressed

Diagnostic Procedure

Approximately 4.2V

K
BBS0047C

1. CHCEK GROUND CONNECTIONS

L

1.
2.

Turn ignition switch OFF.
Loosen and retighten ground screw on the body.
Refer to EC-1703, «Ground Inspection» .
–
Body ground (1)
–
Priming pump (2)
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace ground connections.

M

MBIB1520E

EC-1859

DTC P2120 APP SENSOR
[K9K]

2. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT
1.
–
–

2.

Disconnect accelerator pedal position (APP) sensor harness
connector (1).
Accelerator pedal position sensor (2)
Accelerator pedal (3)
Turn ignition switch ON.

MBIB1345E

3.

Check voltage between APP sensor terminal 5 and ground with
CONSULT-II or tester.
Voltage: Approximately 5.0V

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

PBIB1597E

3. DETECT MALFUNCTIONING PART
Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK APP SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM harness connector.
Check harness continuity between APP sensor terminal 1 and ECM terminal 6.
Refer to Wiring Diagram.
Continuity should exist.

4. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM
●

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-1860

DTC P2120 APP SENSOR
[K9K]

6. CHECK APP SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1.

A

Check harness continuity between ECM terminal 12 and APP sensor terminal 6.
Refer to Wiring Diagram.
EC

Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

C

7. DETECT MALFUNCTIONING PART

D

Check the following.
●
Harness connectors M201, M8 (RHD models)
●
Harness connectors M1, E101 (RHD models)
●
Harness for open or short between APP sensor and ECM

E

F

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK APP SENSOR

G

Refer to EC-1861, «Component Inspection» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace accelerator pedal assembly.

H

I

9. CHECK INTERMITTENT INCIDENT
Refer to EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .

J

>> INSPECTION END

Component Inspection

BBS0047D

K

ACCELERATOR PEDAL POSITION SENSOR
1.

Disconnect APP sensor harness connector (1).
● Accelerator pedal position sensor (2)
● Accelerator pedal (3)

L

M

MBIB1345E

EC-1861

DTC P2120 APP SENSOR
[K9K]
2.

Check resistance between the APP sensor terminals 2 and 4, 1
and 5.
Terminals
2 and 4:
1 and 5:

3.

Resistance
1.7 ± 0.9 kΩ
2.4 ± 1.2 kΩ

If NG, replace accelerator pedal assembly.

MBIB1489E

Removal and Installation

BBS0047E

ACCELERATOR PEDAL
Refer to ACC-2, «ACCELERATOR CONTROL SYSTEM» .

EC-1862

DTC P2226 BARO SENSOR
[K9K]

DTC P2226 BARO SENSOR
Description

PFP:22693

A
BBS0047F

The barometric pressure sensor is built into ECM. The sensor
detects ambient barometric pressure and sends the voltage signal to
the microcomputer.

EC

C

D
MBIB1517E

E

On Board Diagnosis Logic
DTC No.

BBS0047G

Trouble diagnosis name

Possible cause

F

BAROMETRIC PRESSURE SENSOR CIRCUIT
P2226

●

CC.1: Shoet circuit to +12V

●

CO.0: Short circuit to ground or open circuit

●

ECM

G

Diagnostic Procedure

BBS0047I

1. REPLACE ECM
1.
2.
3.

Replace ECM.
Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, «ECM
Re-communicating Function» .
Perform Injector Adjustment Value Registration. Refer to EC-1625, «Injector Adjustment Value Registration» .

H

I

J

>> INSPECTION END
K

L

M

EC-1863

COOLING FAN
[K9K]

COOLING FAN
System Description
Sensor

PFP:21486
BBS004UC

Input Signal to ECM

Crankshaft position sensor (POS)
Camshaft position sensor (PHASE)

Engine speed

Battery

Battery voltage

Wheel sensor

Vehicle speed*

Engine coolant temperature sensor

Engine coolant temperature

Air conditioner switch

Air conditioner ON signal*

Refrigerant pressure sensor

Refrigerant pressure

ECM function

Cooling fan
control

Actuator

IPDM E/R
(Cooling fan relays)

*: This signal is sent to ECM through CAN communication line.

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, refrigerant
pressure, and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF].

EC-1864

COOLING FAN
[K9K]
COOLING FAN OPERATION
A

EC

C

D

E

F

G

H

I

J

K

L

M

MBIB1472E

EC-1865

COOLING FAN
[K9K]

Wiring Diagram

BBS004UG

MBWA1566E

EC-1866

COOLING FAN
[K9K]

Diagnostic Procedure

BBS004UH

1. CHECK COOLING FAN OPERATION

A

Perform IPDM E/R auto active test and check cooling fan motors operation, refer to PG-22, «Auto Active
Test» .
EC
2. Make sure that cooling fan operates at each speed (Low/High).
OK or NG
C
OK
>> INSPECTION END
NG
>> GO TO 2.

1.

2. CHECK IPDM E/R POWER SUPPLY CIRCUIT
1.
2.
3.

D

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector E6.
Check voltage between IPDM E/R terminal 14 and ground with
CONSULT-II or tester.

E

Voltage: Battery voltage

F

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

G

H
MBIB1556E

3. DETECT MALFUNCTIONING PART

I

Check the following.
●
40A fusible link
●
Harness for open or short between IPDM E/R and battery
>> Repair open circuit or short to ground in harness or connectors.

J

K

4. CHECK IPDM E/R GROUND CIRCUIT FOR OPEN AND SHORT
1.
2.

Disconnect IPDM E/R harness connectors E11 and E12.
Check harness continuity between IPDM E/R terminals 3, 54 and ground.
Refer to Wiring Diagram.

L

M

Continuity should exist.
3. Also check harness for short to power.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to power in harness or connectors.

EC-1867

COOLING FAN
[K9K]

5. CHECK COOLING FAN MOTOR CIRCUIT FOR OPEN AND SHORT
1.
2.

Disconnect cooling fan motor harness connector.
Check harness continuity between the following terminals.
Cooling fan motor terminal 1 and IPDM E/R terminal 12,
Cooling fan motor terminal 1 and IPDM E/R terminal 10,
Cooling fan motor terminal 2 and ground.
Refer to Wiring diagram.
Continuity should exist.

3. Also check harness for short to ground and short to power.
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

6. DETECT MALFUNCTIONING PART
Check the following.
●
Resistor E62
●
Harness for open or short between cooling fan motor and IPDM E/R
●
Harness for open or short between cooling fan motor and ground
>> Repair open circuit or short to ground in harness or connectors.

7. CHECK COOLING FAN MOTOR
Refer to EC-1868, «Component Inspection» .
OK or NG
OK
>> GO TO 8.
NG
>> Replace cooling fan motor.

8. CHECK INTERMITTENT INCIDENT
Perform EC-1697, «TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-18, «IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)» .
NG
>> Repair or replace harness or connector.

Component Inspection

BBS004UJ

COOLING FAN MOTOR
1.
2.
3.

Disconnect cooling fan motor harness connector.
Supply cooling fan motor terminals with battery voltage and
check operation.
If NG, replace cooling fan motor.

MBIB1557E

EC-1868

MI & DATA LINK CONNECTORS
[K9K]

MI & DATA LINK CONNECTORS
Wiring Diagram

PFP:24814

A
BBS00417

EC

C

D

E

F

G

H

I

J

K

L

M

MBWA1569E

EC-1869

SERVICE DATA AND SPECIFICATIONS (SDS)
[K9K]

SERVICE DATA AND SPECIFICATIONS (SDS)

PFP:00100
BBS004U1

Engines
Vehicles
Type

E11

Suffix
274

K9K

276

Bore
(mm, in)

Stroke
(mm, in)

Displacement cm 3
(cu in)

Compression ratio

Catalytic
converter

Emission
control
standard

76
(2.99)

80.5
(3.17)

1,461
(89.15)

18.25/1

228

Euro 4

ENGINE SPEED (rpm)

SMOKE OPACITY

IDLE SPEED

Max. — no load

Max. — under load

Homologation value

Max. — legal

800 ± 50

4,500 ± 150

5,000 ± 150

2.26 m-1 (46%)

3 m-1 (73%)

DESCRIPTION

MARQUE/TYPE

SPECIAL NOTES

High pressure pump

DELPHI

Located on the high pressure pump
0 to 1,400 bars continuous pressure

Fuel rail fuel pressure sensor

DELPHI

Incorporated into the fuel rail
Non measurable resistance

Fuel injector

DELPHI

Solenoid injector
Maximum pressure 1600 bar
Non measurable resistance

Fuel pump

DELPHI

Resistance: 5.3 ± 0.5 Ω at 20°C

ECM

DELPHI

ECM (computer) (112 terminals)

Glow control unit

NAGARES BED 7-12

With pre-postheating function controlled by the ECM

Glow plug

BERU or CHAMPION

Resistance: Less than 0.6 Ω
connector disconnected
Double track potentiometer
Resistance:

Accelerator pedal position sensor

CTS

●

sensor 1: terminals 2 and 4: 1.7 ± 0.9 kΩ

●

sensor 2: terminals 5 and 1: 2.4 ± 1.2 kΩ

Intake air temperature sensor

JAEGER

CTN thermistor
Resistance:
50,000 ± 6,800 Ω at — 40°C
9,500 ± 900 Ω at — 10°C
2,051 ± 120 Ω at 25°C
810 ± 47 Ω at 50°C
310 ± 17 Ω at 80°C

Fuel pump temperature sensor

DELPHI

Located on the high pressure pump
CTN thermistor
Resistance: 2.2 kΩ at 25° C

Engine coolant temperature sensor

ELTH

CTN thermistor Resistance:
76,000 ± 7,000Ω at — 40° C
12,500 ± 1,130 Ω at — 10°C
2,252 ± 112 Ω at 25° C
810 ± 40 Ω at 50° C
280 ± 8 Ω at 80° C
115 ± 3 Ω at 110°C
88 ± 2 Ω at 120° C

Crankshaft position sensor

MGI

Variable reluctance sensor
Resistance: 760 Ω

Barometric pressure sensor

DELPHI

Built into the ECM

Turbocharger boost sensor

BOSCF/LDF6 20-300

Non measurable resistance

Camshaft position sensor

SAGEM

Hall effect sensor

Knock sensor

SAGEM

Non measurable resistance

EC-1870

SERVICE DATA AND SPECIFICATIONS (SDS)
[K9K]
DESCRIPTION
EGR volume control valve

MARQUE/TYPE
PIERBURG

SPECIAL NOTES
Resistance:
●

Turbocharger boost control solenoid valve

BITRON

A

terminals 2 and 6: 8 ± 2.3 Ω at 25°C

Resistance:
18.6 ± 1.8 Ω at -30°C
21 ± 2.1 Ω at 23°C
18 ± 1.8 Ω at 110°C

EC

C

D

E

F

G

H

I

J

K

L

M

EC-1871

SERVICE DATA AND SPECIFICATIONS (SDS)
[K9K]

EC-1872

ENGINE COOLING SYSTEM

B ENGINE

SECTION

CO

ENGINE COOLING SYSTEM

A

CO

C

D

E

CONTENTS
CR
PRECAUTIONS …………………………………………………. 3
Precautions For Liquid Gasket …………………………… 3
REMOVAL OF LIQUID GASKET SEALING ………. 3
LIQUID GASKET APPLICATION PROCEDURE….. 3
PREPARATION ………………………………………………….. 4
Special Service Tools ……………………………………….. 4
Commercial Service Tool ………………………………….. 4
OVERHEATING CAUSE ANALYSIS …………………….. 5
Troubleshooting Chart ………………………………………. 5
COOLING SYSTEM ……………………………………………. 7
Cooling Circuit …………………………………………………. 7
ENGINE COOLANT ……………………………………………. 8
Inspection ……………………………………………………….. 8
LEVEL CHECK …………………………………………….. 8
LEAK CHECK ………………………………………………. 8
Changing Engine coolant ………………………………….. 9
DRAINING ENGINE COOLANT ……………………… 9
REFILLING ENGINE COOLANT …………………… 10
FLUSHING COOLING SYSTEM ……………………..11
RADIATOR ………………………………………………………. 12
Removal and Installation …………………………………. 12
REMOVAL ………………………………………………….. 13
INSTALLATION …………………………………………… 14
Disassembly and Assembly of Cooling Fan ……….. 14
DISASSEMBLY …………………………………………… 15
ASSEMBLY ………………………………………………… 15
Checking Radiator Cap (Models without A/C) …….. 15
Checking Reservoir Tank Cap (Models with A/C)… 16
Checking Cooling System Hoses ……………………… 16
WATER PUMP …………………………………………………. 17
Removal and Installation …………………………………. 17
REMOVAL ………………………………………………….. 17
INSPECTION AFTER REMOVAL ………………….. 18
INSTALLATION …………………………………………… 18
INSPECTION AFTER INSTALLATION …………… 18

THERMOSTAT …………………………………………………. 19
Removal and Installation …………………………………. 19
REMOVAL ………………………………………………….. 19
INSPECTION AFTER REMOVAL ………………….. 19
INSTALLATION …………………………………………… 20
INSPECTION AFTER INSTALLATION ……………. 20
SERVICE DATA AND SPECIFICATIONS (SDS) …… 21
Standard and Limit ………………………………………….. 21
CAPACITY ………………………………………………….. 21
THERMOSTAT ……………………………………………. 21
RADIATOR …………………………………………………. 21
Tightening Torque …………………………………………… 21

HR
PRECAUTIONS ……………………………………………….. 22
Precautions For Liquid Gasket …………………………. 22
REMOVAL OF LIQUID GASKET SEALING …….. 22
LIQUID GASKET APPLICATION PROCEDURE… 22
PREPARATION ………………………………………………… 23
Special Service Tools ……………………………………… 23
Commercial Service Tool …………………………………. 23
OVERHEATING CAUSE ANALYSIS …………………… 24
Troubleshooting Chart …………………………………….. 24
COOLING SYSTEM ………………………………………….. 26
Cooling Circuit ……………………………………………….. 26
ENGINE COOLANT ………………………………………….. 27
Inspection ……………………………………………………… 27
LEVEL CHECK ……………………………………………. 27
LEAK CHECK ……………………………………………… 27
Changing Engine coolant ………………………………… 28
DRAINING ENGINE COOLANT …………………….. 28
REFILLING ENGINE COOLANT ……………………. 29
FLUSHING COOLING SYSTEM ……………………. 30
RADIATOR ………………………………………………………. 31
Removal and Installation …………………………………. 31
REMOVAL ………………………………………………….. 32
INSTALLATION …………………………………………… 33
Disassembly and Assembly of Cooling Fan ……….. 33
DISASSEMBLY …………………………………………… 34

CO-1

F

G

H

I

J

K

L

M

ASSEMBLY ………………………………………………… 34
Checking Radiator Cap (All Models Except M/T with
A/C) ……………………………………………………………… 34
Checking Reservoir Tank Cap (M/T with A/C Models) ……………………………………………………………….. 35
Checking Radiator ………………………………………….. 35
Checking Cooling System Hoses ……………………… 35
WATER PUMP ………………………………………………….. 36
Removal and Installation …………………………………. 36
REMOVAL ………………………………………………….. 36
INSPECTION AFTER REMOVAL …………………… 37
INSTALLATION ……………………………………………. 37
INSPECTION AFTER INSTALLATION ……………. 37
THERMOSTAT …………………………………………………. 38
Removal and Installation …………………………………. 38
REMOVAL ………………………………………………….. 38
INSPECTION AFTER REMOVAL …………………… 38
INSTALLATION ……………………………………………. 39
INSPECTION AFTER INSTALLATION ……………. 39
WATER OUTLET ………………………………………………. 40
Removal and Installation …………………………………. 40
REMOVAL ………………………………………………….. 40
INSTALLATION ……………………………………………. 40
INSPECTION AFTER INSTALLATION ……………. 41
SERVICE DATA AND SPECIFICATIONS (SDS) …… 42
Standard and Limit ………………………………………….. 42
CAPACITY ………………………………………………….. 42
THERMOSTAT ……………………………………………. 42
RADIATOR …………………………………………………. 42

K9K
PRECAUTIONS ………………………………………………… 43
Precautions For Liquid Gasket …………………………. 43
REMOVAL OF LIQUID GASKET ……………………. 43
LIQUID GASKET APPLICATION PROCEDURE… 43

PREPARATION …………………………………………………44
Special Service Tools ……………………………………….44
OVERHEATING CAUSE ANALYSIS ……………………45
Troubleshooting Chart ………………………………………45
COOLING SYSTEM …………………………………………..47
Cooling Circuit …………………………………………………47
ENGINE COOLANT …………………………………………..48
Inspection ……………………………………………………….48
LEVEL CHECK …………………………………………….48
LEAK CHECK ………………………………………………48
Changing Engine Coolant …………………………………49
DRAINING ENGINE COOLANT ……………………..49
REFILLING ENGINE COOLANT …………………….49
FLUSHING COOLING SYSTEM …………………….50
RADIATOR ……………………………………………………….51
Removal and Installation …………………………………..51
REMOVAL ……………………………………………………51
INSTALLATION …………………………………………….52
Disassembly and Assembly Radiator Fan …………..52
DISASSEMBLY …………………………………………….53
ASSEMBLY ………………………………………………….53
Checking Reservoir Tank Cap …………………………..53
Checking Radiator …………………………………………..53
WATER PUMP …………………………………………………..54
Removal and Installation …………………………………..54
REMOVAL ……………………………………………………54
INSPECTION AFTER REMOVAL ……………………54
INSTALLATION …………………………………………….55
INSPECTION AFTER INSTALLATION …………….55
THERMOSTAT …………………………………………………..56
Inspection ……………………………………………………….56
WATER OUTLET ……………………………………………….57
Removal and Installation …………………………………..57
REMOVAL ……………………………………………………57
INSTALLATION …………………………………………….57

CO-2

PRECAUTIONS
[CR]

PRECAUTIONS
Precautions For Liquid Gasket
[CR]

PFP:00001

A
BBS002RV

REMOVAL OF LIQUID GASKET SEALING
After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the liquid gasket.
CAUTION:
Be careful not to damage the mating surfaces.
●
In areas where the seal cutter is difficult to use, use a plastic
hammer to lightly tap the gasket area.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating surfaces.
●

CO

C

D

PBIC0275E

E

LIQUID GASKET APPLICATION PROCEDURE
1.
●

2.

3.

Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
Remove the liquid gasket completely from the groove of the gasket application surface, mounting bolts and bolt holes.
Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.

F

G

H
PBIC0003E

I

4.
●

Apply the gasket without breaks to the specified location with the
specified dimensions.
If there is a groove for the liquid gasket application, apply the
gasket to the groove.

J

K

L
EMA0622D

As for the bolt holes, normally apply the gasket inside the holes.
Occasionally, it should be applied outside the holes. Make sure
to read the instruction in this manual.
●
Within five minutes of gasket application, install the mating component.
●
If the liquid gasket protrudes, wipe it off immediately.
●
Do not retighten after the installation.
●
After 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION:
If there are additional instructions in this manual, observe them.

M

●

CO-3

SEM164F

PREPARATION
[CR]

PREPARATION
Special Service Tools

PFP:00002
BBS002RW

NISSAN Tool number
(RENAULT tool number)
Tool name

Description

WS39930000
(
—
)
Tube presser

Pressing the tube of liquid gasket

S-NT052

EG17650301
(
—
)
Radiator cap tester adapter

Adapting radiator cap tester to radiator filler
neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
S-NT564

—
(M.S. 554_07)
Tester

Leak checking
Checking reservoir tank and reservoir tank
cap

MLIA0012E

—
(M.S. 554_01)
Reservoir tank tester adapter

Adapting tester to reservoir tank

MLIA0013E

—
(M.S. 554_06)
Reservoir tank cap tester adapter

Adapting tester to reservoir tank cap

MLIA0014E

Commercial Service Tool

BBS002RX

Tool name

Description

Radiator cap tester

Checking radiator and radiator cap

PBIC1982E

CO-4

OVERHEATING CAUSE ANALYSIS
[CR]

OVERHEATING CAUSE ANALYSIS
Troubleshooting Chart

PFP:00012

A
BBS002RY

Symptom

Check items

Water pump malfunction
Thermostat stuck closed
Poor heat transfer

CO

Worn or loose drive belt
—
Dust contamination or
paper clogging

Damaged fins

—

C

Mechanical damage
Clogged radiator cooling
tube

Excess foreign material
(rust, dirt, sand, etc.)

D

Cooling fan does not operate
Reduced air flow

High resistance to fan rotation

E
Fan assembly

—

Damaged fan blades

Cooling system parts
malfunction

F

Damaged radiator shroud

—

—

—

Improper coolant mixture
ratio

—

—

—

Poor coolant quality

—

Coolant viscosity

G

—
Loose clamp

Cooling hose

Engine coolant leaks

Cracked hose

Water pump

Poor sealing

Radiator cap (M/T models
without A/C and A/T models
Reservoir tank cap (M/T
models with A/C)

Loose

Insufficient engine coolant

H

I

Poor sealing

J
O-ring for damage, deterioration or improper fitting

Radiator

Cracked radiator tank

K

Cracked radiator core
Reservoir tank
Overflowing reservoir tank

CO-5

Exhaust gas leaks into
cooling system

Cracked reservoir tank
Cylinder head deterioration
Cylinder head gasket deterioration

L

M

OVERHEATING CAUSE ANALYSIS
[CR]
Symptom

Check items
High engine rpm under no
load
Abusive driving

Driving in low gear for
extended time
Driving at extremely high
speed

—

Overload on engine

Powertrain system malfunction
Installed improper size
wheels and tires

Except cooling system
parts malfunction

—

Dragging brakes
Improper ignition timing
Blocked bumper

—
Installed car brassiere

Blocked radiator grille
Blocked or restricted air
flow

Blocked radiator

Mud contamination or
paper clogging
—

Blocked condenser
Installed large fog lamp

CO-6

Blocked air flow

—

COOLING SYSTEM
[CR]

COOLING SYSTEM
Cooling Circuit

PFP:21020

A
BBS002RZ

CO

C

D

E

F

G

H

I
PBIC1475E

J

K

L

M

CO-7

ENGINE COOLANT
[CR]

ENGINE COOLANT
Inspection

PFP:KQ100
BBS002S0

LEVEL CHECK
Models without A/C
●

●

Check if the reservoir tank engine coolant level is within “MIN” to
“MAX” when engine is cool.
adjust the engine coolant level as necessary.

SMA412B

Models with A/C
●
●

Check if the reservoir tank coolant level is within MIN to MAX when engine is cool.
Adjust coolant if too much or too little.
Vehicle front

MBIB1360E

MBIA0092E

LEAK CHECK
Model without A/C
●

To check for leakage, apply pressure to the cooling system with
a radiator cap tester (commercial service tool) and radiator cap
tester adapter (SST).
Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi)
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.

CO-8

SLC134B

ENGINE COOLANT
[CR]

●

NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
If anything is found, repair or replace damaged parts.

A

Models with A/C
●

CO

To check for leakage, fit the adapter to the reservoir tank (1),
and then connect it to the tester.

C

D

E
MBIB1362E

●
●

Warm up the engine and turn it off.
Apply pressure to the cooling system and stop pumping.
Testing pressure

●
●

F

: 90 kpa
(0.9 bar, 0.92 kg/cm2 , 13.1 psi)

If the pressure drops, look for leakage.
Unscrew slowly the adapter from the reservoir tank to reduce
the pressure in cooling system, and install the reservoir tank
cap.
WARNING:
Never remove the reservoir tank cap when the engine is
hot. Serious burns could occur from high pressure engine
coolant escaping from the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.

Changing Engine coolant

G

H

I
MBIA0094E

J
BBS002S1

WARNING:
●
To avoid being scalded, never change the coolant when the engine is hot.
●
Wrap a thick cloth around radiator cap and carefully remove the cap. First, turn the cap a quarter
of a turn to release built-up pressure. Then turn the cap all the way.

DRAINING ENGINE COOLANT
Models without A/C
Disconnect radiator lower hose and radiator cap.
CAUTION:
Make sure to drain when the engine coolant temperature is cold.

2.

Remove reservoir tank and drain the engine coolant in the following procedures.
Move relay case in front of the battery.
Disconnect the reservoir tank from fan shroud to remove. With
force applied in the left direction of vehicle, pull up reservoir
tank.
Check drain coolant for contaminants such as rust, corrosion or
discoloration.
If contaminated, flush engine cooling system.
Refer to CO-11, «FLUSHING COOLING SYSTEM» .

3.

L

M

1.

a.
b.

K

PBIC1476E

CO-9

ENGINE COOLANT
[CR]
Models with A/C
1.

Disconnect radiator lower hose and reservoir tank cap.
CAUTION:
Make sure to drain when the engine coolant temperature is cold.

2.

Remove reservoir tank and drain the engine coolant.
: Vehicle front

3.

Check drain coolant for contaminants such as rust, corrosion or
discoloration.
If contaminated, flush engine cooling system.
Refer to CO-11, «FLUSHING COOLING SYSTEM» .

MBIB1360E

REFILLING ENGINE COOLANT
1.
2.
3.

Install reservoir tank.
Connect radiator lower hose.
Disconnect heater hose (at heater hose outlet side: upper side)
as shown in figure. Keep hose end at the same height as that of
before removal.

PBIC1477E

4.

Fill radiator and reservoir tank to specified level.
● Pour coolant slowly of less than 2
(1-3/4 lmp qt) a
minute to allow air in system to escape.
● When coolant from heater hose starts to drain, connect
heater hose and continue to fill.
● Use Nissan Genuine Coolant L250 or equivalent mixed
with water (distilled or demineralized).
Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS» .
SMA182B

Engine coolant capacity
Models without A/C
With reservoir tank

: Approx. 4.9

Reservoir tank

: 0.7

(4-3/8 Imp qt)

(5/8 lmp qt)

SMA412B

CO-10

ENGINE COOLANT
[CR]
Models with A/C
With reservoir tank

: Approx. 5.3

Reservoir tank

: 1.2

A

(4-5/8 Imp qt)

(1-1/8 lmp qt)
CO

: Vehicle front

C

D

MBIB1360E

E

F

G

H
MBIA0092E

5.
6.

7.
8.
9.
10.
11.
12.
13.
14.

Warm up engine to normal operating temperature with radiator cap installed.
Warm up until thermostat opens. Keep warming at 3,000 rpm for approximately 10 minutes as guide.
● For thermostat opening, touch radiator upper hose by hand to insure that water flow is hot.
CAUTION:
Be careful not to overheat.
Stop the engine.
After cooling engine [approximately 50°C (122 °F) or lower], remove radiator cap and check coolant level.
If the level is low, fill up to the radiator neck again and repeat from step 5.
When the coolant level stabilizes, fill reservoir tank up to the “MAX” line.
Check cooling system for leaks with engine running.
Allow the engine to cool [approximately 50°C (122°F) or lower].
Start the engine. Perform the following cycle three times. Keep an engine speed of 1,000 rpm for approximately 30 seconds. Then increase it gradually to 3,000 rpm.
During the above step 12, make sure water flow sound is not heard from heater core.
● Sound may be noticeable at heater unit.
If water flow sound is heard, repeat from step 4 to 13.
● Clean excess coolant from engine.

FLUSHING COOLING SYSTEM
1.
2.
3.
4.
5.
6.

Fill radiator and reservoir tank with water and reinstall radiator cap.
Run engine and warm it up to normal operating temperature.
Rev engine two or three times under no-load.
Stop engine and wait until it cools down.
Drain water.
Repeat steps 1 through 5 until clear water begins to drain from radiator.

CO-11

I

J

K

L

M

RADIATOR
[CR]

RADIATOR
Removal and Installation

PFP:21400
BBS002S2

Models without A/C

MBIB1366E

: Vehicle front
1.

Cooling fan assembly

2.

Hose clamp

3.

Radiator hose (upper)

4.

Radiator

5.

Radiator cap

6.

Mounting rubber (upper)

7.

Mounting rubber (lower)

8.

Radiator hose (lower)

9.

Bracket

10.

Reservoir tank cap

11. Reservoir tank

12. Reservoir tank hose

A.

To water outlet

B.

C.

To water suction pipe

Refer to GI-9, «Contents» for symbol marks in the figure.

CO-12

To a of radiator

RADIATOR
[CR]
Models with A/C
A

CO

C

D

E

F

G

H

PBIC1479E

1.

Radiator

2.

Mounting rubber

3.

4.

Hose clamp

5.

Reserve tank cap

6.

Hose clamp

7.

Reservoir tank hose

8.

Reservoir tank

9.

Cooling fan assembly

10. Hose clamp

11. Radiator hose (lower)

13. Reservoir tank hose

14. Mounting rubber

Radiator hose (upper)

3.
4.

5.
6.

J

12. Hose clamp

K

REMOVAL
1.
2.

I

Disconnect both battery cables.
Drain coolant. Refer to CO-8, «ENGINE COOLANT» .
CAUTION:
Make sure to drain when the engine coolant temperature is cold.
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator.
Remove mounting bolts to make relay case movable.
Remove the following parts.
● Front grille; Refer to EI-10, «FRONT GRILLE» .
● Reservoir tank (models with A/C)
● Remove radiator core support (upper). Refer to BL-13, «Radiator Core Upper Support» .
● Remove refrigerant lines for A/C models. Refer to ATC-135, «REFRIGERANT LINES» , MTC-81,
«REFRIGERANT LINES» .
● Air Duct; Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
Remove harness connectors
Remove radiator hose (upper) and (lower).
CAUTION:
● Install plug to hoses and fluid pipes removed, and be sure to prevent fluid leak.
● Be careful not to damage radiator core and A/C condenser core.

CO-13

L

M

RADIATOR
[CR]
7.

Remove reservoir tank (models without A/C).
● Disconnect the reservoir tank from fan shroud to remove.
With force applied in the left direction of vehicle, pull up reservoir tank.

PBIC1476E

8.

Remove cooling fan assembly from radiator.

INSTALLATION
Install in the reverse order of removal which being careful of the following.
●
When installing radiator core support (lower), make sure upper and lower mount units of radiator and A/C
condenser are fitted in mounting holes of radiator core support (upper/lower).

Disassembly and Assembly of Cooling Fan

BBS002S3

Models without A/C

MBIB1368E

1.

Fan shroud

2.

Fan motor

3.

CO-14

Fan

RADIATOR
[CR]
Models with A/C
A

CO

C

D

E

F
MBIB1369E

1.

Resistor

4.

Fan

2.

Fan shroud

3.

Fan motor

G

DISASSEMBLY
1.

2.

H

Remove fan.
CAUTION:
Reverse screw are used for the fan attachment screw. When
removing or attaching, turn the screw the opposite way as
for a normal screw.
Remove fan motor from fan shroud.

I

J

PBIC1486E

K

ASSEMBLY
Assemble cooling fan in the reverse order of disassembly.
●
Apply thread locking sealant and tighten screw to assemble the fan.

Checking Radiator Cap (Models without A/C)
1.

L

BBS002S4

Pull the negative-pressure valve to open it and check that it closes completely when released.
● Check that there is no dirt or damage on the valve seat of the radiator cap negative-pressure valve.
● Check that there are no unusual conditions in the opening
and closing conditions of the negative-pressure valve.

SMA967B

CO-15

M

RADIATOR
[CR]
2.

Check radiator cap relief pressure.
Standard:
78 — 98 kPa
(0.78 — 0.98 bar, 0.8 — 1.0 kg/cm2 , 11 — 14 psi)
Limit:
59 kPa (0.59 bar, 0.6 kg/cm2 , 9 psi)
When connecting the radiator cap to the tester, apply water or
engine coolant to the cap seal part.
SLC135B
● Replace the radiator cap if there is an unusual conditions in
the negative-pressure valve, or if the open-valve pressure is
outside of the standard values.
CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue or foreign material.
●

Checking Reservoir Tank Cap (Models with A/C)
●
●

●

BBS002S5

Fit the adapter to the tester as shown.
When connecting the reservoir tank cap to the tester, apply
water or LLC to the cap seal part.
Check reservoir tank cap relief pressure.
88 kPa (0.88 bar, 0.90 kg/cm2 , 12.8 psi)

●

Replace the reservoir tank cap if the engine coolant passes
through it, or if any fur signs is detected.
MBIB1079E

Checking Cooling System Hoses

BBS002S6

Check hoses for improper attachment, leaks, cracks, damage, loose connections, chaffing and deterioration.

CO-16

WATER PUMP
[CR]

WATER PUMP
Removal and Installation

PFP:21020

A
BBS002S8

CO

C

D

E

F

G

H

I
PBIC1487E

1.

Water pump pulley

2.

Water pump

3.

O-ring

4.

Water suction pipe

5.

Heater hose

6.

Radiator hose (lower)

REMOVAL
1.

2.
3.
4.
5.
6.

7.

8.

J

K

Drain engine coolant. Refer to CO-8, «ENGINE COOLANT» .
CAUTION:
Make sure to drain when the engine coolant temperature is cold.
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator.
Steer front wheel to the right.
Remove front fender protector (RH). Refer to EI-14, «FENDER PROTECTOR» .
Loosen mounting bolts of water pump pulley before loosening belt tension of drive belt.
Remove drive belt from water pump pulley. Refer to EM-14, «DRIVE BELTS» .
Remove the water pump pulley.
NOTE:
To remove it easily, loosen water pump pulley mounting bolt, then water pump belt.
Remove water pump.
● Place a piece of wood or something onto water pump, and tap it with a hammer. Disconnect liquid gasket to remove.
● Engine coolant remaining in the engine is drained. Use tray to collect it.
CAUTION:
● Handle the water pump vane so that it does not contact any other parts.
● Water pump cannot be disassembled and should be replaced as a unit.
Remove water suction pipe in the following procedures.

CO-17

L

M

WATER PUMP
[CR]
a.
b.
c.
d.

Remove air cleaner case assembly. Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
Remove radiator hose (upper and lower), and heater hose.
Move harnesses around suction pipe.
Remove mounting bolts, and pull water suction pipe toward engine rear side.
● Coolant remaining in the engine is drained. Use tray to collect it.

INSPECTION AFTER REMOVAL
●

●

●

Visually check that there is no significant dirt or rusting on the
water pump body and vane.
Check that there is no looseness in the vane shaft, and that it
turns smoothly when rotated by hand.
If unusualness is found, replace the water pump.

PBIC1488E

INSTALLATION
●

Install in the reverse order of removal which being careful of the following.

Water Suction Pipe Installation
1.
2.
a.
b.

Apply neutral detergent on O-ring. Fit O-ring in the groove
securely.
Tighten mounting bolts with the following procedures.
Temporarily tighten bolts in order: A to B.
Tighten bolts in order: B to A

PBIC1489E

Water Pump Installation
●

Apply liquid gasket as shown in figure, and install.
Use Genuine Liquid Gasket or equivalent.
CAUTION:
Wait at least 30 minutes after water pump installation. Refill
coolant and start the engine.

PBIC1490E

INSPECTION AFTER INSTALLATION
●

●

Check for engine coolant leaks using radiator cap tester adapter (SST: EG17650301) and radiator cap
tester (commercial service tool) (M/T models without A/C and A/T models) or reservoir tank cap tester and
reservoir cap tester adapter (M/T models with A/C). Refer to CO-8, «LEAK CHECK»
.
Start and warm up engine. Visually check if there is no leaks of engine coolant.

CO-18

THERMOSTAT
[CR]

THERMOSTAT
Removal and Installation

PFP:21200

A
BBS002S9

CO

C

D

E

F

MBIB1358E

1.

Thermostat

2.

Rubber ring

3.

Water outlet

4.

Radiator hose (upper)

5.

Heater hose

6.

Heater pipe

7.

Copper washer

8.

Engine coolant temperature sensor

H

REMOVAL
1.

2.
3.
4.
5.
6.

Drain engine coolant. Refer to CO-8, «ENGINE COOLANT» .
CAUTION:
Make sure to drain when the engine coolant temperature is cold.
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator.
Remove air duct and air cleaner body. Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
Remove radiator hose (upper).
Remove water outlet and thermostat.
● Coolant remaining in the engine is drained. Use tray to collect it.
Remove engine coolant temperature sensor if necessary.
Remove heater pipe if necessary.

INSPECTION AFTER REMOVAL
●

●

●
●

●

Place a thread so that it is caught in the valves of the thermostat.
Immerse fully in a container filled with water. Heat while stirring.
(The example in the figure shows the thermostat.)
The valve opening temperature is the temperature at which the
valve opens and falls from the thread.
Continue heating. Check the full-open lift amount.
After checking the full-open lift amount, lower the water temperature and check the valve closing temperature.
If the measured value is out of the standard value or unusual
valve seating condition is found, replace the thermostat.

CO-19

G

SLC252B

I

J

K

L

M

THERMOSTAT
[CR]
Standard values
Thermostat
Valve opening temperature
Full-open lift amount

86.5 — 89.5°C (188 — 193°F)
8 mm or more/ 101°C (0.31 in/ 214 °F)

Valve closing temperature

83°C (181°F)

INSTALLATION
Install in the reverse order of removal which being careful of the following.

Installation of Thermostat
1.

Install the thermostat with the whole circumference of each
flange part fit securely inside the rubber ring.

PBIC0157E

2.

Install thermostat with jiggle valve facing the direction shown in
the figure.
NOTE:
Care must be taken not to trap the thermostat jiggle valve.

PBIC1492E

Water Outlet Installation
●
●

Install water pipe with it facing upward.
Install thermostat in place.

PBIC1493E

Heater Pipe Installation
●

Apply liquid gasket to the threads, and install.
Use Genuine Liquid Gasket or equivalent.

INSPECTION AFTER INSTALLATION
●

●

Check for leaks of engine coolant using radiator cap tester adapter (SST: EG17650301) and a radiator
cap tester (commercial service tool) (models without A/C) or reservoir tank cap tester and reservoir tank
cap tester adapter (models with A/C). Refer to CO-8, «LEVEL CHECK» .
Start and warm up engine. Visually check if there is no leaks of engine coolant.

CO-20

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR]

SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit

PFP:00030

A
BBS002SA

CAPACITY
Unit:
Coolant capacity
[With reservoir tank (MAX level)]

Models without A/C

Approximately 4.9 (4-3/8)

Models with A/C

Approximately 5.3 (4-5/8)

Models without A/C
Reservoir tank

(Imp qt)

0.7 (5/8)

Models with A/C

CO

C

1.2 (1-1/8)

THERMOSTAT

D

Valve opening temperature

86.5 — 89.5°C (188 — 193°F)

Valve lift

8 mm or more/ 101°C (0.31 in/ 214°F)

Valve closing temperature

E

83°C (181°F)

RADIATOR
Unit: kPa (bar, kg/cm2 , psi)
Radiator cap relief pressure

Standard

78 — 98 (0.78 — 0.98, 0.8 — 1.0, 11 — 14)

Limit

59 (0.59, 0.6, 9)

Reservoir tank cap relief pressure
Leakage test pressure

F

88 (0.88, 0.90, 12.8)
Models without A/C

157 (1.57, 1.6, 23)

Models with A/C

90 (0.9, 0.92, 13.1)

G

H

Tightening Torque

BBS002SB

*1: Parts to be tightened in particular orders
Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)*2
Cooling fan assembly

3.8 — 4.5 (0.39 — 0.45, 34 — 39)*2

Reservoir tank (models without A/C)

3.8 — 4.5 (0.39 — 0.45, 34 — 39)*2

Cooling fan motor

3.0 — 4.0 (0.31 — 0.40, 27 — 35)*2

Cooling fan (reverse screw)

1.7 — 2.3 (0.18 — 0.23, 15 — 20)*2

Water pump

*1

I

J

K

10.0 — 13.7(1.1 — 1.3, 8 — 10)

Water pump pulley

6.9 — 9.5 (0.71 — 0.96, 61 — 84)*2

Water suction pipe

16.6 — 23.5 (1.7 — 2.3, 13 — 17)

Water outlet

6.3 — 8.3 (0.65 — 0.84, 56 — 73)*2

Heater pipe

29.0 — 39.0 (3.0 — 4.0, 21 — 29)

Engine coolant temperature sensor

20 — 27(2.1 — 2.7, 15 — 19)

CO-21

L

M

PRECAUTIONS
[HR]

PRECAUTIONS
Precautions For Liquid Gasket
[HR]

PFP:00001
BBS002SC

REMOVAL OF LIQUID GASKET SEALING
After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the liquid gasket.
CAUTION:
Be careful not to damage the mating surfaces.
●
In areas where the seal cutter is difficult to use, use a plastic
hammer to lightly tap the gasket area.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating surfaces.
●

PBIC0275E

LIQUID GASKET APPLICATION PROCEDURE
1.
●

2.

3.

Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
Remove the liquid gasket completely from the groove of the gasket application surface, mounting bolts and bolt holes.
Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
PBIC0003E

4.
●

Apply the gasket without breaks to the specified location with the
specified dimensions.
If there is a groove for the liquid gasket application, apply the
gasket to the groove.

EMA0622D

As for the bolt holes, normally apply the gasket inside the holes.
Occasionally, it should be applied outside the holes. Make sure
to read the instruction in this manual.
●
Within five minutes of gasket application, install the mating component.
●
If the liquid gasket protrudes, wipe it off immediately.
●
Do not retighten after the installation.
●
After 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION:
If there are additional instructions in this manual, observe them.
●

CO-22

SEM164F

PREPARATION
[HR]

PREPARATION
Special Service Tools

PFP:00002

A
BBS002SD

NISSAN Tool number
(RENAULT tool number)
Tool name

CO

Description

WS39930000
(
—
)
Tube presser

Pressing the tube of liquid gasket

C

D
S-NT052

EG17650301
(
—
)
Radiator cap tester adapter

Adapting radiator cap tester to radiator filler
neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)

E

F

S-NT564

—
(M.S. 554_07)
Tester

Leak checking
Checking reservoir tank and reservoir tank
cap

G

H

I

MLIA0012E

—
(M.S. 554_01)
Reservoir tank tester adapter

Adapting tester to reservoir tank

J

K
MLIA0013E

—
(M.S. 554_06)
Reservoir tank cap tester adapter

Adapting tester to reservoir tank cap

L

M
MLIA0014E

Commercial Service Tool

BBS002SE

Tool name

Description

Radiator cap tester

Checking radiator and radiator cap

PBIC1982E

CO-23

OVERHEATING CAUSE ANALYSIS
[HR]

OVERHEATING CAUSE ANALYSIS
Troubleshooting Chart

PFP:00012
BBS002SF

Symptom

Check items

Water pump malfunction

Worn or loose drive belt

Thermostat stuck closed
Poor heat transfer

—
Dust contamination or
paper clogging

Damaged fins

—

Physical damage
Clogged radiator cooling
tube

Excess foreign material
(rust, dirt, sand, etc.)

Cooling fan does not operate
Reduced air flow

High resistance to fan rotation

Fan assembly

—

Damaged fan blades

Cooling system parts
malfunction

Damaged radiator shroud

—

—

—

Improper engine coolant
mixture ratio

—

—

—

Poor engine coolant quality

—

Engine coolant viscosity

—
Loose clamp

Cooling hose
Water pump

Cracked hose
Poor sealing
Loose

Radiator cap
Engine coolant leaks
Radiator (without A/C models)
Reservoir tank cap (with A/
C models)

Insufficient engine coolant

Reservoir tank

Poor sealing
O-ring for damage, deterioration or improper fitting
Cracked radiator tank
Cracked radiator core
Cracked reservoir tank
Cylinder head deterioration

Overflowing reservoir tank

CO-24

Exhaust gas leaks into
cooling system

Cylinder head gasket deterioration

OVERHEATING CAUSE ANALYSIS
[HR]
Symptom

Check items
High engine rpm under no
load
Abusive driving

Driving in low gear for
extended time

A

CO

Driving at extremely high
speed
—

Overload on engine

Installed improper size
wheels and tires

Except cooling system
parts malfunction

C

Power train system malfunction
—

D

Dragging brakes
Improper ignition timing
Blocked bumper

E

—
Installed car brassiere

Blocked radiator grille
Blocked or restricted air
flow

Blocked radiator

Mud contamination or
paper clogging
—

Blocked condenser
Installed large fog lamp

F
—

Blocked air flow

G

H

I

J

K

L

M

CO-25

COOLING SYSTEM
[HR]

COOLING SYSTEM
Cooling Circuit

PFP:21020
BBS002SG

PBIC3820E

CO-26

ENGINE COOLANT
[HR]

ENGINE COOLANT
Inspection

PFP:KQ100

A
BBS002SH

LEVEL CHECK
All Models Except M/T with A/C
●

●

CO

Check if the reservoir tank engine coolant level is within “MIN” to
“MAX” when engine is cool.
adjust the engine coolant level as necessary.

C

D

E
SMA412B

M/T with A/C Models
●
●

F

Check if the reservoir tank coolant level is within MIN to MAX when engine is cool.
Adjust coolant if too much or too little.
: Vehicle front

G

H

I

MBIB1360E

J

K

L

M
MBIA0092E

LEAK CHECK
All Models Except M/T with A/C
●

To check for leakage, apply pressure to the cooling system with
a radiator cap tester (commercial service tool) and radiator cap
tester adapter (SST).
Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi)
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.

CO-27

SLC134B

ENGINE COOLANT
[HR]

●

NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
If anything is found, repair or replace damaged parts.

M/T with A/C Models
●

To check for leakage, fit the adapter to the reservoir tank (1),
and then connect it to the tester as shown.

MBIB1362E

●
●

Warm up the engine and turn it off.
Apply pressure to the cooling system and stop pumping.
Testing pressure

●
●

: 90 kpa
(0.9 bar, 0.92 kg/cm2 , 13.1 psi)

If the pressure drops, look for leakage.
Unscrew slowly the adapter from the reservoir tank to reduce
the pressure in cooling system, and install the reservoir tank
cap.
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure engine coolant
escaping from the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.

Changing Engine coolant

MBIA0094E

BBS002SI

WARNING:
●
To avoid being scalded, never change the coolant when the engine is hot.
●
Wrap a thick cloth around radiator cap and carefully remove the cap. First, turn the cap a quarter
of a turn to release built-up pressure. Then turn the cap all the way.

DRAINING ENGINE COOLANT
All Models Except M/T with A/C
1.

2.
a.
b.

3.

Disconnect radiator lower hose and radiator cap.
CAUTION:
Make sure to drain when the engine coolant temperature is cold.
Remove reservoir tank and drain the engine coolant in the following procedures.
Move relay case in front of the battery.
Disconnect the reservoir tank from fan shroud to remove. With
force applied in the left direction of vehicle, pull up reservoir
tank.
Check drain coolant for contaminants such as rust, corrosion or
discoloration.
If contaminated, flush engine cooling system.
Refer to CO-30, «FLUSHING COOLING SYSTEM» .
PBIC1476E

CO-28

ENGINE COOLANT
[HR]
M/T with A/C Models
1.

2.

A

Disconnect radiator lower hose and reservoir tank cap.
CAUTION:
Make sure to drain when the engine coolant temperature is cold.
Remove reservoir tank and drain the engine coolant.

CO

: Vehicle front

3.

Check drain coolant for contaminants such as rust, corrosion or
discoloration.
If contaminated, flush engine cooling system.
Refer to CO-30, «FLUSHING COOLING SYSTEM» .

C

D

E
MBIB1360E

REFILLING ENGINE COOLANT
1.
2.
3.

Install reservoir tank.
Connect radiator lower hose.
Disconnect heater hose (1) (at heater hose outlet side: upper side) as shown in figure. Keep hose end at
the same height as that of before removal.

F

G

: Vehicle front

H

: Disconnect

I

J
MBIB1361E

4.

Fill radiator and reservoir tank to specified level.
● Pour coolant slowly of less than 2
(1-3/4 lmp qt) a
minute to allow air in system to escape.
● When coolant from heater hose starts to drain, connect
heater hose and continue to fill.
● Use Nissan Genuine Coolant L250 or equivalent mixed
with water (distilled or demineralized).
Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS».

K

L

M

SMA182B

Engine coolant capacity
All models except M/T with A/C
With reservoir tank
: Approx. 5.6
Reservoir tank

: 0.7

(4-7/8 Imp qt)

(5/8 lmp qt)

SMA412B

CO-29

ENGINE COOLANT
[HR]
M/T with A/C models
With reservoir tank : Approx. 6.0 (5-1/4 Imp qt)
Reservoir tank
: 1.2 (1-1/8 lmp qt)
: Vehicle front

MBIB1360E

MBIA0092E

5.
6.

7.
8.
9.
10.
11.
12.
13.
●

14.
●

Warm up engine to normal operating temperature with radiator cap installed.
Warm up until thermostat opens. Keep warming at 3,000 rpm for approximately 10 minutes as guide.
● For thermostat opening, touch radiator upper hose by hand to insure that water flow is hot.
CAUTION:
Be careful not to overheat.
Stop the engine.
After cooling engine [approximately 50°C (122 °F) or lower], remove radiator cap and check coolant level.
If the level is low, fill up to the radiator neck again and repeat from step 5.
When the coolant level stabilizes, fill reservoir tank up to the “MAX” line.
Check cooling system for leaks with engine running.
Allow the engine to cool [approximately 50°C (122°F) or lower].
Start the engine. Perform the following cycle three times. Keep an engine speed of 1,000 rpm for approximately 30 seconds. Then increase it gradually to 3,000 rpm.
During the above step 12, make sure water flow sound is not heard from heater core.
Sound may be noticeable at heater unit.
If water flow sound is heard, repeat from step 4 to 13.
Clean excess coolant from engine.

FLUSHING COOLING SYSTEM
1.
2.
3.
4.
5.
6.

Fill radiator and reservoir tank with water and reinstall radiator cap.
Run engine and warm it up to normal operating temperature.
Rev engine two or three times under no-load.
Stop engine and wait until it cools down.
Drain water.
Repeat steps 1 through 5 until clear water begins to drain from radiator.

CO-30

RADIATOR
[HR]

RADIATOR
Removal and Installation

PFP:21400

A
BBS002SJ

All models except M/T with A/C
CO

C

D

E

F

G

H

I

J

K
MBIB1366E

Vehicle front

1.

Cooling fan assembly

2.

Hose clamp

3.

Radiator hose (upper)

4.

Radiator

5.

Radiator cap

6.

Mounting rubber (upper)

7.

Mounting rubber (lower)

8.

Radiator hose (lower)

9.

Bracket

10. Reservoir tank cap

11. Reservoir tank

B.

C.

12. Reservoir tank hose
A.

To water outlet

L

M
To water suction pipe

Refer to GI-11, «Components» for symbol marks in the figure.

CO-31

To a of radiator

RADIATOR
[HR]
M/T with A/C models

MBIB1367E

Vehicle front

1.

Radiator

2.

Mounting rubber (upper)

3.

Radiator hose (upper)

4.

6.

Hose clamp

7.

Hose clamp

5.

Reserve tank cap

Reservoir tank hose

8.

9.

Cooling fan assembly

Reservoir tank

10. Hose clamp

11

Radiator hose (lower)

12. Hose clamp

13

Reservoir tank hose

14. Mounting rubber (lower)

A.

B.

To water suction pipe

To water outlet

Refer to GI-9, «Contents» for symbol marks in the figure.

REMOVAL
1.
2.

3.
4.

5.
6.

Disconnect both battery cables.
Drain coolant. Refer to CO-27, «ENGINE COOLANT» .
CAUTION:
Make sure to drain when the engine coolant temperature is cold.
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator.
Remove mounting bolts to make relay case movable.
Remove the following parts.
● Reservoir tank (M/T with A/C models)
● Front grille; Refer to EI-10, «FRONT GRILLE» .
● Remove radiator core support (upper). Refer to BL-13, «Radiator Core Upper Support» .
● Remove harness connectors
● Air Duct; Refer to EM-118, «AIR CLEANER AND AIR DUCT» .
Remove radiator hose (upper) and (lower).
Disconnect AT cooler hose.

CO-32

RADIATOR
[HR]
7.

Remove reservoir tank (M/T with A/C models).
● Disconnect the reservoir tank from fan shroud to remove.
With force applied in the left direction of vehicle, pull up reservoir tank.

A

CO

C
PBIC1476E

D

8.

Remove cooling fan assembly from radiator.

INSTALLATION
Install in the reverse order of removal which being careful of the following.
●
When installing radiator core support (lower), make sure upper and lower mount units of radiator and A/C
condenser are fitted in mounting holes of radiator core support (upper/lower).

E

F

Disassembly and Assembly of Cooling Fan

BBS002SK

All models except M/T with A/C
G

H

I

J

K

L
MBIB1368E

1.

Fan shroud

2.

Fan motor

3.

CO-33

Fan

M

RADIATOR
[HR]
M/T with A/C models

MBIB1369E

1.

Resistor

4.

Fan

2.

Fan shroud

3.

Fan motor

DISASSEMBLY
1.

2.

Remove fan.
CAUTION:
Reverse screw are used for the fan attachment screw. When
removing or attaching, turn the screw the opposite way as
for a normal screw.
Remove fan motor from fan shroud.

PBIC1486E

ASSEMBLY
Assemble cooling fan in the reverse order of disassembly.
●
Apply thread locking sealant and tighten screw to assemble the fan.

Checking Radiator Cap (All Models Except M/T with A/C)
1.

BBS002SL

Pull the negative-pressure valve to open it and check that it closes completely when released.
● Check that there is no dirt or damage on the valve seat of the radiator cap negative-pressure valve.
● Check that there are no unusual conditions in the opening
and closing conditions of the negative-pressure valve.

SMA967B

CO-34

RADIATOR
[HR]
2.

Check radiator cap relief pressure.
A

Standard:
78 — 98 kPa
(0.78 — 0.98 bar, 0.8 — 1.0 kg/cm2 , 11 — 14 psi)
Limit:

CO

59 kPa (0.59 bar, 0.6 kg/cm2 , 9 psi)
When connecting the radiator cap to the tester, apply water or
engine coolant to the cap seal part.
SLC135B
● Replace the radiator cap if there is an unusual conditions in
the negative-pressure valve, or if the open-valve pressure is
outside of the standard values.
CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue or foreign material.
●

Checking Reservoir Tank Cap (M/T with A/C Models)
●
●

●

BBS002SM

Fit the adapter to the tester as shown.
When connecting the reservoir tank cap to the tester, apply
water or LLC to the cap seal part.
Check reservoir tank cap relief pressure.

D

E

F

G

140 kPa (1.4 bar, 1.43 kg/cm2 , 20.3 psi)
●

C

H

Replace the reservoir tank cap if the engine coolant passes
through it, or if any fur signs is detected.
I
MBIB1079E

Checking Radiator

BBS002SN

Check radiator for mud or clogging. If necessary, clean radiator as follows.
●
Be careful not to bend or damage the radiator fins.
●
When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, fan shroud
and horns. Then tape the harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downwards.
2. Apply water again to all radiator core surface once per minute.
3. Stop washing if any stains no longer flow out from the radiator.
4. Blow air into the back side of radiator core vertically downwards.
●

5.

Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2 , 71 psi) and keep distance more than 30 cm
(11.8 in).
Blow air again into all the radiator core surface once per minute until no water sprays out.

Checking Cooling System Hoses

BBS002SO

Check hoses for improper attachment, leaks, cracks, damage, loose connections, chaffing and deterioration.

CO-35

J

K

L

M

WATER PUMP
[HR]

WATER PUMP
Removal and Installation

PFP:21020
BBS002SQ

PBIC3807E

1.

Gasket

2.

Water pump

3.

Water pump pulley

Refer to GI-11, «Components» for symbol marks in the figure.

REMOVAL
1.

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

Drain engine coolant from radiator. Refer to CO-28, «DRAINING ENGINE COOLANT» .
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator.
CAUTION:
Perform this step when engine is cold.
Steer front wheel to the right.
Remove front fender protector (RH). Refer to EI-14, «FENDER PROTECTOR» .
Loosen mounting bolts of water pump pulley before loosening belt tension of drive belt.
Remove drive belt. Refer to EM-114, «DRIVE BELTS» .
Remove water pump pulley.
Remove water pump.
● Loosen mounting bolts in reverse order as shown in the figure.
● Engine coolant will leak from cylinder block, so have a receptacle ready below.
CAUTION:
● Handle water pump vane so that it does not contact any
other parts.
● Water pump cannot be disassembled and should be
replaced as a unit.
KBIA3393J

CO-36

WATER PUMP
[HR]
INSPECTION AFTER REMOVAL
●

●

●

A

Visually check if there is no significant dirt or rusting on water
pump body and vane (A).
Make sure that there is no looseness in vane shaft, and that it
turns smoothly when rotated by hand.
Replace water pump, if necessary.

CO

C

PBIC3808E

D

INSTALLATION
Note the following, and install in the reverse order of removal.

E

Water Pump
●

Tighten mounting bolts in numerical order as shown in the figure.

F

G

H

KBIA3393J

I

Water Pump Pulley
CAUTION:
Do not install mounting bolts (A) to oblong holes (B).
1

J

: Water pump pulley

K

L

PBIC3809E

INSPECTION AFTER INSTALLATION
●

●

Check for engine coolant leaks using radiator cap tester adapter (SST: EG17650301) and radiator cap
tester (commercial service tool) (without A/C models) or reservoir tank cap tester and reservoir tank cap
tester adapter (with A/C models). Refer to CO-27, «LEAK CHECK» .
Start and warm up engine. Visually check if there is no leaks of engine coolant.

CO-37

M

THERMOSTAT
[HR]

THERMOSTAT
Removal and Installation

PFP:21200
BBS002SR

PBIC3810E

1.

Radiator hose (lower)

4.

Thermostat

A.

To radiator

2.

Water inlet

3.

Rubber ring

Refer to GI-11, «Components» for symbol marks in the figure.

REMOVAL
1.

2.
3.
4.

Drain engine coolant from radiator. Refer to CO-28, «DRAINING ENGINE COOLANT» .
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator.
CAUTION:
● Perform this step when engine is cold.
● Do not spill engine coolant on drive belt.
Remove reservoir tank. Refer to CO-31, «RADIATOR» .
Disconnect radiator hose (lower). Refer to CO-31, «RADIATOR» .
Remove water inlet and thermostat.
● Engine coolant will leak from cylinder block, so have a receptacle ready below.

INSPECTION AFTER REMOVAL
●

●

●
●

Place a thread (A) so that it is caught in the valves of thermostat
(1). Immerse fully in a container (B) filled with water. Heat while
stirring.
The valve opening temperature is the temperature at which the
valve opens and falls from the thread.
Continue heating. Check the full open valve lift amount.
After checking the maximum valve lift amount, lower the water
temperature and check the valve closing temperature.
PBIC3314J

CO-38

THERMOSTAT
[HR]
Standard:
Items
Valve opening temperature

80.5 — 83.5°C (177 — 182°F)

Maximum valve lift

8 mm/ 95°C (0.315 in/ 203°F)

Valve closing temperature
●

A

Thermostat

CO

77°C (171°F)

If out of the standard, replace thermostat.
C

INSTALLATION
Note the following, and install in the reverse order of removal.

Thermostat
●

D

Install thermostat with making rubber ring (1) groove fit to thermostat flange (A) with the whole circumference.
E

F

G
PBIC3811E

●

Install thermostat (2) with jiggle valve (A) facing upwards.
1

H

: Cylinder block

I

J

PBIC3812E

K

Water Inlet
After installation, fix water inlet clip (A) on the oil level gauge guide
(1) as shown in the figure.
B

L

: Positioning

M

PBIC3755E

INSPECTION AFTER INSTALLATION
●

●

Check for leaks of engine coolant using radiator cap tester adapter (SST: EG17650301) and a radiator
cap tester (commercial service tool) (without A/C models) or reservoir tank cap tester and reservoir cap
tester adapter (with A/C models). Refer to CO-27, «LEAK CHECK» .
Start and warm up engine. Visually check if there is no leaks of engine coolant.

CO-39

WATER OUTLET
[HR]

WATER OUTLET
Removal and Installation

PFP:11060
BBS002SS

REMOVAL

PBIC3816E

1.

Engine coolant temperature sensor 2.

Washer

3.

Gasket

4.

Radiator hose (upper)

5.

Water outlet

6.

Heater hose

7.

Heater hose

8.

Water hose

9.

Water hose

A.

To electric throttle control actuator

B.

To heater

C.

To radiator

Refer to GI-9, «Contents» for symbol marks in the figure.
1. Drain engine coolant from radiator. Refer to CO-28, «DRAINING ENGINE COOLANT» .
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator.
CAUTION:
Perform step when engine is cold.
2. Remove air duct (inlet) and air duct. Refer to EM-118, «AIR CLEANER AND AIR DUCT» .
3. Disconnect radiator hose (upper). Refer to CO-31, «RADIATOR» .
4. Disconnect harness connector from engine coolant temperature sensor.
5. Remove water hose and heater hose.
6. Remove water outlet.
7. Remove engine coolant temperature sensor from water outlet, as necessary.

INSTALLATION
Installation is the reverse order of removal.

CO-40

WATER OUTLET
[HR]
INSPECTION AFTER INSTALLATION
●

●

Check for leaks of engine coolant using radiator cap tester adapter (SST: EG17650301) and a radiator A
cap tester (commercial service tool) (without A/C models) or reservoir tank cap tester and reservoir tank
cap tester adapter (with A/C models). Refer to CO-27, «LEAK CHECK» .
CO
Start and warm up engine. Visually check if there is no leaks of engine coolant.

C

D

E

F

G

H

I

J

K

L

M

CO-41

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR]

SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit

PFP:00030
BBS002ST

CAPACITY
Unit:
Coolant capacity
[With reservoir tank (MAX level)]

All models except M/T with A/C

Approximately 5.6 (4-7/8)

M/T with A/C models

Approximately 6.0 (5-1/4)

All models except M/T with A/C
Reservoir tank

M/T with A/C models

(Imp qt)

0.7 (5/8)
1.2 (1-1/8)

THERMOSTAT
Valve opening temperature

80.5 — 83.5°C (177 — 182°F)

Maximum valve lift

8 mm/ 95°C (0.315 in/ 203°F)

Valve closing temperature

More than 77°C (171°F)

RADIATOR
Unit: kPa (bar, kg/cm2 , psi)
Standard
Radiator cap relief pressure

78 — 98 (0.78 — 0.98, 0.8 — 1.0, 11 — 14)

Limit

59 (0.59, 0.6, 9)

Reservoir tank cap relief pressure
Leakage test pressure

140 (1.4, 1.43, 20.3)
Without A/C models

157 (1.57, 1.6, 23)

With A/C models

10 (0.1, 0.10, 1.5)

CO-42

PRECAUTIONS
[K9K]

PRECAUTIONS
Precautions For Liquid Gasket
[K9K]

PFP:00001

A
BBS002SV

REMOVAL OF LIQUID GASKET
●

●

After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the liquid gasket.
CAUTION:
Be careful not to damage the mating surfaces.
In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the gasket applied area.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating
surfaces.

CO

C

D

PBIC0275E

E

LIQUID GASKET APPLICATION PROCEDURE
1.

2.

3.

Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
● Remove the liquid gasket completely from the groove of the
gasket application surface, mounting bolts and bolt holes.
Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.

F

G

H
PBIC0003E

I

4.

Apply the gasket without breaks to the specified location with the
specified dimensions.
● If there is a groove for the liquid gasket application, apply the
gasket to the groove.

J

K

L
EMA0622D

As for the bolt holes, normally apply the gasket inside the
holes. If specified, it should be applied outside the holes.
Make sure to read the instruction in this manual.
● Within five minutes of gasket application, install the mating
component.
● If the liquid gasket protrudes, wipe it off immediately.
● Do not retighten after the installation.
● After 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION:
If there are instructions in this manual, observe them.
●

CO-43

M

SEM159F

PREPARATION
[K9K]

PREPARATION
Special Service Tools

PFP:00002
BBS002SW

NISSAN tool number
(RENAULT too number)
Tool name

Description

WS39930000
(
—
)
Tube pressure

Pressing the tube of liquid gasket

S-NT052

—
(M.S. 554_07)
Tester

Leak checking
Checking reservoir tank cap

MLIA0012E

—
(M.S. 554_01)
Reservoir tank cap tester adapter A

Adapting tester to reservoir tank

MLIA0013E

—
(M.S. 554_06)
Reservoir tank cap tester adapter B

Adapting tester to reservoir tank cap

MLIA0014E

CO-44

OVERHEATING CAUSE ANALYSIS
[K9K]

OVERHEATING CAUSE ANALYSIS
Troubleshooting Chart

PFP:00012

A
BBS002SX

Symptom

Check items

Water pump malfunction
Thermostat stuck closed
Poor heat transfer

CO

Worn timing belt
—
Dust contamination or
paper clogging

Damaged fins

—

C

Mechanical damage
Clogged radiator cooling
tube

Excess foreign material
(rust, dirt, sand, etc.)

D

Cooling fan does not operate
Reduced air flow

High resistance to fan rotation

E
Fan assembly

—

Damaged fan blades

Cooling system parts
malfunction

F

Damaged radiator shroud

—

—

—

Improper coolant mixture
ratio

—

—

—

Poor coolant quality

—

—

—

G

Loose clamp
Cooling hose
Water pump

Cracked hose
Poor sealing
Loose

Reservoir tank cap
Coolant leaks

Radiator

I

Poor sealing
O-ring for damage, deterioration or improper fitting

Insufficient coolant

H

J

Cracked radiator tank
Cracked radiator core

Reservoir tank

Cracked reservoir tank

K

Cylinder head deterioration
Overflowing reservoir tank

Exhaust gas leaks into
cooling system

Cylinder head gasket deterioration

L

M

CO-45

OVERHEATING CAUSE ANALYSIS
[K9K]
Symptom

Check items
High engine rpm under no
load
Abusive driving

Driving in low gear for
extended time
Driving at extremely high
speed

—

Overload on engine

Powertrain system malfunction
Installed improper size
wheels and tires

Except cooling system
parts malfunction

—

Dragging brakes
Improper ignition timing
Blocked bumper

—
Installed car brassiere

Blocked radiator grille
Blocked or restricted air
flow

Blocked radiator

Mud contamination or
paper clogging
—

Blocked condenser
Installed large fog lamp

CO-46

—

—

COOLING SYSTEM
[K9K]

COOLING SYSTEM
Cooling Circuit

PFP:21020

A
BBS002SY

CO

C

D

E

F

G

H

I

J
MBIB9046E

K
1.

Engine

2.

Radiator

3.

Heater core

4.

Reservoir tank

5.

Water pump

6.

Thermostat

7.

Air relief plug

8.

Oil cooler

9.

EGR cooler

L

M

CO-47

ENGINE COOLANT
[K9K]

ENGINE COOLANT
Inspection

PFP:KQ100
BBS002SZ

LEVEL CHECK
●
●

Check if the reservoir tank coolant level is within MIN to MAX when engine is cool.
Adjust coolant if too much or too little.

MBIA0092E

MBIA0093E

LEAK CHECK
To check for leakage, fit the adapter to the reservoir tank, and
then connect it to the tester as shown.
●
Warm up the engine and turn it off.
●
Apply pressure to the cooling system and stop pumping at 10
kPa (0.1 bar, 0.10 kg/cm2 , 1.5psi) .
●
If the pressure drops, look for leakage.
●
Unscrew slowly the adapter from the reservoir tank to reduce
the pressure in cooling system, and install the reservoir tank
cap.
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure engine coolant escaping from the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.
●

CO-48

MBIA0094E

ENGINE COOLANT
[K9K]

Changing Engine Coolant

BBS002T0

A
WARNING:
●
To avoid being scalded, never change the coolant when the engine is hot.
●
Wrap a thick cloth around cap and carefully remove the cap. First, turn the cap a quarter of a turn
CO
to release built-up pressure. Then turn the cap all the way.

DRAINING ENGINE COOLANT
1.
2.
3.
4.

5.

Remove engine undercover.
Disconnect lower radiator hose, and remove reservoir tank cap
and air relief plug.
Remove reservoir tank, drain coolant, then clean reservoir tank.
Check drained coolant for contaminants such as rust, corrosion
or discoloration.
If contaminated, flush engine cooling system. Refer to CO-50,
«FLUSHING COOLING SYSTEM» .
Remove air relief plug from water outlet.
Refer to CO-57, «WATER OUTLET» .

C

D

E

F
MBIB1056E

REFILLING ENGINE COOLANT
●

1.
2.

Before start working, turn off the automatic air conditioner and the blower motor.
Install reservoir tank, lower radiator hose and air relief plug.
Fill reservoir tank slowly with coolant until coolant spills from the air relief hole. Refer to CO-57, «WATER
OUTLET» .
● Put a cloth under the air relief plug to prevent engine coolant to dampen the crankshaft position
sensor.
● Fill coolant to the MAX level line of the reservoir tank at a rate
of 2 litre (1-3/4 lmp qt)/min or lower.

G

H

I

J

K

L
SMA412B

3.

Close the air relief plug.
CAUTION:
If the filling rate is too fast, this could lead to air being mixed in the coolant. Be sure to fill the coolant slowly according to the rate indicated above.
Use Nissan Genuine Coolant L250 or equivalent mixed with water (distilled or demineralised).
Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS» .
Engine coolant capacity (With reservoir tank) Approx. 6.0
Reservoir tank capacity 1.0

4.

(5 — 1/4 lmp qt)

(7/8 lmp qt)

Warm up the engine for approximately five minutes without reservoir tank cap installed, and then turn off
the engine and loose air relief plug until coolant spills from air relief hole.
● If coolant overflows reservoir tank hole, install filler cap.
● Watch engine coolant temperature warning light so as not overheat the engine during all of the
operation.
WARNING:
● Be careful not be scaled with hot engine coolant or vacuum pump when operating.

CO-49

M

ENGINE COOLANT
[K9K]
5.

6.

7.
8.

9.

● Radiator fan blade can start at any time and make personal injuries.
Close the air relief plug and run the engine at 2,000 rpm until the upper hose comes hot and radiator fan
operates. Let the engine running approximately 5 minutes at idle speed and check for sound of coolant
flow while running engine from idle up to 3,000 rpm.
● Sound may be noticeable at heater water cock.
If sound is heard, bleed air from cooling system by repeating steps 4 through 5 until coolant lever no
longer drops.
● Check the radiator lower hose for any signs of leakage.
Turn off the engine and let it cool down.
● Cool down using a fan to reduce the time.
After cooling period, loose the air relief plug and check if coolant spills from the air relief hole. In other
case, remove the air relief plug until the coolant spills, and then close the relief air plug. Bleed air from
cooling system by repeating steps 5 through 8 until the coolant spills immediately.
Check the engine coolant level when engine is cool and refill to MAX level line if the level is lower.
● Clean excess coolant from engine.

FLUSHING COOLING SYSTEM
1.
2.
3.
4.
5.
6.
7.

Fill reservoir tank with water until water spills from the air relief hole, then close air relief plug. Reinstall
reservoir tank cap.
Run engine and warm it up to normal operating temperature.
Rev engine two or three times under no-load.
Stop engine and wait until it cools down.
Drain water.
Repeat steps 1 through 5 until clear water begins to drain from radiator.
Blow compressed air into cooling circuit through the reservoir tank valve hole to drain all the water.

CO-50

RADIATOR
[K9K]

RADIATOR
Removal and Installation

PFP:21400

A
BBS002T1

CO

C

D

E

F

G

H

I

J

MBIB9048E

1.

Radiator (models with A/C)

2.

Mounting rubber

4.

Hose clamp

5.

Hose clamp

6.

Reservoir tank hose

7.

Reservoir tank

8.

Cooling fan assembly

9.

Radiator (models without A/C)

10. Radiator hose (lower)

11. Hose clamp

13. Mounting rubber

14. Hose clip

3.

REMOVAL

7.
8.

Remove engine room cover. Refer to EM-241, «ENGINE ROOM COVER» .
Remove air cleaner case and air duct (inlet). Refer to EM-245, «AIR CLEANER AND AIR DUCT» .
Remove reservoir tank hose bracket bolt from radiator upper mounting bracket (RH side).
Remove radiator fan motor harnesses.
Remove engine undercover.
Drain engine coolant. Refer to CO-49, «DRAINING ENGINE COOLANT» .
CAUTION:
Perform when engine is cold.
Disconnect radiator upper hose, reservoir tank hose and mounting bracket.
Release charge air cooler from the radiator. Refer to EM-247, «Removal and Installation (For 50kW)» ,
EM-249, «Removal and Installation (For 65kW)» .

CO-51

L

12. Reservoir tank hose

WARNING:
Never remove the reservoir tank cap when the engine is hot. Serious burns could occur from high
pressure coolant escaping from the radiator. Wrap a thick cloth around the cap. Slowly turn it a quarter turn to allow built-up pressure to escape. Carefully remove the cap by turning it all the way.
1.
2.
3.
4.
5.
6.

K

Radiator hose (upper)

M

RADIATOR
[K9K]
9.

Remove radiator and radiator fan assembly.
For model with A/C, remove radiator and condenser assembly. Refer to ATC-135, «REFRIGERANT
LINES» , MTC-81, «REFRIGERANT LINES» .
CAUTION:
●
Do not damage or scratch radiator core when removing.
●

INSTALLATION
●
●

Reinstall any parts removed in reverse order of removal.
Check for engine coolant leaks. Refer to CO-48, «LEAK CHECK» .

Disassembly and Assembly Radiator Fan

BBS002T2

MBIB9047E

1.

Radiator fan motors

2.

Radiator fan shroud

: Moulded clip
: Insertion
: To radiator core upper
: To radiator core lower

CO-52

3.

Radiator fan

RADIATOR
[K9K]
DISASSEMBLY
1.
2.
3.

A

Remove radiator fan and shroud assembly.
Remove radiator fan reverse screw.
Remove fan motor from fan shroud.

CO

C

D
PBIC1486E

E

ASSEMBLY
Install in the reverse order of removal.

Checking Reservoir Tank Cap
●
●

●

BBS002T3

Fit the adapter to the tester as shown.
When connecting the reservoir tank cap to the tester, apply
water or LLC to the cap seal part.
Check reservoir tank cap relief pressure.

G

130 — 150 kPa (1.3 — 1.5 bar, 1.33 — 1.53 kg/cm2 , 18.9 21.8 psi)
●

F

H

Replace the reservoir tank cap if the engine coolant passes
through it, or if any fur signs is detected.

I
MBIB1079E

Checking Radiator

BBS002T4

Check radiator for mud or clogging. If necessary, clean radiator as follows.
●
Be careful not to bend or damage the radiator fins.
●
When radiator is cleaned without removal, remove all surrounding parts such as radiator fan, radiator
shroud and horns. Then tape the harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downwards.
2. Apply water again to all radiator core surface once per minute.
3. Stop washing if any stains no longer flow out from the radiator.
4. Blow air into the back side of radiator core vertically downwards.
●

5.

Use compressed air lower than 490 kPa (4.9 bar 5 kg/cm2 , 71psi) and keep distance more than 30 cm
(11.8 in).
Blow air again into all the radiator core surface once per minute until no water sprays out.

CO-53

J

K

L

M

WATER PUMP
[K9K]

WATER PUMP
Removal and Installation

PFP:21020
BBS002T5

MBIB1232E

1.

Water pump

2.

Gasket

3.

Cylinder block

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator.

REMOVAL
1.

2.
3.
4.

5.
6.

Remove the following parts.
● Battery ground cable
● Undercover
● RH front wheel
Remove right side splash cover.
Remove drive belt. Refer to EM-242, «DRIVE BELTS» .
Drain engine coolant. Refer to CO-49, «DRAINING ENGINE COOLANT» .
CAUTION:
Perform when engine is cold.
Remove timing belt and inner cover. Refer to EM-272, «TIMING BELT» .
Remove the water pump.
● Coolant will leak from the cylinder block, so have a receptacle ready below.
CAUTION:
● Handle the water pump vane so that it does not contact any other parts.
● Water pump cannot be disassembled and should be replaced as a unit.

INSPECTION AFTER REMOVAL
●

●

●

Visually make sure there is no significant dirt or rusting on the
water pump body and vane.
Make sure there is no looseness in the vane shaft, and that it
turns smoothly when rotated by hand.
If there are any unusualness, replace the water pump assembly.

MBIB0546E

CO-54

WATER PUMP
[K9K]
INSTALLATION
●

A

Install in the reverse order of removal.

INSPECTION AFTER INSTALLATION
●

Check for engine coolant leaks using reservoir tank cap tester. Refer to CO-48, «LEAK CHECK» .

CO

C

D

E

F

G

H

I

J

K

L

M

CO-55

THERMOSTAT
[K9K]

THERMOSTAT
Inspection
●

●

●
●

●

PFP:21200
BBS002T6

Place a thread so that it is caught in the valves of the thermostat.
Immerse fully in a container filled with water. Heat while stirring.
(The example in the figure shows the thermostat.)
The valve opening temperature is the temperature at which the
valve opens and falls from the thread.
Continue heating. Check the full-open lift amount.
After checking the full-open lift amount, lower the water temperature and check the valve closing temperature.
If the measured value is out of the standard value or unusual
valve seating condition is found, replace water inlet and thermostat assembly.

SLC949A

Temperature °C (°F)
Start of opening

89 (192)

End of opening

97 — 101 (207 — 214)

CO-56

WATER OUTLET
[K9K]

WATER OUTLET
Removal and Installation

PFP:11060

A
BBS002T7

CO

C

D

E

F

G

H

I
MBIA0090E

1.

Clip

2.

Gasket

3.

Radiator upper hose

4.

Water outlet

5.

O-ring

6.

Water temperature sensor

7.

Heater hose

8.

Air relief plug

J

K

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

Remove engine room cover. Refer to EM-241, «ENGINE ROOM COVER» .
Remove air cleaner case and air duct (inlet). Refer to EM-245, «AIR CLEANER AND AIR DUCT» .
Remove rear engine slinger. Refer to EM-280, «REMOVAL» .
Remove vacuum hose.
Remove vacuum pump. Refer to EM-261, «VACUUM PUMP» .
Drain engine coolant. Refer to CO-49, «DRAINING ENGINE COOLANT» .
CAUTION:
Perform when engine is cold.
7. Remove radiator upper hose. Refer to CO-51, «RADIATOR» .
8. Remove heater hose.
9. Disconnect reservoir tank hose. Refer to CO-51, «RADIATOR» .
10. Remove water outlet.

INSTALLATION
Install in the reverse order of removal.

CO-57

L

M

WATER OUTLET
[K9K]

CO-58

ENGINE LUBRICATION SYSTEM

B ENGINE

SECTION

LU

ENGINE LUBRICATION SYSTEM

A

LU

C

D

E

CONTENTS
CR

HR

PRECAUTIONS …………………………………………………. 3
Precautions For Liquid Gasket …………………………… 3
REMOVAL OF LIQUID GASKET SEALING ………. 3
LIQUID GASKET APPLICATION PROCEDURE….. 3
PREPARATION ………………………………………………….. 4
Special Service Tools ……………………………………….. 4
Commercial Service Tool ………………………………….. 4
LUBRICATION SYSTEM …………………………………….. 5
Lubrication Circuit ……………………………………………. 5
ENGINE OIL ……………………………………………………… 6
Inspection ……………………………………………………….. 6
OIL LEVEL AND CONTAMINATION ………………… 6
OIL LEAK …………………………………………………….. 6
OIL PRESSURE CHECK ……………………………….. 6
Changing Engine Oil ………………………………………… 7
OIL FILTER ……………………………………………………….. 9
Removal and Installation …………………………………… 9
REMOVAL ……………………………………………………. 9
INSTALLATION …………………………………………….. 9
INSPECTION AFTER INSTALLATION …………….. 9
OIL PUMP ……………………………………………………….. 10
Removal and Installation …………………………………. 10
REMOVAL ………………………………………………….. 10
INSTALLATION …………………………………………… 10
Disassembly and Assembly …………………………….. 10
DISASSEMBLY …………………………………………… 10
INSPECTION AFTER DISASSEMBLY …………… 10
ASSEMBLY ………………………………………………….11
SERVICE DATA AND SPECIFICATIONS (SDS) …… 12
Standard and Limit …………………………………………. 12
OIL PRESSURE ………………………………………….. 12
OIL PUMP ………………………………………………….. 12
OIL CAPACITY ……………………………………………. 12
TIGHTENING TORQUE ……………………………….. 12

PRECAUTIONS ……………………………………………….. 13
Precautions for Liquid Gasket ………………………….. 13
REMOVAL OF LIQUID GASKET SEALING …….. 13
LIQUID GASKET APPLICATION PROCEDURE… 13
PREPARATION ………………………………………………… 14
Special Service Tools ……………………………………… 14
Commercial Service Tool …………………………………. 14
LUBRICATION SYSTEM …………………………………… 15
Lubrication Circuit …………………………………………… 15
ENGINE OIL …………………………………………………….. 16
Inspection ……………………………………………………… 16
OIL LEVEL AND CONTAMINATION ………………. 16
ENGINE OIL LEAKAGE ……………………………….. 16
OIL PRESSURE CHECK ……………………………… 16
Changing Engine Oil ……………………………………….. 17
OIL FILTER ……………………………………………………… 19
Removal and Installation …………………………………. 19
REMOVAL ………………………………………………….. 19
INSTALLATION …………………………………………… 19
INSPECTION AFTER INSTALLATION ……………. 19
SERVICE DATA AND SPECIFICATIONS (SDS) …… 20
Standard and Limit ………………………………………….. 20
OIL PRESSURE ………………………………………….. 20
OIL CAPACITY (APPROXIMATE) ………………….. 20
TIGHTENING TORQUE ……………………………….. 20

K9K
PRECAUTIONS ……………………………………………….. 21
Precautions For Liquid Gasket …………………………. 21
REMOVAL OF LIQUID GASKET ……………………. 21
LIQUID GASKET APPLICATION PROCEDURE… 21
PREPARATION ………………………………………………… 22
Special Service Tools ……………………………………… 22
ENGINE OIL …………………………………………………….. 23
Inspection ……………………………………………………… 23
OIL LEVEL AND MUDDINESS ……………………… 23
OIL LEAKAGE …………………………………………….. 23

LU-1

F

G

H

I

J

K

L

M

OIL PRESSURE CHECK ……………………………… 23
Changing Engine Oil ……………………………………….. 24
OIL FILTER ……………………………………………………… 25
Removal and Installation …………………………………. 25
REMOVAL ………………………………………………….. 25
INSTALLATION ……………………………………………. 25
OIL PUMP ……………………………………………………….. 26
Removal and Installation …………………………………. 26
REMOVAL ………………………………………………….. 26
INSTALLATION ……………………………………………. 26

OIL COOLER …………………………………………………….27
Removal and Installation …………………………………..27
REMOVAL ……………………………………………………27
INSPECTION ……………………………………………….27
INSTALLATION …………………………………………….27
SERVICE DATA AND SPECIFICATIONS (SDS) ……29
Standard and Limit …………………………………………..29
OIL PRESSURE …………………………………………..29
OIL CAPACITY (APPROXIMATE) …………………..29
TIGHTENING TORQUE ………………………………..29

LU-2

PRECAUTIONS
[CR]

PRECAUTIONS
Precautions For Liquid Gasket
[CR]

PFP:00001

A
BBS002R5

REMOVAL OF LIQUID GASKET SEALING
After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the liquid gasket.
CAUTION:
Be careful not to damage the mating surfaces.
●
In areas where the seal cutter is difficult to use, use a plastic
hammer to lightly tap the gasket area.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating surfaces.
●

LU

C

D

PBIC0275E

E

LIQUID GASKET APPLICATION PROCEDURE
1.
●

2.

3.

Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
Remove the liquid gasket completely from the groove of the gasket application surface, mounting bolts and bolt holes.
Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.

F

G

H
PBIC0003E

I

4.
●

Apply the gasket without breaks to the specified location with the
specified dimensions.
If there is a groove for the liquid gasket application, apply the
gasket to the groove.

J

K

L
EMA0622D

As for the bolt holes, normally apply the gasket inside the holes.
Occasionally, it should be applied outside the holes. Make sure
to read the instruction in this manual.
●
Within five minutes of gasket application, install the mating component.
●
If the liquid gasket protrudes, wipe it off immediately.
●
Do not retighten after the installation.
●
After 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION:
If there are additional instructions in this manual, observe them.

M

●

LU-3

SEM164F

PREPARATION
[CR]

PREPARATION
Special Service Tools

PFP:00002
BBS002R6

Tool number
Tool name

Description

ST25051001
Oil pressure gauge

Measuring oil pressure
Maximum measuring range:
2,452 kPa (24.5 bar, 25 kg/cm2 , 356 psi)

S-NT050

ST25052000
Hose

Adapting oil pressure gauge to cylinder block

S-NT559

KV10115801
Oil filter wrench

Removing oil filter

S-NT772

WS39930000
Tube presser

Pressing the tube of liquid gasket

S-NT052

Commercial Service Tool

BBS002R7

Tool name

Description

Deep socket

Removing and installing oil pressure switch
a: 24 mm (0.94 in)

PBIC2072E

LU-4

LUBRICATION SYSTEM
[CR]

LUBRICATION SYSTEM
Lubrication Circuit

PFP:15010

A
BBS002R8

LU

C

D

E

F

G

H

I

J

K

L

M

PBIC1465E

LU-5

ENGINE OIL
[CR]

ENGINE OIL
Inspection

PFP:KLA92
BBS002R9

OIL LEVEL AND CONTAMINATION
●

●
●
●
●

●

Before starting the engine, put vehicle horizontally and check the oil level. If the engine is already started,
stop it and allow 10 minutes before checking.
Check that the oil level is within the range shown in the figure.
If oil level is outside the range, adjust level.
Check the oil for white turbidity or remarkable contamination.
If the oil becomes turbid and white, it is highly probable that it is
contaminated with coolant. Find the cause and repair.
When oil level gauge is inserted in guide, apply engine oil to rubber seal of grip.

PBIC1466E

OIL LEAK
Check the following parts for engine oil leaks.
●
Oil pan
●
Oil pan drain plug
●
Oil pressure switch
●
Oil filter
●
Front cover
●
Cylinder head front cover
●
Mating surfaces of cylinder block and cylinder head
●
Mating surfaces of cylinder head and rocker cover
●
Crankshaft oil seals (front and rear)

OIL PRESSURE CHECK
WARNING:
●
Be careful not to burn yourself, as the engine oil is hot.
●
Oil pressure check should be done in Neutral position.
1. Check the engine oil level. Refer to LU-6, «OIL LEVEL AND CONTAMINATION»
2. Remove oil filter. Refer to LU-9, «OIL FILTER» .
3. Remove oil pressure switch using a deep socket (commercial
service tool).

PBIC1467E

LU-6

ENGINE OIL
[CR]
4.
5.
6.

Install oil pressure gauge and hose (SST).
Install oil filter. Refer to LU-9, «OIL FILTER» .
After warming up the engine, check that oil pressure corresponding to the engine speed is produced.
NOTE:
Low oil temperature creates high pressure.

A

LU

C
SLC926-A

D

Engine oil pressure [When oil temperature is 80 °C (176 °F)]
Engine speed (rpm)

Idle speed

Engine oil pressure

Approx. 44.1 (0.441, 0.45, 6.4) or
more

kPa (bar, kg/cm2 , psi)

2,000
Approx. 265 (2.65, 2.7, 38) or
more

6,000
Approx. 373 (3.73, 3.8, 54) or
more

E

If difference is extreme, check oil passage and oil pump for oil leaks.

7.
a.
b.

F

After checking the oil pressure, install oil pressure switch as follows:
Remove old liquid gasket on the switch and engine.
Apply liquid gasket and tighten oil pressure switch to specification.
Use Genuine Liquid Gasket or equivalent.

G

: 18.7 — 20.5 N·m (1.9 — 2.0 kg-m, 14 — 15 ft-lb)
H

CAUTION:
Be careful not to get burned when engine or engine oil is heated.

Changing Engine Oil

BBS002RA

WARNING:
●
Be careful not to burn yourself, as the engine oil is hot.
●
Prolonged and repeated contact with used engine oil may cause skin cancer: try to avoid direct
skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as
soon as possible.
1. Warm up engine, and check for oil leakage from engine components.
Refer to LU-6, «OIL LEAK» .
2. Stop engine and wait for 10 minutes.
3. Remove oil filler cap, and remove drain plug.
4. Drain engine oil.
5. Install drain plug with new washer. Refer to EM-26, «OIL PAN AND OIL STRAINER» .
CAUTION:
● Be sure to clean drain plug and install with new washer.
Oil pan drain plug:
: 29.4 — 39.2 N·m (3.0 — 3.9 kg-m, 22 — 28 ft-lb)
Engine oil specification and viscosity:
Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS».
Refill with new engine oil.
●

6.

LU-7

I

J

K

L

M

ENGINE OIL
[CR]
Oil capacity (Approximate):
Unit:
Drain and refill

With oil filter change

(Imp qt)

3.4 (3)

Without oil filter change

3.2 (2-7/8)

Dry engine (engine overhaul)

3.9 (3-3/8)

CAUTION:
●
The refill capacity depends on the oil temperature and drain time. Use these specifications for reference only.
●
Always use oil level gauge to determine the proper amount of oil is in the engine.
7. Warm up engine and check area around drain plug and oil filter for oil leakage.
8. Stop engine and wait for 10 minutes.
9. Check oil level. Refer to LU-6, «OIL LEVEL AND CONTAMINATION» .

LU-8

OIL FILTER
[CR]

OIL FILTER
Removal and Installation

PFP:15208

A
BBS002RB

REMOVAL
Using an oil filter wrench (special service tool), remove oil filter.
CAUTION:
●
Oil filter is provided with relief valve. Use genuine NISSAN
oil filter or equivalent.
●
Be careful not to get burned when the engine and engine oil
are hot.
●
When removing, prepare a shop cloth to absorb any oil
leakage or spillage.
●
Do not allow engine oil to adhere to the drive belts.
●
Completely wipe off any oil that adheres to the engine and
vehicle.

LU

C

D

PBIC1469E

E

INSTALLATION
1.
2.

Remove foreign materials adhering to the oil filter installation surface.
Apply engine oil to the oil seal circumference of the new oil filter.
CAUTION:
● Use genuine NISSAN oil filter or the equivalent.

F

G

H

I
SMA010

3.

Screw the oil filter manually until it touches the installation surface, then tighten it by 2/3 turn.

J

Oil filter:
K

:11 — 14 N·m (1.2 — 1.4 kg-m, 9 — 10 ft-lb)

L

SMA229B

INSPECTION AFTER INSTALLATION
1.
2.
3.
4.

Check the engine oil level. Refer to LU-6, «OIL LEVEL AND CONTAMINATION» .
After warming up the engine, check for engine oil leakage.
Stop engine and wait for 10 minutes.
Check the engine oil level. Refer to LU-6, «OIL LEVEL AND CONTAMINATION»

LU-9

M

OIL PUMP
[CR]

OIL PUMP
Removal and Installation

PFP:15010
BBS002RC

REMOVAL
●

Remove front cover. Refer to EM-50, «TIMING CHAIN» .

INSTALLATION
●

Install in the reverse order of removal.

Disassembly and Assembly

BBS002RD

MBIB1233E

1.

Front cover

4.

Oil pump cover

2.

Inner rotor

3. Outer rotor

CAUTION:
Prior to installation, apply new engine oil to the parts marked in figure.

DISASSEMBLY
1.
2.

Remove oil pump cover.
Remove outer rotor and inner rotor from front cover.

INSPECTION AFTER DISASSEMBLY
Clearances of Oil Pump Parts
●

Measure clearance with feeler gauge and straightedge.
Side clearance between inner rotor and front cover (position 1).
Standard

: 0.025 — 0.075 mm (0.0010 — 0.0030 in)

Side clearance between outer rotor and front cover (position 2).
Standard

: 0.025 — 0.075 mm (0.0010 — 0.0030 in)

PBIC1472E

●

Calculate the clearance from inner rotor to front cover socket with the following procedures.

LU-10

OIL PUMP
[CR]
1.

Using a micrometer, measure the outer diameter of inner rotor
protrusion (Position 3).

A

LU

C
PBIC1473E

D

2.

Using an inside micrometer, measure the inner diameter of front
cover. (Position 4)
(Clearance) = (Inner diameter of front cover) — (outer diameter of
inner rotor protrusion)
Standard

E

: 0.045 — 0.095 mm (0.0011 — 0.0037 in)
F

G
PBIC1474E

ASSEMBLY
H

Install in the reverse order of disassembly.

I

J

K

L

M

LU-11

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR]

SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit

PFP:00030
BBS002RE

OIL PRESSURE
Engine speed rpm

Approximate discharge pressure kPa (bar, kg/cm2 , psi)

Idle speed
2,000
6,000

Approx. 44.1 (0.441, 0.45, 6.4) or more
Approx. 265 (2.65, 2.7, 38) or more
Approx. 373 (3.73, 3.8, 54) or more

OIL PUMP
Unit: mm (in)
Body to inner rotor axial clearance

0.025 — 0.075 (0.0010 — 0.0030)

Body to outer rotor axial clearance

0.025 — 0.075 (0.0010 — 0.0030)

Inner rotor to brazed portion of housing clearance

0.045 — 0.095 (0.0018 — 0.0037)

OIL CAPACITY
Unit:
With oil filter change

(Imp qt)

Approximately 3.4 (3)

Without oil filter change

Approximately 3.2 (2-7/8)

Dry engine (engine overhaul)

Approximately 3.9 (3-3/8)

TIGHTENING TORQUE
Oil pressure switch

Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)*
18.7 — 20.5 (1.9 — 2.0, 14 — 15)

Oil pan drain plug

29.4 — 39.2 (3.0 — 3.9, 22 — 28)

Oil filter

11 — 14 (1.2 — 1.4, 9 — 10)

Oil pump cover

6.3 — 8.3 (0.65 — 0.84, 56 — 73)*

LU-12

PRECAUTIONS
[HR]

PRECAUTIONS
Precautions for Liquid Gasket
[HR]

PFP:00001

A
BBS002RF

REMOVAL OF LIQUID GASKET SEALING
After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the liquid gasket.
CAUTION:
Be careful not to damage the mating surfaces.
●
In areas where the seal cutter is difficult to use, use a plastic
hammer to lightly tap the gasket area.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating surfaces.
●

LU

C

D

PBIC0275E

E

LIQUID GASKET APPLICATION PROCEDURE
1.
●

2.

3.

Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
Remove the liquid gasket completely from the groove of the gasket application surface, mounting bolts and bolt holes.
Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.

F

G

H
PBIC0003E

I

4.
●

Apply the gasket without breaks to the specified location with the
specified dimensions.
If there is a groove for the liquid gasket application, apply the
gasket to the groove.

J

K

L
EMA0622D

As for the bolt holes, normally apply the gasket inside the holes.
Occasionally, it should be applied outside the holes. Make sure
to read the instruction in this manual.
●
Within five minutes of gasket application, install the mating component.
●
If the liquid gasket protrudes, wipe it off immediately.
●
Do not retighten after the installation.
●
After 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION:
If there are additional instructions in this manual, observe them.

M

●

LU-13

SEM164F

PREPARATION
[HR]

PREPARATION
Special Service Tools

PFP:00002
BBS002RG

Tool number
Tool name

Description

ST25051001
Oil pressure gauge

Measuring oil pressure
Maximum measuring range:
2,452 kPa (24.52 bar, 25 kg/cm2 , 356 psi)

S-NT050

ST25052000
Hose

Adapting oil pressure gauge to cylinder block

S-NT559

KV10115801
Oil filter wrench

Removing and installing oil filter
a: 64.3 mm (2.531 in)

S-NT375

WS39930000
Tube presser

Pressing the tube of liquid gasket

S-NT052

Commercial Service Tool

BBS002RH

Tool name

Description

Deep socket

Removing and installing oil pressure switch
a: 27 mm (1.06 in)

PBIC2072E

LU-14

LUBRICATION SYSTEM
[HR]

LUBRICATION SYSTEM
Lubrication Circuit

PFP:15010

A
BBS002RI

LU

C

D

E

F

G

H

I

J

K

L

M

PBIC3819E

LU-15

ENGINE OIL
[HR]

ENGINE OIL
Inspection

PFP:KLA92
BBS002RJ

OIL LEVEL AND CONTAMINATION
●

●
●
●
●

●

Before starting the engine, put vehicle horizontally and check the oil level. If the engine is already started,
stop it and allow 10 minutes before checking.
Check that the oil level is within the range shown in the figure.
If oil level is outside the range, adjust level.
Check the oil for white turbidity or remarkable contamination.
If the oil becomes turbid and white, it is highly probable that it is
contaminated with coolant. Find the cause and repair.
When oil level gauge is inserted in guide, apply engine oil to rubber seal of grip.

PBIC1466E

ENGINE OIL LEAKAGE
Check for engine oil leakage around the following area.
●
Oil pan (upper and lower)
●
Oil pan drain plug
●
Oil pressure switch
●
Oil filter
●
Intake valve timing control solenoid valve
●
Front cover
●
Mating surface between cylinder block and cylinder head
●
Mating surface between cylinder head and rocker cover
●
Crankshaft oil seals (front and rear)
●
Oil filter (for intake valve timing control)

OIL PRESSURE CHECK
WARNING:
●
Be careful not to burn yourself, as engine oil may be hot.
●
Engine oil pressure check should be in Neutral position and should apply parking brake securely.
1. Check oil level. Refer to LU-16, «OIL LEVEL AND CONTAMINATION»
2. Remove oil filter. Refer to LU-19, «OIL FILTER» .
3. Disconnect harness connector at oil pressure switch (2), and
remove oil pressure switch using a deep socket (commercial
service tool).
1

Cylinder block

3.

Oil level sensor

MBIB1356E

LU-16

ENGINE OIL
[HR]
4.

Install oil pressure gauge and hose (SST).
A

LU

C
SLC926-A

D

5.
6.
7.
8.

Install oil filter. Refer to LU-19, «OIL FILTER» .
Check engine oil level. Refer to LU-16, «OIL LEVEL AND CONTAMINATION» .
Start engine and warm it up to normal operating temperature.
Check oil pressure with engine running under no-load.
NOTE:
When engine oil temperature is low, engine oil pressure becomes high.

E

F

Engine oil pressure [Engine oil temperature at 80°C (176°F)]

9.
a.
b.
c.

Engine speed
rpm

Approximate discharge pressure

Idle speed

More than 60 (0.60, 0.61, 9)

2,000

More than 275 (2.7, 2.8, 40)

G

kPa (bar, kg/cm2 , psi)

H

If difference is extreme, check oil passage and oil pump for oil leaks.
After the inspections, install oil pressure switch as follows:
Remove oil filter. Refer to LU-19, «OIL FILTER» .
Remove old liquid gasket adhering to oil pressure switch and engine.
Apply liquid gasket and tighten oil pressure switch to specification.
Use Genuine Liquid Gasket or equivalent.

I

J

: 19.6 N·m (2.0 kg-m, 14 ft-lb)
d.
e.
f.

K

Install oil filter. Refer to LU-19, «OIL FILTER» .
Check engine oil level. Refer to LU-16, «OIL LEVEL AND CONTAMINATION» .
After warming up engine, make sure there is no leaks of engine oil with running engine.

Changing Engine Oil

L
BBS002RK

WARNING:
●
Be careful not to burn yourself, as engine oil may be hot.
●
Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct
skin contact with used engine oil. If skin contact is made, wash thoroughly with soap or hand
cleaner as soon as possible.
1. Warm up engine, put vehicle horizontally and check for engine oil leakage from engine components.
Refer to LU-16, «ENGINE OIL LEAKAGE» .
2. Stop engine and wait for 10 minutes.
3. Loosen oil filler cap and then remove drain plug.
4. Drain engine oil.
5. Install drain plug with new washer. Refer to EM-127, «OIL PAN AND OIL STRAINER» .
CAUTION:
Be sure to clean drain plug and install with new washer.
Oil pan drain plug:
: 34.3 N·m (3.5 kg-m, 25 ft-lb)

LU-17

M

ENGINE OIL
[HR]
6.

Refill with new engine oil.
Engine oil specification and viscosity:
Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS» .
Engine oil capacity (Approximate):
Unit:
With oil filter change

Drain and refill

4.6 (4)

Without oil filter change

4.4 (3-7/8)

Dry engine (Overhaul)

7.
8.
9.

(lmp qt)

4.8 (4-1/4)

CAUTION:
● The refill capacity depends on the engine oil temperature and drain time. Use these specifications for reference only.
● Always use oil level gauge to determine the proper amount of engine oil in the engine.
Warm up engine and check area around drain plug and oil filter for engine oil leakage.
Stop engine and wait for 10 minutes.
Check the engine oil level. Refer to LU-16, «OIL LEVEL AND CONTAMINATION» .

LU-18

OIL FILTER
[HR]

OIL FILTER
Removal and Installation

PFP:15208

A
BBS002RL

REMOVAL
Using oil filter wrench (SST: KV10115801) (A), remove oil filter.

LU

: Vehicle font

CAUTION:
●
Oil filter is provided with relief valve. Use Genuine NISSAN
oil filter or equivalent.
●
Be careful not to get burned when engine and engine oil
may be hot.
●
When removing, prepare a shop cloth to absorb any engine
oil leakage or spillage.
●
Do not allow engine oil to adhere to drive belt.
●
Completely wipe off any engine oil that adheres to engine and vehicle.

C

D

MBIB1357E

INSTALLATION
1.
2.

E

F

Remove foreign materials adhering to the oil filter installation surface.
Apply new engine oil to the oil seal contact surface of new oil filter.
CAUTION:
Use genuine NISSAN oil filter or the equivalent.

G

H

I
SMA010

3.

J

Screw oil filter manually until it touches the installation surface,
then tighten it by 2/3 turn. Or tighten to specification.
Oil filter:

K

: 17.7 N·m (1.8 kg-m, 13 ft-lb)
L

M
SMA229B

INSPECTION AFTER INSTALLATION
1.
2.
3.
4.

Check the engine oil level. Refer to LU-16, «OIL LEVEL AND CONTAMINATION» .
Start engine, and make sure there is no leaks of engine oil.
Stop engine and wait for 10 minutes.
Check the engine oil level. Refer to LU-16, «OIL LEVEL AND CONTAMINATION» .

LU-19

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR]

SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit

PFP:00030
BBS002RM

OIL PRESSURE
Engine speed rpm

Approximate discharge pressure kPa (bar, kg/cm2 , psi)

Idle speed
2,000

60 (0.60, 0.61, 9)
275 (2.7, 2.8, 40)

OIL CAPACITY (APPROXIMATE)
Unit:
With oil filter change

·(Imp qt)

4.6 (4 Imp qt)

Without oil filter change

4.4 (3-7/8 Imp qt)

Dry engine (overhaul)

4.8 (4-1/4 Imp qt)

TIGHTENING TORQUE
Unit: N·m (kg-m, ft-lb)
Oil pressure switch

19.6 (2.0, 14)

Oil pan drain plug

34.3 (3.5, 25)

Oil filter

17.7 (1.8, 13)

LU-20

PRECAUTIONS
[K9K]

PRECAUTIONS
Precautions For Liquid Gasket
[K9K]

PFP:00001

A
BBS002RO

REMOVAL OF LIQUID GASKET
●

●

After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the liquid gasket.
CAUTION:
Be careful not to damage the mating surfaces.
In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the gasket applied area.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating
surfaces.

LU

C

D

PBIC0275E

E

LIQUID GASKET APPLICATION PROCEDURE
1.

2.

3.

Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
● Remove the liquid gasket completely from the groove of the
gasket application surface, mounting bolts and bolt holes.
Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.

F

G

H
PBIC0003E

I

4.

Apply the gasket without breaks to the specified location with the
specified dimensions.
● If there is a groove for the liquid gasket application, apply the
gasket to the groove.

J

K

L
EMA0622D

As for the bolt holes, normally apply the gasket inside the
holes. If specified, it should be applied outside the holes.
Make sure to read the instruction in this manual.
● Within five minutes of gasket application, install the mating
component.
● If the liquid gasket protrudes, wipe it off immediately.
● Do not retighten after the installation.
● After 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION:
If there are instructions in this manual, observe them.
●

LU-21

M

SEM159F

PREPARATION
[K9K]

PREPARATION
Special Service Tools

PFP:00002
BBS002RP

NISSAN tool number
(RENAULT tool number)
Tool name

Description

KV113C0010
(Mot.1329)
Oil filter wrench

Removing and installing oil filter

MBIB0369E

KV113E0020
(Mot.836-05)
Oil pressure gauge set

Measuring oil pressure
Use C, E, F.

MBIB0663E

WS39930000
(
—
)
Tube presser

Pressing the tube of liquid gasket

S-NT052

LU-22

ENGINE OIL
[K9K]

ENGINE OIL
Inspection

PFP:KLA92

A
BBS002RQ

OIL LEVEL AND MUDDINESS
●

●
●
●
●

Before starting the engine, check the oil level placing vehicle
horizontally. If the engine is already started, stop it and allow 10
minutes before checking.
Make sure the oil level is within the range shown in the figure.
If it is out of range, adjust it.
Check the oil for white turbidity or remarkable contamination.
If the oil becomes turbid and white, it is highly probable that it is
contaminated with coolant. Find the cause and repair.

LU

C

D

MBIB0548E

E

OIL LEAKAGE
Check for oil leakage around the following area.
●
Oil pan
●
Oil pan drain plug
●
Oil pressure switch
●
Oil filter bracket
●
Vacuum pump
●
Oil pump housing
●
Mating surface between cylinder block and cylinder head
●
Mating surface between cylinder head and rocker cover
●
Oil cooler
●
Crankshaft oil seals

F

G

H

I

OIL PRESSURE CHECK

J

WARNING:
●
Be careful not to burn yourself, as the engine oil is hot.
●
Oil pressure check should be done in Neutral “N” position.
1. Check the oil level. Refer to LU-23, «OIL LEVEL AND MUDDINESS» .
2. Remove engine undercover.
3. Remove the oil pressure switch to connect the oil pressure
gauge (special service tool).
4. After warming up the engine, make sure oil pressure corresponding to the engine speed is produced.

5.
a.
b.

Idle speed

: Approx. 120 kPa (1.2 bar, 1.22 kg/cm2 ,
17.4 psi)

3000 rpm

: Approx. 350 kPa (3.5 bar, 3.57 kg/cm2 ,
50.8 psi)

After checking, install the oil pressure switch as follows.
Remove old sealant adhering to the switch and engine.
Apply thread sealant.
Use Genuine Liquid Gasket or equivalent.
Oil pressure switch:
: 25 N·m (2.55 kg-m, 18.4 ft-lb)

6.

Start engine and check for oil leakage.

LU-23

K

L

M

MBIB0549E

ENGINE OIL
[K9K]

Changing Engine Oil

BBS002RR

WARNING:
●
Be careful not to burn yourself, as the engine oil is hot.
●
Prolonged and repeated contact with used engine oil may cause skin cancer: try to avoid direct
skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as
soon as possible.
1. Put vehicle horizontally.
2. Warm up engine, and check for oil leakage from engine components.
3. Stop engine and wait for 10 minutes.
4. Remove drain plug and oil filler cap.
5. Drain oil and refill with new engine oil.
● Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS» .
Oil capacity (Approximate):
With oil filter change

4.40

(3-7/8 Imp qt)

Without oil filter change

4.24

(3-3/4 Imp qt)

Drain and refill
Dry engine (overhaul)
●

6.
7.
8.

4.56

(4 Imp qt)

The refill capacity depends on the oil temperature and drain
MBIB0548E
time. Use these specifications for reference only.
Always use the dipstick to the determine when the proper amount of oil is in the engine.
CAUTION:
● Be sure to clean drain plug and install with new washer.
● The refill capacity depends on the oil temperature and drain time. Use these specifications for
reference only.
Always use the dipstick to the determine when the proper amount of oil is in the engine.
Warm up engine and check area around drain plug and oil filter for oil leakage.
Stop engine and wait for 10 minutes.
Check oil level.

LU-24

OIL FILTER
[K9K]

OIL FILTER
Removal and Installation

PFP:15208

A
BBS002RS

LU

C

D

E

F

MBIA0089E

1.

Oil filter

4.

Connecting bolt

2.

O-ring

3.

G

Oil filter bracket

H

REMOVAL
1. Using an oil filter wrench (special service tool), remove oil filter.
CAUTION:
●
Be careful not to get burned when the engine and engine oil
are hot.
●
When removing, prepare a shop cloth to absorb any oil
leakage or spillage.
●
Do not allow engine oil to adhere to the drive belts.
●
Completely wipe off any oil that adhere to the engine and
the vehicle.

I

J

K

MBIB0551E

L

INSTALLATION
1.
2.

3.
4.
5.
6.
7.

Remove foreign materials adhering to the oil filter installation surface.
Install oil filter bracket to oil cooler.
CAUTION:
Install oil filter bracket, positioning lug in the hole of oil cooler.
Apply engine oil to the oil seal contact surface of the new oil filter.
Install the oil filter until it comes into contact with the oil seal on
the engine bracket.
Tighten the oil filter three-quarters of a turn by hand.
After warming up the engine, check for engine oil leakage.
Check oil level and add engine oil. Refer to LU-23, «ENGINE
OIL» .

M

SMA010

LU-25

OIL PUMP
[K9K]

OIL PUMP
Removal and Installation

PFP:15010
BBS002RT

MBIB0552E

1.

Oil pump drive chain

2.

Crankshaft sprocket

3.

Oil pump assembly

REMOVAL
1.

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

Remove the following parts.
● Battery ground cable
● Undercover
● RH front wheel
Remove right side splash cover.
Remove drive belt. Refer to EM-242, «DRIVE BELTS» .
Remove oil pan. Refer to EM-257, «OIL PAN» .
Remove rear oil seal retainer. Refer to EM-272, «TIMING BELT» .
Remove oil pump drive chain. Refer to EM-297, «Disassembly of The Bottom Engine» .
Remove oil pump assembly.

INSTALLATION
Install in the reverse order of removal paying attention to the following.

Rear Oil Seal Retainer and Oil Pump
●

Refer to EM-310, «INSTALLATION OF REAR OIL SEAL RETAINER AND OIL PUMP» .

LU-26

OIL COOLER
[K9K]

OIL COOLER
Removal and Installation

PFP:21305

A
BBS002RU

LU

C

D

E

F

G

H

I
MBIB9049E

1.

Cylinder block

2.

Water pipe

3.

O-ring

4.

Oil cooler

5.

Connecting stud

6.

O-ring

7.

Oil filter Bracket

8.

O-ring

9.

Connecting bolt

11.

Oil filter

12. O-ring

10. Oil pressure switch

J

K

: To radiator lower hose
: To water pump

L

CAUTION:
●
Be careful not to get burned when the engine and engine oil are hot.
●
When removing, prepare a shop cloth to absorb any oil leakage or spillage.
●
Completely wipe off any oil that abhere to the engine and the vehicle.

REMOVAL
1.

2.
3.
4.

Drain engine coolant. Refer to CO-49, «DRAINING ENGINE COOLANT» .
CAUTION:
Perform when engine is cold.
Remove oil filter and oil filter bracket. Refer to LU-25, «OIL FILTER» .
Remove water hoses from oil cooler.
Remove oil cooler.

INSPECTION
Oil Cooler
Check oil cooler for cracks and clogging by blowing through coolant inlet. If necessary, replace oil cooler
assembly.

INSTALLATION
Installation is in reverse order of removal.

LU-27

M

OIL COOLER
[K9K]
●

Replace the O-ring (A) of the oil cooler, positioning the lip (B) of
the seal behind the lug (C) of the oil cooler.

MBIB0458E

●

Confirm that no foreign objects are adhering to the installation planes of the oil cooler and block.

LU-28

SERVICE DATA AND SPECIFICATIONS (SDS)
[K9K]

SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit

PFP:00030

A
BBS005AO

OIL PRESSURE
Engine speed rpm

Approximate discharge pressure kPa (bar, kg/cm2 , psi)

Idle speed
3,000

120 (1.2, 1.22, 17.4)
350 (3.5, 5.57, 50.8)

LU

C

OIL CAPACITY (APPROXIMATE)
Unit:
With oil filter change

4.40 (3 — 7/8 lmp qt)

Without oil filter change

4.24 (3 — 3/4 lmp qt)

Dry engine (overhaul)

·(Imp qt)

D

4.56 (4 Imp qt)

E

TIGHTENING TORQUE
Unit: N·m (kg-m, ft-lb)
Oil pressure switch

25 (2.55, 18.4)

F

G

H

I

J

K

L

M

LU-29

SERVICE DATA AND SPECIFICATIONS (SDS)
[K9K]

LU-30

ENGINE MECHANICAL

B ENGINE

SECTION

EM

ENGINE MECHANICAL

A

EM

C

D

CONTENTS
CR
PRECAUTIONS …………………………………………………. 7
Precautions for Draining Coolant ……………………….. 7
Precautions for Disconnecting Fuel Piping ………….. 7
Precautions for Removal and Disassembly …………. 7
Precautions for Inspections, Repairs, and Replacement ………………………………………………………………. 7
Precautions for Assembling and Installing …………… 7
Parts Requiring Angle Tightening ……………………….. 7
Precautions for Liquid Gasket ……………………………. 8
REMOVAL OF LIQUID GASKET SEALING ………. 8
LIQUID GASKET APPLICATION PROCEDURE….. 8
PREPARATION ………………………………………………….. 9
Special Service Tools ……………………………………….. 9
Commercial Service Tools …………………………………11
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ………………………………………. 12
NVH Troubleshooting —Engine Noise ………………. 12
Use the Chart Below to Help You Find the Cause
of the Symptom. …………………………………………….. 13
DRIVE BELTS ………………………………………………….. 14
Checking drive Belts ………………………………………. 14
Tension Adjustment ………………………………………… 14
ALTERNATOR AND A/C COMPRESSOR BELT
(WITH A/C MODELS) ………………………………….. 15
ALTERNATOR BELT (WITHOUT A/C MODELS)… 15
WATER PUMP BELT …………………………………… 16
Removal and Installation …………………………………. 16
REMOVAL ………………………………………………….. 16
INSTALLATION …………………………………………… 16
Removal and Installation of Drive Belt Idler Pulley… 16
REMOVAL ………………………………………………….. 17
INSTALLATION …………………………………………… 17
AIR CLEANER AND AIR DUCT …………………………. 18
Removal and Installation …………………………………. 18
REMOVAL ………………………………………………….. 18
INSTALLATION …………………………………………… 19
Changing Air Cleaner Filter ……………………………… 21
REMOVAL ………………………………………………….. 21
INSTALLATION …………………………………………… 21

INTAKE MANIFOLD …………………………………………. 22
Removal and Installation …………………………………. 22
REMOVAL ………………………………………………….. 22
INSTALLATION …………………………………………… 23
EXHAUST MANIFOLD AND THREE WAY CATALYST ……………………………………………………………….. 24
Removal and Installation …………………………………. 24
REMOVAL ………………………………………………….. 24
INSPECTION AFTER REMOVAL ………………….. 25
INSTALLATION …………………………………………… 25
OIL PAN AND OIL STRAINER …………………………… 26
Removal and Installation …………………………………. 26
REMOVAL ………………………………………………….. 26
INSTALLATION …………………………………………… 27
INSPECTION AFTER INSTALLATION ……………. 28
IGNITION COIL ………………………………………………… 29
Removal and Installation …………………………………. 29
REMOVAL ………………………………………………….. 29
INSTALLATION …………………………………………… 29
SPARK PLUG (PLATINUM-TIPPED TYPE) …………. 30
Removal and Installation …………………………………. 30
REMOVAL ………………………………………………….. 30
INSPECTION AFTER REMOVAL ………………….. 30
INSTALLATION …………………………………………… 31
FUEL INJECTOR AND FUEL TUBE …………………… 32
Removal and Installation …………………………………. 32
REMOVAL ………………………………………………….. 32
INSTALLATION …………………………………………… 33
INSPECTION AFTER INSTALLATION ……………. 34
ROCKER COVER …………………………………………….. 35
Removal and Installation …………………………………. 35
REMOVAL ………………………………………………….. 35
INSTALLATION …………………………………………… 36
CAMSHAFT …………………………………………………….. 38
Removal and Installation …………………………………. 38
REMOVAL ………………………………………………….. 38
INSTALLATION …………………………………………… 41
INSPECTION AFTER REMOVAL ………………….. 44

EM-1

E

F

G

H

I

J

K

L

M

INSPECTION AFTER INSTALLATION ……………. 47
Valve Clearance ……………………………………………… 47
INSPECTION ………………………………………………. 47
ADJUSTMENT ……………………………………………. 49
TIMING CHAIN …………………………………………………. 50
Removal and Installation …………………………………. 50
REMOVAL ………………………………………………….. 51
INSPECTION AFTER REMOVAL …………………… 53
INSTALLATION ……………………………………………. 53
INSPECTION AFTER INSTALLATION ……………. 56
OIL SEAL ………………………………………………………… 57
Removal and Installation of Valve Oil Seal …………. 57
REMOVAL ………………………………………………….. 57
INSTALLATION ……………………………………………. 57
Removal and Installation of Front Oil Seal …………. 57
REMOVAL ………………………………………………….. 57
INSTALLATION ……………………………………………. 58
Removal and Installation of Rear Oil Seal ………….. 58
REMOVAL ………………………………………………….. 58
INSTALLATION ……………………………………………. 58
CYLINDER HEAD …………………………………………….. 60
On Vehicle Inspection ……………………………………… 60
COMPRESSION PRESSURE INSPECTION …… 60
Removal and Installation …………………………………. 61
REMOVAL ………………………………………………….. 61
INSPECTION AFTER REMOVAL …………………… 62
INSTALLATION ……………………………………………. 62
Disassembly and Assembly ……………………………… 63
DISASSEMBLY …………………………………………… 64
ASSEMBLY ………………………………………………… 64
INSPECTION AFTER DISASSEMBLY ……………. 65
ENGINE ASSEMBLY ………………………………………… 70
Removal and Installation …………………………………. 70
REMOVAL ………………………………………………….. 71
INSTALLATION ……………………………………………. 73
INSPECTION AFTER INSTALLATION ……………. 73
CYLINDER BLOCK …………………………………………… 74
Disassembly and Assembly ……………………………… 74
DISASSEMBLY …………………………………………… 75
ASSEMBLY ………………………………………………… 77
How to Select Piston and Bearing …………………….. 82
DESCRIPTION ……………………………………………. 82
HOW TO SELECT PISTON …………………………… 83
HOW TO SELECT MAIN BEARING ……………….. 84
Inspection After Disassembly …………………………… 85
CRANKSHAFT SIDE CLEARANCE ……………….. 85
CONNECTING ROD SIDE CLEARANCE ……….. 85
PISTON AND PISTON PIN CLEARANCE ………. 85
PISTON RING SIDE CLEARANCE ………………… 86
PISTON RING END GAP ……………………………… 86
CONNECTING ROD BEND AND TORSION ……. 87
CONNECTING ROD BEARING HOUSING
DIAMETER (BIG END) …………………………………. 87
CONNECTING ROD BUSHING OIL CLEARANCE DIAMETER (SMALL END) ………………….. 87
CYLINDER BLOCK DISTORTION …………………. 88
INNER DIAMETER OF MAIN BEARING HOUS-

ING ……………………………………………………………..88
PISTON TO CYLINDER BORE CLEARANCE …89
OUTER DIAMETER OF CRANKSHAFT JOURNAL …………………………………………………………….90
OUTER DIAMETER OF CRANKSHAFT PIN ……90
OUT-OF-ROUND AND TEPER OF CRANKSHAFT ………………………………………………………..90
CRANKSHAFT RUNOUT ………………………………91
OIL CLEARANCE OF CONNECTING ROD
BEARING …………………………………………………….91
OIL CLEARANCE OF MAIN BEARING ……………92
CRUSH HEIGHT OF MAIN BEARING OR CONNECTING ROD BEARING ……………………………..92
FLYWHEEL RUNOUT …………………………………..93
SERVICE DATA AND SPECIFICATIONS (SDS) ……94
Standard and Limit …………………………………………..94
GENERAL SPECIFICATIONS ………………………..94
INTAKE MANIFOLD AND EXHAUST MANIFOLD ………………………………………………………….94
DRIVE BELTS ………………………………………………95
SPARK PLUG ………………………………………………95
CYLINDER HEAD …………………………………………95
VALVE …………………………………………………………96
CAMSHAFT AND CAMSHAFT BEARING ………..99
CYLINDER BLOCK ……………………………………….99
PISTON, PISTON RING AND PISTON PIN …… 100
CONNECTING ROD …………………………………… 101
CRANKSHAFT …………………………………………… 101
MAIN BEARING …………………………………………. 101
CONNECTING ROD BEARING ……………………. 102
MISCELLANEOUS COMPONENTS ……………… 102
Tightening Torque …………………………………………. 103

HR
PRECAUTIONS ………………………………………………. 105
Precautionsfor ProcedureswithoutCowl TopCover. 105
Precautions for Draining Engine Coolant ………….. 105
Precautions for Disconnecting Fuel Piping ……….. 105
Precautions for Removal and Disassembly ………. 105
Precautions for Inspection, Repair and Replacement ……………………………………………………………. 105
Precautions for Assembly and Installation ………… 105
Parts Requiring Angle Tightening ……………………. 105
Precautions For Liquid Gasket ………………………… 106
REMOVAL OF LIQUID GASKET ………………….. 106
LIQUID GASKET APPLICATION PROCEDURE.106
PREPARATION ………………………………………………. 108
Special Service Tools …………………………………….. 108
Commercial Service Tools ……………………………… 110
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING …………………………………….. 112
NVH Troubleshooting — Engine Noise …………….. 112
Use the Chart Below to Help You Find the Cause
of the Symptom. ……………………………………………. 113
DRIVE BELTS …………………………………………………. 114
Checking Drive Belts ……………………………………… 114
Tension Adjustment ……………………………………….. 114
Removal and Installation ………………………………… 115

EM-2

REMOVAL ………………………………………………….115
INSTALLATION …………………………………………..115
Removal and Installation of Drive Belt Idler Pulley..116
REMOVAL ………………………………………………….116
INSTALLATION …………………………………………..117
AIR CLEANER AND AIR DUCT …………………………118
Components ………………………………………………….118
Removal and Installation …………………………………118
REMOVAL ………………………………………………….118
INSTALLATION …………………………………………..119
Changing Air Cleaner Filter ……………………………..119
REMOVAL ………………………………………………….119
INSPECTION AFTER REMOVAL ………………….119
INSTALLATION …………………………………………..119
INTAKE MANIFOLD ……………………………………….. 120
Components ………………………………………………… 120
Removal and Installation ……………………………….. 121
REMOVAL ………………………………………………… 121
INSTALLATION …………………………………………. 122
EXHAUST MANIFOLD ……………………………………. 124
Components ………………………………………………… 124
Removal and Installation ……………………………….. 125
REMOVAL ………………………………………………… 125
INSPECTION AFTER REMOVAL ………………… 126
INSTALLATION …………………………………………. 126
OIL PAN AND OIL STRAINER …………………………. 127
Components ………………………………………………… 127
Removal and Installation ……………………………….. 127
REMOVAL ………………………………………………… 127
INSTALLATION …………………………………………. 128
INSPECTION AFTER INSTALLATION …………. 131
IGNITION COIL ………………………………………………. 132
Components ………………………………………………… 132
Removal and Installation ……………………………….. 132
REMOVAL ………………………………………………… 132
INSTALLATION …………………………………………. 132
SPARK PLUG (PLATINUM-TIPPED TYPE) ……….. 133
Components ………………………………………………… 133
Removal and Installation ……………………………….. 133
REMOVAL ………………………………………………… 133
INSPECTION AFTER REMOVAL ………………… 133
INSTALLATION …………………………………………. 134
FUEL INJECTOR AND FUEL TUBE …………………. 135
Components ………………………………………………… 135
Removal and Installation ……………………………….. 135
REMOVAL ………………………………………………… 135
INSTALLATION …………………………………………. 137
INSPECTION AFTER INSTALLATION …………. 139
ROCKER COVER …………………………………………… 140
Components ………………………………………………… 140
Removal and Installation ……………………………….. 140
REMOVAL ………………………………………………… 140
INSTALLATION …………………………………………. 141

TIMING CHAIN ……………………………………………….. 142
Components ………………………………………………… 142
Removal and Installation ……………………………….. 143
REMOVAL ………………………………………………… 143
INSPECTION AFTER REMOVAL ………………… 146
INSTALLATION …………………………………………. 146
INSPECTION AFTER INSTALLATION ………….. 150
CAMSHAFT …………………………………………………… 151
Components ………………………………………………… 151
Removal and Installation ……………………………….. 151
REMOVAL ………………………………………………… 151
INSPECTION AFTER REMOVAL ………………… 157
INSTALLATION …………………………………………. 161
INSPECTION AFTER INSTALLATION ………….. 165
Valve Clearance …………………………………………… 166
INSPECTION ……………………………………………. 166
ADJUSTMENT ………………………………………….. 168
OIL SEAL ………………………………………………………. 170
Removal and Installation of Valve Oil Seal ……….. 170
REMOVAL ………………………………………………… 170
INSTALLATION …………………………………………. 170
Removal and Installation of Front Oil Seal ……….. 171
REMOVAL ………………………………………………… 171
INSTALLATION …………………………………………. 171
Removal and Installation of Rear Oil Seal ………… 172
REMOVAL ………………………………………………… 172
INSTALLATION …………………………………………. 172
CYLINDER HEAD …………………………………………… 173
On-Vehicle Service ……………………………………….. 173
CHECKING COMPRESSION PRESSURE ……. 173
Components ………………………………………………… 174
Removal and Installation ……………………………….. 174
REMOVAL ………………………………………………… 174
INSPECTION AFTER REMOVAL ………………… 175
INSTALLATION …………………………………………. 176
INSPECTION AFTER INSTALLATION ………….. 176
Components ………………………………………………… 177
Disassembly and Assembly ……………………………. 178
DISASSEMBLY …………………………………………. 178
ASSEMBLY ………………………………………………. 178
Inspection After Disassembly …………………………. 179
VALVE DIMENSIONS …………………………………. 179
VALVE GUIDE CLEARANCE ………………………. 179
VALVE GUIDE REPLACEMENT ………………….. 180
VALVE SEAT CONTACT …………………………….. 181
VALVE SEAT REPLACEMENT ……………………. 181
VALVE SPRING SQUARENESS ………………….. 182
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ……………………….. 182
ENGINE ASSEMBLY ………………………………………. 184
Components ………………………………………………… 184
Removal and Installation ……………………………….. 184
REMOVAL ………………………………………………… 185
INSTALLATION …………………………………………. 187
INSPECTION AFTER INSTALLATION ………….. 188
CYLINDER BLOCK ………………………………………… 189
Components ………………………………………………… 189
Disassembly and Assembly ……………………………. 190
DISASSEMBLY …………………………………………. 190

EM-3

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ASSEMBLY ………………………………………………. 193
How to Select Piston and Bearing …………………… 199
DESCRIPTION ………………………………………….. 199
HOW TO SELECT CONNECTING ROD BEARING ………………………………………………………….. 199
HOW TO SELECT MAIN BEARING ……………… 202
Inspection After Disassembly …………………………. 206
CRANKSHAFT END PLAY ………………………….. 206
CONNECTING ROD SIDE CLEARANCE ……… 206
PISTON TO PISTON PIN OIL CLEARANCE …. 206
PISTON RING SIDE CLEARANCE ………………. 207
PISTON RING END GAP ……………………………. 207
CONNECTING ROD BEND AND TORSION ….. 208
CONNECTING ROD BIG END DIAMETER …… 208
CONNECTING ROD BUSHING OIL CLEARANCE ……………………………………………………….. 208
CYLINDER BLOCK DISTORTION ……………….. 209
MAIN BEARING HOUSING INNER DIAMETER. 209
PISTON TO CYLINDER BORE CLEARANCE . 210
CRANKSHAFT MAIN JOURNAL DIAMETER … 211
CRANKSHAFT PIN JOURNAL DIAMETER …… 211
OUT-OF-ROUND AND TAPER OF CRANKSHAFT ……………………………………………………… 211
CRANKSHAFT RUNOUT ……………………………. 211
CONNECTING ROD BEARING OIL CLEARANCE ……………………………………………………….. 211
MAIN BEARING OIL CLEARANCE ………………. 212
MAIN BEARING CRUSH HEIGHT ……………….. 213
CONNECTING ROD BEARING CRUSH
HEIGHT ……………………………………………………. 213
MAIN BEARING CAP BOLT OUTER DIAMETER. 213
CONNECTING ROD BOLT OUTER DIAMETER. 214
FLYWHEEL DEFLECTION ………………………….. 214
SERVICE DATA AND SPECIFICATIONS (SDS) …. 215
Standard and Limit ………………………………………… 215
GENERAL SPECIFICATIONS ……………………… 215
DRIVE BELT ……………………………………………… 215
EXHAUST MANIFOLD ……………………………….. 215
SPARK PLUG (PLATINUM-TIPPED TYPE) …… 215
CYLINDER HEAD ……………………………………… 215
VALVE ………………………………………………………. 216
CAMSHAFT AND CAMSHAFT BEARING …….. 220
CYLINDER BLOCK ……………………………………. 220
PISTON, PISTON RING AND PISTON PIN …… 221
CONNECTING ROD ………………………………….. 222
CRANKSHAFT ………………………………………….. 222
MAIN BEARING ………………………………………… 224
CONNECTING ROD BEARING …………………… 225

K9K
APPLICATION NOTICE …………………………………… 226
How to Check Vehicle Type ……………………………. 226
PRECAUTIONS ………………………………………………. 227
Precautions for Drain Coolant ………………………… 227
Precautions for Disconnecting Fuel Piping ……….. 227
Precautions for Removal and Disassembly ………. 227

Precautions for Inspection, Repair and Replacement ……………………………………………………………. 227
Precautions for Assembly and Installation ………… 227
Parts Requiring Angular Tightening …………………. 227
Precautions For Liquid Gasket ………………………… 228
REMOVAL OF LIQUID GASKET ………………….. 228
LIQUID GASKET APPLICATION PROCEDURE.228
Precautions for Diesel Equipment ……………………. 229
CLEANLINESS ………………………………………….. 229
SPECIAL FEATURES …………………………………. 231
PREPARATION ………………………………………………. 233
Special Service Tools …………………………………….. 233
Commercial Service Tools ……………………………… 236
IDENTIFICATION INFORMATION …………………….. 238
Engine Identification ………………………………………. 238
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING …………………………………….. 239
NVH Troubleshooting —Engine Noise ……………… 239
Use the Chart Below to Help You Find the Cause
of the Symptom. ……………………………………………. 240
ENGINE ROOM COVER ………………………………….. 241
Removal and Installation ………………………………… 241
REMOVAL …………………………………………………. 241
INSTALLATION ………………………………………….. 241
DRIVE BELTS …………………………………………………. 242
Checking Drive Belts ……………………………………… 242
Tension Adjustment ……………………………………….. 242
MODELS WITH A/C COMPRESSOR ……………. 242
MODELS WITHOUT A/C COMPRESSOR …….. 242
Removal and Installation ………………………………… 243
REMOVAL …………………………………………………. 243
INSTALLATION ………………………………………….. 243
AIR CLEANER AND AIR DUCT ………………………..245
Removal and Installation ………………………………… 245
REMOVAL …………………………………………………. 245
INSTALLATION ………………………………………….. 245
Changing Air Cleaner Filter …………………………….. 246
REMOVAL …………………………………………………. 246
INSTALLATION ………………………………………….. 246
CHARGE AIR COOLER …………………………………… 247
Removal and Installation (For 50kW) ……………….. 247
REMOVAL …………………………………………………. 247
INSPECTION AFTER REMOVAL …………………. 248
INSTALLATION ………………………………………….. 248
Removal and Installation (For 65kW) ……………….. 249
REMOVAL …………………………………………………. 249
INSPECTION AFTER REMOVAL …………………. 250
INSTALLATION ………………………………………….. 250
EGR UNIT ………………………………………………………. 251
Removal and Installation ………………………………… 251
REMOVAL …………………………………………………. 251
INSTALLATION ………………………………………….. 252
EXHAUST MANIFOLD, TURBOCHARGER, CATALYST ……………………………………………………………… 253
Removal and Installation ………………………………… 253
REMOVAL …………………………………………………. 253
INSTALLATION ………………………………………….. 254

EM-4

INSPECTION AFTER INSTALLATION …………. 254
Disassembly and Assembly …………………………… 255
DISASSEMBLY …………………………………………. 255
INSPECTION AFTER DISASSEMBLY …………. 255
ASSEMBLY ………………………………………………. 256
OIL PAN ………………………………………………………… 257
Removal and Installation ……………………………….. 257
REMOVAL ………………………………………………… 257
INSPECTION AFTER REMOVAL ………………… 259
INSTALLATION …………………………………………. 259
INSPECTION AFTER INSTALLATION …………. 259
GLOW PLUG …………………………………………………. 260
Removal and Installation ……………………………….. 260
REMOVAL ………………………………………………… 260
INSTALLATION …………………………………………. 260
VACUUM PUMP …………………………………………….. 261
Removal and Installation ……………………………….. 261
INSPECTION BEFORE REMOVAL ……………… 261
REMOVAL ………………………………………………… 261
INSTALLATION …………………………………………. 261
HIGH PRESSURE PIPES ………………………………… 262
Removal and Installation ……………………………….. 262
REMOVAL ………………………………………………… 262
INSTALLATION …………………………………………. 263
FUEL INJECTOR ……………………………………………. 266
Removal and Installation ……………………………….. 266
REMOVAL ………………………………………………… 266
INSTALLATION …………………………………………. 266
INJECTOR RAIL …………………………………………….. 267
Removal and Installation ……………………………….. 267
REMOVAL ………………………………………………… 267
INSTALLATION …………………………………………. 267
HIGH PRESSURE PUMP ………………………………… 268
Removal and Installation ……………………………….. 268
REMOVAL ………………………………………………… 268
INSTALLATION …………………………………………. 269
ROCKER COVER …………………………………………… 270
Removal and Installation ……………………………….. 270
REMOVAL ………………………………………………… 270
INSTALLATION …………………………………………. 271
TIMING BELT …………………………………………………. 272
Removal and Installation ……………………………….. 272
REMOVAL ………………………………………………… 272
INSTALLATION …………………………………………. 275
CYLINDER HEAD …………………………………………… 276
Removal and Installation ……………………………….. 276
REMOVAL ………………………………………………… 276
INSTALLATION …………………………………………. 277
Disassembly and Assembly …………………………… 277
DISASSEMBLY …………………………………………. 277
INSPECTION AFTER DISASSEMBLY …………. 277
ASSEMBLY ………………………………………………. 278
ENGINE ASSEMBLY ………………………………………. 279
Removal and Installation ……………………………….. 279
REMOVAL ………………………………………………… 280
INSTALLATION …………………………………………. 281
INSPECTION AFTER INSTALLATION …………. 281
OVERHAUL …………………………………………………… 282
Tightening Torques ……………………………………….. 282

UPPER ENGINE ……………………………………….. 282
BOTTOM ENGINE …………………………………….. 282
Standard Replacement ………………………………….. 283
PREPARING USED ENGINE ………………………. 283
Disassembly ………………………………………………… 284
REMOVING THE UPPER ENGINE ………………. 284
POSITIONING THE BELT AT THE TIMING
POINT ……………………………………………………… 285
DISASSEMBLY OF THE CYLINDER HEAD ….. 288
Cleaning ……………………………………………………… 291
Inspection ……………………………………………………. 291
GASKET FACE …………………………………………. 291
CAMSHAFT END PLAY ……………………………… 291
Valve Clearance …………………………………………… 292
CHECKING AND ADJUSTING THE VALVE
CLEARANCE ……………………………………………. 292
Assembly …………………………………………………….. 293
ASSEMBLY OF THE CYLINDER HEAD ……….. 293
Disassembly of The Bottom Engine ………………… 297
REMOVAL ………………………………………………… 297
Assembly …………………………………………………….. 301
INSTALLATION OF OIL JETS ……………………… 301
METHOD FOR INSTALLING THE OIL COOLER
AND OIL FILTER ……………………………………….. 302
Removing The Piston Pins …………………………….. 302
CONNECTING ROD BEARING …………………… 303
ON THE CONNECTING ROD BODY ……………. 303
ON THE CONNECTING ROD CAP ……………… 304
INSTALLATION OF MAIN BEARING ……………. 306
ON THE CYLINDER BLOCK ………………………. 306
ON THE BEARING CAPS …………………………… 307
INSTALLATION OF NO. 1 BEARING ……………. 308
CONNECTING RODS / PISTON ASSEMBLY . 308
DIRECTION FOR INSTALLATION THE SNAP
RINGS ON THE PISTON ……………………………. 308
INSTALLATION OF THE SNAP RINGS ………… 308
CHECKING PISTON PROTRUSION ……………. 309
INSTALLATION OF REAR OIL SEAL RETAINER
AND OIL PUMP …………………………………………. 310
INSTALLATION OF THE CRANKSHAFT SEAL
GASKETS ………………………………………………… 311
INSTALLATION OF THE CYLINDER HEAD ….. 315
TIMING ADJUSTMENT ………………………………. 316
BASIC INSPECTION ………………………………………. 321
Cylinder Head ………………………………………………. 321
CYLINDER HEAD TIGHTENING PROCEDURE. 321
THICKNESS OF THE CYLINDER HEAD GASKET …………………………………………………………. 321
INSPECTION OF THE PISTON PROTRUSION. 321
VALVE ……………………………………………………… 322
VALVE SEAT …………………………………………….. 322
VALVE GUIDE …………………………………………… 322
VALVE SPRING …………………………………………. 324
PISTON ……………………………………………………. 324
INSPECTION OF VALVE CLEARANCE ……….. 324
CAMSHAFT ………………………………………………. 325
Piston ………………………………………………………….. 326
PISTON MARKING ……………………………………. 326
TABLE OF PISTON PIN HEIGHT ………………… 326

EM-5

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MEASURING THE PISTON DIAMETER ……….. 326
PISTON RING …………………………………………… 327
PISTON RING END GAP ……………………………. 327
Connecting Rod ……………………………………………. 327
DIRECTION OF INSTALLATION OF THE CONNECTING ROD IN RELATION TO THE PISTON. 328
DIRECTION FOR INSTALLATION THE SNAP
RINGS ON THE PISTON ……………………………. 328
Crankshaft …………………………………………………… 328
WORKING OUT THE CLASS OF MAIN BEARING (ORIGINAL FITMENT) …………………………. 329

Cylinder Block ………………………………………………. 329
TABLE OF CYLINDER BLOCK MAIN BEARING
HOUSING INNER DIAMETERS …………………… 329
MATCHING THE MAIN BEARING ………………… 330
Main Bearing and Cap …………………………………… 330
MAIN BEARING …………………………………………. 330
CONNECTING ROD BEARING ……………………. 331
Preparing the engine to be on the stand …………… 331
Parts To Be Replaced After Removal ………………. 332
Installation of Thread Inserts …………………………… 333

EM-6

PRECAUTIONS
[CR]

PRECAUTIONS
Precautions for Draining Coolant
[CR]

●

PFP:00001

A
BBS002MS

Drain coolant only after the engine has cooled down.

Precautions for Disconnecting Fuel Piping
●
●
●

Before starting work, make sure no fire or spark producing items are in the work area.
Release fuel pressure before disassembly.
After disconnecting pipes, plug openings to stop fuel leakage.

Precautions for Removal and Disassembly
●
●
●
●

●

●

●
●

●

●
●
–

–

●

–
–
–
●

●

BBS002MW

BBS002MX

Use an angle wrench when attaching the following parts.
Cylinder head bolt
Main bearing cap bolt
Connecting rod cap nut
The specified torque written for these parts is not the final tightening value, but is the torque used for tightening before angle tightening.
When tightening, make sure there is no debris on the threads or mating surfaces, and lubricate the
threads with engine oil.

EM-7

D

E

F

BBS002MV

Always use a torque wrench when tightening nuts and bolts.
Unless otherwise specified, tighten nuts and bolts from inside to outside in crisscross pattern. Tighten
them gradually and evenly in two to three steps.
Always replace gasket, packing, oil seals, and O-rings with new ones.
Thoroughly wash, clean, and blow dry each part. Be sure that engine oil and coolant passages are free of
clogs.
Remove any dirt and lint on sliding and mating surfaces. Before assembly, apply ample amount of engine
oil to sliding surfaces.
If coolant was drained, bleed air from the system.
Follow the procedure below to make sure there are no fuel leaks.
Turn the ignition switch to ON (do not start engine), and with fuel pressure applied in the fuel line, check to
make sure there are no fuel leaks from the connection.
Start the engine, and at in creased speed, check again to see if there are any fuel leaks from the connection.
After assembly, start engine and increase the engine speed, then check coolant, fuel, oil, grease, and
exhaust gas for leakage.

Parts Requiring Angle Tightening
●

BBS002MU

Thoroughly inspect each part following inspection procedure, then correct or replace as necessary.
Inspect new parts in the same way, and replace if necessary.

Precautions for Assembling and Installing
●

C

Use correct special service tool in the specified position. Always pay attention to safety.
Be careful not to damage surface accuracy of mating or sliding surfaces.
To prevent foreign material from entering the engine, close openings with appropriate tape as necessary.
Arrange disassembled parts in their normal positions in order to simplify locating the cause of damage or
excessive wear and to insure correct reassembly.
The removal order of nuts and bolts should in principle move diagonally from the outside. Locations for
which order is stipulated should follow that order.

Precautions for Inspections, Repairs, and Replacement
●

EM
BBS002MT

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PRECAUTIONS
[CR]

Precautions for Liquid Gasket

BBS002MY

REMOVAL OF LIQUID GASKET SEALING
●

●

Unscrew nuts and bolts. Use a seal cutter to cut the liquid gasket and remove the joined parts.
CAUTION:
Be careful not to damage the mating surfaces.
In positions where a seal cutter is difficult to use, lightly tap with
a plastic hammer and remove.
CAUTION:
When using a screwdriver, be careful not to scratch the
mating surfaces.
PBIC0275E

LIQUID GASKET APPLICATION PROCEDURE
1.

2.
3.

Using a scraper (1), remove any old liquid gasket remaining on
the gasket application surface and its mating surface.
● Remove any old liquid gasket remaining in the gasket application groove and on the threads of bolts and bolt holes.
Using white gasoline, wipe the gasket application surface and its
mating surface to remove any moisture, oil, and foreign material.
Set the genuine liquid gasket in a tube presser.

PBIC1289E

4.

Apply a continuous bead of liquid gasket to the specified position at the specified diameter.
● Apply liquid gasket in the application groove.

EMA0622D

Apply liquid gasket inside bolt holes. There may be times
when application to the exterior is required, so follow those
instructions if such are found in the text.
● Attaching should be done within 5 minutes after gasket application.
● Immediately wipe off any protruding liquid gasket.
● Do nor retighten nuts and bolts after installation.
● After finishing work, wait at least 30 minutes before refilling
engine oil and coolant.
CAUTION:
Follow all specific instructions in this manual.
●

EM-8

SEM164F

PREPARATION
[CR]

PREPARATION
Special Service Tools

PFP:00002

A
BBS002MZ

Tool number
Tool name

Description

KV10111100
Seal cutter

EM

Removing parts attached with liquid gasket

C

D
ZZA0013D

KV10117100
Heated oxygen sensor wrench

Removing and Installing heated oxygen
sensor
For 22 mm (0.87 in) width hexagon nut

E

F
NT379

KV10105630
Ring gear stopper

Removing and installing crankshaft pulley
Removing and installing flywheel, drive
plate

G

H
ZZA1005D

KV10105610
Stopper plate

Removing and installing crankshaft pulley

I

J

K

ZZA0009D

KV10112100
Angle wrench

Tightening bolts for bearing cap, cylinder
head, etc.

L

M
NT014

ST10120000
Cylinder head bolt wrench

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

NT583

KV101092S0
Valve spring compressor set
1. KV10116200
Valve spring compressor set
2. KV10109220
Adapter

Removing and installing valve mechanism

ZZA0993D

EM-9

PREPARATION
[CR]
Tool number
Tool name

Description

KV10107902
Valve oil seal puller

Removing valve oil seal

NT011

KV10115600
Valve oil seal drift

Installing valve oil seal

ZZA0996D

EM03470000
Piston ring compressor

piston assembly into cylinder bore

NT044

1. ST15243000
Valve seat drift
2. KV11103710
Adapter
3. KV11103720
Adapter

Installing valve seat

PBIC1120E

KV10107400
Piston pin Press stand
1. KV10107310
Center shaft
2. ST03140030
Stand
3. ST13040030
Spring
4. KV10107320
Cap
5. ST13040050
Drift

Disassembling and assembling piston with
connecting rod

NT013

WS39930000
Tube presser

Pressing the tube of liquid gasket

NT052

EM-10

PREPARATION
[CR]

Commercial Service Tools

BBS002N0

A
Tool name

Description

Spark plug wrench

Removing and installing spark plug

EM

C
NT047

Crankshaft pulley puller

Removing crankshaft pulley

D

E

PBIC0887E

Manual lift table caddy

Removing and installing engine

F

G

H

ZZA1210D

Valve seat cutter set

Finishing valve seat dimensions

I

J
NT048

Piston ring expander

Removing and installing piston ring

K

L
NT030

Valve guide drift

Removing and installing valve guide
Intake & Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.

NT015

Valve guide reamer

Reaming valve guide 1 or hole for oversize
valve guide 2
Intake & Exhaust:
d1 : 5.0 mm (0.217 in) dia.
d2 : 9.675 mm (0.381 in) dia.

NT016

EM-11

M

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
[CR]

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

PFP:00003
BBS002N1

PBIC1413E

EM-12

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
[CR]

Use the Chart Below to Help You Find the Cause of the Symptom.

BBS002N2

A

1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.

EM

C

Operating condition of engine
Location
of noise
Top of
engine
Rocker
cover
Cylinder
head

Type of
noise

Front of
engine

When
starting

When
idling

When
racing

C

A

—

A

B

Rattle

C

A

—

A

B

Slap or
rap

Knock

Knock
Front of
engine
Timing
chain
cover

After
warmup

Ticking or
clicking

Slap or
knock

Crankshaft pulley
Cylinder
block
(Side of
engine)
Oil pan

Before
warmup

Tapping or
ticking

—

A

A

A

A

A

—

B

B

A

—

—

C

—

—

B

B

B

A

B

B

B

B

B

B

While
driving

Source of
noise

Check item

D

—

Tappet
noise

Valve clearance

EM-47

C

Camshaft
bearing
noise

Camshaft journal clearance
Camshaft runout

EM-45
EM-44

—

Piston pin
noise

Piston and piston pin
clearance
Connecting rod bushing clearance

EM-85
EM-87

A

Piston
slap noise

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

EM-89
EM-86
EM-86
EM-87

B

Connecting rod
bearing
noise

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

EM-87
EM-87

C

Main
bearing
noise

Main bearing oil clearance
Crankshaft runout

EM-92
EM-91

K

B

Timing
chain and
chain
tensioner
noise

Timing chain cracks
and wear
Timing chain tensioner
operation

EM-53
EM-51

L

C

Drive belts
(Sticking
or slipping)

Drive belts deflection

A

Creaking

A

B

A

B

A

B

Drive belts
(Slipping)

Idler pulley bearing
operation

Squall
Creak

A

B

—

B

A

B

Water
pump
noise

Water pump operation

A: Closely related

B: Related

—

C: Sometimes related

B

—

—: Not related

EM-13

E

F

G

H

I

J

M

Squeaking or fizzing

B

Reference page

EM-14

CO-17

DRIVE BELTS
[CR]

DRIVE BELTS
Checking drive Belts
●

●

●

●

PFP:02117
BBS002N3

Inspection should be done only when engine is cold or over 30
minutes after the engine is stopped.
Turn the crankshaft pulley two times clockwise, and make sure
tension on all pulleys is equal before doing the test.
Visually check the belts for wear, damage, and cracks on inside
and edges.
When measuring deflection, apply 98.1 N (10 kg, 22lb) at the
marked point.
PBIC1414E

PBIC1415E

CAUTION:
When measuring belt tension immediately after the belt is installed, first set the tension to the standard, rotate the crankshaft for more than two turns in order to eliminate variance in the belt tension
between pulleys, then measure and adjust tension to the standard again.
Deflection [mm (in)]
[When pressed by force of 98.1N (10 kg,
22lb)]

Tension [N (kg, lb)]
Location
New

Alternator and
A/C compressor belt

Alternator belt

Water pump belt

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

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

446 — 534 (45.5 — 54.5,
100.3 — 120.0)

At adjustment

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

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

348 — 436 (35.5 — 44.5,
78.2 — 98.0)

Tension Adjustment
Location

Limit

Measuring
point

New belt

At adjustment

Limit

A

6.6 — 7.8
(0.260 0.307)

7.3 — 8.5
(0.287 0.335)

13.8
(0.543)

B

5.6 — 6.6
(0.220 0.260)

7.1 — 8.3
(0.280 0.327)

11.9
(0.469)

A

3.1 — 4.1
(0.122 0.161)

9.8 — 10.6
(0.386 0.417)

13.8
(0.543)

C

6.7 — 7.3
(0.264 0.287)

7.6 — 8.6
(0.299 0.339)

12.4
(0.448)

D

4.7 — 5.6
(0.185 0.220)

7.0 — 7.7
(0.276 0.303)

8.6
(0.339)

196 (20,
44.1)

196 (20,
44.1)

137 (14,
30.9)

BBS002N4

Location of adjuster and tightening
method

Alternator and A/C compressor
drive belt

Adjusting bolt on idler pulley

Water pump belt

Adjusting bolt on idler pulley

EM-14

DRIVE BELTS
[CR]
CAUTION:
●
When the belt is replaced with new one, adjust the belt tension to the value for “New belt”, A
because new belt will not fully seat in the pulley groove.
●
When tension of the belt being used exceeds “Limit”, adjust it to the value for “At adjustment”.
●
When installing a belt, make sure that it is correctly engaged with the pulley groove.
EM
●
Do not allow oil or engine coolant to get on the belt.
●
Do not twist or bend the belt strongly.
C

ALTERNATOR AND A/C COMPRESSOR BELT (WITH A/C MODELS)
1.
2.
3.
4.
5.

6.

Remove RH front fender protector.
Loosen lock nut (1).
Tighten lock nut (1) with fingers.
Loosen lock nut (1) half a turn counter-clockwise.
Adjust the belt tension by turning the adjuster bolt (2).
For the specified belt tension, refer to EM-14, «Checking drive
Belts» .
Tighten lock nut (1).

D

E

F

Nut (1) :
: 24.5 — 31.4 N·m (2.5 — 3.2 kg-m, 18 — 23 ft-lb)
7.
8.

G

Turn the crankshaft pulley two times clockwise.
Check that the belt tension is within the standard. Refer to MA27, «Checking Drive Belts» .

H

I

PBIC1290E

J

ALTERNATOR BELT (WITHOUT A/C MODELS)
1.
2.
3.
4.
5.

6.

K

Remove RH front fender protector.
Loosen lock nut (1).
Tighten lock nut (1) with fingers.
Loosen lock nut (1) half a turn counter-clockwise.
Adjust the belt tension by turning the adjuster bolt (2).
For the specified belt tension, refer to EM-14, «Checking drive
Belts» .
Tighten lock nut (1).

L

M

Nut (1) :
: 24.5 — 31.4 N·m (2.5 — 3.2 kg-m, 18 — 23 ft-lb)
7.
8.

Turn the crankshaft pulley two times clockwise.
Check that the belt tension is within the standard. Refer to MA27, «Checking Drive Belts» .

PBIC1416E

EM-15

DRIVE BELTS
[CR]
WATER PUMP BELT
1.
2.
3.
4.
5.

Remove RH front fender protector.
Loosen lock nut (3).
Tighten lock nut (3) with fingers.
Adjust the belt tension by turning the adjuster bolt (4).
For the specified belt tension, refer to EM-14, «Checking drive Belts» .
Tighten lock nut (3).
Nut (3) :
: 24.5 — 31.4 N·m (2.5 — 3.2 kg-m, 18 — 23 ft-lb)

6.
7.

Turn the crankshaft pulley two times clockwise.
Check that the belt tension is within the standard. Refer to MA-27, «Checking Drive Belts» .

Removal and Installation

BBS002N5

REMOVAL
●

Fully loosen each belt while referring to EM-14, «Tension Adjustment» . Remove them one by one, starting
with the one in the front.

INSTALLATION
1.

2.

3.
4.

Install belts to the pulley in the reverse order of removal.
CAUTION:
● Make sure the belt is securely inside the groove on each pulley.
● Make sure there is no oil, grease, or coolant in pulley grooves.
Adjust tension of each belt.
CAUTION:
● When measuring belt tension immediately after the belt is installed, first set the tension to the
standard, rotate the crankshaft for more than two turns in order to eliminate variance in the belt
tension between pulleys, then measure and adjust tension to the standard.
● When measuring belt tension, hand tighten idler pulley lock nut to eliminate any looseness.
Tighten the lock nut of adjustment parts to the specified torque.
Make sure that tension of each belt is within the standard.

Removal and Installation of Drive Belt Idler Pulley

BBS002N6

PBIC1417E

1. Adjuster bolt (for water pump belt)

2. Idler pulley assembly

EM-16

3. Shaft

DRIVE BELTS
[CR]
4. Cover
7. Cover

5. Spacer
8. Bracket

6.

Idler pulley

9.

Adjuster bolt
(for alternator and A/C compressor belt)

REMOVAL
1.
2.
3.
4.

EM

Remove drive belts. Refer to EM-16, «Removal and Installation» .
Pull the adjuster bolt out from the shaft.
Move the idler pulley assembly along the bracket slide groove and remove by turning the shaft end at the
wider part of the groove. (For alternator and A/C compressor belt)
Remove the lock nut and remove the shaft by pulling towards the rear of the engine. (For water pump belt)

2.
3.
4.

C

D

INSTALLATION
1.

A

Install belts to pulley in reverse order of removal.
CAUTION:
● Make sure belt is correctly engaged with the pulley groove.
● Check for oil and coolant on belt and each pulley groove.
Adjust belt tension. Refer to EM-14, «Tension Adjustment» .
Tighten each adjusting bolt and nut to the specified torque.
Make sure that tension of each belt is within the standard.

E

F

G

H

I

J

K

L

M

EM-17

AIR CLEANER AND AIR DUCT
[CR]

AIR CLEANER AND AIR DUCT
Removal and Installation

PFP:16500
BBS002N7

PBIC1418E

1.

EVAP canister purge volume control solenoid valve

2.

Vacuum hose

3.

Vacuum hose

4.

Manifold absolute pressure sensor

5.

O-ring

6.

Vacuum hose

7.

Air cleaner case (upper)

8.

Gasket

9.

Air cleaner case (lower)

10. Gasket

11. Clip

12. Air duct

13. Gasket

14. Gasket

15. Electric throttle control actuator

16. Air cleaner body

17. Air cleaner filter

18. Gasket

REMOVAL
NOTE:
The steps 1 to 2 can be skipped, moving straight to the step 3 (separation of harnesses and hoses, etc. cannot be skipped)
1. Remove the harness connector and then the manifold absolute pressure sensor.
CAUTION:
● Handle manifold absolute pressure sensor with care. Avoid impacts.
● Make sure no foreign matter is attached to the sensor (oils, chemicals, etc.)
2. Remove the harness connector and vacuum hose and then the EVAP canister purge volume control solenoid valve.
CAUTION:
Handle EVAP canister purge volume control solenoid valve with care. Avoid impacts.
3. Remove air duct.

EM-18

AIR CLEANER AND AIR DUCT
[CR]
Remove the clips, and with air duct (2) turned to nearly 90
degrees, pull off from the air cleaner body (1).
Remove the clips, pull the air cleaner body down then forward,
and then remove the air cleaner body and the air cleaner filter.
NOTE:
Removal and disassembly of the air cleaner case (upper) and
(lower) follows below.
Move the transaxle breather hose.
Remove the air cleaner case assembly in the following order.
● The entire air cleaner case (upper and lower) is referred to as
the air cleaner case assembly.
Separate the harness connector from the electronic throttle control actuator.
Separate the brake booster vacuum hose.
Loosen bolts in the reverse of the order shown in figure.
Remove the air cleaner case assembly by raising.
● Slowly raise the force evenly on the intake manifold joint to lift
it and remove the air cleaner case assembly.
CAUTION:
● To avoid damaging parts, do not use sudden force.
● Block the intake manifold openings with tape to make
sure no foreign particles get inside it while you are
removing the air cleaner case assembly.
●

4.

5.
6.

a.
b.
c.
7.

A

EM

C
PBIC1293E

D

E

F

G

PBIC1419E

8.

Loosen the bolts in reverse of the order shown in the figure and
separate the air cleaner case (upper) and (lower).

H

I

J

K

PBIC1420E

9.

Remove the electronic throttle control actuator from the air cleaner case (upper).
● Turn the air cleaner case (upper) over on the protective sheet to make sure the surface does not get
scratched.
● The electronic throttle control actuator should be handled with the following precautions in mind.
CAUTION:
● Handle electronic throttle control actuator with care. Avoid impacts.
● Do not disassemble or adjust.

INSTALLATION
1.
a.
b.
c.

Install the electronic throttle control actuator (1) to the air cleaner
case (upper) (2) in the following procedure:
Install the gasket (3) to the connector base.
Attach the gasket (4) to the outer groove on the throttle bore on
the side of the air cleaner case (upper) (2).
Install electronic throttle control actuator.
● There is no pre-determined order in which the mounting bolts
should be tightened.
● Perform the “Throttle Valve Closed Position Learning” when
harness connector of the electric throttle control actuator is

EM-19

PBIC1294E

L

M

AIR CLEANER AND AIR DUCT
[CR]

2.

disconnected. Refer to EC-69, «Throttle Valve Closed Position Learning» (WITH EURO-OBD), EC-486,
«Throttle Valve Closed Position Learning» (WITHOUT EURO-OBD).
● Perform the “Idle Air Volume Learning” and “Throttle Valve Closed Position Learning” when the electric
throttle control actuator is replaced. Refer to EC-69, «Idle Air Volume Learning» and EC-69, «Throttle
Valve Closed Position Learning» (WITH EURO-OBD), EC-486, «Idle Air Volume Learning» and EC486, «Throttle Valve Closed Position Learning» (WITHOUT EURO-OBD).
Assemble the air cleaner case (upper) and (lower).
● Tighten bolts evenly in two steps in the order shown in figure.
1st step
: 1.9 — 2.2 N·m (0.20 — 0.22 kg-m, 17 — 19 in-lb)
2nd step
: 3.8 — 4.4 N·m (0.40 — 0.44 kg-m, 35 — 38 in-lb)

PBIC1420E

3.
a.

b.

c.

Attach the air cleaner case assembly in the following order.
Attach the gasket (for the intake manifold (1) and the PCV path
(2))
● Attach for the intake manifold so that the case protrusion (4)
fit into the cutout hole (3) on the side of the gasket.
● Make sure foreign particles do not attach to the gasket or the
sealing area.
Insert the air cleaner case assembly into the intake manifold.
● At the same time, insert the bottom path protrusions into the
PCV path holes on the rocker cover.
PBIC1295E
CAUTION:
Insert straight, making sure the axis is lined up, to prevent the gaskets from being crooked or
twisted.
Tighten bolts in the numerical order shown in figure.
● Tighten bolts evenly in several steps.
CAUTION:
Tighten after making sure the positioning of bolts 5 and 6
is true.

PBIC1419E

4.
5.
6.
7.

Install air cleaner body and air cleaner filter. Refer to EM-21, «Changing Air Cleaner Filter» .
Attach air duct.
Attach EVAP canister purge volume control solenoid valve.
Attach the manifold absolute pressure sensor.
● Make sure no foreign particles attach to the flange, O-ring, or attachment hole.
● Tighten the mounting bolt after making sure it is fully inserted into the mounting hole.

EM-20

AIR CLEANER AND AIR DUCT
[CR]

Changing Air Cleaner Filter

BBS002N8

A

REMOVAL
1.
2.
3.

4.

Remove air duct. Refer to EM-18, «REMOVAL» .
Remove clips (2) of air cleaner body (1).
After moving the air cleaner body downward, remove it by pulling it forward.
● While pressing down the radiator upper hose, remove air
cleaner body (1).
Remove air cleaner filter from the air cleaner body.
NOTE:
In some cases the air cleaner filter might remain in the air
cleaner case (upper).

EM

C

D
PBIC1296E

INSTALLATION
1.
2.

3.

E

Set the air cleaner filter on the air cleaner case (upper) (1).
Insert the two projections (3) on the air cleaner body (2) into the
two notch holes (4) on the rear of the air cleaner case (upper)
(1), then lift up and fasten with the clip.
Attach air duct.

F

G

H
PBIC1297E

I

J

K

L

M

EM-21

INTAKE MANIFOLD
[CR]

INTAKE MANIFOLD
Removal and Installation

PFP:14003
BBS002N9

PBIC1421E

1.

Support bracket

4.

Intake manifold

2.

Gasket

3.

Stud bolt

REMOVAL
1.
2.
3.
4.

Remove air duct and air cleaner case assembly. Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
Remove the PCV hose (between the intake manifold and the rocker cover) from the intake manifold side.
Remove the support bracket mounting bolt (No. 1 port upper engine front side)
Loosen nuts and bolts in the reverse of the order shown in the
figure to remove the intake manifold.
CAUTION:
Disregard No. 6 shown in figure in the loosening order.

PBIC1422E

NOTE:
Removal and installation of No. 5 nut is made easier by inserting
the tool into the recommended cutout part (2) on the No. 1 port
(1). (The same applies to No. 4 nut)

PBIC1298E

EM-22

INTAKE MANIFOLD
[CR]
INSTALLATION
●

A

Install in the reverse order of removal paying attention to the following.

Attachment of the Intake Manifold
●
●

●

Check for damage or foreign material on the mounting surfaces.
Tighten nuts and bolts in numerical order shown in figure.
NOTE:
No. 6 in the figure shows the 2nd tightening of No. 1 bolt.
When installing support bracket, refer to EM-22, «Removal and
Installation» .

EM

C

D

PBIC1422E

E

F

G

H

I

J

K

L

M

EM-23

EXHAUST MANIFOLD AND THREE WAY CATALYST
[CR]

EXHAUST MANIFOLD AND THREE WAY CATALYST
Removal and Installation

PFP:14004
BBS002NA

PBIC1423E

1.

Bracket

2.

Gasket

3.

Exhaust manifold

4.

Heated oxygen sensor 1

5.

Exhaust manifold cover

6.

Stud bolt

7.

Three way catalyst (manifold)

8.

Three way catalyst cover

9.

Support

REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.

a.
b.

Remove air duct. Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
Remove RH front fender protector.
Remove alternator and A/C compressor belt. Refer to EM-14, «DRIVE BELTS» .
Remove A/C compressor with piping connected, move A/C compressor to body side and secure it onto
body with a rope.
Remove exhaust front tube connection at front. Refer to EX-3, «EXHAUST SYSTEM» .
Remove RH engine mount stay and alternator bracket.
Loosen the lower bolt and move the alternator to the front of the vehicle.
As needed, remove the heated oxygen sensor 1 in the following
order.
NOTE:
Steps 2 to 7 above are not needed for heated oxygen sensor 1
removal.
Separate the harness connector and remove it from bracket.
Using heated oxygen sensor wrench (special service tool),
remove heated oxygen sensor 1.
CAUTION:
● Handle it carefully, avoid any chance of impact caused by
PBIC1424E
dropping.

EM-24

EXHAUST MANIFOLD AND THREE WAY CATALYST
[CR]
Do not over torque the heated oxygen sensor. Doing so may cause damage to the heated oxygen sensor, resulting in the MI coming on.
A
9. Remove exhaust manifold cover.
10. Remove the three way catalyst cover.
EM
11. Loosen nuts and bolts in the reverse of the order shown in figure
to remove the exhaust manifold and three way catalyst.
CAUTION:
C
Be careful not to damage the A/C piping.
●

D

PBIC1425E

E

12. Separate the exhaust manifold and three way catalyst.
CAUTION:
Avoid impacts to three way catalyst.

F

INSPECTION AFTER REMOVAL
Surface Distortion

G

●

Using a reliable straightedge (1) and feeler gauge (2), check distortion of mounting surface on exhaust manifold.
Limit

●

H

: 0.3 mm (0.012 in)

If it exceeds the limit, replace the exhaust manifold.
I

J
PBIC1299E

INSTALLATION
●

K

Install in the reverse order of removal paying attention to the following.

Installation of Exhaust Manifold and Three Way Catalyst
●
●

L

Check for damage or foreign material on the mounting surfaces.
Tighten nuts in numerical order shown in figure.

M

PBIC1425E

Installation of Heated Oxygen Sensor 1
CAUTION:
●
Do not over torque the heated oxygen sensor. Doing so may cause damage to the heated oxygen
sensor, resulting in the MI coming on.

EM-25

OIL PAN AND OIL STRAINER
[CR]

OIL PAN AND OIL STRAINER
Removal and Installation

PFP:11110
BBS002NB

PBIC1426E

1.

Oil pan (upper)

2.

Transaxle connecting bolt

3.

Oil strainer

4.

Drain plug

5.

Washer

6.

Oil pan (lower)

7.

Rear plate cover

8.

Transaxle connecting bolt

REMOVAL
NOTE:
Installation and removal of manual transmission vehicle oil pan (upper) require removal of the transaxle.
1. Remove RH front fender protector.
2. Drain the engine oil.
3. Remove the oil pan (lower) in the following order.
a. Loosen bolts in the reverse of the order shown in figure.
b. Insert seal cutter (special service tool) between oil pan (upper)
and oil pan (lower). Slide seal cutter by tapping on the side of
the tool with a hammer. Remove oil pan (lower).
CAUTION:
Exercise care not to damage mating surface.
NOTE:
The following is the order for removing the oil pan (upper).
4. Remove the oil level gauge.
PBIC1427E
5. Remove drive belts. Refer to EM-14, «DRIVE BELTS» .
6. Remove the A/C compressor with piping connected and move the A/C compressor aside.
CAUTION:
Hang it with rope and temporarily tighten to body to avoid putting stress on air conditioner piping.
7. Remove the exhaust front tube. Refer to EX-3, «EXHAUST SYSTEM» .

EM-26

OIL PAN AND OIL STRAINER
[CR]
8.

Remove three way catalyst support. Refer to EM-24, «EXHAUST MANIFOLD AND THREE WAY CATALYST» .
A
9. Remove the transaxle in the following order.
a. Mount engine slingers on cylinder head. Refer to EM-71, «REMOVAL» .
EM
b. Lift with a hoist and position engine.
c. Remove transaxle. Refer to MT-7, «Removal» .
10. Remove oil pan (upper) with the following procedure.
C
a. Loosen oil pan (upper) mounting bolts in the reverse of the order
shown in figure.
D

E

F
PBIC1428E

b.
c.

Insert a flathead offset screwdriver into the cutout (1) shown in
figure and create a crack between the oil pan and cylinder block.
Insert seal cutter (special service tool) between oil pan (upper)
and cylinder block. Slide seal cutter by tapping on the side of the
tool with a hammer. Remove oil pan (upper).
CAUTION:
Exercise care not to damage mating surface.

G

H

I

PBIC1429E

J

11. Remove oil strainer.

INSTALLATION
1.

2.
a.

K

Install oil strainer.
NOTE:
Do not use O-ring, gasket, or other seal parts.
Attach the oil pan (upper) in the following order.
Apply the liquid gasket to the position shown in figure.
Use Genuine Liquid Gasket or equivalent.
CAUTION:
● For bolt holes with
marks (3 locations), apply liquid
gasket outside the holes.
● Apply a bead of 5.5 to 6.5 mm (0.127 — 0.256 in) in diameter to area “A” and “B”.

L

M

PBIC1430E

EM-27

OIL PAN AND OIL STRAINER
[CR]
b.

Tighten bolts in the numerical order shown in figure.
NOTE:
See below for mounting positions of bolts
Under head 70 mm (2.76 in)
Under head 90 mm (3.54 in)
Under head 25 mm (0.98 in)

3.
4.
a.

: 4, 8, 12
: 9,10
: Other than the above

Install transaxle assembly.
Install oil pan (lower) in the following procedure:
Apply the liquid gasket to the position shown in figure.
Use Genuine Liquid Gasket or equivalent.

PBIC1428E

PBIC1431E

b.

Tighten bolts in the numerical order shown in figure.

PBIC1427E

5.
6.

Install oil pan drain plug.
● For washer installation direction, refer to components figure on EM-26, «Removal and Installation» .
Reinstall removed parts in reverse order of removal.
CAUTION:
Engine oil should be filled at least 30 minutes after the oil pan is installed.

INSPECTION AFTER INSTALLATION
●
●

Check engine oil level. Refer to LU-6, «ENGINE OIL» .
Warm up engine and check the oil amount and no leakage of oil. Refer to LU-6, «ENGINE OIL» .

EM-28

IGNITION COIL
[CR]

IGNITION COIL
Removal and Installation

PFP:22448

A
BBS002NC

EM

C

D

E

F

PBIC1432E

1.

Ignition coil

2.

Spark plug

H

REMOVAL
1.
2.
3.

G

Remove air duct and air cleaner case assembly. Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
Disconnect harness connector from the ignition coil.
Remove ignition coil.
CAUTION:
● Handle ignition coil with care. Avoid impacts.
● Do not disassemble.

I

J

INSTALLATION
K

Install in the reverse order of removal.

L

M

EM-29

SPARK PLUG (PLATINUM-TIPPED TYPE)
[CR]

SPARK PLUG (PLATINUM-TIPPED TYPE)
Removal and Installation

PFP:22401
BBS002ND

REMOVAL
1.
2.

Remove ignition coil. Refer to EM-29, «IGNITION COIL» .
Remove spark plugs with a spark plug wrench.
CAUTION:
Handle spark plug with care. Avoid impacts.

SMA581C

INSPECTION AFTER REMOVAL
●
●

–
–
●

–
–

Use standard type spark plug for normal condition.
The hot type spark plug is suitable when fouling occurs with the standard type spark plug under conditions
such as:
Frequent engine starts
Low ambient temperatures
The cold type spark plug is suitable when spark plug knock occurs with the standard type spark plug
under conditions such as:
Extended highway driving
Frequent high engine revolution
Make

NGK

Champion

Standard type

LFR5AP-11

REC10PYC4

Hot type

LFR4AP-11

—

Cold type

LFR6AP-11

—

Gap (Nominal)

: 1.1 mm (0.043 in)

CAUTION:
●
Do not use a wire brush for cleaning.
●
If plug tip is covered with carbon, spark plug cleaner may
be used.
Cleaner air pressure:
Less than 588 kPa (6 kg/cm2 , 85 psi)
Cleaning time:
Less than 20 seconds
SMA773C

EM-30

SPARK PLUG (PLATINUM-TIPPED TYPE)
[CR]
●

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

A

EM

C
SMA806CA

D

INSTALLATION
Install in the reverse order of removal.
Spark plug

E

: 19.6 — 29.4 N·m (2.0 — 3.0 kg-m, 15 — 21 ft-lb)
F

G

H

I

J

K

L

M

EM-31

FUEL INJECTOR AND FUEL TUBE
[CR]

FUEL INJECTOR AND FUEL TUBE
Removal and Installation

PFP:16600
BBS002NE

PBIC1433E

1.

O-ring (brown)

2.

Clip

3.

O-ring (black)

4.

Fuel tube

5.

Fuel feed hose

6.

Fuel injector

REMOVAL
1.
2.
3.
4.

5.

6.

Release fuel pressure. Refer to EC-71, «FUEL PRESSURE RELEASE» (WITH EURO-OBD), EC-488,
«FUEL PRESSURE RELEASE» (WITHOUT EURO-OBD).
Remove air duct and air cleaner case assembly. Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
Remove intake manifold support bracket.
Remove the fuel hose on the side of the fuel tube.
CAUTION:
Attach a plug to the removed hose to prevent fuel leaks.
Separate the fuel injector harness and move to a position where it will not get in the way of work.
● If it is stuck or otherwise difficult to remove, remove the fuel injector and fuel tube assembly from the
cylinder head and separate fuel injector harness in a better position.
Loosen bolts in the reverse of the order shown in the figure and
then remove the fuel injector and fuel tube assembly.
CAUTION:
● Make sure the fuel injector nozzle does not touch the
other parts.
● Take out without tipping, as this will cause fuel to leak.

PBIC1434E

EM-32

FUEL INJECTOR AND FUEL TUBE
[CR]
7.
a.
b.

Remove the fuel injector (2) from the fuel tube (1) in the following order.
Open and pull out the clip (3).
Remove fuel injector from the fuel tube by pulling straight.
CAUTION:
● Be careful not to damage the nozzle.
● Do not drop or impact the fuel injector.
● Do not disassemble or adjust fuel injector.

A

EM

C
PBIC1301E

D

INSTALLATION
1.

Keep in mind the following points when attaching the O-ring to the fuel injector.
CAUTION:
● The upper and lower O-rings are different, so use caution when attaching them.
Fuel tube side
Nozzle side

E

: Black
: Brown

F

Handle O-ring with bare hands. Never wear gloves.
● Lubricate O-ring with engine oil.
● Do not clean O-ring with solvent.
● Make sure the O-ring and its mating part are free of foreign material.
● When installing the O-ring, be careful not to scratch it with tools or your fingernails. Also be
careful not to twist or stretch O-ring. If O-ring is stretched while it is being attached, do not
insert it into fuel tube immediately.
Install the fuel injector onto the fuel tube in the following procedure:
Insert the clip (3) into the clip mounting groove (2) on the fuel
injector (1).
● Insert clip cutout (5) into fuel injector protrusion (4).
CAUTION:
● Always replace clip with new one.
● Make sure the clip does not interfere with the O-ring. If
it does, replace the O-ring.
With the clip assembly as is, insert the fuel injector (1) into the
fuel tube (6).
● Make sure the axis is lined up when inserting.
● Insert clip cutout (8) into fuel tube protrusion (7).
● Make sure the flange (10) on the fuel tube fits securely in the
clip flange groove (9).
Make sure the fuel injector does not spin or come off.
●

2.
a.

b.

c.

PBIC1302E

EM-33

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FUEL INJECTOR AND FUEL TUBE
[CR]
3.

Install fuel tube and injector assembly onto cylinder head.
CAUTION:
Make sure the injector nozzle does not touch the other
parts.
● Tighten bolts evenly in two steps in the order shown in figure.
1st step
: 11.8 — 13.8 N·m (1.2 — 1.4 kg-m, 9 — 10 ft-lb)
2ne step
: 20.8 — 28.2 N·m (2.1 — 2.9 kg-m, 16 — 20 ft-lb)

4.

5.

PBIC1434E

Connect fuel feed hose.·
CAUTION:
Securely tighten the hose clamp at a position where it does not get in the way of the bulge.
Install intake manifold support bracket.
● Tighten mounting bolts in the following order.
– Tighten bolts temporarily in numerical order shown in the figure.
– Tighten bolts to the specification in numerical order shown in
the figure.
Bolt 1
: 6.9 — 9.5 N·m (0.7 — 0.96 kg-m, 61 — 84 in-lb)
Bolts 2 and 3

PBIC1572E

: 8.4 — 10.8 N·m (0.86 — 1.1 kg-m, 75 — 95 in-lb)
6.

Reinstall removed parts in reverse order of removal.

INSPECTION AFTER INSTALLATION
●

1.
2.

Follow the procedure below to make sure there are no fuel leaks.
Turn the ignition switch to ON (do not start engine), and with fuel pressure applied in the fuel line, check to
make sure there no fuel leaks from the connection.
Start the engine, and with the increased speed, check again to see if there are any fuel leaks from the
connection.

EM-34

ROCKER COVER
[CR]

ROCKER COVER
Removal and Installation

PFP:13264

A
BBS002NF

EM

C

D

E

F

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PBIC1436E

1.

Harness bracket

2.

Grommet

3.

PCV control valve

4.

PCV hose

5.

Oil filler cap

6.

Intake valve timing control solenoid
valve

7.

O-ring

8.

Rocker cover

9.

Rocker cover oil seal

10. Gasket

3.
4.
5.
6.
7.

K

11. Gasket

REMOVAL
1.
2.

J

L

Remove air duct and air cleaner case assembly. Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
Remove RH engine mount stay. Refer to EM-70, «Removal and Installation» .
NOTE:
It is not necessary to support the engine using a jack.
Remove ignition coil. Refer to EM-29, «IGNITION COIL» .
Remove ignition coil harness bracket.
Disconnect PCV hose and intake valve timing control sorenoid valve harness connector.
Remove the PCV control valve if necessary.
Remove the intake valve timing control solenoid valve if necessary.
CAUTION:
● Handle intake valve timing control solenoid valve with care. Avoid impacts.
● Do not disassemble.

EM-35

M

ROCKER COVER
[CR]
8.

Loosen bolts in the reverse of the order shown in the figure to
remove rocker cover.

PBIC1437E

9.

Remove the rocker cover oil seal using a screwdriver.
CAUTION:
Be careful not to damage the rocker cover.

INSTALLATION
1.

Install rocker cover oil seal.
● Using drift with outer diameter 97 mm (3.82 in) and inner
diameter 83 mm (3.27 in) to 88 mm (3.46 in), press oil seal in.
● Press-fit the oil seal evenly to the mounting surface.

PBIC1303E

2.
a.

b.

Install the rocker cover in the following procedure:
Install the gasket (1) to the No. 1 camshaft bracket upper surface.
● Match up the positioning pins (2) and gasket holes in the
direction of the shape of the camshaft bracket when attaching.
Install the gasket to the rocker cover mounting groove.

MBIB9034E

c.

Apply the liquid gasket to the position shown in figure.
Use Genuine Liquid Gasket or equivalent.

PBIC0555E

EM-36

ROCKER COVER
[CR]
d.

Tighten bolts evenly in two steps in the order shown in the figure, to the specified torque.
● See below for mounting positions of bolts
Under head
45 mm (1.77 in)
Under head
20 mm (0.79 in)

A

: 1, 2 (inside bolts)

EM

: Other than above (outside bolts)
C
PBIC1437E

3.

4.
5.

Install intake valve timing control solenoid valve.
● Make sure no foreign particles attach to the flange, O-ring, or attachment hole.
● Tighten the mounting bolt after making sure it is fully inserted into the mounting hole.
Install PCV control valve.
● Insert until the flange is flush with the grommet.
Reinstall removed parts in reverse order of removal.

D

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EM-37

CAMSHAFT
[CR]

CAMSHAFT
Removal and Installation

PFP:13001
BBS002NG

PBIC1438E

1.

Camshaft bracket (No. 2 — 5)

4.

Camshaft (exhaust)

5.

Valve lifter

6.

Camshaft sprocket (intake)

7.

Camshaft sprocket (exhaust)

8.

Chain tensioner

9.

Cylinder head front cover

10. Timing chain

2.

Camshaft bracket (No. 1)

11. Cylinder head

3.

Camshaft (intake)

12. O-ring

13. Camshaft position sensor (PHASE)

REMOVAL
1.
2.

3.
4.

5.
6.
7.

Remove RH front fender protector.
Secure the engine position using one of the following methods. Remove RH engine mount stay and
engine mount bracket (upper). Refer to EM-70, «Removal and Installation» .
● Mount engine slingers and hook with hoist. Refer to EM-70, «Removal and Installation» .
● Support the oil pan bottom with a jack stand, etc.
Remove rocker cover. Refer to EM-35, «ROCKER COVER» .
Remove the camshaft position sensor (PHASE) from the back of the cylinder head if necessary.
CAUTION:
● Handle camshaft position sensor (PHASE) with care. Avoid impacts.
● The tip of the sensor is magnetic, so do not let metal dust get on it or place it next to objects
which can be affected by magnets.
Remove RH headlamp. Refer to LT-32, «Removal and Installation» .
Remove the cylinder head front cover.
Following the procedure below, place cylinder No. 1 at TDC of its compression stroke

EM-38

CAMSHAFT
[CR]
a.
b.
c.

d.

Turn the crankshaft pulley clockwise.
When doing this, make sure both the intake and exhaust cam noses on cylinder No. 1 are facing out- A
wards. (No. 1 cylinder at TDC of its compression stroke)
Confirm mating marks (1) stamped on intake and exhaust
sprockets are located as shown.
EM
● If there is no position mark at the position in the figure, turn
the crankshaft pulley once more to position them as in the figure.
C
Make sure mating marks on intake and exhaust camshaft
sprockets are located as shown in the figure, then paint mating
marks on the timing chain links.
D
PBIC1306E

E

8.

a.

Make sure the intake camshaft sprocket is in the most advanced position.
CAUTION:
Installation and removal of the intake camshaft sprocket must be done in the most advanced position for the following reasons, so make sure you follow the procedure exactly.
● The sprocket (1) and vane (camshaft coupling) (3) are
designed to spin and move within the range of a certain
angle.
● With the engine stopped the vane (3) is in the most
retarded position. It will not spin because it is locked to
the sprocket side by the internal lock pin (2).
● If the camshaft sprocket mounting bolts are turned in the
situation described above (the most retarded position),
the lock pin (2) will become damaged and cause malfunctions because of the increased horizontal load (cutting
PBIC1439E
force) on the lock pin (2).
● Put the intake camshaft sprocket in the most advance position
in the following steps.
CAUTION:
The chain tensioner must not be removed before doing this step.
NOTE:
The spinning direction in the following description is as seen from the engine front.
Immobilize the hexagonal part of the camshaft with a wrench (1)
to prevent the intake camshaft from moving.

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PBIC1308E

EM-39

CAMSHAFT
[CR]
b.

Apply air pressure with an air gun (2) to the advanced angle side
oil passage of the intake valve timing control on the top surface
of the No. 1 camshaft bracket (1).
Compression pressure
: 300 kPa (3.00 bar, 3 kg/cm2 , 43.5 psi) or more

c.

d.

e.

NOTE:
The air pressure is used to move the lock pin into the disengage
position.
● Keep applying air pressure until step “e” is completed.
PBIC1309E
CAUTION:
● Be sure not to damage the oil passage with the tip of the air gun.
● Wipe all the oil off on the top surface of the No. 1 camshaft bracket to prevent oil from being
blown with the air, and the area around the air gun should be covered with a rag when applying
air pressure. Eye protection should be worn as needed.
Turn the intake camshaft slowly counter-clockwise in direction A
(towards the intake manifold).
● Keep the air pressure on.
CAUTION:
Also be sure the wrench immobilizing the camshaft does
not come loose.
While doing the above, once you hear a click (the sound of the
internal lock pin disengaging) from inside the intake camshaft
sprocket, start turning the intake camshaft in the opposite direction, direction B (clockwise: towards the exhaust manifold) and
PBIC1440E
to the most advanced angle position.
● Keep the air pressure on.
● If there is no click, as soon as the vane (camshaft coupling) starts moving independently of the camshaft sprocket, the lock pin has become disengaged.
● If the lock pin does not become disengaged, shake the wrench immobilizing the camshaft slightly.
● If this still does not help in disengaging the lock pin, tap the intake camshaft front very lightly with a plastic hammer.
Once the vane starts to spin and then the camshaft sprocket starts to spin with the camshaft, it has
reached the most advanced position, so stop.
● Make sure the most advanced position locating intake valve
timing control advance mark (1) of vane (3) and alignment
mark (2) of sprocket (4) as shown in the figure.

PBIC1634E

EM-40

CAMSHAFT
[CR]
9.

Attach the stopper pin (1) such as a paper clip to secure the
plunger in the full compressed position and remove the chain
tensioner (2).

A

EM

C
PBIC1312E

D

10. Keeping the wrench on the camshaft hexagonal part, loosen the
mounting bolts and remove the intake and exhaust camshaft
sprockets.
CAUTION:
● Make sure the tools do not come in contact with the A/C
piping.
● Do not loosen mounting bolts with securing anything
other than the camshaft hexagonal part or with tensioning the timing chain.
NOTE:
With the front cover attached, the timing chain and crankshaft
sprocket will not come off, so there is no need to take steps to
maintain the timing chain tension.

E

F

G
EMD0826D

The intake camshaft sprocket should be handled with the following precautions in mind.
CAUTION:
● When removing intake camshaft sprocket, using adhesive tape or equivalent, prevent vane from
rotating so that lock pin will not rejoin in the most retarded position.
● Handle it carefully, and avoid any chance of impact caused by dropping.
● Do not disassemble. (Do not loosen the four front bolts.)
NOTE:
While removing the intake camshaft sprocket, if the lock pin has been rejoined in the most retarded position, do the following to restore it.
a. Reinstall the intake camshaft sprocket to the intake camshaft and tighten the mounting bolts enough to
prevent air leaking out when the air pressure is applied later.
CAUTION:
To prevent internal lock pin from damaging, keep the torque on the mounting bolts to the minimum required to prevent air from escaping.
b. Apply the air pressure, disengage the lock pin following step 8, and turn the vane to the most advanced
position. (The timing chain need not be attached for this step.)
c. Remove the intake camshaft sprocket from camshaft.
11. Remove camshaft brackets.
● Loosen bolts in several steps in reverse order shown in the
figure.
12. Remove camshaft.
CAUTION:
Do not deform or damage intake camshaft rear end signal
plate.
13. Remove valve lifter.
● Identify installation position of each valve. Arrange removed
valve lifters so they cannot be mixed up.
PBIC0969E

H

●

INSTALLATION
1.

Install valve lifter.

EM-41

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CAMSHAFT
[CR]
2.

● Install it in its original positions.
Install camshaft.
● You can distinguish between the intake and the exhaust by
looking at the different shapes of the front and rear ends of
the camshaft.

MBIB0204E

●

Install the camshaft front ends dowel pin hole (1) and dowel
pin (2) so that they are positioned as shown in the figure.

PBIC1316E

3.

Install camshaft brackets.
● Completely remove any foreign material on bottom surfaces
of camshaft brackets and top surface of cylinder head.
● Referring to the marks on top of the camshaft bracket, install
so that it is in the same position and facing the same direction
as when removed.

MBIB0206E

4.
a.

Tighten camshaft bracket bolts in the following order.
Bolt sizes vary with installation position. Refer to the following
when installing bolts.
Bolt color
1 — 10
11, 12

b.

: Black
: Gold

First tighten bolts 9 through 12, then tighten bolts 1 through 8 in
numerical order.
PBIC0969E

: 2.0 N·m (0.2 kg-m, 18 in-lb)
c.

Tighten all bolts in numerical order shown in the figure.
: 5.9 N·m (0.6 kg-m, 52 in-lb)

d.

Retighten all bolts in numerical order shown in the figure.
: 9.0 — 11.8 N·m (0.92 — 1.2 kg-m, 80 — 104 in-lb)

5.

Install the intake camshaft sprocket in the following procedure:

EM-42

CAMSHAFT
[CR]
●

Make sure the most advanced position checking intake valve
timing control advance mark (1) of vane (3) and alignment
mark (2) of sprocket (4) are located as shown in the figure.

A

EM

C
PBIC1634E

D

a.

Install timing chain (2) by aligning its mating mark (3) (marked
when timing chain is removed) with mark (4) on camshaft
sprocket (1).
● Install by aligning the dowel pin on the back of the camshaft
sprocket with dowel pin hole on the camshaft.

E

F

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PBIC1317E

b.

Keeping the camshaft hexagonal part still with the wrench (2),
tighten the mounting bolt for the intake camshaft sprocket (1).

H

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PBIC1318E

c.
6.
a.

b.
c.

Remove adhesive tape or equivalent from camshaft sprocket.
Install the exhaust camshaft sprocket (1) in the following procedure:
Install timing chain (2) by aligning its mating mark (3) (marked
when timing chain is removed) with mark (4) on camshaft
sprocket (1).
● Install by aligning the dowel pin groove of the sprocket with
dowel pin on the camshaft.
Keeping the camshaft hexagonal part still with the wrench,
tighten the mounting bolt for the exhaust camshaft sprocket.
Make sure the markings for the intake and the exhaust camshaft
sprockets and the timing chain are all lined up.

EM-43

K

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PBIC1319E

CAMSHAFT
[CR]
7.

Install chain tensioner (2).
● Install the stopper pin (1) with plunger secured.
● After installation, remove the stopper pin (1) and release the
plunger.
● Make sure again that mating marks on the intake and exhaust
camshaft sprockets and mating marks on timing chain are
aligned.

PBIC1312E

8.

Turn the crankshaft pulley (1) slowly clockwise to return the
intake camshaft sprocket to the most retarded position.

PBIC1322E

●

●

When first turning the crankshaft the intake camshaft sprocket will turn. Once it is turned more, and the
vane (camshaft) also turns, then it has reached the most retarded position.
After spinning the crankshaft slightly in a counterclockwise direction, you can make sure the lock pin
has joined by seeing if the vane and the sprocket move together.

9.

Install the cylinder head front cover.
● Evenly apply the liquid gasket to the position shown in figure.
Use Genuine Liquid Gasket or equivalent.
● Install so that the cylinder head front cover matches up with
the dowel pin on the cylinder head side.
10. Install camshaft position sensor (PHASE).
● Make sure no foreign particles attach to the flange, O-ring, or
attachment hole.
● Tighten the mounting bolt after making sure it is fully inserted
into the mounting hole.
11. Inspect and adjust valve clearance. Refer to EM-47, «Valve
Clearance» .
12. Reinstall removed parts in reverse order of removal.

PBIC1441E

INSPECTION AFTER REMOVAL
Camshaft Runout
●

●
●

Put V block on precise flat bed, and support No. 2 and No. 5
journal of camshaft.
CAUTION:
Do not support journal No. 1 (on the side of the camshaft
sprocket) because it has a different diameter from the other
four locations.
Set a dial gauge (1) vertically onto journal No. 3.
Rotate the camshaft in one direction by hand and read indication
on the gauge. (Total indication reading)
Limit

●

: 0.04 mm (0.0016 in) or less

PBIC1323E

If exceeds the limit, replace the camshaft.

EM-44

CAMSHAFT
[CR]
Camshaft Cam Height
●

Standard
CR14DE
Intake
Exhaust
●

A

Measure with a micrometer (1).

EM

: 40.359 — 40.549 mm (1.5889 — 1.5964 in)
: 39.743 — 39.933 mm (1.5647 — 1.5722 in)
C

If it exceeds the standard, replace the camshaft.

PBIC1324E

D

Camshaft Journal Clearance
Outer Diameter of Camshaft Journal
●
Measure with a micrometer (1).

E

Standard
No. 1
: 27.935 — 27.955 mm (1.0998 — 1.1006 in)
No. 2 to No. 5
: 23.450 — 23.470 mm (0.9232 — 0.9240 in)

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PBIC1325E

Inner Diameter of Camshaft Journal
●
Tighten camshaft bracket bolts to the specified torque.
●
Using an inside micrometer (1), measure inner diameter of the
camshaft bracket.

I

J

Standard
No. 1
: 28.000 — 28.021 mm (1.1024 — 1.1032 in)
No. 2 to No. 5
: 23.500 — 23.525 mm (0.9252 — 0.9262 in)

K

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PBIC1326E

Calculation of Camshaft Journal Clearance
(Journal clearance) = (inner diameter of camshaft bracket) — (outer diameter of camshaft journal).
Standard
No. 1
: 0.045 — 0.086 mm (0.0018 — 0.0034 in)
No. 2 to No. 5
: 0.030 — 0.071 mm (0.0012 — 0.0028 in)
If clearance exceeded the standard, replace the camshaft and/or the cylinder head. Refer to the standard
values for each individual part.
NOTE:
Since the camshaft brackets and the cylinder head are machined together, replacement must be done using
the cylinder head assembly.

●

EM-45

M

CAMSHAFT
[CR]
Camshaft End Play
●

Set a dial gauge (1) to the camshaft front end in thrust direction.
Move the camshaft back and forth (axially) and read indication
on the gauge.
Standard

●

●

: 0.070 — 0.143 mm (0.0028 — 0.0056 in)

When out of the standard, replace with new camshaft and measure again.
When out of the standard again, replace with new cylinder head.

PBIC1327E

Camshaft Sprocket Runout
●
●

Put V block on precise flat bed, and support No. 2 and No. 5 journal of camshaft.
Using a dial gauge, measure camshaft sprocket runout.
Limit
Intake
Exhaust

●

: 0.20 mm (0.0079 in)
: 0.15 mm (0.0059 in)

If it exceeds the limit, replace camshaft sprocket.

KBIA1493J

Valve Lifter
Check for cracks and wear on valve lifter surface.
●
If anything above is found, replace valve lifter.

KBIA1597J

Valve Lifter Clearance
Outer Diameter of Valve Lifter
●
Measure with a micrometer (1).
Standard

: 29.960 — 29.975 mm(1.1795 — 1.1801 in) dia.

PBIC1328E

EM-46

CAMSHAFT
[CR]
Valve Lifter Hole Diameter
●
Using an inside micrometer (1), measure the valve lifter hole
diameter in cylinder head.
Standard

A

: 30.000 — 30.021 mm (1.1811 — 1.1819 in) dia.

EM

C

PBIC1329E

Calculation of valve lifter clearance
(Valve lifter clearance) = (valve lifter hole diameter) — (outer diameter of valve lifter)
Standard
●

E

: 0.025 — 0.061 mm (0.0010 — 0.0024 in)

If clearance exceeded the standard, replace either one or both of valve lifter and cylinder head. Refer to
the standard values for valve lifter outer diameter and hole diameter.

INSPECTION AFTER INSTALLATION
Inspection of Camshaft Sprocket (INT) Oil Groove

Valve Clearance

BBS002NH

INSPECTION

1.

Whenever the camshaft and valve related parts are removed and installed or replaced, or symptoms due
to changes in valve clearance as a result of aging (poor starting, rough idle, unusual noise) are obvious,
check valve clearance with the following procedure:
Warm up engine and stop it.

EM-47

F

G

CAUTION:
●
Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-II
and it is directed according to inspection procedure of EC section. Refer to EC-104, «SELF-DIAG
RESULTS MODE» (WITH EURO-OBD) or EC-521, «SELF-DIAG RESULTS MODE» (WITHOUT
EURO-OBD).
●
Check when the engine is cold so as to prevent burns from any splashing engine oil.
1. Check the engine oil level. Refer to LU-6, «ENGINE OIL» .
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a. Release fuel pressure. Refer to EC-71, «FUEL PRESSURE RELEASE» (WITH EURO-OBD) or EC-488,
«FUEL PRESSURE RELEASE» (WITHOUT EURO-OBD).
b. Disconnect ignition coil and injector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to EM-35, «ROCKER COVER» .
4. Crank the engine, and then make sure that engine oil comes out from intake valve timing control cover oil
hole. End crank after checking.
WARNING:
Be careful not to touch rotating parts (drive belt, idler pulley, and crankshaft pulley, etc.).
CAUTION:
Engine oil may squirt from intake valve timing control solenoid valve installation hole during
cranking. Use a shop cloth to prevent the engine components and the vehicle. Do not allow engine
oil to get on rubber components such as drive belt or engine mount insulators. Immediately wipe
off any splashed engine oil.
●
Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not
come out from intake valve timing control cover oil hole. Refer to LU-5, «LUBRICATION SYSTEM» .
5. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
● Clean oil groove if necessary. Refer to LU-5, «LUBRICATION SYSTEM» .
6. After inspection, install removed parts.

●

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CAMSHAFT
[CR]
2.

3.
4.

Remove the following parts.
● RH front fender protector
● Rocker cover; Refer to EM-35, «ROCKER COVER» .
Turn the crankshaft pulley clockwise.
When doing this, make sure both the intake and exhaust cam noses on cylinder No. 1 are facing outwards. (No. 1 cylinder at TDC of its compression stroke)
● If they are not facing out, turn the crankshaft pulley further. It is OK to do step 6 first (checking when No.
4 cylinder at TDC of its compression stroke).

5.

Referring to the figure, measure valve clearances of valves with × in table below using a feeler gauge (1).

Cylinder
No. 1 cylinder at TDC of
its compression stroke.

No. 1

No. 2

INT

×

×

EXH

×

No. 3

No. 4

×

PBIC1442E

PBIC1331E

Valve clearance standard:
Hot
Intake
: 0.314 — 0.426 mm (0.012 — 0.017 in)
Exhaust
: 0.338 — 0.462 mm (0.013 — 0.018 in)
Cold* Intake
: 0.29 — 0.37 mm (0.011 — 0.015 in)
Exhaust
: 0.32 — 0.40 mm (0.013 — 0.016 in)

6.
7.

*: Approximately 20°C (68°F) (Reference data)
When adjusted for cold engine, the standard values for warm engine must be checked to see if they are
correct, too.
Rotate crankshaft by 360° clockwise (when viewed from font) to align No. 4 cylinder at TDC of its compression stroke.
Referring to the figure, measure valve clearances of valves with
× in table below.

Cylinder
No. 4 cylinder at TDC of
its compression stroke.

8.

No. 1

No. 2

INT
EXH

No. 3

No. 4

×

×

×

×

Adjustment of places outside range of standard values is done
as follows.
PBIC1443E

EM-48

CAMSHAFT
[CR]
ADJUSTMENT
A
NOTE:
●
The adjustment is made by selecting the thickness of the head of the valve lifter. (An adjuster shim is not
used)
●
The set thickness for the valve filter is measured at normal temperature, but any changes in dimension EM
because of temperature differences maybe ignored. Accordingly, adjustment should use values for a
warmed up engine (ready for inspection).
1. Remove camshaft. Refer to EM-38, «Removal and Installation» .
C
2. Remove the valve lifters for parts which are outside the range of standard values.
3. Using a micrometer (1), measure thickness of the removed
valve lifter center part.
D

E

F
PBIC1333E

G

4.

Measure the thickness of the valve lifter to be replaced using the following formula.
How to determine valve lifer thickness
t = Valve lifter thickness to be replaced
t1 = Removed valve lifter thickness
C1 = Valve clearance measurement
C2 = Standard valve clearance
Intake
Exhaust
●

: t = t1 + (C1 — C2 )
H

I

: 0.37 mm (0.015 in)
: 0.40 mm (0.016 in)

J

New valve lifter thickness (1) can be identified by stamp
marks (2) on the reverse side (inside of cylindrical part).
K
Stamp mark

Valve lifter thickness

00
02
·
·
68

3.00 mm (0.1181 in)
3.02 mm (0.1189 in)
·
·
3.68 mm (0.1449 in)

L

M
●

5.
6.
7.
8.
9.

Valve lifter thickness settings: Thickness 3.00 — 3.68 mm (0.1181
PBIC1334E
— 0.1449 in) in 0.02 mm (0.0008 in) intervals and 35 types.
Install selected valve lifter.
Install camshaft. Refer to EM-38, «Removal and Installation» .
Manually turn crankshaft a few turns.
Make sure that the valve clearance is within the standard using the reference value when engine is cold.
After restoring, make sure the valve clearance is within the range of standard values with the engine
warmed up.

EM-49

TIMING CHAIN
[CR]

TIMING CHAIN
Removal and Installation

PFP:13028
BBS002NI

PBIC1444E

1.

Cylinder head front cover

2.

Camshaft sprocket (intake)

3.

Camshaft sprocket (exhaust)

4.

Chain tensioner

5.

Slack guide

6.

Front cover

7.

Front oil seal

8.

Crankshaft pulley

9.

Timing chain

10. Tension guide

11.

Dowel pin

12. Oil pump drive spacer

13. Crankshaft sprocket

14. O-ring

EM-50

TIMING CHAIN
[CR]
REMOVAL
Operation Description

A

1. Remove engine and transaxle assembly from the vehicle. Refer to EM-70, «Removal and Installation» .
2. Separate engine from transaxle. Refer to MT-7, «REMOVAL AND INSTALLATION» .
EM
3. Remove parts remaining in step 3 and proceed to step 5.
NOTE:
The reason for doing work with the engine by itself is stated below.
C
●
It is necessary to remove the transaxle when removing and installing the oil pan (upper).
●
For this reason, the entirety of the supporting engine mount disappears when removing and installing the
front cover.
D
1. Remove RH front wheel and RH front fender protector.
2. Drain the engine oil.
3. Remove the following parts.
E
● Drive belts and drive belt idler pulleys; Refer to EM-14, «DRIVE BELTS» .
● Rocker cover; Refer to EM-35, «ROCKER COVER» .
● Exhaust front tube; Refer to EX-3, «EXHAUST SYSTEM» .
F
● Starter motor; Refer to SC-51, «Removal and Installation (CR Engine Models)» .
● Oil pan (lower and upper) and oil strainer; Refer to EM-26, «OIL PAN AND OIL STRAINER» .
G
● RH headlamp; Refer to LT-32, «Removal and Installation» .
4. Using the following procedure, remove the RH engine mount stay and the RH engine mount brackets
(upper and lower).
H
a. The engine should be immobilized using any one of the following methods.
● Mount engine slingers and hook with hoist. Refer to EM-70, «Removal and Installation» .
● Support the transaxle bottom with a jack stand, etc.
I
CAUTION:
Make sure the transaxle is not scratched while the bottom is being supported.
b. Remove RH engine mount stay and RH engine mount bracket (upper and lower). Refer to EM-70, J
«Removal and Installation» .
5. Remove alternator. Refer to SC-15, «CHARGING SYSTEM» .
6. Remove cylinder head front cover. Refer to EM-38, «CAMSHAFT» .
K
7. Remove the cylinder head auxiliary bolts (1).
L

M

PBIC1335E

8.
a.
b.

Set No. 1 cylinder at TDC on its compression stroke.
Turn the crankshaft pulley clockwise.
When doing this, make sure both the intake and exhaust cam noses on cylinder No. 1 are facing outwards. (No. 1 cylinder at TDC of its compression stroke)

EM-51

TIMING CHAIN
[CR]
c.

Confirm mating marks (1) stamped on intake and exhaust
sprockets are rotated as shown.
● If there is no position mark in the figure, turn the crankshaft
pulley once more to position them as in the figure.

PBIC1306E

9.
a.

b.

Remove the crankshaft pulley in the following order.
Using the starter motor mounting hole, attach a ring gear stopper (special service tool) and secure the crankshaft.
● You can also secure the crankshaft counterweight using hammer handle, etc., after removing the oil pan (upper). Make
sure no foreign matter gets inside the engine.
Loosen crankshaft bolt and pull it out.
CAUTION:
Do not remove the mounting bolts as they will be used as a
supporting point for the pulley puller.
PBIC1445E

c.

Place the crankshaft pulley puller (1) tab on the crank pulley
hole, and pull the crankshaft pulley (2) through.
CAUTION:
Do not put the pulley tab on the crank pulley wide-diameter
pulley, as this will damage the internal dampers.
10. Remove the idler pulley bracket assembly for drive belts from
the front cover. Refer to EM-14, «DRIVE BELTS» .

PBIC1338E

11. Remove the front cover in the following order.
a. To give more freedom to the front cover position during installation and removal, pull out the oil pump drive spacer (2) over the
front oil seal (1).
● Pull out straight, using long nosed pliers or two screwdrivers,
etc.
CAUTION:
Be careful not to damage oil pump drive spacer surface.
PBIC1339E

EM-52

TIMING CHAIN
[CR]
b.

Remove front cover carefully.
● Remove bolts A to C shown in the figure.
CAUTION:
● To prevent the front of the cylinder head gasket from getting bent or damaged, remove so that it comes apart
cleanly from the front cover top and the gasket bottom.
● Replace the cylinder head gasket with a new one if it is
damaged.

A

EM

C
KBIA1502J

D

c. Remove O-ring from the cylinder block.
12. Remove the front cover dowel pins (1) from the cylinder block.
● After warming with an industrial drier (2), use locking pliers (3)
to pull out the dowel pins.
NOTE:
This step is in preparation for installing the front cover. If the
timing chain is to be removed, it can be done later.

E

F

G
PBIC1340E

13. Remove the front oil seal from the front cover.
● Insert a screwdriver behind the oil seal and pull up to remove.
14. Secure the intake camshaft sprocket in the most advanced position. Refer to EM-38, «CAMSHAFT» .
NOTE:
The following steps are for removing the timing chain and other related parts.
15. Remove chain tensioner. Refer to EM-38, «CAMSHAFT» .
16. Remove camshaft sprocket. Refer to EM-38, «CAMSHAFT» .
NOTE:
No markings are needed between the camshaft sprocket and timing chain.
17. Remove timing chain, the timing chain slack guide, and the tension guide.
18. Remove the crankshaft sprocket.

H

I

J

K

L

INSPECTION AFTER REMOVAL
Make sure there are no noticeable cracks or wear on the timing
chain, and replace if there are.

M

PBIC0282E

INSTALLATION
CAUTION:
●
Completely remove liquid gasket attached to mounting surfaces using a scraper, and clean off
with white gasoline.
●
After installation, wipe off any extra liquid gasket.
1. Install the timing chain and related parts in the following steps.

EM-53

TIMING CHAIN
[CR]
See the figure for positions sprockets, timing chain (1), and
installation of other parts.
● Attach each sprocket with its mating mark towards the engine
front.
Install timing chain and crankshaft sprocket (2).
● You can make sure the No. 1 cylinder is at the TDC of its compression stroke by checking if the crankshaft key is straight
up.
● Place the timing chain on the front of the camshaft to make
sure it does not fall.
Install timing chain slack guide (3) and the tension guide (4).
Install camshaft sprockets. Refer to EM-38, «CAMSHAFT» .
● Align the mating marks on camshaft sprocket and timing
chain here.
●

a.

b.
c.

PBIC1341E

d.
e.
f.
g.
h.
i.
2.

Install chain tensioner. Refer to EM-38, «CAMSHAFT» .
Check again to make sure all the mating marks are in place.
Temporarily install the oil pump drive spacer, the crankshaft pulley, and the crankshaft pulley bolt, and
make it so that the crankshaft can be turned.
Turn the crankshaft clockwise viewing from engine front. Place intake side camshaft in the most retarded
position. Refer to EM-38, «CAMSHAFT» .
Turn the crankshaft a few more times clockwise and make sure nothing is wrong with it.
Remove the parts installed in step f.
Install front oil seal to front cover.
● Make sure the oil seal lettering is towards the engine front.
● Using suitable drift, press oil seal in until it is flush with end
surface of mounting position.
● Do this without damaging the outer diameter of the oil seal.

PBIC1446E

3.
a.
b.

Install the front cover with the following procedure:
Install O-ring (1) to the cylinder block.
Apply liquid gasket to the contact area between the bottom of
the cylinder head gasket (2) and the cylinder block (two places
in the figure) using a screwdriver.
Use Genuine Liquid Gasket or equivalent.

PBIC1342E

EM-54

TIMING CHAIN
[CR]
c.
d.

Evenly apply the liquid gasket to the back of the front cover as
per the position in the figure.
Apply a thin, even layer of liquid gasket to the entire upper surface of the front cover.
Use Genuine Liquid Gasket or equivalent.

A

EM

C
PBIC1447E

D

e.

f.

g.
h.

With the inner rotor internal diameter part of the oil pump resting
on the top of the crankshaft [with a space between the top of the
front cover and the bottom of the cylinder head gasket (3)], bring
the front cover (1) as close as possible to the cylinder block. (To
the left in the figure)
To make sure the front cover comes into contact with the cylinder head gasket (3) bottom and the cylinder block (2) front at the
same time, lift it diagonally and set it in the mounting position.
(To the right in the figure)
CAUTION:
● Be careful not to damage the cylinder head gasket (3).
● Attach using caution not to let the liquid gasket get cut
off by getting attached to unnecessary parts.
Temporarily secure the front cover so it does not move using
several bolts.
Press fit dowel pins (1) to the cylinder block through the front
cover.

E

F

G
PBIC1343E

H

I

J

K
PBIC1344E

i.

j.
k.

Temporarily tighten the front cover bolts.
● A [Under head length: 25 mm (0.98 in)], B [Under head
length: 40 mm (1.57 in)], C [Under head length: 50 mm (1.97
in)]

L

M

Temporarily tighten the cylinder head auxiliary bolts.
Tighten front cover bolts and the cylinder head auxiliary bolts to
the specified torque.
KBIA1502J

EM-55

TIMING CHAIN
[CR]
4.

Install oil pump drive spacer (1).
● When installing, align with flat face of oil pump inner rotor.
● If they are not aligned properly, turn the inner rotor with a
screwdriver until they do.
CAUTION:
Be careful not to damage the oil seal lip.

PBIC1345E

5.
6.

7.

8.
9.

Install the drive belt idler pulley bracket assembly. Refer to EM-14, «DRIVE BELTS» .
Install crankshaft pulley.
● When installing, make sure the front oil seal lip does not fold back and the garter spring of oil seal lip
does not fall.
● Secure the crankshaft as in “REMOVAL” and tighten the bolts.
CAUTION:
The bolt seats have a special lubricant applied in order to stabilize torque, so do not wipe off or
apply oil.
Install the cylinder head front cover.
● Evenly apply the liquid gasket to the position shown in figure.
Use Genuine Liquid Gasket or equivalent
Install RH engine mount bracket and RH engine mount stay.
Refer toEM-70, «Removal and Installation» .
Reinstall removed parts in reverse order of removal.

PBIC1441E

INSPECTION AFTER INSTALLATION
●

●

In order to allow liquid gasket to be cured, perform inspection at least 30 minutes after the last step in
which parts sealed with liquid gasket are installed.
With engine warmed up, check each part for engine oil leakage.

EM-56

OIL SEAL
[CR]

OIL SEAL
Removal and Installation of Valve Oil Seal

PFP:12279

A
BBS002NJ

REMOVAL
1.
2.
3.

4.

5.

Remove camshaft. Refer to EM-38, «CAMSHAFT» .
Remove valve lifter. Refer to EM-38, «CAMSHAFT» .
Turn the crankshaft, put the cylinder to have the oil seal
removed in the TDC position to prevent the valve from falling
into the cylinder.
CAUTION:
When rotating the crankshaft, make sure the timing chain
does not get caught in the front cover.
Using a valve spring compressor (special service tool), remove
the valve collet, valve spring retainer, and valve spring.

EM

C

D

SEM914F

E

Using a valve oil seal puller (special service tool), remove the
valve oil seal.
F

G

H
SEM909F

INSTALLATION
1.
2.
3.

I

Apply engine oil to the new valve oil seal joint and seal lip.
Using a valve oil seal drift (special service tool), press fit the
valve oil seal to the height shown in the figure.
Reinstall removed parts in reverse order of removal.

J

K

L
PBIC0576E

Removal and Installation of Front Oil Seal
REMOVAL
1.

2.

Remove the following parts.
● RH front fender protector
● Drive belt; Refer to EM-14, «DRIVE BELTS» .
● Crankshaft pulley; Refer to EM-50, «TIMING CHAIN» .
Using a screwdriver, remove the front oil seal.
CAUTION:
Be careful not to damage the front cover or the crankshaft.

EM-57

BBS002NK

M

OIL SEAL
[CR]
INSTALLATION
1.
2.

Apply engine oil to the new front oil seal joint and seal lip.
Using a suitable drift (1), press fit until the front end of front oil
seal is level with the mounting surface.
● Suitable drift (1) : outer diameter 50 mm (1.97 in), inner diameter 44 mm (1.73 in).
CAUTION:
● Be careful not to damage the front cover or the crankshaft.
● Press in straight, making sure the oil seal does not curl
or tilt.

PBIC1346E

See the figure for the direction the front oil seal should be fitted.
Reinstall removed parts in reverse order of removal.
●

3.

SEM715A

Removal and Installation of Rear Oil Seal

BBS002NL

REMOVAL
1.
2.
3.
4.

Remove transaxle assembly. Refer to MT-7, «REMOVAL AND INSTALLATION» .
Remove clutch cover and clutch disc. Refer to CL-11, «CLUTCH DISC, CLUTCH COVER AND FLYWHEEL» .
Remove flywheel. Refer to EM-74, «CYLINDER BLOCK» .
Using a screwdriver, remove the rear oil seal.
CAUTION:
Be careful not to damage the mounting surface.

INSTALLATION
1.

Using a suitable drift (1), press fit until the rear end of front oil
seal is level with the mounting surface.
● Suitable drift (1): outer diameter 102 mm (4.02 in), inner diameter 90 mm (3.54 in).
CAUTION:
● Do not touch the grease applied to the oil seal lip.
● Be careful not to damage the rear oil seal retainer or the
crankshaft.
● Press in straight, making sure the oil seal does not curl
or tilt.

EM-58

PBIC1347E

OIL SEAL
[CR]
●

Press rear oil seal (2) into rear oil seal retainer (3) so that
it does not project from the end.

A

EM

C
PBIC1348E

D

2.

Reinstall removed parts in reverse order of removal.
E

F

G

H

I

J

K

L

M

EM-59

CYLINDER HEAD
[CR]

CYLINDER HEAD
On Vehicle Inspection

PFP:11041
BBS002NM

COMPRESSION PRESSURE INSPECTION
1.
2.
a.
b.
c.

Warm up engine thoroughly. Then, stop it.
Release fuel pressure with the following procedure.
Remove rear seat assembly.
Open the inspection hole cover.
Disconnect fuel level sensor unit, fuel filter, and fuel pump assembly connector, and start engine. Refer to
FL-4, «FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY» .
d. After you stop the engine, crank it two or three times to consume the fuel in the pipes.
CAUTION:
After release the fuel pressure and until the compression pressure inspection, leave the harness connector off.
3. Remove ignition coil and spark plug from all the cylinders. Refer to EM-29, «IGNITION COIL» and EM-30,
«SPARK PLUG (PLATINUM-TIPPED TYPE)» .
4. Attach a engine tachometer (not required in use of CONSULT-II).
5. Install compression tester (1) with adapter onto spark plug hole.

PBIC1349E

Use compression tester whose picking up end inserted to
spark plug hole is smaller than 20 mm (0.79 in) in diameter.
Otherwise, it may be caught by cylinder head during removal.
With accelerator pedal fully depressed, turn ignition switch to
“START” for cranking. When the gauge pointer stabilizes, read
the compression pressure and engine rpm. Perform these steps
to check each cylinder.
●

6.

[kPa (bar, kg/cm2 , psi)/350rpm]
Engine type

CR14DE

Standard

1,383 (13.83, 14.1, 201)

Minimum

1,187 (11.87, 12.1, 172)

SEM387C

Difference limit among cylinders

98 (0.98, 1.0, 14)

CAUTION:
Always use a fully charged battery to obtain specified engine speed.
● If the engine speed is out of specified range, check battery liquid for proper gravity. Check engine
speed again with normal battery gravity.
● If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure compression pressure again.
● If some cylinders have low compression pressure, pour small amount of engine oil into the spark plug
hole of the cylinder to re-check it for compression.
– If the added engine oil improves the compression, the piston rings may be worn out or damaged. Check
the piston rings and replace if necessary.
– If the compression pressure remains at low level despite the addition of engine oil, the valves may be
malfunctioning. Check the valves for damage. Replace the valve or valve seat accordingly.

EM-60

CYLINDER HEAD
[CR]
If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, the gasket is leaking. In such a case, replace the cylinder head
gasket.
After inspection, install removed parts in reverse order of removal.
●

7.

Removal and Installation

BBS002NN

A

EM

C

D

E

F

G

PBIC1448E

1.

Cylinder head assembly

2.

Cylinder head bolt

3.

Washer

4.

Cylinder head auxiliary bolt

5.

Cylinder head auxiliary bolt

6.

Gasket

H

I

REMOVAL
1.
2.
3.

Release the fuel pressure. Refer to EC-71, «FUEL PRESSURE RELEASE» (WITH EURO-OBD), EC-488,
«FUEL PRESSURE RELEASE» (WITHOUT EURO-OBD).
Drain engine coolant. Refer to CO-8, «ENGINE COOLANT» .
Remove the following components and related parts.
● RH front fender protector
● Alternator and A/C compressor drive belt; Refer to EM-14, «DRIVE BELTS» .
● Air duct and air cleaner case assembly; Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
● Intake manifold; Refer to EM-22, «INTAKE MANIFOLD» .
● Fuel injector and fuel tube assembly; Refer to EM-32, «FUEL INJECTOR AND FUEL TUBE» .
● Radiator upper hose and lower hose; Refer to CO-12, «RADIATOR» .
● Alternator and alternator bracket; Refer to SC-39, «Removal and Installation (CR Engine Models)» .
● Exhaust manifold and three way catalyst assembly; Refer to EM-24, «EXHAUST MANIFOLD AND
THREE WAY CATALYST» .
● Ignition coil; Refer to EM-29, «IGNITION COIL» .
● Rocker cover; Refer to EM-35, «ROCKER COVER» .
● Camshaft; Refer to EM-38, «CAMSHAFT» .
CAUTION:
For the method for maintaining engine position, select the method which supports the bottom of
the oil pan.
● Heated oxygen sensor harness bracket; Refer to EM-24, «EXHAUST MANIFOLD AND THREE WAY
CATALYST» .
● Water outlet, thermostat, engine coolant temperature sensor and heater pipe; Refer to CO-19, «THERMOSTAT» .
● Water suction pipe mounting bolt; Refer to CO-17, «WATER PUMP» .

EM-61

J

K

L

M

CYLINDER HEAD
[CR]
4.
5.

Loosen bolts in the reverse order shown in the figure and then
remove the cylinder head assembly.
Remove cylinder head gasket.

PBIC1449E

INSPECTION AFTER REMOVAL
Cylinder Head Bolt Outer Diameter
●

Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between d1 and d2
exceeds the limit, replace them with new one.
Limit (d1 — d2)

●

: 0.12 mm (0.0047 in)

If reduction of outer diameter appears in a position other than
d2, use it as d2 point.

PBIC1450E

INSTALLATION
1.

Evenly apply the liquid gasket to the position in the figure and
then install the cylinder head gasket.
Use Genuine Liquid Gasket or equivalent.

PBIC0573E

2.

a.
b.
c.
d.
e.

Attach the cylinder head assembly and then tighten bolts 1 to 10
in the order shown in the figure.
CAUTION:
For step c, loosen them in reverse of the order in the figure.
NOTE:
Bolts 11 to 13 should be tightened in step 3 after tightening bolts
1 to 10.
Apply new engine oil to threads and seat surfaces of bolts.
Tighten at 61.7 — 71.7 N·m (6.3 — 7.3 kg-m, 46 — 52 ft-lb).
Loosen completely to 0 N·m (0 kg-m).
PBIC1449E
Tighten at 22.5 — 32.5 N·m (2.3 — 3.3 kg-m, 17 — 23 ft-lb).
Tighten with 90 — 95 degrees clockwise [Target: 90 degrees]. (Angle tightening)
CAUTION:
Check and confirm the tightening angle by using angle wrench (special service tool). Avoid judgment by visual inspection without the tool.

EM-62

CYLINDER HEAD
[CR]
●

Check tightening angle indicated on the angle wrench indicator plate.

A

EM

C
PBIC0574E

D

3.

Tighten auxiliary bolts (11 to 13) in the numerical order shown in
the figure.
E

F

G
PBIC1449E

4.

Reinstall removed parts in reverse order of removal.

H

Disassembly and Assembly

BBS002NO

I

J

K

L

M

PBIC1451E

1.

Spark plug

2.

Valve collet

3.

Valve spring retainer

4.

Valve spring

5.

Valve spring seat

6.

Valve oil seal

7.

Valve guide

8.

Cylinder head

9.

Valve seat (INT)

EM-63

CYLINDER HEAD
[CR]
10. Valve (INT)

11. Valve (EXH)

12. Valve seat (EXH)

13. Spark plug tube

DISASSEMBLY
1.
2.

Remove spark plugs with a spark plug wrench.
Remove valve lifter.
● Mark position on valve lifter for assembly.
3. Remove valve collet.
● Compress the valve spring with a valve spring compressor
(special service tool). Remove valve collet with a magnetic
driver.
CAUTION:
When working, take care not to damage valve lifter holes.
4. Remove valve spring retainer and valve spring.
5. Push the valve stem toward the combustion chamber side and
remove the valve.
● Before removal, check valve guide clearance. Refer to EMPBIC1015E
66, «Valve Guide Clearance» .
● Mark position on valve for assembly.
6. Remove valve oil seal.
● Use valve oil seal puller (special service tool).
7. Remove valve spring seat.
8. When valve seat replacement is necessary, refer to EM-67,
«Replacement of Valve Seat» .
9. When valve guide replacement is necessary, refer to EM-66,
«Valve Guide Replacement» .
10. Remove spark plug tube, as necessary.
● Using a pair of pliers, pull spark plug tube out of cylinder
SEM909F
head.
CAUTION:
● Take care not to damage cylinder head.
● Once removed, a spark plug tube will be deformed and cannot be reused. Do not remove it
unless absolutely necessary.

ASSEMBLY
1.
2.
3.

4.
5.

Install valve guide. Refer to EM-66, «Valve Guide Replacement» .
Install valve seat. Refer to EM-67, «Replacement of Valve Seat» .
Install valve oil seal.
● Using a valve oil seal drift (special service tool), install to the
dimensions specified in the figure.
Install valve spring seat.
Install valve.
● Valves of larger diameter are for intake side.

PBIC0576E

6.
7.
8.

Install valve spring.
Install valve spring retainer.
Install valve collet.
● Use a valve spring compressor (special service tool) to compress the valve spring, then install collet
with a magnetic finger.

EM-64

CYLINDER HEAD
[CR]
● After installing valve component parts, tap valve stem tip with a plastic hammer to assure a proper fit.
Install valve lifter.
● Install it in its original positions.
10. Install spark plug tube.
● Press-fit into cylinder head in the following order.
a. Remove the old liquid gasket which has become attached to the
cylinder head mounting hole.
b. Apply the liquid gasket to the area around the spark plug tube
press-fit.
● Use Genuine Liquid Gasket or equivalent.
c. Using a drift, press-fit spark plug tube so that its height “H” is as
specified in the figure.

9.

Standard press-fit height “H”
: 41.0 — 42.0 mm (1.614 — 1.654 in)

KBIA1248E

A

EM

C

D

E

CAUTION:
● Press-fit, making sure not to deform the spark plug tube.
● After press-fitting, wipe off liquid gasket protruding onto cylinder head upper face.
11. Install spark plug.
● Use a spark plug wrench.

G

INSPECTION AFTER DISASSEMBLY
Cylinder Head Distortion

H

1.

2.

F

Using a scraper, wipe off oil, scale, gasket, sealant, and carbon
deposits from surface of cylinder head.
CAUTION:
Do not allow gasket fragments to enter oil or engine coolant
passages.
Check flatness of the cylinder head lower surface. Measure distortion in six directions shown in figure, at several points in each
direction.
Limit
●

I

J

: 0.1 mm (0.004 in)

K

if it exceeds the limit, replace the cylinder head.

PBIC0075E

Valve Dimensions
●

●

L

Check dimensions of each valve. For dimensions, refer to EM96, «VALVE» .
If dimensions are out of the standard, replace valve.

M

SEM188A

EM-65

CYLINDER HEAD
[CR]
Valve Guide Clearance
Check valve guide clearance before removing the valve guide.
1. Make sure valve stem diameter is within the standard.
2. Push the valve out toward combustion chamber for approximately 15 mm (0.59 in). Measure runout while pushing the valve
toward the dial gauge (1).
3. The half of the dial gauge reading is the valve guide clearance.
Standard
Intake
Exhaust

: 0.020 — 0.053 mm (0.0008 — 0.0021 in)
: 0.040 — 0.073 mm (0.0016 — 0.0029 in)

PBIC1352E

Valve Guide Replacement
When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide.
1. To remove valve guide, heat cylinder head to 110 to 130°C (230
to 266°F) by soaking in heated oil.

SEM008A

2.

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

SEM931C

3.

Ream cylinder head valve guide hole.
Valve guide hole diameter (for service parts):
Intake and exhaust
: 9.685 — 9.696 mm (0.3813 — 0.3817 in) dia.

SEM932C

EM-66

CYLINDER HEAD
[CR]
4.

Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.

A

EM

C
SEM008A

D

5.

Press valve guide from camshaft side to dimensions as in illustration.
CAUTION:
Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.

E

F

G
PBIC0577E

6.

H

Using valve guide reamer, apply reamer finish to valve guide.
Standard
Intake and exhaust
: 5.500 — 5.518 mm (0.2165 — 0.2172 in) dia.

I

J

K
SEM932C

Valve Seat Contact
●

●

●

●

After confirming that the dimensions of valve guides and valves
are within specifications, perform this procedure.
Apply prussian blue (or white lead) onto contacting surface of
valve seat to check the condition of the valve contact on the surface.
Check if the contact area band is continuous all around the circumference.
If not, grind to adjust valve fitting and check again. If the contacting surface still has N.G conditions even after the re-check,
replace valve seat.

L

M

EMA0487D

Replacement of Valve Seat
When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this.

EM-67

CYLINDER HEAD
[CR]
2.

Ream cylinder head recess diameter for service valve seat.
Oversize [0.5 mm (0.020 in)]:
Intake: 29.000 — 29.016 mm (1.1417 — 1.1424 in)
Exhaust: 24.000 — 24.016 mm (0.9449 — 0.9455 in)

●
●

Be sure to ream in circles concentric to the valve guide center.
This will enable valve seat to fit correctly.

SEM795A

3.

Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.

SEM008A

4.

Provide valve seats cooled well with dry ice. Force fit valve seat
into cylinder head.
CAUTION:
● Avoid directly to touching cold valve seats.
● Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.

PBIC0579E

5.

Using valve seat cutter set (commercial service tool) or valve
seat grinder, finish the seat to the specified dimensions.
CAUTION:
When using valve seat cutter, firmly grip the cutter handle
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with the cutter or cutting many different times
may result in stage valve seat.

SEM934C

EM-68

CYLINDER HEAD
[CR]
Grind to obtain the dimensions indicated in figure.
Standard:
D1 dia.
D2 dia.
D3 dia.
D4 dia.
D5 dia.
6.
7.

A

: 25.4 mm (1.000 in)
: 27.0 — 27.2 mm (1.062 — 1.070 in)
: 28.7 — 28.9 mm (1.129 — 1.137 in)
: 22.0 — 22.2 mm (0.866 — 0.874 in)
: 23.7 — 23.9 mm (0.933 — 0.940 in)

Using compound, grind to adjust valve fitting.
Check again for normal contact.

EM

C
PBIC0974E

D

Valve Spring Squareness
Set try square (1) along the side of valve spring and rotate the
spring. Measure the maximum clearance between the top face of
spring and try square (1).
Limit
●

E

: 1.6 mm (0.063 in)
F

if exceeds the limit, replace the valve spring.

G

PBIC1355E

Valve Spring Dimensions and Valve Spring Pressure Load
●

Check valve spring pressure load at specified spring height.
Standard
Free height
Installation
height
Installation load
Height during
valve open
Load with valve
open

●

H

I

: 53.3 mm (2.098 in)
: 32.82 mm (1.2921 in)

J

: 149 — 165 N (15.2 — 16.8 kg, 33.5 37 lb)
: 24.73 mm (0.9736 in)

K
SEM113

: 228 — 250 N (23.3 — 25.5 kg, 51.3 56.2 lb)

L

If the dimensions exceed the standard, replace the valve spring.
M

EM-69

ENGINE ASSEMBLY
[CR]

ENGINE ASSEMBLY
Removal and Installation

PFP:10001
BBS002NP

MBIB9032E

LH engine mount bracket
(vehicle side)

3.

LH engine mount bracket
(transaxle side)

RH engine mount stay
5.
(The shape may not be the same as figure)

RH engine mount insulator

6.

RH engine mount bracket (upper)

RH engine mount bracket (lower)

Rear engine mount bracket

9.

Rear torque rod

1.

LH engine mount insulator

4.
7.

2.

8.

10. Engine mounting bracket rear

WARNING:
●
Situate vehicle on a flat and solid surface.
●
Place chocks at front and back of rear wheels.
●
For engines not equipped with engine slingers, attach proper slingers and bolts described in
PARTS CATALOG.
CAUTION:
●
Always be careful to work safely, avoid forceful or uninstructed operations.
●
Do not start working until exhaust system and engine coolant are cool enough.
●
If items or work required are not covered by the engine main body section, refer to the applicable
sections.
●
Always use the support point specified for lifting.
●
Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for
unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool
before starting work, in preparation for the backward shift of center of gravity.
●
For supporting points for lifting and jacking point at rear axle, refer to GI-40, «Garage Jack, Safety
Stand and 2-Pole Lift» .

EM-70

ENGINE ASSEMBLY
[CR]
REMOVAL
A
Description of work
Remove engine and transaxle assembly from vehicle, and separate engine and transaxle.
Preparation
EM
1. When engine can be hoisted, remove engine hood.
2. Release fuel pressure. Refer to EC-71, «FUEL PRESSURE RELEASE» (WITH EURO-OBD), EC-488,
«FUEL PRESSURE RELEASE» (WITHOUT EURO-OBD).
C
3. Drain engine coolant. Refer to CO-8, «ENGINE COOLANT» .
4. Remove the following parts.
● RH and LH front wheel
D
● RH and LH front fender protector
● Exhaust front tube; Refer to EX-3, «EXHAUST SYSTEM» .
● Drive belt; Refer toEM-14, «DRIVE BELTS» .
E
● Air duct; Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
● Battery
● Radiator; Refer to CO-12, «RADIATOR» .
F
Engine room LH
5. Disconnect the harness connectors and terminals from the following parts.
G
NOTE:
● Remove the ECM (1) from the bracket and disconnect the two
harness connectors.
H
CAUTION:
Avoid impacts to ECM.
● Disconnect the intermediate connector (2) for the main harI
ness between the vehicle and the engine room below the
ECM.
PBIC1356E
● Disconnect the harness connectors on the battery positive
J
terminal (3).
● Disconnect the ground wire on the transaxle (4) side.
6. Disconnect heater hose. Plug the hose immediately to prevent engine coolant from draining.
K
7. Disconnect the shift cable from the transaxle. Refer to MT-12, «CONTROL LINKAGE» .
8. Disconnect the clutch tube from the transaxle side and temporarily fasten to vehicle.
L
● Install the plug to prevent the clutch fluid from leaking.
9. Remove the crankshaft position sensor (POS) from the transaxle.
CAUTION:
M
Handle it carefully, avoid any chance of impact caused by dropping.
Engine room front and RH
10. Remove the ground wire between the alternator bracket and the vehicle.
11. Remove RH engine mount stay, alternator bracket, and alternator.
12. Remove A/C compressor from engine with piping connected, and temporarily install it to vehicle with rope
to avoid putting stress on air conditioner pipes.
13. Remove fuel tube protector. Refer to EM-32, «FUEL INJECTOR AND FUEL TUBE» .
14. Disconnect fuel hose. Plug the hose immediately to prevent fuel from draining.
Vehicle underbody
15. Remove the ABS wheel sensor from the steering knuckle.
16. Remove brake caliper from steering knuckle. Temporarily fix on vehicle side with rope or so to avoid putting stress on brake hose. Refer to BR-21, «FRONT DISC BRAKE» .
17. Remove RH and LH drive shafts. Refer to FAX-10, «FRONT DRIVE SHAFT» .

EM-71

ENGINE ASSEMBLY
[CR]
18. Remove rear torque rod (1).

MBIB1377E

Removal
19. Install engine slinger to cylinder head front left side (1) and rear
right side (2) and support the engine position with a hoist.
NOTE:
Front side and rear side engine slinger are common parts.
: 16.6 — 23.5 N·m (1.7 — 2.3 kg-m, 13 — 17 in)
●

For front side, remove harness bracket under fuel tube protector and mount by using harness bracket mounting hole.
Refer to EM-32, «FUEL INJECTOR AND FUEL TUBE» .
PBIC1358E

20. Lift to a height sufficient to allow easy work, support the bottom
of the engine with either a manual lift table caddy (commercial
service tool) or two suitable jacks, and adjust the tension of the
hoist.
CAUTION:
● Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
● Make sure the hanging chain or hanging hook does not
come into contact with the A/C piping or the vehicle (cowl
top). Also make sure they do not get in the way by moving while the work is being done.

PBIC1454E

21. Remove the RH engine mount bracket (upper) (1) mounting
bolts (2).
22. Remove the LH engine mount bolt-securing nut (3).

MBIB9050E

23. Carefully lower the manual lift table caddy or suitable jack, (or carefully raise the lift), and remove the
engine and transaxle assembly from the vehicle.
● If you are going to lower the engine side, do this in tandem with the hoist.
CAUTION:
● This should be done making sure it does not come in contact with the vehicle.
● Check that all connection points have been disconnected.
● Make sure the hanging chain or hanging hook does not come into contact with the A/C piping or
the vehicle (cowl top).

EM-72

ENGINE ASSEMBLY
[CR]
During engine and transaxle assembly removal, always be careful to prevent the vehicle from
falling off the lift due to changes in the center of gravity.
A
● If necessary, support the rear side of the vehicle with jack to prevent it from falling off.
Separation Work
EM
●
On level ground, separate engine and transaxle with the following procedure:
CAUTION:
During the operation, securely support the engine by placing a piece of wood under the engine oil pan,
C
transaxle oil pan, and suspension member, and suspend the engine slingers by hoist.
24. Remove the starter motor. Refer to SC-51, «Removal and Installation (CR Engine Models)» .
25. Separate the engine and the transaxle. Refer to MT-7, «REMOVAL AND INSTALLATION» .
D
●

INSTALLATION

Install in the reverse order of removal while being careful of the following.
●
Do not allow the engine mount insulator to be damaged and be careful no oil gets on it.
●
For a part with a specified installation orientation, refer to component figure in EM-70, «Removal and
Installation» .
●
Make sure all mount insulators are seated properly, then tighten nuts and bolts.

E

F

INSPECTION AFTER INSTALLATION
●

●
–

–
●
●

●
●

Before starting engine, check the levels of engine coolant, lubrications and working oils. If less than
required quantity, fill to the specified level.
Use procedure below to check for fuel leakage.
Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
Start engine. With engine speed increased, check again for fuel leakage at connection points.
Run engine to check for unusual noise and vibration.
Warm up engine thoroughly to make sure there is no leakage of engine coolant, lubricants, working oil,
fuel and exhaust gas.
Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.
After cooling down engine, again check amounts of engine coolant, lubricants, oil, and fluid. Refill to specified level, if necessary.

G

H

I

J

K

L

M

EM-73

CYLINDER BLOCK
[CR]

CYLINDER BLOCK
Disassembly and Assembly

PFP:11010
BBS002NQ

PBIC1455E

EM-74

CYLINDER BLOCK
[CR]
1.

Rear oil seal

2.

Rear oil seal retainer

3.

Knock sensor

4.

Cylinder block

5.

Oil level gauge guide

6.

Top ring

7.

Second ring

8.

Oil ring

9.

Piston

A

10. Piston pin

11. Connecting rod

12. Connecting rod bearing

13. Thrust bearing

14. Main bearing

15. Crankshaft

16. Key

17. Connecting rod cap

18. Connecting rod nut

19. Main bearing cap bolt

20. Main bearing cap

21. Rear plate

22. Flywheel (M/T models)

23. Adapter (A/T models)

24. Drive plate (A/T models)

25. O-ring

26. Crankshaft position sensor (POS)

EM

D

DISASSEMBLY
1.
2.

a.
b.

C

Remove engine and transaxle assembly from the vehicle and separate transaxle from the vehicle. Refer
to EM-70, «Removal and Installation» .
Install engine to engine stand in the following procedure.
NOTE:
We will use as an example the engine stand (commercial service tool) specified to support the cylinder
block rear (transaxle mounting surface).
Remove clutch cover and clutch disc. Refer to CL-11, «CLUTCH DISC, CLUTCH COVER AND FLYWHEEL» .
Remove the flywheel.
● Using a ring gear stopper (special service tool), secure the
crankshaft, loosen the bolts diagonally and remove.

E

F

G

H

I

J
PBIC1456E

c.

K

CAUTION:
Make sure signal plate (1) are not damaged or deformed.
NOTE:
Figure shows the drive plate.
Remove rear plate.

L

M

PBIC1360E

d.

Lift engine using a hoist and mount it on an engine stand (1).
● For installation of engine slingers, refer to EM-70, «Removal
and Installation» .

PBIC1361E

EM-75

CYLINDER BLOCK
[CR]
3.
4.

Drain engine oil and engine coolant from engine.
Remove following components and related parts.
● Air cleaner case assembly; Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
● Intake manifold; Refer to EM-22, «INTAKE MANIFOLD» .
● Fuel injector and fuel tube assembly; Refer to EM-32, «FUEL INJECTOR AND FUEL TUBE» .
● Ignition coil; Refer to EM-29, «IGNITION COIL» .
● Rocker cover; Refer to EM-35, «ROCKER COVER» .
● Oil pan and oil strainer; Refer to EM-26, «OIL PAN AND OIL STRAINER» .
● Front cover and timing chain; Refer to EM-50, «TIMING CHAIN» .
● Camshaft; Refer to EM-38, «CAMSHAFT» .
● Cylinder head assembly; Refer to EM-61, «Removal and Installation» .
● Oil filter; Refer to LU-9, «OIL FILTER» .
● Oil pressure switch; Refer to LU-6, «OIL PRESSURE CHECK» .
5. Remove knock sensor.
CAUTION:
Avoid impact such as a dropping.
6. Remove oil level gauge guide, if necessary.
CAUTION:
Once removed, it cannot be reused. Do not remove it unless absolutely necessary.
7. Remove rear oil seal retainer.
● Remove by inserting a screwdriver between main bearing cap and rear oil seal retainer.
8. Remove rear oil seal from rear oil seal retainer.
● Remove by driving it out using a screwdriver.
CAUTION:
Make sure the rear oil seal retainer is not damaged.
9. Remove piston and connecting rod assembly.
● Before removing connecting rod, check connecting rod side
clearance. Refer to EM-85, «CONNECTING ROD SIDE
CLEARANCE» .
a. Position the crankshaft pin corresponding to the connecting rod
to be removal onto the bottom dead center.
b. Remove connecting rod cap.
c. Push the piston and connecting rod assembly out toward cylinder head side with handle of a hammer.
10. Remove connecting rod bearings from connecting rod and connecting rod cap.
EMG0025D
CAUTION:
When removing, check each part, and arrange them in a way that prevents mixing them up.
11. Remove piston rings from piston.
● Use piston ring expander (1).
CAUTION:
● Be careful not to damage piston.
● Do not expand piston rings excessively. It can damage
piston rings.
● Before removal of piston ring, check piston ring side clearance. Refer to EM-86, «PISTON RING SIDE CLEARANCE» .
PBIC1362E

EM-76

CYLINDER BLOCK
[CR]
12. Remove piston from connecting rod.
● Use a piston pin press stand and a press to remove the piston
pin.
NOTE:
The joint between the connecting rod and the piston pin is a
press fit.
CAUTION:
Be careful not to damage the piston and connecting rod.

A

EM

C
PBIC1574E

D

13. Remove the main bearing cap in the following order.
a. Loosen and remove bolts in several steps in reverse of the
numerical order shown in figure.
● Before loosening main bearing cap bolts, measure the crankshaft side clearance. Refer to EM-85, «CRANKSHAFT SIDE
CLEARANCE» .
b. Tapping lightly with a plastic hammer, remove the main bearing
cap.
14. Remove crankshaft.
15. Remove main bearing and thrust bearing from cylinder block
PBIC1457E
and main bearing cap.
CAUTION:
Identify installation position of each part. Arrange removed parts so as not to mix them up.

E

F

G

H

ASSEMBLY
1.

2.

Thoroughly clean engine coolant and oil passages in cylinder
block, as well as inside of crank case and cylinder bores, with
compressed air.
If the plug (1) in figure is removed, apply liquid gasket to the plug
screw.
Use Genuine Liquid Gasket or equivalent.
● Do not reuse washer. Replace it with a new washer.
● Tighten to the specified torque.

I

J

K

: 58.8 — 68.6 N·m (6.0 — 6.9 kg-m, 44 — 50 ft-lb)
PBIC1363E

3.
a.

b.

Install main bearings and thrust bearings.
Clean bearing mounting surfaces on cylinder block and main
bearing cap to remove any foreign material, dust, and oil on
them.
Install thrust bearings (1) on both sides of cylinder block No. 3
housing (2).
● Install thrust bearing with its oil groove (3) facing crankshaft
arm side (outer side).

M

PBIC1364E

EM-77

L

CYLINDER BLOCK
[CR]
c.

Install main bearing (1) in paying attention to the direction.
Install main bearing with oil groove and oil hole (2) to cylinder
block, and the one without oil groove and oil hole to main
bearing cap (5).
● Before installing the main bearing, lubricate bearing surface
(inside) with new engine oil. Do not apply engine oil to back
surface, but thoroughly clean it.
● When installing, align the bearing stopper (3) to the notch (4).
● Make sure that oil holes in cylinder block and main bearing
are aligned.
Install crankshaft to cylinder block.
● Rotate crankshaft by hand and make sure it turns smoothly.
Install main bearing cap.
● Install main bearing cap with its front mark (1) facing front of
engine.
NOTE:
Since it is machined together with the cylinder block, it cannot
be replaced on its own.
●

4.
5.

PBIC1365E

PBIC1366E

6.
a.
b.
c.

Tighten main bearing cap bolts in numerical order shown in figure with the following steps.
Lubricate threads and seat surface of each bolt with new engine
oil.
Tighten it to 24.5 — 30.3 N·m (2.5 — 3.0 kg-m, 18 — 22 ft-lb).
Tighten with 95 — 100 degrees clockwise [Target: 95
degrees].(Angle tightening)

PBIC1457E

●

●

●

Use an angle wrench (special service tool) to check tightening
angle.
CAUTION:
Check tightening angle with an angle wrench. Do not
visually check the tightening angle.
After tightening main bearing cap bolts, rotate crankshaft by
hand and make sure that it turns smoothly.
Check crankshaft side clearance. Refer to EM-85, «CRANKSHAFT SIDE CLEARANCE» .
PBIC1458E

7.

Install the piston onto the connecting rod in the following procedure:

EM-78

CYLINDER BLOCK
[CR]
a.

Set so that the piston front mark (1) on the piston head and the
connecting rod cylinder number (2) engraving are in the position
shown in figure.

A

EM

C
PBIC1367E

D

b.

Press fit the piston pin using the piston pin press stand (special
service tool).
NOTE:
The joint between the connecting rod and the piston pin is a
press fit.
● After finishing work, make sure the piston moves freely.

E

F

G
PBIC1574E

8.

Install piston rings with piston ring expander as shown in the figure.
CAUTION:
● Be careful not to damage piston.
● Make sure the piston ring does not spread out too much
and break.

H

I

J

PBIC1582E

●

●

Against the piston front mark (1), position end gaps of each
piston ring as shown in figure.
Install top ring and second ring with stamp mark side facing
up.

K

L

M

PBIC1368E

9.

Install connecting rod bearing to connecting rod and connecting
rod cap.
● When installing connecting rod bearing, lubricate bearing surface (inside) with new engine oil. Do not apply engine oil to
back surface, but thoroughly clean it.
● Install connecting rod bearing by aligning the stopper protrusion (1) with notch (2) on connecting rod.

PBIC1369E

EM-79

CYLINDER BLOCK
[CR]
10. Install piston and connecting rod assembly to crankshaft.
● Position the crankshaft pin corresponding to the connecting
rod to be removal onto the bottom dead center.
● Apply enough engine oil to cylinder bore, piston and crankshaft pin.
● Install connecting rod to cylinder position corresponding to
cylinder No. stamped on it.
● Using a piston ring compressor (special service tool) (1),
install piston so that piston grade number on piston head
faces toward engine front.
PBIC1370E
CAUTION:
Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the
connecting rod big end.
11. Install connecting rod cap.
● Be sure that cylinder No. (1) on connecting rod and connecting rod cap match.

PBIC1371E

12. Tighten connecting rod nuts in following steps.
a. Lubricate threads and seat surface of connecting rod nuts and
bolts with new engine oil.
b. Tighten at 13.7 — 15.7 N·m (1.4 — 1.6 kg-m, 10.1 — 11.5 ft-lb).
c. Tighten with 45 — 50 degrees clockwise [Target: 45 degrees].
(Angle tightening)
CAUTION:
Check tightening angle with an angle wrench (special service tool). Do not visually check the tightening angle.
● After the nuts were tightened, rotate crankshaft by hand and
PBIC1459E
make sure that it turns smoothly.
● Check connecting rod side clearance. Refer to EM-85, «CONNECTING ROD SIDE CLEARANCE» .
13. Install rear oil seal.
● Make sure the area surrounding the oil seal is not damaged,
and use an oil seal drift to press fit.
● Press fit until the end of rear oil seal is level with the edges of
the retainer.

PBIC1460E

EM-80

CYLINDER BLOCK
[CR]
14. Install rear oil seal retainer.
● Evenly apply the liquid gasket to the position shown in figure.
Use Genuine Liquid Gasket or equivalent.
● Install so that it matches up with the dowel pin on the cylinder
block side.

A

EM

C
PBIC1461E

D

15. Install oil level gauge guide (1).
● Press fit the oil level gauge guide (1) into the cylinder block
with the assembly reference surface on the plate set as
shown in the figure.
● Apply sealant to the press fit areas.
CAUTION:
Replace used oil level gauges with new ones.

E

F

G

H

I

J

PBIC1372E

16. Install knock sensor.
● Install connector so that it is positioned towards the engine
front.
CAUTION:
● Handle it carefully to avoid impact. If any impact is
applied, replace it with new one.
● Confirm no foreign material adhere to cylinder block and
knock sensor mounting surfaces.
● Be sure to use specified bolts.
● Do not hold connector when tightening bolts.
PBIC1373E
● Make sure installed sensor connector is away from contact with other parts.
17. For the following, install the parts disassembled in step 4 in the reverse order.
18. Secure the position of the engine with the hoist, remove the bolts, and lower from the engine stand.
19. Install rear plate.

EM-81

K

L

M

CYLINDER BLOCK
[CR]
20. Install the flywheel (1).
● Install so that signal plate (4) is towards the back of the
engine.
● Install by aligning the dowel pin hole (6) with the dowel pin (5)
on the back of the crankshaft.
CAUTION:
Make sure signal plate (4) are not damaged or deformed.

PBIC1374E

●

Using a ring gear stopper (special service tool), secure the
crankshaft, and tighten the bolts diagonally.

PBIC1456E

21. Reinstall removed parts remained in reverse order of removal.

How to Select Piston and Bearing

BBS002NR

DESCRIPTION
Selection points

●

●

●

Between cylinder block and
crankshaft

Between cylinder block and
piston

Selection parts

Selection items

Selection methods

Main bearing

Main bearing grade
(Bearing thickness)

Determined by cylinder block bearing
housing grade (inner diameter of
housing) and crankshaft journal
grade (outer diameter of journal).

Piston and piston pin
assembly
Note: Piston and piston pin
are a set. They make up
one part as an assembly.

Piston grade
(Piston outer diameter)

Piston grade = cylinder bore grade
(inner diameter of bore)

The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.

EM-82

CYLINDER BLOCK
[CR]
HOW TO SELECT PISTON
When New Cylinder Block is Used
●

A

Check cylinder bore grade (1, 2, or 3) on cylinder block bottom
rear surface and select piston of the same grade.
EM

C

D
PBIC1463E

E

NOTE:
The piston head shape varies from engine to engine, as do their
positions shown in figure.

F

G

H
PBIC1462E

When Cylinder Block is Reused
1.
2.
3.

Measure cylinder bore inner diameter.
Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the “Piston Selection Table”.
Select the piston of the same grade.

I

J

Piston selection Table
CR14DE

K
Unit: mm (in)

Grade

1

2

3

Inner diameter of cylinder bore

73.000 — 73.010
(2.8740 — 2.8744)

73.010 — 73.020
(2.8744 — 2.8748)

73.020 — 73.030
(2.8748 — 2.8752)

Outer diameter of piston

72.980 — 72.990
(2.8732 — 2.8736)

72.990 — 73.000
(2.8736 — 2.8740)

73.000 — 73.010
(2.8740 — 2.8744)

EM-83

L

M

CYLINDER BLOCK
[CR]
HOW TO SELECT MAIN BEARING
When New Cylinder Block and Crankshaft are Used
1.

“Main Bearing Selection Table” rows correspond to bearing
housing grade (0, 1, 2, or 3) on cylinder block bottom rear surface.

PBIC1463E

2.
3.

Apply journal diameter grade (0, 1, 2, or 3) stamped on crankshaft front side to column in “Main Bearing Selection Table”.
Select main bearing (STD 1 to 7) at the point where selected
row and column meet in the following selection table.

PBIC1464E

When Cylinder Block and Crankshaft are Reused
1.
2.
3.
4.

Measure inner diameter of cylinder block main bearing housing and outer diameter of crankshaft journal.
Find measured dimension in “Cylinder block bearing housing inner diameter” row of “Main Bearing Selection Table”.
Find the measured dimension in “Crankshaft main journal diameter” column in the following selection
table.
Select main bearing (STD 1 to 7) at the point where selected row and column meet in the following selection table.

Main bearing Selection Table
Units: mm (in)
Cylinder block main bearing
housing inner diameter
Crankshaft journal diameter
44.970/44.966
(1.7705/1.7703)

44.966/44.962
(1.7703/1.7702)

44.962/44.958
(1.7702/1.7700)

44.958/44.954
(1.7700/1.7698)

—

49.004/49.000
(1.9293/1.9291)

49.008/49.004
(1.9294/1.9293)

49.012/49.008
(1.9296/1.9294)

49.016/49.012
(1.9298/1.9296)

—

0

1

2

3

●

Bearing grade No.

●

Bearing thickness

●

Identification color

STD1
2.002/2.006
(0.0788/0.0790)
Red

STD 2
2.004/2.008
(0.0789/0.0791)
Green

STD 3
2.006/2.010
(0.0790/0.0791)
Yellow

STD 4
2.008/2.012
(0.0791/0.0792)
Blue

●

Bearing grade No.

●

Bearing thickness

●

Identification color

STD 2
2.004/2.008
(0.0789/0.0791)
Green

STD 3
2.006/2.010
(0.0790/0.0791)
Yellow

STD 4
2.008/2.012
(0.0791/0.0792)
Blue

STD 5
2.010/2.014
(0.0791/0.0793)
Pink

●

Bearing grade No.

●

Bearing thickness

●

Identification color

STD 3
2.006/2.010
(0.0790/0.0791)
Yellow

STD 4
2.008/2.012
(0.0791/0.0792)
Blue

STD 5
2.010/2.014
(0.0791/0.0793)
Pink

STD 6
2.012/2.016
(0.0792/0.0794)
White

●

Bearing grade No.

●

Bearing thickness

●

Identification color

STD 4
2.008/2.012
(0.0791/0.0792)
Blue

STD 5
2.010/2.014
(0.0791/0.0793)
Pink

STD 6
2.012/2.016
(0.0792/0.0794)
White

STD 7
2.014/2.018
(0.0793/0.0794)
Blue/yellow

Grade
(stamped)

0

1

2

3

EM-84

CYLINDER BLOCK
[CR]
Undersize Bearing Usage Guide
A
If specified oil clearance cannot be obtained by standard size main bearing, use undersize (US) bearing.
●
When using undersize bearing, install it, measure bearing inner diameter, and grind journal to obtain specified oil clearance.
EM
Bearing undersize table
●

Unit: mm (in)
Size

Thickness

US 0.25 (0.0098)

2.123 — 2.131 (0.836 — 0.839)

C

CAUTION:
Keep fillet R when grinding crankshaft journal (1) in order to
use undersize bearing (All journals).

D

PBIC1375E

Inspection After Disassembly

BBS002NS

CRANKSHAFT SIDE CLEARANCE
●

●

F

Using a dial gauge (1), measure the clearance between the
thrust bearings and the crankshaft arm when the crankshaft is
moved fully forward or backward.
Standard
Limit

E

G

: 0.060 — 0.260 mm (0.0024 — 0.0102 in)
: 0.3 mm (0.012 in)
H

If the measured value exceeds the limit, replace the thrust bearings, and measure again. If it still exceeds the limit, replace the
crankshaft also.

I
PBIC1376E

CONNECTING ROD SIDE CLEARANCE
●

Standard
Repair limit
●

J

Measure side clearance between connecting rod and crankshaft
arm with feeler gauge (1).
: 0.050 — 0.420 mm (0.0020 — 0.0165 in)
: 0.5 mm (0.0197 in)

K

If the measured value exceeds the limit, replace the connecting
rod, and measure again. If it still exceeds the limit, replace the
crankshaft also.

L

M
PBIC1377E

PISTON AND PISTON PIN CLEARANCE
Inner Diameter of Piston Pin
●

Measure the inner diameter of piston pin bore with an inside
micrometer (1).
Standard

: 18.008 — 18.012 mm (0.7090 — 0.7091 in)

PBIC1378E

EM-85

CYLINDER BLOCK
[CR]
Outer Diameter of Piston Pin
●

Using a micrometer (1), measure piston pin outer diameter.
Standard

: 17.996 — 18.000 mm (0.7085 — 0.7087 in)

PBIC1379E

Piston and Piston pin Clearance
(Piston pin clearance) = (Piston pin bore diameter) – (Outer diameter of piston pin)
Standard
●
●

: 0.008 — 0.016 mm (0.0003 — 0.0006 in)

If clearance exceeds the standard, replace piston and piston pin assembly.
When replacing piston and piston pin assembly, refer to EM-83, «HOW TO SELECT PISTON»

PISTON RING SIDE CLEARANCE
●

Measure side clearance of piston ring and piston ring groove
with feeler gauge (1).
Standard:
Top ring
2nd ring
Oil ring
Limit:
Top ring
2nd ring

●

: 0.040 — 0.080 mm (0.0016 — 0.0031 in)
: 0.025 — 0.070 mm (0.0010 — 0.0028 in)
: 0.030 — 0.140 mm (0.0021 — 0.0055 in)
: 0.11 mm (0.0043 in)
: 0.1 mm (0.0039 in)

PBIC1380E

If out of specification, replace piston and/or piston ring assembly.

PISTON RING END GAP
●

●

Check if inner diameter of cylinder bore is within specification.
Refer to EM-89, «PISTON TO CYLINDER BORE CLEARANCE»
.
Insert piston ring (1) until middle of cylinder with piston (2), and
measure gap.
Standard:
Top ring
2nd ring
Oil ring
Limit:
Top ring
2nd ring
Oil ring

●

: 0.18 — 0.33 mm (0.0071 — 0.0130 in)
: 0.50 — 0.65 mm (0.0197 — 0.0256 in)
: 0.20 — 0.70 mm (0.0079 — 0.0276 in)

PBIC1381E

: 0.57 mm (0.0224 in)
: 0.85 mm (0.0335 in)
: 0.96 mm (0.0378 in)

If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylinder and use oversized piston and piston ring.

EM-86

CYLINDER BLOCK
[CR]
CONNECTING ROD BEND AND TORSION
●

A

Check connecting rod bend and torsion with a connecting rod
aligner.
Bend:
Limit : 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
Torsion:
Limit : 0.30 mm (0.0118 in) per 100 mm (3.94 in) length

EM

C

SEM038F

●

D

If it exceeds the limit, replace connecting rod assembly.
E

F

G
SEM003F

H

CONNECTING ROD BEARING HOUSING DIAMETER (BIG END)
●

Install the connecting rod cap without the connecting rod bearing
installed. After tightening the connecting rod bolt to the specified
torque, measure the connecting rod big end inner diameter
using an inside micrometer (1). Refer to EM-77, «ASSEMBLY»
for the tightening procedure.
Standard

●

I

J

: 43.000 — 43.013 mm (1.6929 — 1.6934 in) dia.

If it exceeds the standard, replace the connecting rod.
K
PBIC1382E

L

CONNECTING ROD BUSHING OIL CLEARANCE DIAMETER (SMALL END)
Inner Diameter of Connecting Rod Bushing (Small End)
●

Using an inside micrometer (1), measure inner diameter of
bushing.
Standard

M

: 17.962 — 17.978 mm (0.7072 — 0.7078 in) dia.

PBIC1383E

EM-87

CYLINDER BLOCK
[CR]
Outer Diameter of Piston Pin
●

Using a micrometer (1), measure piston pin outer diameter.
Standard

: 17.996 — 18.000 mm (0.7996 — 0.7087 in) dia.

PBIC1379E

Connecting Rod Bushing Oil Clearance (Small End)
(Connecting rod small end oil clearance) = (Inner diameter of connecting rod small end) – (Outer diameter of
piston pin)
Standard
●

●

: –0.018 — –0.038 mm (–0.0007 — –0.0015 in)

If the measured value exceeds the standard, replace the connecting rod assembly and/or piston and piston pin assembly.
If replacing the piston and piston pin assembly, refer to EM-83, «HOW TO SELECT PISTON» .

CYLINDER BLOCK DISTORTION
●

●

Using a scraper, remove gasket on the cylinder block surface,
and also remove oil, scale, carbon, or other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter the oil or coolant passages.
Measure the distortion on the block upper face at some different
points in 6 directions.
Limit

●

: 0.1 mm (0.004 in)

If out of the distortion limit, replace the cylinder block.
PBIC0121E

INNER DIAMETER OF MAIN BEARING HOUSING
●

●

Install the main bearing cap with the main bearings removed,
and tighten the mounting bolts to the specified torque. Refer to
EM-77, «ASSEMBLY» for the tightening procedure.
Using a bore gauge (1), measure the inner diameter of the main
bearing housing.
Standard

●

: 49.000 — 49.016 mm (1.9291 — 1.9298 in) dia.

If out of specification, replace cylinder block and main bearing
cap as an assembly.
NOTE:
Cylinder block cannot be replaced as a single part because it is
machined together with main bearing cap.

EM-88

PBIC1384E

CYLINDER BLOCK
[CR]
PISTON TO CYLINDER BORE CLEARANCE
Inner Diameter of Cylinder Bore
●

A

Using a bore gauge (1), measure cylinder bore for wear, out-ofround and taper at 6 different points on each cylinder. (X and Y
directions at A, B and C) (Y is in longitudinal direction of engine)

EM

C

D
PBIC1385E

E

Standard inner diameter:
CR14DE : 73.000 — 73.030 mm (2.8740 — 2.8744 in) dia.
Wear limit:
0.2 mm (0.008 in)
Out-of-round (Difference between X and Y):
0.015 mm (0.0006 in)
Taper limit (Difference between A and C):
0.01 mm (0.0004 in)

F

G

H
PBIC0613E

●

●

●

If the measured value exceeds the limit, or if there are scratches
and/or seizure on the cylinder inner wall, hone or rebore the inner wall.
An oversize piston is provided. When using an oversize piston, rebore the cylinder so that the clearance
of the piston-to-cylinder bore satisfies the standard.
When using an oversize piston, use it for all cylinders with oversize piston rings.

I

J

Oversize (OS)

: 0.2 mm (0.008 in)

Outer Diameter of piston
●

K

Measure piston skirt outer diameter using micrometer (1).
Measurement point (Distance from the top)
CR14DE : 32.3 mm (1.272 in)
Standard
CR14DE : 72.980 — 73.010 mm (2.7953 — 2.7957 in) dia.

L

M

PBIC1386E

Piston to Cylinder Bore Clearance
●

Calculate by outer diameter of piston skirt and inner diameter of cylinder (direction X, position B).
(Clearance) = (Inner diameter of cylinder) – (Outer diameter of piston skirt).
Standard

●

: 0.010 — 0.030 mm (0.0004 — 0.0012 in)

If clearance exceeds the standard, replace piston and piston pin assembly. Refer to EM-83, «HOW TO
SELECT PISTON» .

EM-89

CYLINDER BLOCK
[CR]
Reboring Cylinder Bore
1.

Cylinder bore size is determined by adding piston-to-cylinder bore clearance to piston diameter “A”.
Rebored size calculation: D = A + B — C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston — to — cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)

2.
3.
●
●

4.
5.
●

Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted
in final assembly.
Cut cylinder bores.
When any cylinder needs boring, all other cylinders must also be bored.
Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a
time.
Hone cylinders to obtain specified piston-to-cylinder bore clearance.
Measure finished cylinder bore for out-of-round and taper.
Measurement should be done after cylinder bore cools down.

OUTER DIAMETER OF CRANKSHAFT JOURNAL
●

Using a micrometer (1), measure outer diameter of crankshaft
journals.
Standard

●

: 44.954 — 44.970 mm (1.7698 — 1.7705 in) dia.

If it is out of the standard, measure the main bearing oil clearance. Then use the undersize bearing. Refer to EM-92, «OIL
CLEARANCE OF MAIN BEARING» .

PBIC1387E

OUTER DIAMETER OF CRANKSHAFT PIN
●

Using a micrometer, measure outer diameter of crankshaft pin.
Standard

●

: 39.961 — 39.974 mm (1.5733 — 1.5738 in) dia.

If it is out of the standard, measure the connecting rod bearing oil clearance. Then use the undersize
bearing. Refer to EM-91, «OIL CLEARANCE OF CONNECTING ROD BEARING» .

OUT-OF-ROUND AND TEPER OF CRANKSHAFT
●

●

●

Using a micrometer, measure the dimensions at 4 different
points shown in the figure on each journal and pin.
Out-of-round (1) is indicated by the difference in dimensions
between 1 and 2 at A and B.
Taper (2) is indicated by the difference in dimension between A
and B at 1 and 2.
Limit:
Out-of-round (X – Y)
Taper (1 – 2)

: 0.005 mm (0.0002 in)
: 0.005 mm (0.0002 in)
PBIC1388E

●

●

If the measured value exceeds the limit, correct or replace the
crankshaft.
If corrected, measure the bearing oil clearance of the corrected journal or pin. Then select the main bearing or connecting rod bearing. Refer to EM-92, «OIL CLEARANCE OF MAIN BEARING» or EM-91, «OIL
CLEARANCE OF CONNECTING ROD BEARING» .

EM-90

CYLINDER BLOCK
[CR]
CRANKSHAFT RUNOUT
●

●
●

Limit
●

A

Place a V-block on a precise flat table to support the journals on
the both end of the crankshaft.
Place a dial gauge (1) straight up on the No. 3 journal.
Rotate crankshaft and read indication on the gauge. (Total indicator reading)

EM

: 0.05 mm (0.002 in)

C

If it exceeds the limit, replace the crankshaft.
PBIC1389E

OIL CLEARANCE OF CONNECTING ROD BEARING
Method of Measurement
●

●

E

Install the connecting rod bearings to the connecting rod and the
cap, and tighten the connecting rod nuts to the specified torque.
Using a inside micrometer (1) measure the inner diameter of
connecting rod bearing. Refer to EM-77, «ASSEMBLY» for the
tightening procedure.
(Oil clearance) = (Inner diameter of connecting rod bearing) –
(Outer diameter of crankshaft pin)
Standard
Limit

F

G

: 0.010 — 0.044 mm (0.0004 — 0.0017 in)
: 0.064 mm (0.0025 in)

When exceeding limit, use undersize bearing so that oil clearance remains within the standard value. Refer to EM-91,
«Undersize Bearing Usage Guide» .

D

H
PBIC1382E

I

Method of Using Plastigage
●

●

●

●

Remove oil and dust on the crankshaft pin and the surfaces of
each bearing completely.
Cut a plastigage (1) slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
Install the connecting rod bearings to the connecting rod cap,
and tighten the connecting rod nuts to the specified torque.
Refer to EM-77, «ASSEMBLY» for the tightening procedure.
CAUTION:
Never rotate crankshaft while Plastigage is in place.
Remove the connecting rod cap and bearings, and using the
PBIC1390E
scale on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is same as that described in the “Method of
Measurement”.

Undersize Bearing Usage Guide
●

●

If specified oil clearance cannot be obtained by standard size connecting rod bearing, use undersize (US)
bearing.
When using undersize bearing, install it, measure bearing inner diameter, and grind crankshaft pin to
obtain specified oil clearance.

EM-91

J

K

L

M

CYLINDER BLOCK
[CR]
Bearing undersize table
Unit: mm (in)
Size

Thickness

STD (Reference)

1.504 — 1.508 (0.0529 — 0.0594)

US 0.25 (0.0098)

1.627 — 1.635 (0.0641 — 0.0644)

CAUTION:
Keep fillet R when grinding crankshaft pin (1) in order to use
undersize bearing (All crankshaft pin).
PBIC1391E

OIL CLEARANCE OF MAIN BEARING
Method of Measurement
●

Install the main bearings to the cylinder block and bearing cap. Measure the main bearing inner diameter
with the bearing cap bolt tightened with main bearing cap to the specified torque. Refer to EM-77,
«ASSEMBLY» for the tightening procedure.
(Oil clearance) = (Inner diameter of main bearing) – (Outer diameter of crankshaft journal)
Standard
Limit

●

: 0.018 — 0.034 mm (0.0007 — 0.0013 in)
: 0.05 mm (0.002 in)

If the measured value exceeds the limit, select main bearings (including the undersize) referring to the
main bearing inner diameter and crankshaft journal outer diameter, so that the oil clearance satisfies the
standard. Refer to EM-84, «HOW TO SELECT MAIN BEARING» .

Method of Using Plastigage
●

●

●

●

Remove oil and dust on the crankshaft journal and the surfaces
of each bearing completely.
Cut a plastigage (1) slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
Tighten the main bearing bolts with main bearing cap to the
specified torque. Refer to EM-77, «ASSEMBLY» for the tightening procedure.
CAUTION:
Never rotate crankshaft while Plastigage is in place.
Remove the bearing cap and bearings, and using the scale on
PBIC1392E
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is same as that described in the “Method of
Measurement”.

CRUSH HEIGHT OF MAIN BEARING OR CONNECTING ROD BEARING
●

When the bearing cap is removed after being tightened to the
specified torque with main bearings or connecting rod bearings
(1) installed, the tip end of bearing must protrude. Refer to EM77, «ASSEMBLY» for the tightening procedure.
Standard

●

: There must be crush height (2).

If the standard is not met, replace main bearings or connecting
bearings.

PBIC1393E

EM-92

CYLINDER BLOCK
[CR]
FLYWHEEL RUNOUT
●

A

The runout of the clutch contact surface of the flywheel should
be measured using a dial gauge (1). (Total indicator reading)
Flywheel
Limit

EM

: 0.15 mm (0.0059 in)
C

PBIC1394E

D

E

F

G

H

I

J

K

L

M

EM-93

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR]

SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit

PFP:00030
BBS002NT

GENERAL SPECIFICATIONS
Engine

CR14DE

Cylinder arrangement

4, in-line
cm3 (cu in)

Displacement
Bore and stroke

1,386 (84.57)

mm (in)

73.0 x 82.8 (2.874 x 3.260)

Valve arrangement

DOHC

Firing order

1-3-4-2

Number of piston rings

Compression

2

Oil

1

Number of main bearings

5

Compression ratio

9.9

Compression pressure
kPa (bar, kg/cm2 , psi) / 350 rpm

Standard

1,383 (13.83, 14.1, 201)

Minimum

1,187 (11.87, 12.1, 172)

Differential limit between cylinders

98 (0.98, 1.0, 14)

Valve timing
(Intake valve timing control — OFF)

PBIC0187E

Unit: degree

CR14DE

a

b

c

d

e

f

216

224

− 11

55

4

32

INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
Limit
Surface distortion

0.3 (0.012)

EM-94

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR]
DRIVE BELTS
Deflection [mm (in)]
[When pressed by force of 98.1N (10 kg,
22lb)]

Tension [N (kg, lb)]
Location
New

Alternator and
A/C compressor belt

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

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

Alternator belt

446 — 534 (45.5 — 54.5,
100.3 — 120.0)

Water pump belt

At adjustment

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

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

348 — 436 (35.5 — 44.5,
78.2 — 98.0)

Limit

EM

Measuring
point

New belt

At adjustment

Limit

A

6.6 — 7.8
(0.260 0.307)

7.3 — 8.5
(0.287 0.335)

13.8
(0.543)

C

B

5.6 — 6.6
(0.220 0.260)

7.1 — 8.3
(0.280 0.327)

11.9
(0.469)

D

A

3.1 — 4.1
(0.122 0.161)

9.8 — 10.6
(0.386 0.417)

13.8
(0.543)

E

C

6.7 — 7.3
(0.264 0.287)

7.6 — 8.6
(0.299 0.339)

12.4
(0.448)

D

4.7 — 5.6
(0.185 0.220)

7.0 — 7.7
(0.276 0.303)

8.6
(0.339)

196 (20,
44.1)

196 (20,
44.1)

A

137 (14,
30.9)

F

G

H

I

J
PBIC1414E

PBIC1415E

SPARK PLUG
Make

K
NGK

Champion

Standard type

LFR5AP-11

REC10PYC4

Hot type

LFR4AP-11

—

Cold type

LFR6AP-11

—

Gap (nominal)

L

1.1 mm (0.043 in)

M

CYLINDER HEAD
Unit: mm (in)
Limit
Cylinder head distortion

0.1 (0.004)

Height

121.2 (4.77)

EM-95

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR]
VALVE
Valve Dimensions
Unit: mm (in)

SEM188A

Standard
Valve head diameter “D”

Valve length “L”

Valve stem diameter “d”

Intake

27.4 — 27.6 (1.079 — 1.087)

Exhaust

22.4 — 22.6 (0.882 — 0.890)

Intake

97.85 (3.8524)

Exhaust

97.92 (3.8551)

Intake

5.465 — 5.480 (0.2152 — 0.2157)

Exhaust

5.445 — 5.460 (0.2144 — 0.2150)

Valve seat angle “α”

45°15′ — 45°45′

Valve margin “T”

1.05 — 1.35 (0.0413 — 0.0531)

Valve Clearance
Unit: mm (in)
Hot

Cold* (reference data)

Intake

0.314 — 0.426 (0.012 — 0.017)

0.29 — 0.37 (0.011 — 0.015)

Exhaust

0.338 — 0.462 (0.013 — 0.018)

0.32 — 0.40 (0.013 — 0.016)

*: At a temperature of approximately 20°C (68°F)

Valve Guide
Unit: mm (in)
Engine Models

CR14DE
Intake

Outer diameter
Valve guide

Inner diameter
(Finished size)

Exhaust

Standard

Service

Standard

Service

9.522 — 9.534
(0.3749 — 0.3754)

9.723 — 9.734
(0.3828 — 0.3832)

9.522 — 9.534
(0.3749 — 0.3754)

9.723 — 9.734
(0.3828 — 0.3832)

5.500 — 5.518
(0.2165 — 0.2172)

5.500 — 5.518
(0.2165 — 0.2172)

Cylinder head valve guide hole diameter

9.475 — 9.496
(0.3730 — 0.3739)

9.685 — 9.696
(0.3813 — 0.3817)

9.475 — 9.496
(0.3730 — 0.3739)

9.685 — 9.696
(0.3813 — 0.3817)

Interference fit of valve guide

0.026 — 0.059
(0.0010 — 0.0023)

0.027 — 0.049
(0.0011 — 0.0019)

0.026 — 0.059
(0.0010 — 0.0023)

0.027 — 0.049
(0.0011 — 0.0019)

Stem to guide clearance
Valve deflection limit (Dial gauge reading)

0.020 — 0.053 (0.0008 — 0.0021)

0.040 — 0.073 (0.0016 — 0.0029)

0.2 (0.0079)

0.2 (0.0079)

EM-96

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR]
Valve Seat
Unit: mm (in)

A

EM

C

D

E

F

G

MBIB1127E

MBIB1128E

Dia.

CR14DE

A

25.4 (1.00)

B

27.0 — 27.2 (1.062 — 1.070)

C

28.7 — 28.9 (1.129 — 1.137)

D

29.000 — 29.016 (1.1417 — 1.1424)

E

22.0 — 22.2 (0.866 — 0.874)

F

23.7 — 23.9 (0.933 — 0.940)

G

24.000 — 24.016 (0.9449 — 0.9455)

H

I

J

K

Valve Spring
Free height
Pressure load

mm (in)
N (kg, lb) at height mm (in)

Standard

Out-of-square
mm (in)

L

53.3 (2.098)

Installation

149 — 165 N (15.2 — 16.8, 33.5 — 37.1) at 32.82 (1.2921)

Valve open

228 — 250 N (23.3 — 25.5, 51.3 — 56.2) at 24.73 (0.9736)

Limit

Less than 1.6 (0.063)

Valve Lifter
Unit: mm (in)
Standard
Valve lifter outer diameter

29.960 — 29.975 (1.1795 — 1.1801)

Valve lifter hole inner diameter

30.000 — 30.021 (1.1811 — 1.1819)

Clearance between valve lifter and valve lifter hole

0.025 — 0.061 (0.0010 — 0.0024)

Available Valve Lifter
Thickness mm (in)

Identification Mark

3.000 (0.1181)

00

3.020 (0.1189)

02

3.040 (0.1197)

04

EM-97

M

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR]
Thickness mm (in)

Identification Mark

3.060 (0.1205)

06

3.080 (0.1213)

08

3.100 (0.1220)

10

3.120 (0.1228)

12

3.140 (0.1236)

14

3.160 (0.1244)

16

3.180 (0.1252)

18

3.200 (0.1260)

20

3.220 (0.1268)

22

3.240 (0.1276)

24

3.260 (0.1283)

26

3.280 (0.1291)

28

3.300 (0.1299)

30

3.320 (0.1307)

32

3.340 (0.1315)

34

3.360 (0.1323)

36

3.380 (0.1323)

38

3.400 (0.1339)

40

3.420 (0.1346)

42

3.440 (0.1354)

44

3.460 (0.1362)

46

3.480 (0.1370)

48

3.500 (0.1378)

50

3.520 (0.1386)

52

3.540 (0.1394)

54

3.560 (0.1402)

56

3.580 (0.1409)

58

3.600 (0.1417)

60

3.620 (0.1425)

62

3.640 (0.1433)

64

3.660 (0.1441)

66

3.680 (0.1449)

68

PBIC1077E

EM-98

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR]
CAMSHAFT AND CAMSHAFT BEARING
Unit: mm (in)

A

Standard
Camshaft runout [TIR*]

0.04 (0.0016)

EM

C

D

E
SEM671

CR14DE

F

Standard
Intake

40.359 — 40.549
(1.5889 — 1.5964)

Exhaust

39.743 — 39.933
(1.5647 — 1.5722)

Cam height “A”

G

No. 1 journal

27.935 — 27.955 (1.0998 — 1.1006)

No. 2 to No. 5 journals

23.450 — 23.470 (0.9232 — 0.9240)

Outer diameter of camshaft journal

No. 1 journal

28.000 — 28.021 (1.1024 — 1.1032)

No. 2 to No. 5 journals

23.500 — 23.525 (0.9252 — 0.9262)

No. 1 journal

0.045 — 0.086 (0.0018 — 0.0034)

No. 2 to No. 5 journals

0.030 — 0.071 (0.0012 — 0.0028)

Inner diameter of camshaft bracket

Camshaft journal clearance
Camshaft end play

0.070 — 0.143 (0.0028 — 0.0056)

H

I

J

*: Total indicator reading

K

CYLINDER BLOCK
Unit: mm (in)

L

M

PBIC0613E

CR14DE

Limit

Standard
Surface flatness
Height “H” (nominal)

Cylinder bore inner diameter

—

0.1 (0.004)

189 (8.4232 — 8.4271)

—

Grade No. 1

73.000 — 73.010 (2.8740 — 2.8744)

Grade No. 2

73.010 — 73.020 (2.8744 — 2.8748)

Grade No. 3

73.020 — 73.030 (2.8748 — 2.8752)

Out-of-round (Difference between X and Y)

—

EM-99

0.2 (0.008)*

0.015 (0.0006)

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR]
Taper (Difference between A and C)

—

0.01 (0.0004)

0.05 (0.0020)

0.2 (0.008)

Grade 0

49.000 — 49.004 (1.9291 — 1.9293)

—

Grade 1

49.004 — 49.008 (1.9293 — 1.9294)

—

Grade 2

49.008 — 49.012 (1.9294 — 1.9296)

—

Grade 3

49.012 — 49.016 (1.9296 — 1.9298)

—

Difference in inner diameter between cylinders

Main bearing housing inner diameter

*: Cylinder bore wear

PISTON, PISTON RING AND PISTON PIN
Available Piston
Unit: mm (in)

PBIC0188E

CR14DE
Standard

Piston skirt diameter “A”

Grade No. 1

72.980 — 72.990 (2.8732 — 2.8736)

Grade No. 2

72.990 — 73.000 (2.8736 — 2.8740)

Grade No. 3

73.000 — 73.010 (2.8740 — 2.8744)

0.2 (0.002) oversize (service)

73.180 — 73.210 (2.8811 — 2.8823)

“H” dimension

32.3 (1.272)

Piston pin hole inner diameter

18.008 — 18.012 (0.7090 — 0.7091)

Piston to cylinder bore clearance

0.010 — 0.030 (0.0004 — 0.0012)

Piston Ring
Unit: mm (in)

Side clearance

End gap

Standard

Limit

Top

0.040 — 0.080 (0.0016 — 0.0031)

0.110 (0.0043)

2nd

0.025 — 0.070 (0.0010 — 0.0028)

0.1 (0.0039)

Oil ring

0.030 — 0.140 (0.0021 — 0.0055)

—

Top

0.18 — 0.33 (0.0071 — 0.0130)

0.57 (0.0224)

2nd

0.50 — 0.65 (0.0197 — 0.0256)

0.85 (0.0335)

Oil (rail ring)

0.20 — 0.70 (0.0079 — 0.0276)

0.96 (0.0378)

Piston Pin
Unit: mm (in)
Piston pin outer diameter

Standard

17.996 — 18.000 (0.7085 — 0.7087)

Piston pin to piston clearance

Standard

0.008 — 0.016 (0.0003 — 0.0006)

Piston pin to connecting rod bushing clearance

Standard

–0.018 — –0.038 (–0.0007 — –0.0015)

EM-100

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR]
CONNECTING ROD
Unit: mm (in)

A

CR14DE
Center distance

129.45 — 129.55 (5.096 — 5.100)

EM

Bend [per 100 (3.94)]

Limit

0.15 (0.0059)

Torsion [per 100 (3.94)]

Limit

0.30 (0.0118)

Connecting rod bushing inner diameter*
(small end)

Standard

17.962 -17.978 (0.7072 — 0.7078)

Connecting rod big end inner diameter

Standard

43.000 — 43.013 (1.6929 — 1.6934)

Standard

0.050 — 0.420 (0.0020 — 0.0165)

Side clearance

Limit

C

D

0.5 (0.0197)

*: After installing in connecting rod

E

CRANKSHAFT
Unit: mm (in)
Grade No. 0

44.966 — 44.970 (1.7703 — 1.7705)

Grade No. 1

44.962 — 44.966 (1.7702 — 1.7703)

Grade No. 2

44.958 — 44.962 (1.7700 — 1.7702)

Grade No. 3

44.954 — 44.958 (1.7698 — 1.7700)

Pin dia. “Dp”

Standard

39.961 — 39.974 (1.5733 — 1.5738)

Out-of-round (X − Y)

Limit

0.005 (0.0002)

Taper (A − B)

Limit

0.005 (0.0002)

Runout [TIR*]

Limit

Main journal dia. “Dm”

G

H

0.05 (0.0020)

Standard
Side clearance

F

I

0.060 — 0.260 (0.0024 — 0.0102)

Limit

0.3 (0.012)

J

K

L

SEM645

M

SEM715

*: Total indicator reading

MAIN BEARING
Standard size
Unit: mm (in)
Grade No.

Thickness

Identification color

STD1

2.002 — 2.006 (0.0788 — 0.0790)

Red

STD2

2.004 — 2.008 (0.0789 — 0.0791)

Green

STD3

2.006 — 2.010 (0.0790 — 0.0791)

Yellow

STD4

2.008 — 2.012 (0.0791 — 0.0792)

Blue

STD5

2.010 — 2.014 (0.0791 — 0.0793)

Pink

STD6

2.012 — 2.016 (0.0792 — 0.0794)

White

STD7

2.014 — 2.018 (0.0793 — 0.0794)

Blue/yellow

EM-101

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR]
Undersize
Unit: mm (in)
Grade

Thickness

US 0.25 (0.0098)

2.123 — 2.131 (0.836 — 0.839)

Bearing Clearance
Unit: mm (in)
Standard

Main bearing clearance

0.018 — 0.034 (0.0007 — 0.0013)

Limit

0.05 (0.002)

CONNECTING ROD BEARING
Standard Size
Unit: mm (in)
Grade

Thickness

Standard

1.504 — 1.508 (0.0529 — 0.0594)

Grade

Thickness

US 0.25 (0.0098)

1.627 — 1.635 (0.0641 — 0.0644)

Undersize
Unit: mm (in)

Bearing Clearance
Unit: mm (in)
Standard
Connecting rod bearing clearance

0.010 — 0.044 (0.0004 — 0.0017)

Limit

0.064 (0.0025)

MISCELLANEOUS COMPONENTS
Unit: mm (in)
Flywheel runout [TIR*]
Camshaft sprocket runout [TIR*]

Limit

Limit

0.15 (0.0059)

Intake

0.20 (0.0079)

Exhaust

0.15 (0.0059)

*: Total indicator reading

EM-102

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR]

Tightening Torque

BBS002NU

A

*1: Parts to be tightened in particular orders
1)-: Order of tightening when tightening two or more steps separately.
Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)*2
24.5 — 31.4 (2.5 — 3.2, 18 — 23)

Idler pulley locknut (for water pump belt)

*1

*1

*1

Idler pulley locknut (for alternator and A/C compressor belt)

24.5 — 31.4 (2.5 — 3.2, 18 — 23)

Idler pulley bracket (for alternator and A/C compressor belt)

16.6 — 23.5 (1.7 — 2.4, 13 — 17)

Manifold absolute pressure sensor

1.2 — 1.7 (0.12 — 0.17, 11 — 15)*2

Air cleaner case (upper) to (lower)

1)
2)

*1

*1

*1

C

1.9 — 2.2 (0.20 — 0.22, 17 — 19)*2
5.4 — 7.3 (0.55 — 0.74, 48 — 64)*2

Electronic throttle control actuator

7.2 — 9.6 (0.73 — 0.99, 64 — 86)*2

EVAP canister purge volume control solenoid valve

4.3 — 5.8 (0.44 — 0.59, 38 — 51)*2

Intake manifold

6.9 — 9.4 (0.71 — 0.96, 61 — 84)*2
M6 × 15 mm (0.59 in)

6.9 — 9.5 (0.71 — 0.96, 61 — 84)*2

M6 × 12 mm (0.47 in)

8.4 — 10.8 (0.86 — 1.1, 75 — 95)*2

Fuel injector and fuel tube assembly

1)
2)

Exhaust manifold

25.5 — 29.4 (2.6 — 2.9, 19 — 21)

Exhaust manifold cover

6.3 — 8.3 (0.65 — 0.84, 56 — 73)*2

Heated oxygen sensor 1

40 — 50 (4.1 — 5.1, 30 — 36)

Heated oxygen sensor harness bracket

6.9 — 9.5 (0.71 — 0.96, 61 — 84)*2

Three way catalyst (under exhaust manifold)

29.4 — 34.3 (3.0 — 3.4, 22 — 25)

Three way catalyst support

33.3 — 46.1 (3.4 — 4.7, 25 — 34)

Three way catalyst cover

6.3 — 8.3 (0.65 — 0.84, 56 — 73)*2

Ignition coil

3.8 — 4.4 (0.39 — 0.44, 34 — 38)*

Spark plug

19.6 — 29.4 (2.0 — 2.9, 15 — 21)

G

M6 × 20 mm (0.79 in)

6.9 — 10.8 (0.71 — 1.1, 61 — 95)*2

Intake valve timing control solenoid valve

6.3 — 8.3 (0.65 — 0.84, 56 — 73)*2

Harness bracket

6.3 — 8.3 (0.65 — 0.84, 56 — 73)*2

*1

Oil pan (upper)

6.9 — 9.5 (0.71 — 0.96, 61 — 84)*2

*1

Oil pan (lower)

6.9 — 9.5 (0.71 — 0.96, 61 — 84)*2

Oil pan drain plug

29.4 — 39.2 (3.0 — 3.9, 22 — 28)

Connecting bolt between oil pan (upper) and transaxle

16.6 — 23.5 (1.7 — 2.3, 13 — 17)

Oil strainer

6.3 — 8.3 (0.65 — 0.84, 56 — 73)*2

Cylinder head front cover

6.9 — 9.5 (0.71 — 0.96, 61 — 84)*2

Chain tensioner

6.9 — 9.5 (0.71 — 0.96, 61 — 84)*2

Camshaft position sensor (PHASE)

7.1 — 10.8 (0.73 — 1.1, 63 — 95)*2
78.4 — 88.2 (8.0 — 8.9, 58 — 65)

Exhaust

78.4 — 88.2 (8.0 — 8.9, 58 — 65)

K

2

8.8 — 10.8 (0.90 — 1.1, 78 — 95)*2

Intake

I

J

M6 × 45 mm (1.77 in)

EM-103

F

H

1.0 — 1.5 (0.10 — 0.15, 9- 13)*2

Camshaft sprocket

E

11.8 — 13.8 (1.2 — 1.4, 9 — 10)
20.8 — 28.2 (2.1 — 2.9, 16 — 20)

Clamp for fuel feed hose

Rocker cover

D

3.8 — 4.4 (0.40 — 0.44, 35 — 38)*2

Air cleaner case assembly

Support bracket

EM

L

M

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR]
*1

*1

*1

*1

Camshaft bracket

1)

2.0 (0.2, 18)*2

2)

5.9 (0.6, 52)*2

3)

9.0 — 11.8 (0.92 — 1.2, 80 — 104)*2

Chain tension guide

16.6 — 23.5 (1.7 — 2.3, 13 — 17)

Chain slack guide

12.7 — 18.6 (1.3 — 1.8, 10 — 13)

Crankshaft pulley

132.4 — 152.0 (14 — 15, 98 — 112)

Front cover

6.3 — 8.3 (0.65 — 0.84, 56 — 73)*2

Cylinder head bolt

1)

61.7 — 71.7 (6.3 — 7.3, 46 — 52)

2)

0 (0.0, 0)

3)

22.5 — 32.5 (2.3 — 3.3, 17 — 23)

4)

90° — 95° (Angle tightening)

Cylinder head auxiliary bolt

9.0 — 11.8 (0.92 — 1.2, 80 — 104)*2

Engine slinger

16.6 — 23.5 (1.7 — 2.3, 13 — 17)

LH engine mount insulator

95 — 115 (9.7 — 11, 70 — 84)

LH engine mount bracket (vehicle side)

43 — 54 (4.4 — 5.5, 32 — 39)

LH engine mount bracket (transaxle side)

60 — 70 (6.2 — 7.1, 45 — 51)

RH engine mount stay

40 — 50 (4.1 — 5.1, 30 — 36)

RH engine mount insulator RH

60 — 70 (6.2 — 7.1, 45 — 51)

RH engine mount bracket (upper)

40 — 50 (4.1 — 5.1, 30 — 36)

RH engine mount bracket (lower)

40 — 50 (4.1 — 5.1, 30 — 36)

Rear engine mount bracket

75 — 85 (7.7 — 8.7, 56 — 62)

Rear torque rod

75 — 85 (7.7 — 8.7, 56 — 62)

Connecting nut between LH engine mount insulator and LH engine mount bracket
(transaxle side)

60 — 70 (6.2 — 7.1, 45 — 51)

Connecting bolt between RH engine mount insulator and RH engine mount bracket
(upper)

90 — 100 (9.2 — 10, 67 — 73)

Main bearing cap

Connecting rod cap

1)

24.5 — 30.3 (2.5 — 3.0, 18 — 22)

2)

95° — 100° (Angle tightening)

1)

13.7 — 15.7 (1.4 — 1.6, 10.1 — 11.5)

2)

45° — 50° (Angle tightening)

Rear oil seal retainer

6.9 — 9.5 (0.71 — 0.96, 61 — 84)*2

Flywheel

83.4 — 93.2 (8.5 — 9.5, 62 — 68)

Knock sensor

15.7 — 20.6 (1.6 — 2.1, 12 — 15)

Crankshaft position sensor (POS) [Note: transaxle side mounting parts]

7.1 — 10.8 (0.73 — 1.1, 63 — 95)*2

EM-104

PRECAUTIONS
[HR]

PRECAUTIONS
Precautions for Procedures without Cowl Top Cover
[HR]

PFP:00001

A
BBS002NV

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

EM

C

D
PIIB3706J

Precautions for Draining Engine Coolant

E
BBS002NW

Drain engine coolant when engine is cooled.

Precautions for Disconnecting Fuel Piping
●
●
●

Before starting work, make sure no fire or spark producing items are in the work area.
Release fuel pressure before disassembly.
After disconnecting pipes, plug openings to stop fuel leakage.

Precautions for Removal and Disassembly
●

●
●
●
●

BBS002NX

G
BBS002NY

When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
Exercise maximum care to avoid damage to mating or sliding surfaces.
Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.

Precautions for Inspection, Repair and Replacement

●
●

●
●

●

●
●

●

●
–

BBS002O0

Use torque wrench to tighten bolts or nuts to specification.
When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified.
Replace with new gasket, packing, oil seal or O-ring.
Thoroughly wash, clean, and air-blow each part. Carefully check the engine oil and engine coolant passages for any restriction and blockage.
Avoid damaging the sliding or mating surfaces. Completely remove foreign materials such as cloth lint or
dust. Before assembly, oil sliding surfaces well.
Release air within route when refilling after draining coolant.
Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine
stopped). Then make sure there are no leaks at fuel line connections.
After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gas for leakage.

Parts Requiring Angle Tightening

BBS002O1

Use angle wrench (SST: KV10112100) for the final tightening of the following engine parts.
Cylinder head bolts

EM-105

H

I

J

BBS002NZ

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.

Precautions for Assembly and Installation

F

K

L

M

PRECAUTIONS
[HR]
–
–
–

●
●
●

Main bearing cap bolts
Connecting rod cap bolts
Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening)
Do not use a torque value for final tightening.
The torque value for these parts are for a preliminary step.
Ensure thread and seat surfaces are clean and coated with engine oil.

Precautions For Liquid Gasket

BBS002O2

REMOVAL OF LIQUID GASKET
●

●

●

After removing the mounting bolts and nuts, separate the mating
surface using seal cutter (SST) and remove the old liquid gasket
sealing.
CAUTION:
Be careful not to damage the mating surfaces.
Tap seal cutter to insert it (1), and then slide it (2) by tapping on
the side as shown in the figure.
In areas where seal cutter is difficult to use, use plastic hammer
to lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason tool such as screwdriver is
used, be careful not to damage the mating surfaces.

PBIC0275E

LIQUID GASKET APPLICATION PROCEDURE
1.

2.

Using a scraper, remove the old liquid gasket adhering to the liquid gasket application surface and the mating surface.
● Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.

PBIC0003E

3.
4.

Attach liquid gasket tube to the tube presser (SST).
Use Genuine Liquid Gasket or equivalent.
Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
● If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove.

PBIC2160E

EM-106

PRECAUTIONS
[HR]
As for the bolt holes, normally apply the liquid gasket inside
the holes. Occasionally, it should be applied outside the
holes. Make sure to read the text of service manual.
● Within 5 minutes of liquid gasket application, install the mating
component.
● If the liquid gasket protrudes, wipe it off immediately.
● Do not retighten mounting bolts or nut after the installation.
● Wait 30 minutes or more after installation before refilling
engine oil and engine coolant.
CAUTION:
If there are specific instructions in this manual, observe
them.
●

A

EM

C
SEM159F

D

E

F

G

H

I

J

K

L

M

EM-107

PREPARATION
[HR]

PREPARATION
Special Service Tools

PFP:00002
BBS002O3

Tool number
Tool name

Description

KV10111100
Seal cutter

Removing oil pan (lower and upper) etc.

S-NT046

KV10116200
Valve spring compressor
1. KV10115900
Attachment
2. KV10109220
Adapter

Disassembling and assembling valve
mechanism
Part (1) is a component of KV10116200, but
Part (2) is not so.

PBIC1650E

KV10112100
Angle wrench

Tightening bolts for bearing cap, cylinder
head, etc. in angle

S-NT014

KV10117100
Heated oxygen sensor wrench

Loosening or tightening heated oxygen
sensor 1
For 22 mm (0.87 in) width hexagon nut

NT379

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

Removing valve oil seal

S-NT605

KV10115600
Valve oil seal drift

Installing valve oil seal
Use side A.
a: 20 (0.79) dia.
d: 8 (0.31) dia.
b: 13 (0.51) dia.
e: 10.7 (0.421)
c: 10.3 (0.406) dia.
f: 5 (0.20)
Unit: mm (in)
S-NT603

EM03470000
Piston ring compressor

Installing piston assembly into cylinder bore

S-NT044

EM-108

PREPARATION
[HR]
Tool number
Tool name

Description

WS39930000
Tube presser

A

Pressing the tube of liquid gasket

EM

C
S-NT052

KV11103000
Pulley puller

Removing crankshaft pulley

D

E
NT676

Quick connector release

Removing fuel tube quick connectors in
engine room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210)

F

G

PBIC0198E

1. Press stand: ST13030020
2. Center shaft: KV10114120
3. Drift: KV10109730
4. Spring: ST13030030
5. Center cap: KV10110310

Installing and removing piston pin

H

I

J

PBIC3873E

KV11105210
Stopper plate

Fixing flywheel

K

L
ZZA0009D

ST16610001
Pilot bushing puller

Removing pilot converter (A/T models)

M

S-NT045

EM-109

PREPARATION
[HR]

Commercial Service Tools

BBS002O4

Tool name

Description

Spark plug wrench

Removing and installing spark plug

PBIC3874E

Valve seat cutter set

Finishing valve seat dimensions

S-NT048

Piston ring expander

Removing and installing piston ring

S-NT030

Valve guide drift

Removing and installing valve guide

PBIC4012E

Valve guide reamer

1: Reaming valve guide inner hole
2: Reaming hole for oversize valve guide

PBIC4013E

Oxygen sensor thread cleaner

Reconditioning the exhaust system threads
before installing a new heated oxygen sensor
(Use with anti-seize lubricant shown below.)
a = 18 mm (0.71 in) dia. for zirconia heated
oxygen sensor
b = 12 mm (0.47 in) dia. for titania heated
oxygen sensor
AEM488

EM-110

PREPARATION
[HR]
Tool name

Description

Anti-seize lubricant (Permatex 133AR
or equivalent meeting MIL
specification MIL-A-907)

Lubricating oxygen sensor thread cleaning
tool when reconditioning exhaust system
threads

A

EM

C

AEM489

Manual lift table caddy

Removing and installing engine

D

E
ZZA1210D

F

G

H

I

J

K

L

M

EM-111

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
[HR]

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

PFP:00003
BBS002O5

PBIC3870E

EM-112

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
[HR]

Use the Chart Below to Help You Find the Cause of the Symptom.

BBS002O6

A

1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.

EM

C

Operating condition of engine
Location
of noise
Top of
engine
Rocker
cover
Cylinder
head

Type of
noise

When
idling

When
racing

A

—

A

B

Rattle

C

A

—

A

B

—

Slap or
rap

Knock

Front of
engine

When
starting

C

Knock

Front of
engine
Front
cover

After
warmup

Ticking or
clicking

Slap or
knock

Crankshaft pulley
Cylinder
block
(Side of
engine)
Oil pan

Before
warmup

Tapping or
ticking

A

A

A

A

A

—

B

B

A

—

—

C

—

—

B

B

B

A

B

B

B

B

B

B

While
driving

Source of
noise

Check item

D

—

Tappet
noise

Valve clearance

EM-166

C

Camshaft
bearing
noise

Camshaft journal oil
clearance
Camshaft runout

EM-158
EM-158

—

Piston pin
noise

Piston to piston pin oil
clearance
Connecting rod bushing oil clearance

EM-206
EM-208

A

Piston
slap noise

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

EM-210
EM-207
EM-207
EM-208

B

Connecting rod
bearing
noise

Connecting rod bushing oil clearance
Connecting rod bearing oil clearance

EM-208
EM-211

C

Main
bearing
noise

Main bearing oil clearance
Crankshaft runout

EM-212
EM-211

B

Timing
chain and
chain
tensioner
noise

Timing chain cracks
and wear
Timing chain tensioner
operation

EM-142

C

Drive belt
(Sticking
or slipping)

Drive belt deflection

Squeaking or fizzing

A

Creaking

A

B

A

B

A

B

Drive belt
(Slipping)

Idler pulley bearing
operation

Squall
Creak

A

B

—

B

A

B

Water
pump
noise

Water pump operation

A: Closely related

B: Related

B

—

C: Sometimes related

B

—

—: Not related

EM-113

Reference page

E

F

G

H

I

J

K

L

M
EM-114

CO-36

DRIVE BELTS
[HR]

DRIVE BELTS
Checking Drive Belts
●

●

●

●

PFP:02117
BBS002O7

Inspection should be done only when engine is cold or over 30
minutes after the engine is stopped.
1.

: Alternator

2.

: Water pump

3.

: Crankshaft pulley

4.

: A/C compressor (with A/C models)
: Idler pulley (without A/C models)

5.

: Idler pulley

6.

: Drive belt
PBIC3642E

Visually check belts for wear, damage, and cracks on inside and
edges.
Turn crankshaft pulley two time clockwise, and make sure tension on all pulleys is equal before doing the
test.
When measuring deflection, apply 98 N (10 kg, 22 lb) at the ( ) marked point.

Measure the belt tension and frequency with acoustic tension gauge (commercial service tool) at the ( )
marked point.
CAUTION:
●
When the tension and frequency are measured, the acoustic tension gauge should be used.
●
When checking immediately after installation, first adjust it to the specified value. Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection
between pulleys.
●

Belt Deflection
Deflection adjustment *
Location

Drive belt

Unit: mm (in)

Used belt

New belt

Limit

After adjusted

With A/C models

7.9 (0.31)

4.8 — 5.3 (0.19 — 0.21)

4.2 — 4.5 (0.17 — 0.18)

Without A/C models

7.1 (0.28)

4.3 — 4.7 (0.17 — 0.19)

3.6 — 3.9 (0.14 — 0.15)

Applied pushing force

98 N (10 kg, 22lb)

*: When engine is cold.

Tension Adjustment

BBS002O8

Location

Location of adjuster and tightening method

Drive belt

Adjusting bolt on idler pulley

CAUTION:
●
When belt is replaced with new one, adjust belt tension to the value for “New belt”, because new
belt will not fully seat in the pulley groove.
●
When tension of the belt being used exceeds “Limit”, adjust it to the value for “After adjusted”.
●
When installing a belt, make sure it is correctly engaged with the pulley groove.
●
Do not allow oil or engine coolant to get on the belt.
●
Do not twist or bend the belt strongly.
1. Remove front fender protector (RH). Refer to EI-14, «FENDER PROTECTOR» .

EM-114

DRIVE BELTS
[HR]
2.

3.

4.

Loosen the idler pulley lock nut (A) from the tightening position
with the specified torque by 45 degrees.
1

: Alternator

2

: Water pump

3

: Crankshaft pulley

4

: A/C compressor (with A/C models)
: Idler pulley (without A/C models)

5

: Idler pulley

6

: Drive belt

A

EM

C

PBIC3643E
CAUTION:
● When the lock nut is loosened excessively, the idler pulley tilts and the correct tension adjustment cannot be performed. Do not loosen it excessively
(more than 45 degrees).
● Put a matching mark on the lock nut (A), and check turning angle with a protractor. Do not visually check the tightening angle.
Adjust the belt tension by turning the adjusting bolt (B). Refer to EM-114, «Checking Drive Belts» .
CAUTION:
● When checking immediately after installation, first adjust it to the specified value. Then, after
turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in
deflection between pulleys.
● When the tension adjustment is performed, the lock nut should be in the condition at step“ 2”. If
the tension adjustment is performed when the lock nut is loosened more than the standard, the
idler pulley tilts and the correct tension adjustment cannot be performed.
Tighten the lock nut (A).

D

E

F

G

H

: 34.8 N·m (3.5 kg-m, 26 ft-lb)
I

Removal and Installation

BBS002O9

REMOVAL
1.
2.

J

Remove front fender protector (RH). Refer to EI-14, «FENDER PROTECTOR» .
Loosen the lock nut (A), and then adjust the belt tension by turning the adjusting bolt (B).
1

: Alternator

2

: Water pump

3

: Crankshaft pulley

4

: A/C compressor (with A/C models)
: Idler pulley (without A/C models)

5

: Idler pulley

6

: Drive belt

K

L

M
PBIC3643E

3.

Remove drive belt.

INSTALLATION
1.

Pull the idler pulley in the loosening direction, and then temporarily tighten the lock nut (A) to the following torque.
1

: Alternator

2

: Water pump

3

: Crankshaft pulley

4

: A/C compressor (with A/C models)
: Idler pulley (without A/C models)

5

: Idler pulley

6

: Drive belt
PBIC3643E

: 4.4 N·m (0.45 kg-m, 39 in-lb)

EM-115

DRIVE BELTS
[HR]

2.

3.

4.

NOTE:
Do not move the lock nut from the tightened position. Go to step “2”.
Install the drive belt to each pulley.
CAUTION:
● Make sure that there is no oil, grease, or coolant, etc. in pulley grooves.
● Make sure that the belt is securely inside the groove on each pulley.
Adjust drive belt tension by turning the adjusting bolt (B). Refer to EM-114, «Tension Adjustment» .
CAUTION:
● Perform the belt tension adjustment with the lock nut temporarily tightened at the step “1” so as
not to tilt the idler pulley.
● When checking immediately after installation, first adjust it to the specified value. Then, after
turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in
deflection between pulleys.
Tighten the lock nut (A).
: 34.8 N·m (3.5 kg-m, 26 ft-lb)

5.

Make sure that belt tension of each belt within the standard.

Removal and Installation of Drive Belt Idler Pulley

BBS002OA

REMOVAL
1.
2.

Remove drive belts. Refer to EM-115, «Removal and Installation» .
Remove the lock nut, and then remove the plate (7), idler pulley
(6), and washer (5).
1

3.

: Alternator bracket

Remove the center shaft (2) together with the spacer (3) with
inserting the adjusting bolt (4).

PBIC3644E

EM-116

DRIVE BELTS
[HR]
INSTALLATION
1.

2.

A

Insert the center shaft (1) into the slide groove of the spacer (2).
Fully screw in the adjusting bolt (3) in the belt loosening direction ( ).
● At that time, place the flange (a) of the adjusting bolt and the
seat (b) of the center shaft on the spacer.
Place each surface (c, d) of the spacer on the alternator bracket.
Install the washer, idler pulley, and plate, and then temporarily
tighten the lock nut.

EM

C

: 4.4 N·m (0.45 kg-m, 39 in-lb)
D

E

F

G
PBIC3885E

3.

Install removed parts in the reverse order of removal.

H

I

J

K

L

M

EM-117

AIR CLEANER AND AIR DUCT
[HR]

AIR CLEANER AND AIR DUCT
Components

PFP:16500
BBS002OB

MBIB1370E

1.

Air cleaner filter

2.

Mass air flow sensor

3.

O-ring

4.

Holder

5.

Air cleaner cover

6.

Air duct

7.

PCV hose

8.

Clip

9.

Air duct (Inlet)

10. Grommet

11. Air duct

12. Grommet

13. Air cleaner case
A.

To electric throttle control actuator

B.

To rocker cover

Refer to GI-11, «Components» for symbol marks in the figure.

Removal and Installation

BBS002OC

REMOVAL
1.
2.
3.
4.
5.
6.
a.
b.
c.
7.

Remove the air duct (inlet).
Remove the air cleaner filter from the air cleaner case. Refer to EM-119, «Changing Air Cleaner Filter» .
Remove the air duct [between air duct (inlet) and air cleaner case] from the air cleaner case.
Remove the PCV hose.
Remove the air duct (between air cleaner case and electric throttle control actuator).
● Add marks as necessary for easier installation.
Remove air cleaner case with the following procedure.
Remove battery. Refer to SC-5, «BATTERY» .
Disconnect harness connector from mass air flow sensor.
Remove the air cleaner case.
Remove the mass air flow sensor from the air cleaner case, if necessary.
CAUTION:
● Handle it carefully and avoid impacts.
● Do not touch sensor part.

EM-118

AIR CLEANER AND AIR DUCT
[HR]
INSTALLATION
A

Note the following, and install in the reverse order of removal.
●
Align marks. Attach each joint. Screw clamps firmly.

Changing Air Cleaner Filter

BBS002OD

REMOVAL
1.
2.

Push the tabs (A) of both ends of the air cleaner cover (1) into
the inside (B).
Pull up the air cleaner cover forward (C) and remove it.

EM

C

D

E
PBIC3557J

3.
4.

F

Remove the air cleaner filter (1) and holder (2) assembly from
the air cleaner case.
Remove the air cleaner filter from the holder.

G

H

I
PBIC3558J

INSPECTION AFTER REMOVAL
It is necessary to clean air cleaner filter or replace it at the recommended intervals, more often under dusty
driving conditions. Refer to MA-8, «PERIODIC MAINTENANCE» .
●
Blow air into the back side of air cleaner filter until no any object
sprays out.

J

K

L

M
SMA384C

INSTALLATION
Note the following, and install in the reverse order of removal.
●
Install the air cleaner cover (1) in the direction shown in the figure.
2

: Air cleaner filter

3

: Holder

PBIC3559J

EM-119

INTAKE MANIFOLD
[HR]

INTAKE MANIFOLD
Components

PFP:14003
BBS002OE

PBIC3649E

1.

EVAP hose

2.

Vacuum tank

3.

EVAP hose

4.

O-ring

5.

EVAP canister purge volume control
solenoid valve

6.

Electric throttle control actuator

7.

Water hose

8.

Water hose

9.

Gasket

10. Intake manifold support (Rear)

11. Intake manifold

12. Intake manifold support (Front)

13. Intake manifold support (Center)

14. Cylinder head

15. Vacuum hose

B.

C.

16. Gasket
A.

To centralized under-floor piping

To brake booster

Refer to GI-11, «Components» for symbol marks in the figure.

EM-120

To water outlet

INTAKE MANIFOLD
[HR]

Removal and Installation

BBS002OF

A

REMOVAL
1.

Remove engine cover (1).
2

: Intake manifold

3

: Grommet

EM

C

D

E

F

G

MBIB1371E

2.
3.
4.

5.

6.

7.

8.

Remove the air duct (inlet) and the air duct (between air cleaner case and electric throttle control actuator). Refer to EM-118, «AIR CLEANER AND AIR DUCT» .
Move the reservoir tank. Refer to CO-31, «RADIATOR» .
Disconnect water hoses from electric throttle control actuator, attach blind plug to prevent engine coolant
leakage.
CAUTION:
● Perform this step when the engine is cold.
● Do not spill engine coolant on drive belts.
Pull out oil level gauge.
CAUTION:
Cover the oil level gauge guide openings to avoid entry of foreign materials.
Remove electric throttle control actuator.
CAUTION:
● Handle it carefully and avoid impacts.
● Do not disassemble or adjust.
Disconnect the harness connector and EVAP hose from the EVAP canister purge volume control solenoid
valve.
CAUTION:
Handle it carefully and avoid impacts.
Disconnect vacuum hose for brake booster from intake manifold.

EM-121

H

I

J

K

L

M

INTAKE MANIFOLD
[HR]
9.

Remove intake manifold support front (1) and rear (2).

PBIC3650E

10. Remove intake manifold.
● Loosen bolts in the reverse of the order shown in the figure.
: Engine front

PBIC3652E

11. Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary.
CAUTION:
Handle it carefully and avoid impacts.
12. Remove intake manifold support (center) from cylinder head if necessary.
NOTE:
The intake manifold support (center) functions as the guide when the intake manifold is installed.

INSTALLATION
Note the following, and install in the reverse order of removal.

Intake Manifold
1.

Install the gasket to the intake manifold.
● Align the protrusion (A) of gasket to the groove of intake manifold.

PBIC3651E

2.

Place the intake manifold into the installation position.
CAUTION:
Make sure that the oil level gauge guide is not disconnected from the fixing clip of water inlet due
to interference with intake manifold.

EM-122

INTAKE MANIFOLD
[HR]
3.

Tighten bolts in the numerical order shown in the figure.
A

: Engine front

EM

C
PBIC3652E

D

4.

Install intake manifold support (front and rear).

Electric Throttle Control Actuator
●
●

●

Tighten bolts of electric throttle control actuator equally and diagonally in several steps.
Perform “Throttle Valve Closed Position Learning” after repair when removing harness connector of the
electric throttle control actuator. Refer to EC-857, «Throttle Valve Closed Position Learning» (with EUROOBD) or EC-1279, «Throttle Valve Closed Position Learning» (without EURO-OBD).
Perform “Throttle Valve Closed Position Learning” and “Idle Air Volume Learning” after repair when
replacing electric throttle control actuator. Refer to EC-858, «Idle Air Volume Learning» (with EURO-OBD)
or EC-1279, «Idle Air Volume Learning» (without EURO-OBD).

E

F

G

H

I

J

K

L

M

EM-123

EXHAUST MANIFOLD
[HR]

EXHAUST MANIFOLD
Components

PFP:14004
BBS002OG

MBIB9023E

1.

Exhaust manifold cover

2.

Exhaust manifold cover

3.

Harness bracket

4.

Heated oxygen sensor 1

5.

Exhaust manifold stay

6.

Exhaust manifold

7.

Gasket

8.

Stud bolt

9.

Heat insulator

10.

Seal bearing
Engine front

Refer to GI-11, «Components» for symbol marks in the figure.

EM-124

EXHAUST MANIFOLD
[HR]

Removal and Installation

BBS002OH

A

REMOVAL
1.
2.
3.
4.

Remove exhaust front tube. Refer to EX-3, «EXHAUST SYSTEM» .
Remove the harness bracket of heated oxygen sensor 1 from the cylinder head.
Remove exhaust manifold cover.
Remove the heated oxygen sensor 1.
● Using heated oxygen sensor wrench (SST: KV10117100) (A),
remove heated oxygen sensor 1.
CAUTION:
Handle it carefully and avoid impacts.
NOTE:
The exhaust manifold can be removed and installed without
removing the heated oxygen sensor 1 (Disassembly of harness
connector is necessary)

EM

C

D

E

PBIC3654E

5.
6.

Remove exhaust manifold side mounting bolt of exhaust manifold stay.
Remove exhaust manifold mounting bolts from underbody in the
reverse order shown, and remove exhaust manifold.

F

G

H

I

MBIB9021E

●

J

Loosen nuts in the reverse of the order shown in the figure.
K

: Engine front

L

M
PBIC3774E

7.

8.

Remove gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
Remove exhaust manifold cover from back of exhaust manifold.

EM-125

EXHAUST MANIFOLD
[HR]
INSPECTION AFTER REMOVAL
Mounting Surface Distortion
●

Using a straightedge (B) and feeler gauge (A), check distortion
of exhaust manifold mounting surface.
Limit

●

: 0.3 mm (0.012 in)

Replace exhaust manifold if outside the limit.

PBIC3530J

INSTALLATION
Note the following, and install in the reverse order of removal.

Exhaust Manifold
1.

Tighten nuts in numerical order shown in the figure.
: Engine front

2.

Tighten to the specified torque again.

PBIC3774E

EM-126

OIL PAN AND OIL STRAINER
[HR]

OIL PAN AND OIL STRAINER
Components

PFP:11110

A
BBS002OI

EM

C

D

E

F

G

H

I

J

MBIB1372E

1.

Rear oil seal

4.

Chain tensioner

5.

Oil pump drive chain

6.

Crankshaft sprocket

7.

Oil pump sprocket

8.

Oil pan drain plug

9.

Washer

11.

Oil filter stud bolt

12. Oil filter

B.

Refer to LU-19

C.

10. Oil pan (lower)

2.

O-ring

3.

K

Oil pan (upper)

L

13. Oil level sensor
A.

Refer to EM-142

Oil pan side

M

Refer to GI-11, «Components» for symbol marks in the figure.

Removal and Installation

BBS002OJ

NOTE:
The oil strainer and oil pump are included in the oil pan (upper). Individual disassembly is prohibited.

REMOVAL
NOTE:
When removing oil pan (lower) only, steps “2” and “3” are not necessary. Perform step “5” after completing
step “4”.
1. Remove engine undercover.
2. Remove engine and transaxle assembly from the vehicle, and then separate engine and transaxle. Refer
to EM-184, «ENGINE ASSEMBLY» .
3. Install engine assembly to widely use engine stand. Refer to EM-189, «CYLINDER BLOCK» .
4. Drain engine oil. Refer to LU-16, «ENGINE OIL» .
5. Remove the oil pan (lower) with the following procedure.

EM-127

OIL PAN AND OIL STRAINER
[HR]
a.

Loosen bolts in the reverse of the order shown in the figure.
: Engine front

b.

6.
7.
8.
a.

Insert the seal cutter (SST: KV10111100) between oil pan
(upper) and oil pan (lower).
CAUTION:
● Be careful not to damage the mating surface.
● A more adhesive liquid gasket is applied compared to
previous types when shipped, so it should not be forced
off using a flat- bladed screwdriver, etc.

MBIB1433E

Remove front cover and timing chain. Refer to EM-142, «TIMING CHAIN» .
Remove oil pump sprocket and crankshaft sprocket together with oil pump drive chain.
Refer to EM-142, «TIMING CHAIN» .
Remove oil pan (upper) with the following procedure.
Loosen oil pan (upper) mounting bolts in the reverse of the order
shown in the figure.
: Engine front

MBIB1374E

b.

Insert a flat-bladed offset screwdriver into the arrow ( ) in the
figure and open up a crack between the oil pan (upper) cylinder
block.
: Engine front

c.

9.

Insert the seal cutter (SST: KV10111100) between remove the
oil pan (upper) and cylinder block.Slide seal cutter by tapping on
the side of tool with a hammer.
CAUTION:
● Be careful not to damage the mating surface.
MBIB1375E
● A more adhesive liquid gasket is applied compared to
previous types when shipped, so it should not be forced off using a screwdriver, etc. outside the
indicated location.
● Do not remove oil pump and oil strainer from oil pan (upper).
Remove rear oil seal from crankshaft.

INSTALLATION
1.
a.

b.

Install the oil pan (upper) in the following procedure.
Use scraper to remove old liquid gasket from mating surfaces.
● Also remove the old liquid gasket from mating surface of cylinder block.
● Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.
Install O-ring to the cylinder block.

EM-128

OIL PAN AND OIL STRAINER
[HR]
c.

Apply a continuous bead of liquid gasket (C) with the tube
presser (SST: WS39930000) to areas shown in the figure.
Use Genuine Liquid Gasket or equivalent.
A

: 2 mm (0.07 in) protruded to outside

B

: 2 mm (0.07 in) protruded to rear oil seal mounting side

A

EM

: Engine front
: Oil pan out side

C

CAUTION:
Attaching should be done within 5 minutes after coating.
D

E

F

G
MBIB1434E

d.

Tighten bolts in the numerical order shown in the figure.

H

: Engine front

CAUTION:
Install avoiding misalignment of both oil pan gasket and Oring.
● The bolts are different according to the installation position.
Refer to the numbers shown in the figure.
M8 × 180 mm (7.09 in)
M8 × 25 mm (0.98 in)
M8 × 90 mm (3.54 in)
2.

a.
b.
c.

: No. 9, 10
: No. 3, 4, 7, 8
: No. 1, 2, 5, 6

I

J

MBIB1374E

Install rear oil seal with the following procedure:
CAUTION:
● The installation of rear oil seal should be completed within 5 minutes after installing oil pan
(upper).
● Do not touch oil seal lip.
Wipe off any liquid gasket protruding to the rear oil seal mounting part of oil pan (upper) and cylinder block
using a spatula.
Apply the liquid gasket lightly to entire outside area of new rear oil seal.
Use Genuine Liquid Gasket or equivalent.
Press-fit the rear oil seal using a drift with outer diameter 113
mm (4.45 in) and inner diameter 90 mm (3.54 in) (commercial
service tool) (A).

PBIC3660E

EM-129

K

L

M

OIL PAN AND OIL STRAINER
[HR]
●

d.
3.
4.
5.
6.
a.

b.

Press-fit to the dimensions specified in the figure.
1.

Rear oil seal

A.

Rear end surface of cylinder block

CAUTION:
● Do not touch the grease applied to the oil seal lip.
● Be careful not to damage the rear oil seal mounting
part of oil pan (upper) and cylinder block or the crankshaft.
● Press-fit straight make sure that oil seal does not curl
PBIC3761E
or tilt.
After press-fitting the rear oil seal, completely wipe off any liquid gasket protruding to rear end surface
side.
Install crankshaft sprocket, oil pump sprocket, oil pump drive chain, and chain tensioner.
Refer to EM-142, «TIMING CHAIN» .
Install timing chain and related parts. Refer to EM-142, «TIMING CHAIN» .
Install front cover and related parts. Refer to EM-142, «TIMING CHAIN» .
Install oil pan (lower) with the following procedure.
Use scraper to remove old liquid gasket from mating surfaces.
● Also remove the old liquid gasket from mating surface of oil pan (upper).
● Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.
Apply a continuous bead of liquid gasket (A) with the tube
presser (SST: WS39930000) to areas shown in the figure.
: Engine out side

Use Genuine Liquid Gasket or equivalent.
CAUTION:
Attaching should be done within 5 minutes after coating.

MBIB1376E

EM-130

OIL PAN AND OIL STRAINER
[HR]
c.

Tighten bolts in the numerical order shown in the figure.
A

: Engine front

EM

C
MBIB1373E

D

7.
8.

Install oil pan drain plug.
● For installation direction of washer. Refer to EM-127, «Components» .
Install in the reverse order of removal.
CAUTION:
Pour engine oil at least 30 minutes after oil pan is installed.

F

INSPECTION AFTER INSTALLATION
1.
2.
3.
4.

E

Check engine oil level and adjust engine oil. Refer to LU-16, «ENGINE OIL» .
Check for leakage of engine oil when engine is warmed.
Stop engine and wait for 10 minutes.
Check engine oil level again. Refer to LU-16, «ENGINE OIL» .

G

H

I

J

K

L

M

EM-131

IGNITION COIL
[HR]

IGNITION COIL
Components

PFP:22448
BBS002OK

PBIC3662E

1.

Ignition coil

2.

Spark plug

Removal and Installation

BBS002OL

REMOVAL
1.
2.
3.

Remove intake manifold. Refer to EM-120, «INTAKE MANIFOLD» .
Disconnect harness connector from the ignition coil.
Remove ignition coil.
CAUTION:
● Handle it carefully and avoid impacts.
● Do not disassemble.

INSTALLATION
Installation is the reverse order of removal.

EM-132

SPARK PLUG (PLATINUM-TIPPED TYPE)
[HR]

SPARK PLUG (PLATINUM-TIPPED TYPE)
Components

PFP:22401

A
BBS002OM

EM

C

D

E

F

G
PBIC3662E

1.

Ignition coil

2.

Spark plug

Removal and Installation

BBS002ON

H

REMOVAL
1.
2.
3.

Remove intake manifold. Refer to EM-120, «INTAKE MANIFOLD» .
Remove ignition coil. Refer to EM-132, «IGNITION COIL» .
Remove spark plug using spark plug wrench (commercial service tool).
CAUTION:
Do not drop or shock it.

I

J

K

L
PBIC3871E

INSPECTION AFTER REMOVAL

M

Use standard type spark plug for normal condition.
Hot type spark plug is suitable when fouling occurs with standard type spark plug under conditions such as:
●
Frequent engine starts
●
Low ambient temperatures
Cold type spark plug is suitable when spark plug knock occurs with standard type spark plug under conditions
such as:
●
Extended highway driving
●
Frequent high engine revolution
Make

NGK

Standard type

PLZKAR6A-11

Hot type

PLZKAR5A-11

Cold type

PLZKAR7A-11

Gap (Nominal)

: 1.1 mm (0.043 in)

EM-133

SPARK PLUG (PLATINUM-TIPPED TYPE)
[HR]
CAUTION:
●
Do not drop or shock spark plug.
●
Do not use wire brush for cleaning.
●
If plug tip is covered with carbon, spark plug cleaner may
be used.
Cleaner air pressure:
Less than 588 kPa (5.88 bar, 6 kg/cm2 , 85 psi)
Cleaning time:
Less than 20 seconds
SMA773C

●

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

SMA806CA

INSTALLATION
Installation is the reverse order of removal.

EM-134

FUEL INJECTOR AND FUEL TUBE
[HR]

FUEL INJECTOR AND FUEL TUBE
Components

PFP:16600

A
BBS002OO

EM

C

D

E

F

G

H

I
PBIC3663E

1.

Quick connector cap

2.

Fuel feed hose

3.

Fuel tube

4.

Fuel tube protector

5.

O-ring (Black)

6.

Clip

7.

Fuel injector

8.

O-ring (Green)

J

K

CAUTION:
Do not remove or disassemble parts unless instructed as shown in the figure.

Refer to GI-11, «Components» for symbol marks in the figure.
L

Removal and Installation

BBS002OP

WARNING:
●
Put a “CAUTION: INFLAMMABLE” sign in the workshop.
●
Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
●
Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.

REMOVAL
1.
2.

Release the fuel pressure. Refer to EC-860, «FUEL PRESSURE RELEASE» (with EURO-OBD) or EC1281, «FUEL PRESSURE RELEASE» (without EURO-OBD).
Remove intake manifold. Refer to EM-120, «INTAKE MANIFOLD» .

EM-135

M

FUEL INJECTOR AND FUEL TUBE
[HR]
3.

Disconnect quick connector with the following procedure. Disconnect fuel feed hose from fuel tube.
1

: Quick connector cap

NOTE:
There is no fuel return path.

PBIC3771E

a.
b.

Remove quick connector cap (1) from quick connector connection.
Disconnect fuel feed hose from hose clamp.

PBIC3664E

c.
d.

e.

With the sleeve side of quick connector release facing quick connector, install quick connector release
onto fuel tube.
Insert quick connector release into quick connector until sleeve
contacts and goes no further. Hold quick connector release on
that position.
CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.
Draw and pull out quick connector straight from fuel tube.
CAUTION:
● Pull quick connector holding “A” position in the figure.
KBIA0702E
● Do not pull with lateral force applied. O-ring inside quick
connector may be damaged.
● Prepare container and cloth beforehand as fuel will leak out.
● Avoid fire and sparks.
● Keep parts away from heat source. Especially, be careful when welding is performed around
them.
● Do not expose parts to battery electrolyte or other acids.
● Do not bend or twist connection between quick connector and fuel feed hose during installation/removal.
● To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with
plastic bags or something similar.

PBIC2205E

EM-136

FUEL INJECTOR AND FUEL TUBE
[HR]
4.
5.

Disconnect harness connector from fuel injector.
Remove fuel tube protector.
● Loosen bolts in the reverse of the order shown in the figure.

A

EM

: Engine front

C

D
PBIC3665E

6.

E

Remove the fuel injector and fuel tube assembly.
● Loosen bolts in the reverse of the order shown in the figure
: Engine front

F

CAUTION:
● When removing, be careful to avoid any interference with
fuel injector.
● Use a shop cloth to absorb any fuel leaks from fuel tube.

G

H
PBIC3666E

7.
a.
b.

I

Remove the fuel injector (3) from the fuel tube (1) with the following procedure.
Open and remove the clip (2).
Remove fuel injector from the fuel tube by pulling straight.
CAUTION:
● Be careful about fuel leakage remaining in fuel tube.
● Be careful not to damage the nozzle of fuel injector.
● Do not subject it to impact by dropping or hitting.
● Do not disassemble.

J

K

PBIC3667E

L

INSTALLATION
1.

Install new the O-ring to the fuel injector, paying attention to the following.
CAUTION:
● The upper and lower O-rings are different. Be careful not to confuse them.
Fuel tube side
Nozzle side
●
●
●
●
●

●

: Black
: Green

Handle O-ring with bare hands. (Do not wear gloves.)
Lubricate O-ring with engine oil.
Do not clean O-ring with solvent.
Make sure that the O-ring and its mating part are free of foreign material.
Be careful not to scratch O-ring with tool or fingernails when installing it. Also be careful not to
twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it into
fuel tube immediately.
Insert O-ring straight into fuel tube. Do not decenter or twist it.

EM-137

M

FUEL INJECTOR AND FUEL TUBE
[HR]
2.

Install the fuel injector (4) onto the fuel tube (1) with the following
procedure:
3 : O-ring (Black)
5 : O-ring (Green)

a.

b.

c.

Insert the clips (2) into the clip mounting grooves on the fuel
injector.
● Insert clip cut-out (D) into fuel injector protrusion (F).
CAUTION:
● Always replace clip with new one.
● Make sure that the clip does not interfere with the Oring. If interference occurs, replace the O-ring.
Insert the fuel injector into the fuel tube with clip attached.
● Make sure that the axis is lined up when inserting.
● Insert clip cut-out (C) into fuel tube protrusion (B).
● Make sure that the flange (A) on the fuel tube fits securely in
the clip flange fixing groove (E).
Make sure that installation is complete by checking that fuel
injector does not rotate or come off.
PBIC3668E

3.

Install fuel tube and fuel injector assembly onto cylinder head.
● Tighten bolts in the numerical order shown in the figure.
: Engine front

CAUTION:
Be careful not to let tip of fuel injector nozzle come in
contact with other parts.

PBIC3665E

4.

Install fuel tube protector.
● Tighten bolts in the numerical order shown in the figure.
: Engine front

PBIC3666E

5.
6.
a.
b.

Connect harness connector to fuel injector.
Connect fuel feed hose with the following procedure.
Check for damage or foreign material on the fuel tube and quick connector.
Apply new engine oil lightly to area around the top of fuel tube.

EM-138

FUEL INJECTOR AND FUEL TUBE
[HR]
c.

Align center to insert quick connector straightly into fuel tube.
A
● Insert quick connector to fuel tube until the top spool on fuel
tube is inserted completely and the 2nd level spool is positioned slightly below quick connector bottom end.
CAUTION:
EM
● Hold “A” position in the figure when inserting fuel tube
into quick connector.
● Carefully align center to avoid inclined insertion to preC
vent damage to O-ring inside quick connector.
● Insert until you hear a “click” sound and actually feel
KBIA0272E
the engagement.
D
● To avoid misidentification of engagement with a similar sound, be sure to perform the next
step.
d. Before clamping fuel feed hose with hose clamp, pull quick connector hard by hand holding “A” position. E
Make sure it is completely engaged (connected) so that it does not come out from fuel tube.
e. Install quick connector cap (1) to quick connector connection.
● Install quick connector cap with the side arrow facing quick
F
connector side (fuel feed hose side).
CAUTION:
● Make sure that the quick connector and fuel tube are
G
securely engaged with the quick connector cap mounting groove.
● Quick connector may not be connected correctly if
H
quick connector cap cannot be installed easily.
Remove the quick connector cap, and then check the
PBIC3664E
connection of quick connector again.
I
f. Install fuel feed hose to hose clamp.
7. Install in the reverse order of removal.
J
INSPECTION AFTER INSTALLATION

Check on Fuel Leaks
1.

2.

Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then make sure
there are no fuel leaks at connections.
NOTE:
Use mirrors for checking on invisible points.
Start engine. With engine speed increased, make sure again there are no fuel leaks at connections.
CAUTION:
Do not touch engine immediately after stopped as engine becomes extremely hot.

K

L

M

EM-139

ROCKER COVER
[HR]

ROCKER COVER
Components

PFP:13264
BBS002OQ

PBIC3669E

1.

PCV hose

2.

Oil filler cap

3.

Rocker cover

4.

Gasket

5.

Bracket

6.

Grommet

7.

PCV valve

8.

PCV hose

A.

To air duct

Refer to GI-11, «Components» for symbol marks in the figure.

Removal and Installation

BBS002OR

REMOVAL
1.
2.
3.

4.
5.
6.

Remove intake manifold. Refer to EM-120, «INTAKE MANIFOLD» .
Remove ignition coil. Refer to EM-132, «IGNITION COIL» .
Remove engine mounting stay (RH). Refer to EM-184, «ENGINE ASSEMBLY» .
NOTE:
For supporting engine load, it is not necessary that only the engine mounting stay (RH) is removed.
Remove fuel tube protector. Refer to EM-135, «FUEL INJECTOR AND FUEL TUBE» .
Remove the PCV hose from rocker cover.
Remove PCV valve if necessary.

EM-140

ROCKER COVER
[HR]
7.

Loosen bolts in the reverse of the order shown in the figure.
A

: Engine front

NOTE:
13 and 14 shown in the figure are used to tighten the fuel tube
protector.

EM

C
PBIC3670E

D

8.
9.

Remove gasket from rocker cover.
Remove all traces of liquid gasket from cylinder head and front cover.
E

INSTALLATION
1.
a.

Install the rocker cover with the following procedure.
Install the gasket to the rocker cover.
● Check for damage or foreign material.
● Make sure that it is securely inserted in the mounting groove
of rocker cover.
● For the 2 bolt holes shown in the figure, push the gasket into
the boss for the rocker cover bolt hole to prevent it from falling.

F

G

H

KBIA3331J

b.

I

Apply liquid gasket to the position shown in the figure.
1

: Cylinder head

2

: Front cover

J

Use Genuine Liquid Gasket or equivalent.
K

L
PBIC3671E

c.

d.

Install the rocker cover to the cylinder head.
CAUTION:
Make sure the gasket is not dropped.
Tighten bolts in two steps in numerical order as shown in the figure.

M

: Engine front

NOTE:
13 and 14 shown in the figure tighten together with the fuel tube
protector. Refer to EM-135, «Components» .

PBIC3670E

2.

Install in the reverse order of removal.

EM-141

TIMING CHAIN
[HR]

TIMING CHAIN
Components

PFP:13028
BBS002OS

PBIC3709E

1.

Timing chain slack guide

2.

Chain tensioner (For timing chain)

3.

Camshaft sprocket (EXH)

4.

Camshaft sprocket (INT)

5.

Plug

6.

Front oil seal

7.

Crankshaft pulley

8.

Crankshaft pulley bolt

9.

Front cover

10. Crankshaft sprocket

11.

Oil pump sprocket

12. Oil pump drive chain

Chain tensioner (For oil pump drive
13.
chain)

14. Timing chain

A.

Refer to EM-146

Refer to GI-11, «Components» for symbol marks in the figure.

EM-142

15. Timing chain tension guide

TIMING CHAIN
[HR]

Removal and Installation

BBS002OT

CAUTION:
The rotation direction indicated in the text indicates all directions seen from the engine front direction.

REMOVAL
1.
2.
3.

4.

5.
6.
a.

EM

Remove front RH wheel. Refer to WT-5, «ROAD WHEEL AND TYRE ASSEMBLY» .
Remove front fender protector (RH). Refer to EI-14, «FENDER PROTECTOR» .
Drain engine oil. Refer to LU-16, «ENGINE OIL» .
NOTE:
Perform this step when engine is cold.
Remove the following parts.
● Rocker cover: Refer to EM-140, «ROCKER COVER» .
● Drive belt: Refer to EM-114, «DRIVE BELTS» .
● Water pump pulley: Refer to CO-36, «WATER PUMP» .
● Ground cable (between engine mounting bracket (RH) and radiator core support)
Support the bottom surface of engine using a transmission jack, and then remove the engine mounting
bracket and insulator (RH). Refer to EM-184, «ENGINE ASSEMBLY» .
Set No. 1 cylinder at TDC of its compression stroke with the following procedure:
Rotate crankshaft pulley (2) clockwise and align TDC mark
(without paint mark) (A) to timing indicator (1) on front cover.
B

A

C

D

E

F

G

: White paint mark (Not use for service)

H

I

PBIC3673E

b.

Make sure the matching marks on each camshaft sprocket are
positioned as shown in the figure.

●

K

1

: Camshaft sprocket (EXH)

2

: Camshaft sprocket (INT)

A

: Matching mark (stamp)

B

: Matching mark (peripheral stamp line)

L

If not, rotate crankshaft pulley one more turn to align matching
marks to the positions in the figure.

M
PBIC3872E

7.
a.
b.

J

Remove crankshaft pulley with the following procedure:
Secure crankshaft pulley (1) using a pulley holder (commercial
service tool) (A).
Loosen and pull out crankshaft pulley bolts.
CAUTION:
Do not remove the mounting bolts as they will be used as a
supporting point for the pulley puller (SST: KV11103000).

PBIC3710E

EM-143

TIMING CHAIN
[HR]
c.

Attach a pulley puller (SST: KV11103000) (A) in the M 6 thread
hole on crankshaft pulley, and remove crankshaft pulley.
B

: M6 bolt

PBIC3711E

8.
a.

Remove front cover with the following procedure:
Loosen bolts in the reverse of the order shown in the figure.

KBIA3429J

b.

Cut liquid gasket by prying the position (
and then remove the front cover.

) shown in the figure,

PBIC3712E

9.

Remove front oil seal from front cover.
● Remove by lifting it up using a suitable tool.
CAUTION:
Be careful not to damage the front cover.

EM-144

TIMING CHAIN
[HR]
10. Remove chain tensioner (1) with the following procedure.
A
a. Fully push down the chain tensioner lever (A), and then push the
plunger (C) into the inside of tensioner.
● The tab (B) is released by fully pushing the lever down. As a
result, the plunger can be moved.
EM
b. Pull up the lever to align its hole position with the body hole position.
C
● When the lever hole is aligned with the body hole position, the
plunger is fixed.
● When the protrusion parts of the plunger ratchet and the tab
PBIC3713E
face each other, both hole positions are not aligned. At that
D
time, correctly engage them and align these hole positions by slightly moving the plunger.
c. Insert the stopper pin (D) into the body hole through the lever hole, and then fix the lever at the upper
position.
E
● Figure shows the example that a hexagonal wrench for 2.5 mm (0.098 in) is used.
d. Remove chain tensioner.
11. Remove the timing chain tension guide (2) and the timing chain
F
slack guide (1).
G

H

PBIC3714E

12. Remove the timing chain (2).
● Pull the looseness of timing chain toward the camshaft
sprocket (EXH) (1), and then remove the timing chain and
start the removal from camshaft sprocket (EXH) side.
CAUTION:
Do not rotate crankshaft or camshaft while timing chain is
removed. It causes interference between valve and piston.

I

J

K

L
PBIC3715E

13. Remove the crankshaft sprocket and the oil pump drive related parts with the following procedure.
a. Remove chain tensioner (1).
● Pull out from the shaft (B) and spring fixing holes (A).

PBIC3716E

EM-145

M

TIMING CHAIN
[HR]
b.

c.

Hold the top of the oil pump shaft using the TORX socket (size:
E8), and then loosen the oil pump sprocket nuts and remove
them.
Remove the crankshaft sprocket (1), the oil pump drive chain
(2), and the oil pump sprocket (3) at the same time.

PBIC3720E

INSPECTION AFTER REMOVAL
Timing Chain
Check timing chain for cracks (A) and any excessive wear (B) at the
roller links of timing chain. Replace timing chain if necessary.

PBIC3169J

INSTALLATION
NOTE:
The figure shows the relationship between the matching mark on
each timing chain and that on the corresponding sprocket, with the
components installed.

1.

1

: Timing chain

2

: Camshaft sprocket (EXH)

3

: Timing chain slack guide

4

: Chain tensioner

5

: Oil pump drive chain

6

: Oil pump sprocket

7

: Crankshaft sprocket

8

: Timing chain tension guide

9

: Camshaft sprocket (INT)

A

: Yellow link

B

: Matching mark (stamp)

C

: Orange link

D

: Matching mark (stamp)

E

: Crankshaft key (point straight up)

F

: Matching mark (peripheral stamp line)

G

: Yellow link

Install the crankshaft sprocket and the oil pump drive related
parts with the following procedure:

EM-146

PBIC3718E

TIMING CHAIN
[HR]
a.

Install the crankshaft sprocket (1), the oil pump drive chain (2),
and the oil pump sprocket (3) at the same time.

A

: Engine front

Install the crankshaft sprocket so that its invalid gear area (A)
is towards the back of the engine.
● Install the oil pump sprocket so that its hexagonal surface
faces (B) the front of engine.
NOTE:
There is no matching mark in the oil pump drive related parts.
●

EM

C
PBIC3719E

D

b.

Hold the top of the oil pump shaft using the TORX socket (size:
E8), and then tighten the oil pump sprocket nuts.
1

: Crankshaft sprocket

2

: Oil pump drive chain

3

: Oil pump sprocket

E

F

G
PBIC3720E

c.

Install chain tensioner (1).
● Insert the body into the shaft (B) while inserting the spring into
the fixing hole (A) of cylinder block front surface.
● Make sure that the tension is applied to the oil pump drive
chain after installing.

H

I

J

PBIC3716E

2.

K

Install timing chain with the following procedure.
A

: Yellow link

B

: Matching mark (stamp)

C

: Orange link

D

: Matching mark (stamp)

E

: Crankshaft key (point straight up)

F

: Matching mark (peripheral stamp line)

G

: Yellow link

L

M

Install by aligning matching marks on each sprocket and timing chain.
● If these matching marks are not aligned, rotate the camshaft
slightly to correct the position.
CAUTION:
● For the following note, after the matching marks are
aligned, keep them aligned by holding them with a hand.
● To avoid skipped teeth, do not rotate crankshaft and camshaft until front cover is installed.
●

PBIC3721E

EM-147

TIMING CHAIN
[HR]
3.

Install timing chain tension guide (2) and timing chain slack
guide (1).

PBIC3714E

4.

Install chain tensioner (1).
● Fix the plunger at the most compressed position using a stopper pin (A), and then install it.
● Securely pull out the stopper pin after installing the chain
tensioner.

PBIC3722E

5.
6.
7.
a.

Check matching mark position of timing chain and each sprocket again.
Install the front oil seal to the front cover. Refer to EM-171, «Removal and Installation of Front Oil Seal»
Install front cover with the following procedure:
Apply a continuous bead of liquid gasket with tube presser (SST:
WS39930000) to front cover as shown in the figure.
Use Genuine Liquid Gasket or equivalent.
1

: Cylinder head

2

: Cylinder block

3

: Oil pan (upper)

A

: Liquid gasket application area
φ 3.0 — 4.0 mm (0.12 — 0.16 in)

PBIC3724E

EM-148

TIMING CHAIN
[HR]
b.

Apply a continuous bead of liquid gasket with tube presser (SST:
WS39930000) to front cover as shown in the figure.
Use Genuine Liquid Gasket or equivalent.
A

A

: Liquid gasket application area
φ 3.0 — 4.0 mm (0.12 — 0.16 in)

EM

C

D

E

F

G
PBIC3725E

c.
d.

Tighten bolts in the numerical order shown in the figure.
After all bolts are tightened, retighten them to specified torque in
numerical order as shown in the figure.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking to
surface.

H

I

J

K

L

M

KBIA3429J

8.

9.

a.
b.

Insert crankshaft pulley by aligning with crankshaft key.
● When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
CAUTION:
Install protecting front oil seal lip section from any damage.
Tighten crankshaft pulley bolt with the following procedure:
● Secure crankshaft pulley with a pulley holder (commercial service tool), and tighten crankshaft pulley
bolt.
Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
Tighten crankshaft pulley bolt.

EM-149

TIMING CHAIN
[HR]
: 35.0 N·m (3.6 kg-m, 26 ft-lb)
c.

d.

Put a paint mark (B) on crankshaft pulley, mating with any one of
six easy to recognize angle marks (A) on crankshaft bolt flange
(1).
Turn another 60 degrees clockwise (angle tightening).
● Check the tightening angle with movement of one angle mark.

PBIC3726E

10. Make sure that crankshaft turns smoothly by rotating by hand clockwise.
11. Install in the reverse order of removal.

INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
●
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS» .
●
Use procedure below to check for fuel leakage.
–
Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
–
Start engine. With engine speed increased, check again for fuel leakage at connection points.
●
Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises.
●
Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
●
Bleed air from lines and hoses of applicable lines, such as in cooling system.
●
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
Item

Before starting engine

Engine running

After engine stopped

Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Other oils and fluid*

Level

Leakage

Level

Leakage

Leakage

Leakage

—

Leakage

—

Fuel
Exhaust gases

* Transmission/transaxle fluid, power steering fluid, brake fluid, etc.

EM-150

CAMSHAFT
[HR]

CAMSHAFT
Components

PFP:13001

A
BBS002OU

EM

C

D

E

F

G

H

I

J

PBIC3672E

1.

Camshaft bracket (No. 2 to 5)

2.

Camshaft bracket (No. 1)

3.

4.

Camshaft sprocket (INT)

5.

Cylinder head

6.

Oil filter (for intake valve timing control)

7.

Washer

8.

Plug

9.

Intake valve timing control solenoid valve

10. O-ring

11. O-ring

12. Camshaft position sensor (PHASE)

13. Valve lifter

14. Camshaft (INT)

15. Camshaft (EXH)

A.

Refer to EM-161

Removal and Installation

BBS002OV

CAUTION:
The rotation direction indicated in the text indicates all directions seen from the engine front direction.

REMOVAL
NOTE:
This section describes the procedure for removal and installation of camshaft with front cover. If the front cover
is removed first, change the following procedure.

1.

L

M

Refer to GI-11, «Components» for symbol marks in the figure.

·Step 8
·Step 9
·Step 10

K

Camshaft sprocket (EXH)

: After camshaft sprocket is removed, remove the camshaft brackets (No. 2 to 5).
: The camshaft (EXH) can be removed simultaneously with the camshaft (INT).
: When the camshaft sprocket (INT) mounting bolt is removed, the lifting up of camshaft is not necessary.

Support the bottom surface of engine using a transmission jack, and then remove the engine mounting
bracket and insulator (RH). Refer to EM-184, «ENGINE ASSEMBLY» .

EM-151

CAMSHAFT
[HR]
2.
3.

4.
a.

Remove rocker cover. Refer to EM-140, «ROCKER COVER» .
Remove camshaft position sensor (PHASE) from rear end of cylinder head.
CAUTION:
Handle it carefully and avoid impacts.
Place cylinder No. 1 at TDC of its compression stroke with the following procedure.
Rotate crankshaft pulley (2) clockwise and align TDC mark
(without paint mark) (A) to timing indicator (1) on front cover.
B : White paint mark (Not use for service)

PBIC3673E

b.

Make sure that the matching marks on each the camshaft
sprockets are in the position shown in the figure.
1.

: Timing chain

2.

: Camshaft sprocket (EXH)

3.

: Camshaft sprocket (INT)

A

: Matching mark (Paint)

B

: Matching mark (Stamp)

C

: Matching mark (Peripheral stamp line)

If not, rotate crankshaft pulley one more turn to align matching
PBIC3674E
marks to the positions in the figure.
Paint matching marks (A) on the timing chain links
Secure the plunger of chain tensioner in the fully compressed position with the following procedure. And
then, loosen the timing chain tension.
Remove the plug (2) from the front cover (1).
●

c.
5.
a.

PBIC3675E

b.

Fully push down the lever (B) of chain tensioner (2) from the
plug hole, and then insert the stopper pin (A) into the body side
hole and secure the lever at the lowest position.
C : Front cover has been omitted

The tab is released by fully pushing the lever down. As a
result, the plunger (1) can be moved.
NOTE:
Hexagonal wrench [2.5 mm (0.098 in)] is used for a stopper pin
as an example.
CAUTION:
The stopper pin must use a shape that cannot fall in the
front cover when dropping out.
●

EM-152

PBIC3676E

CAMSHAFT
[HR]
c.

Turn the crankshaft pulley (2) counterclockwise with the camshaft (EXH) (1) fixing. Apply the tension to the timing chain, and
then push the plunger of into the inside of chain tensioner.
CAUTION:
Hold the camshaft hexagonal part (A), and then secure the
camshaft.

A

EM

C
PBIC3677E

D

d.

Pull out the stopper pin (A) of chain tensioner (2) side from plug
hole. Lift the lever (B) up to align its hole position with the hole of
the body.

E

D : Front cover has been omitted

When the lever hole (C) is aligned with the body hole position,
the plunger (1) is fixed.
● When the protrusion parts of the plunger ratchet and the tab
face each other, both hole positions are not aligned. At that
time, correctly engage them and align these hole positions by
slightly moving the plunger.
Insert the stopper pin into the body hole through the lever hole,
and then fix the lever at the upper position.
Slightly rotate the crankshaft pulley (2) clockwise to loosen the
timing chain on camshaft sprocket (EXH) (1) side.
CAUTION:
Hold the camshaft hexagonal part (A), and then secure the
camshaft.
●

e.
f.

F

G
PBIC3772E

H

I

J

K
PBIC3773E

6.

7.

Remove camshaft sprocket (EXH) (1).
CAUTION:
● Hold the camshaft hexagonal part (A), and then secure
the camshaft.
● Do not rotate crankshaft and camshaft separately, so as
not to contact valve with piston in the following steps.
NOTE:
The timing chain with the front cover installed is not disengaged
from the crankshaft sprocket and it is not dropped into the front
cover. Therefore, the timing chain tension holding device is not
PBIC3678E
necessary.
Turn the camshaft sprocket (INT) to the most advanced position.
CAUTION:
Installation and removal of the camshaft sprocket (INT) must be done in the most advanced position for the following reasons, so make sure that you follow the procedure exactly.

EM-153

L

M

CAMSHAFT
[HR]
●

●

●

The sprocket (C) and vane (camshaft coupling) (B) are
designed to spin and move within the range of a certain
angle.
With the engine stopped and the vane in the most
retarded angle, it will not spin because it is locked to the
sprocket side by the internal lock pin (A).
If the camshaft sprocket mounting bolts are turned in the
situation described above, the lock pin will become damaged and cause malfunctions because of the increased
horizontal load (cutting force) on the lock pin.
PBIC3679E

Put the camshaft sprocket (INT) in the most advance position with the following procedure.
Remove camshaft bracket (No. 1) (1).
●

a.

: Engine front
●

Loosen the bolts in several steps, and then remove them.

PBIC3680E

b.

Apply the following air pressure to the No. 1 journal oil hole (A)
of camshaft (INT) (1) shown in the figure using an air gun.
Pressure
●

●

: 300 kPa (3.0 bar, 3.1 kg/cm2 , 44psi) or more

Apply the air pressure into the oil hole on the second groove
from the front of camshaft thrust (B).
Proceed all the way through step “e” with the air pressure on.

PBIC3681E

Attach the rubber nozzle (B) narrowed to the top of the air gun
(A) to prevent air leakage from the oil hole. Securely apply the
air pressure to the oil hole.
CAUTION:
● There are other oil holes in the side grooves. Do not use
the incorrect oil holes.
● Be sure not to damage the oil path with the tip of the air
gun.
● Wipe all the oil off the air gun to prevent oil from being
blown all over along with the air, and the area around the
PBIC3682E
air gun should be wiped with a rag when applying air
pressure. Eye protection should be worn as needed.
NOTE:
The air pressure is used to move the lock pin into the disengage position.
Hold the camshaft sprocket (INT) with hands, and then apply the power counterclockwise/clockwise alternatively.
● Finally rotate the sprocket of the camshaft sprocket (INT) counterclockwise [the direction shown by the
arrow ( )].
● Perform the work while applying the air pressure to the oil hole.
●

c.

EM-154

CAMSHAFT
[HR]
●

●

If the lock pin is not released by hands, tap the camshaft
sprocket (INT) lightly with a plastic hammer (A).
If the camshaft sprocket (INT) is not rotated counterclockwise
even if the above procedures are performed, check the air
pressure and the oil hole position.

A

EM

C
PBIC3683E

D

d.

While doing the above, once you hear a click (the sound of the
internal lock pin disengaging) from inside the camshaft sprocket
(INT), start turning the camshaft sprocket (INT) in the counterclockwise direction in the most advanced angle position.
C

: Lock pin engaged

D

: Most advanced angle

E

F

Keep the air pressure on.
● If there is no click, as soon as the vane-side (camshaft side)
starts moving independently of the sprocket, the lock pin has
become disengaged.
PBIC3684E
● Make sure that it is in the most advanced angle position by
seeing if the stopper pin groove (A) and the stopper pin hole (B) are matched up as shown in the figure.
Complete the applying procedure of air pressure and the holding procedure of camshaft (INT).
Insert the stopper pin (A) into the stopper pin holes in the camshaft sprocket (INT) and lock in the most advanced angle position.
CAUTION:
No load is exerted on the stopper pin (spring reaction, etc.).
Since it comes out easily, secure it with tape (B) to prevent
it from coming out.
NOTE:
The stopper pin in the figure shows one example of a hexagonal
wrench for 2.5 mm (0.098 in) [length of inserted section:
PBIC3685E
approximately15 mm (0.59 in)].
●

e.
f.

G

H

I

J

K

L

8.

Remove camshaft brackets (No. 2 to 5).
● Loosen bolts in several steps in the reverse of the order
shown in the figure.
A

: EXH side

B

: INT side

M

: Engine front

NOTE:
The camshaft bracket (No. 1) has been already removed.
PBIC3686E

9.

Remove camshaft (EXH).

EM-155

CAMSHAFT
[HR]
10. Remove the camshaft (INT) (1) and the camshaft sprocket (INT)
(2) with the following procedure.
a. Lift up the camshaft sprocket (INT), and then set the thin tools (a
box wrench, etc.) to the mounting bolt (A).
b. Return the camshaft (INT) to the cylinder head journal quietly.

PBIC3687E

c.

Keeping the camshaft hexagonal part (A) still with the wrench,
loosen mounting the bolts for the camshaft sprocket (INT) (2).
1.

Camshaft (INT)

PBIC3688E

d.

Lift up the camshaft (INT) (1), and then disassemble the camshaft from the camshaft sprocket (INT) (2).

PBIC3689E

e.

Remove camshaft (INT) rearward.
CAUTION:
Do not damage the signal plate of rear end.

f.

Remove camshaft sprocket (INT) (1).
CAUTION:
Do not drop stopper pin.

PBIC3690E

EM-156

CAMSHAFT
[HR]
CAUTION:
● Tape (C) the stopper pin (B) so it does not come out.
● Do not subject it to impact by dropping.
● Do not disassemble. [Do not loosen the three mounting
bolts (A)].
NOTE:
While removing the camshaft sprocket (INT), if you have taken
out the stopper pin and the lock pin has been rejoined in the
most retarded angle, do the following to restore it.

A

EM

C

PBIC3691E

i.

ii.
iii.
iv.
11.
12.
13.

Install the camshaft (INT) and tighten the mounting bolts enough to prevent air from leaking out.
CAUTION:
The internal lock pin will get damaged, so keep the torque on the mounting bolts to the minimum
required to prevent air from escaping.
Apply the air pressure, disengage the lock pin, and turn the vane to the most advanced angle position.
Insert the stopper pin.
Remove camshaft sprocket (INT) from the camshaft.
Remove valve lifter.
● Identify installation positions, and store them without mixing them up.
Remove intake valve timing control solenoid valve (1).
Remove the alternator and bracket, remove the plug (2), and
then remove the oil filter.
Refer to SC-51, «Removal and Installation (HR Engine Models)»
.

D

E

F

G

H

I

J

PBIC3692E

K

INSPECTION AFTER REMOVAL
Oil Filter
●

●
●

L

Make sure that there is no foreign material on the oil filter (1)
and check it for clogging.
Check the oil filter for damage.
If there is some damage, replace the oil filter, the plug, and the
washer as a set.

M

PBIC3693E

EM-157

CAMSHAFT
[HR]
Camshaft Runout
1.

2.
3.

Put V-block on a precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Do not support No. 1 journal (on the side of camshaft
sprocket) because it has a different diameter from the other
four locations.
Set a dial indicator vertically to No. 3 journal.
Turn camshaft to one direction with hands, and measure the
camshaft runout on the dial indicator. (Total indicator reading)
Standard:

PBIC2499E

: 0.02 mm (0.0008 in)
Limit:
: 0.1 mm (0.0039 in)
4.

If it exceeds the limit, replace camshaft.

Camshaft Cam Height
1.

Measure the camshaft cam height with a micrometer (A).
Standard:
Intake
: 41.705 — 41.895 mm (1.6419 — 1.6494 in)
Exhaust
: 40.175 — 40.365 mm (1.5816 — 1.5891 in)
Cam wear limit
: 0.2 mm (0.0078 in)

2.

If wear exceeds the limit, replace camshaft.
PBIC3178J

Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL DIAMETER
Measure the outer diameter of camshaft journal with a micrometer
(A).
Standard:
No. 1
No. 2, 3, 4, 5

: 27.935 — 27.955 mm (1.0998 — 1.1006 in)
: 24.950 — 24.970 mm (0.9822 — 0.9830 in)

PBIC3179J

CAMSHAFT BRACKET INNER DIAMETER
●
Tighten camshaft bracket bolts with the specified torque. Refer to EM-161, «INSTALLATION» for the tightening procedure.

EM-158

CAMSHAFT
[HR]
●

Measure inner diameter (B) of camshaft bracket with a bore
gauge (A).
Standard:
No. 1
No. 2, 3, 4, 5

A

: 28.000 — 28.021 mm (1.1024 — 1.1032 in)
: 25.000 — 25.021 mm (0.9842 — 0.9850 in)

EM

C
PBIC3180J

D

CAMSHAFT JOURNAL OIL CLEARANCE
(Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter)

E

●

Standard
No. 1
No. 2, 3, 4, 5
Limit
●

: 0.045 — 0.086 mm (0.0018 — 0.0034 in)
: 0.030 — 0.071 mm (0.0011 — 0.0027 in)

F

: 0.15 mm (0.0059 in)

G

If it exceeds the limit, replace either or both camshaft and cylinder head.
NOTE:
Camshaft brackets cannot be replaced as single parts, because they are machined together with cylinder
head. Replace whole cylinder head assembly.

Camshaft End Play
1.
2.

I

Install camshaft in cylinder head. Refer to EM-176, «INSTALLATION» for tightening procedure.
Install a dial indicator (A) in thrust direction on front end of camshaft. Measure the camshaft end play on the dial indicator when
camshaft is moved forward/backward (in direction to axis).
Standard
Limit

H

J

: 0.075 — 0.153 mm (0.0029 — 0.0060 in)
: 0.2 mm (0.0078 in)

K

L
PBIC3694E

M
●
–

Measure the following parts if out of the standard.
Dimension “A” for cylinder head No. 1 journal bearing
Standard

–

Dimension “B” for camshaft thrust
Standard

●

: 4.000 — 4.030 mm (0.1574 — 0.1586 in)

: 3.877 — 3.925 mm (0.1526 — 0.1545 in)

Refer to the standards above, and then replace camshaft and/
or cylinder head.
KBIA3345J

Camshaft Sprocket Runout
1.

Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations.

EM-159

CAMSHAFT
[HR]
2.

Measure the camshaft sprocket runout with a dial indicator.
(Total indicator reading)
Limit

●

: 0.15 mm (0.0059 in)

If it exceeds the limit, replace camshaft sprocket.

KBIA1493J

Valve Lifter
Check if surface of valve lifter has any wear or cracks.
●
If anything above is found, replace valve lifter.
Refer to EM-217, «Available Valve Lifter» .

KBIA0182E

Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER
●
Measure the outer diameter of valve lifter with a micrometer (A).
Standard

: 29.977 — 29.987 mm (1.1801 — 1.1805 in)

PBIC3185J

VALVE LIFTER HOLE DIAMETER
Measure the diameter of valve lifter hole of cylinder head with an
inside micrometer (A).
Standard

: 30.000 — 30.021 mm (1.1811 — 1.1819 in)

PBIC3184J

VALVE LIFTER CLEARANCE
●
(Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)
Standard
●

: 0.013 — 0.044 mm (0.0005 — 0.0017 in)

If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole
diameter, replace either or both valve lifter and cylinder head.

EM-160

CAMSHAFT
[HR]
INSTALLATION
1.

A

Install the oil filter (1).
2
●

: Washer

The oil filter is assembled to the plug (3), and then install it to
the cylinder head.

EM

C

PBIC3695E

2.

3.
4.

a.

b.

Install intake valve timing control solenoid valve.
● Insert it straightly into the cylinder head.
● Tighten bolts after placing it completely.

D

E

Install valve lifter.
● If it is reused, install in its original positions.
Put a matching mark for positioning the camshaft (INT) and the camshaft sprocket (INT) with the following
procedure.
NOTE:
It prevents the knock pin from engaging with the incorrect pin hole after installing the camshaft (INT) and
the camshaft sprocket (INT).
Put the matching marks (A) on a line extending from the knock
pin position of camshaft (INT) (1) front surface.
● Put the marks on the visible position with the camshaft
sprocket installed. (The figure shows an example.)
Put the matching marks on a line extending from the knock pin
hole (B) position of camshaft sprocket (INT) (2). (The figure
shows an example.)
● Put the marks on the visible position with it installed to the
camshaft.

F

G

H

I

J

K

PBIC3696E

5.

Set the camshaft sprocket (INT) to between cylinder head and
front cover.
● Set it with the knock pin hole (A) facing up.
CAUTION:
Make sure the stopper pin is inserted at the most advanced
position beforehand.

L

M

PBIC3697E

EM-161

CAMSHAFT
[HR]
6.

Install camshaft.

●

1

: Camshaft (EXH)

2

: Camshaft (INT)

A

: Identification mark

Distinction between camshaft (INT and EXH) is performed
with the different shapes of rear end.

PBIC3698E

●

Install camshafts to the cylinder head so that knock pins (A)
on front end are positioned as shown in the figure.
1

: Camshaft (EXH)

2

: Camshaft (INT)
: Upper side

NOTE:
Though camshaft does not stop at the portion as shown in the
figure, for the placement of cam nose, it is generally accepted
camshaft is placed for the same direction of the figure.
PBIC3699E

7.
a.

Install the camshaft sprocket (INT) to the camshaft (INT) with
the following procedure.
Refer to the matching mark (A) put according to step “4”.
Securely align the knock pin and the pin hole, and then install
them.

PBIC3700E

b.

Lift up the front side of camshaft (INT) (1), and then temporarily
tighten the bolt.
2

: Camshaft sprocket (INT)

PBIC3689E

8.

9.

Put a thick shop cloth (B) to the lower surface, and then set the
tools to the bolt while lifting up the front side of camshaft (INT)
(1).
Tighten the mounting bolt.
CAUTION:
Hold the camshaft hexagonal part (A), and then secure the
camshaft.

PBIC3701E

EM-162

CAMSHAFT
[HR]
10. Return the camshaft (INT) to the cylinder head quietly.
11. Install timing chain (1) by aligning its matching mark (marked
when timing chain is removed) (B) with matching mark (peripheral stamp line) (A) on camshaft sprocket (INT) (2).

A

EM

C

D
PBIC3702E

12. Install camshaft brackets (No. 2 to 5) aligning the identification
marks on upper surface as shown in the figure.
A

: EXH side

B

: INT side

E

F

: Engine front
●

Install so that identification mark can be correctly read when
viewed from the INT side.

G
PBIC3703E

H

13. Tighten mounting bolts of camshaft brackets in the following
steps, in numerical order as shown in the figure.
A

: EXH side

B

: INT side

I

: Engine front

a.

J

Tighten No. 9 to 11 in numerical order.
: 2.0 N·m (0.2 kg-m, 1 ft-lb)

b.

K

Tighten No. 1 to 8 in numerical order.
PBIC3686E

: 2.0 N·m (0.2 kg-m, 1 ft-lb)
c.

L

Tighten all bolts in numerical order.
: 5.9 N·m (0.6 kg-m, 4 ft-lb)

d.

M

Tighten all bolts in numerical order.
: 10.4 N·m (1.1 kg-m, 8 ft-lb)

14. Install the camshaft (EXH) to the camshaft sprocket (EXH) (2)
while aligning the matching make (marked when timing chain is
removed) (A) and the matching mark (stamp) (B) of camshaft
sprocket (EXH).

●

1

: Timing chain

3

: Camshaft sprocket (INT)

C

: Matching mark (peripheral stamp line)

If the positions of knock pin and pin groove are not aligned,
move the camshaft (EXH) slightly to correct these positions.
PBIC3674E

EM-163

CAMSHAFT
[HR]
15. Tighten the mounting bolt.
1

: Camshaft sprocket (EXH)

CAUTION:
Hold the camshaft hexagonal part (A), and then secure
the camshaft.
● Make sure that the matching mark (marked when timing
chain is removed) and each camshaft sprocket matching
mark are in the correct location.
●

PBIC3678E

16. Pull out the stopper pin (A), and then apply the tension to the
timing chain by rotating the crankshaft pulley clockwise slightly.
1

: Plunger

2

: Chain tensioner

B

: Lever

C

: Lever hole

D

: Front cover has been omitted

PBIC3772E

17. Install the plug (2) to the front cover (1).
● Apply liquid gasket to the threads, and tighten them.
Use Genuine Liquid Gasket or equivalent.

PBIC3675E

18. Return the camshaft sprocket (INT) in the most retarded position with the following procedure.
a. Remove the stopper pin (A) from the camshaft sprocket (INT).
B

: Tape

PBIC3685E

EM-164

CAMSHAFT
[HR]
b.

Turn the crankshaft pulley (1) slowly clockwise (A) and return
the camshaft sprocket (INT) to the most retarded angle position.

A

EM

C
PBIC3704E

D
●

●

●

When first turning the crankshaft the camshaft sprocket (INT)
will turn. Once it is turned more, and the vane (camshaft) also
turns, then it has reached the most retarded angle position.
B

: Stopper pin hole

C

: Most advanced angle

D

: Lock pin engaged

E

F

The most retarded angle position can be checked by seeing if
the stopper pin groove (A) is shifted clockwise.
After spinning the crankshaft slightly in the counterclockwise
direction, you can make sure the lock pin has joined by seeing
if the vane (camshaft) and the sprocket move together.

G
PBIC3705E

19. Install the camshaft position sensor (PHASE) to the rear end of cylinder head.
● Tighten bolts with it seated completely.
20. Check and adjust valve clearance. Refer to EM-166, «Valve Clearance» .
21. Install in the reverse order of removal.

INSPECTION AFTER INSTALLATION
Inspection for Leaks

H

I

J

The following are procedures for checking fluids leak, lubricates leak.
●
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS» .
●
Use procedure below to check for fuel leakage.
–
Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
–
Start engine. With engine speed increased, check again for fuel leakage at connection points.
●
Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises.
●
Warm up engine thoroughly to make sure there is no leakage of fuel, or any oil/fluids including engine oil
and engine coolant.
●
Bleed air from lines and hoses of applicable lines, such as in cooling system.
●
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.

EM-165

K

L

M

CAMSHAFT
[HR]
Summary of the inspection items:
Item

Before starting engine

Engine running

After engine stopped

Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Other oils and fluid*

Level

Leakage

Level

Leakage

Leakage

Leakage

—

Leakage

—

Fuel
Exhaust gases

* Transmission/transaxle fluid, power steering fluid, brake fluid, etc.

Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
●
Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-II
and it is directed according to inspection procedure of EC section. Refer to EC-830, «ON BOARD
DIAGNOSTIC (OBD) SYSTEM» (with EURO-OBD) or EC-1264, «ON BOARD DIAGNOSTIC (OBD)
SYSTEM» (without EURO-OBD).
●
Check when engine is cold so as to prevent burns from the splashing engine oil.
1. Check engine oil level. Refer to LU-16, «ENGINE OIL» .
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a. Release the fuel pressure. Refer to EC-860, «FUEL PRESSURE RELEASE» (with EURO-OBD) or EC1281, «FUEL PRESSURE RELEASE» (Without EURO-OBD).
b. Remove intake manifold. Refer to EM-120, «INTAKE MANIFOLD» .
c. Disconnect ignition coil and injector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to EM-151, «CAMSHAFT» .
4. Crank engine, and then make sure that engine oil comes out
from intake valve timing control solenoid valve hole (A). End
crank after checking.
1

: Plug
:Engine front

5.

6.

7.

WARNING:
Be careful not to touch rotating parts (drive belts, idler pulley, and crankshaft pulley, etc.).
CAUTION:
PBIC3706E
● Prevent splashing by using a shop cloth so as to prevent
the worker from injury from engine oil and so as to prevent engine oil contamination.
● Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to
engine and vehicle. Especially, be careful not to apply engine oil to rubber parts of drive belts,
engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
Perform the following inspection if engine oil does not come out from intake valve timing control solenoid
valve oil hole of the cylinder head.
● Remove oil filter, and then clean it. Refer to EM-157, «Oil Filter» .
● Clean oil groove between oil strainer and intake valve timing control solenoid valve.
Refer to LU-15, «Lubrication Circuit» .
Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
● Clean oil groove if necessary. Refer to LU-15, «Lubrication Circuit» .
After inspection, install removed parts in the reverse order.

Valve Clearance

BBS002OW

INSPECTION
Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if
there is unusual engine conditions regarding valve clearance.

EM-166

CAMSHAFT
[HR]
1.
2.
a.

Remove rocker cover. Refer to EM-140, «ROCKER COVER» .
Measure the valve clearance with the following procedure:
Set No. 1 cylinder at TDC of its compression stroke.
● Rotate crankshaft pulley (2) clockwise and align TDC mark
(without paint mark) (A) to timing indicator (1) on front cover.
B

A

EM

: White paint mark

C

D

PBIC3673E

●

●

At the same time, make sure that both intake and exhaust
cam noses of No. 1 cylinder face outside as shown in the figure.
If they do not face outside, rotate crankshaft pulley once more
(360 degrees) and align as shown in the figure.

E

F

G

H
KBIA0400J

b.

Use a feeler gauge, measure the clearance between valve lifter
and camshaft.

I

J

K

SEM139D

L

Valve clearance:
Unit: mm (in)
Cold

Hot * (reference data)

Intake

0.26 — 0.34 (0.010 — 0.013)

0.304 — 0.416 (0.012 — 0.016)

Exhaust

0.29 — 0.37 (0.011 — 0.014)

0.308 — 0.432 (0.012 — 0.017)

M

*:Approximately 80°C (176°F)
●

By referring to the figure, measure the valve clearances at
locations marked “×” as shown in the table below [locations
indicated with black arrow ( ) in the figure] with a feeler
gauge.
A

: No. 1 cylinder compression TDC
: Engine front

Measuring position
Measurement
position

No. 1 CYL.

EXH

×

INT

×

No. 2 CYL.

No. 3 CYL.

No. 4 CYL.

×
×

PBIC3707E

EM-167

CAMSHAFT
[HR]
c.

Rotate crankshaft pulley (2) one revolution (360 degrees) and
align TDC mark (without paint mark) (A) to timing indicator (1) on
front cover.
B

: White paint mark

PBIC3673E

●

By referring to the figure, measure the valve clearance at
locations marked “×” as shown in the table below [locations
indicated with black arrow ( ) in the figure] with a feeler
gauge.
A

: No. 4 cylinder compression TDC
: Engine front

Measuring position
Measurement
point

3.

EXH
INT

No. 1 CYL.

No. 2 CYL.

No. 3 CYL.

No. 4 CYL.

×

×
×

×

PBIC3708E

If out of standard, perform adjustment. Refer to EM-168, «ADJUSTMENT» .

ADJUSTMENT
●

1.
2.
3.

Perform adjustment depending on selected head thickness of valve lifter.
Remove camshaft. Refer to EM-151, «REMOVAL» .
Remove valve lifters at the locations that are out of the standard.
Measure the center thickness of the removed valve lifters with a
micrometer.

KBIA0057E

4.

Use the equation below to calculate valve lifter thickness for replacement.
Valve lifter thickness calculation:
t = t1 + (C1 – C2 )
t
= Valve lifter thickness to be replaced
= Removed valve lifter thickness
t1
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake
: 0.30 mm (0.012 in)
Exhaust
: 0.33 mm (0.013 in)

EM-168

CAMSHAFT
[HR]
●

●

Thickness of new valve lifter can be identified by stamp mark
on the reverse side (inside the cylinder).
Stamp mark “300” indicates 3.00 mm (0.118 in) in thickness.

A

EM

C
KBIA0119E

D

NOTE:
Available thickness of valve lifter: 26 sizes range 3.00 to 3.50 mm (0.118 to 0.137 in) in steps of 0.02 mm
(0.0008 in) (when manufactured at factory). Refer to EM-217, «Available Valve Lifter» .
5. Install the selected valve lifter.
6. Install camshaft. Refer to EM-161, «INSTALLATION» .
7. Manually rotate crankshaft pulley a few rotations.
8. Make sure that valve clearances for cold engine are within specifications by referring to the specified values. Refer to EM-166, «INSPECTION» .
9. Install all removed parts in the reverse order of removal. Refer to EM-161, «INSTALLATION» .
10. Warm up the engine, and check for unusual noise and vibration.

E

F

G

H

I

J

K

L

M

EM-169

OIL SEAL
[HR]

OIL SEAL
Removal and Installation of Valve Oil Seal

PFP:12279
BBS002OX

REMOVAL
1.
2.
3.

4.

Remove camshafts. Refer to EM-151, «CAMSHAFT» .
Remove valve lifters. Refer to EM-151, «CAMSHAFT» .
Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
CAUTION:
When rotating crankshaft, be careful to avoid scarring front cover with timing chain.
Remove valve collet.
● Compress valve spring with the valve spring compressor, the
attachment and the adapter (SST: KV10116200) (A). Remove
valve collet with a magnet hand (B).
CAUTION:
When working, be careful not to damage valve lifter holes.

PBIC3727E

5.
6.

Remove valve spring retainer, valve spring and valve spring seat.
Remove valve oil seal with the valve oil seal puller (SST:
KV10107902) (A).

PBIC3728E

INSTALLATION
1.
2.

Apply new engine oil to valve oil seal joint surface and seal lip.
Press in valve oil seal to the height “H” shown in the figure with
the valve oil seal drift (SST: KV10115600) (A).
Height “H” : 13.2 — 13.8 mm (0.519 — 0.543 in)

PBIC3211J

3.

Install in the reverse order of removal after this step.

EM-170

OIL SEAL
[HR]

Removal and Installation of Front Oil Seal

BBS002OY

A

REMOVAL
1.

2.

Remove the following parts.
● Front fender protector (RH); Refer to EI-14, «FENDER PROTECTOR» .
● Drive belt; Refer to EM-114, «DRIVE BELTS» .
● Crankshaft pulley; Refer to EM-142, «TIMING CHAIN» .
Remove front oil seal with a suitable tool.
CAUTION:
Be careful not to damage front cover and crankshaft.

EM

C

D

INSTALLATION
1.
2.

Apply new engine oil to new front oil seal joint surface and seal lip.
Install front oil seal so that each seal lip is oriented as shown in
the figure.
A

: Dust seal lip

B

: Oil seal lip

E

F

: Engine outside
: Engine inside

G

PBIC3485J

●

Press-fit front oil seal (2) using a drift with outer diameter 50
mm (1.97 in) and inner diameter 44 mm(1.73 in) (commercial
service tool) (A) so as to be the dimension specified in the figure.
1

I

: Front cover

J

: Engine front

CAUTION:
● Be careful not to damage front cover and crankshaft.
● Press-fit oil seal straight to avoid causing burrs or tilting.
3.

H

Install in the reverse order of removal after this step.

K
PBIC3729E

L

M

EM-171

OIL SEAL
[HR]

Removal and Installation of Rear Oil Seal

BBS002OZ

REMOVAL
1.
2.
3.
4.

Remove transaxle assembly. Refer to MT-7, «REMOVAL AND INSTALLATION» for M/T models, AT-356,
«TRANSAXLE ASSEMBLY» for A/T models.
Remove clutch cover and clutch disk.
Refer to CL-11, «CLUTCH DISC, CLUTCH COVER AND FLYWHEEL» .
Remove drive plate (A/T models) or flywheel (M/T models). Refer to EM-189, «CYLINDER BLOCK» .
Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.

INSTALLATION
1.
2.

Apply the liquid gasket lightly to entire outside area of new rear oil seal.
Use Genuine Liquid Gasket or equivalent.
Install rear oil seal so that each seal lip is oriented as shown in
the figure.
A

: Dust seal lip

B

: Oil seal lip
: Engine outside
: Engine inside

PBIC3485J

●

Press-fit rear oil seal with a drift outer diameter 113 mm (4.45
in) and inner diameter 90 mm (3.54 in) (commercial service
tool) (A).
CAUTION:
● Be careful not to damage crankshaft and cylinder
block.
● Press-fit oil seal straight to avoid causing burrs or tilting.
● Do not touch grease applied onto oil seal lip.
PBIC3660E

●

Press in rear oil seal (1) to the position as shown in the figure.
A

: Rear end surface of cylinder block

PBIC3761E

3.
4.

After press-fitting rear oil seal, completely wipe off any liquid gasket protruding to rear end surface side.
Install in the reverse order of removal after this step.

EM-172

CYLINDER HEAD
[HR]

CYLINDER HEAD
On-Vehicle Service

PFP:11041

A
BBS002P0

CHECKING COMPRESSION PRESSURE
1.
2.
3.

Warm up engine thoroughly. Then, stop it.
EM
Release fuel pressure. Refer to EC-860, «FUEL PRESSURE RELEASE» (with EURO-OBD) or EC-1281,
«FUEL PRESSURE RELEASE» (without EURO-OBD).
Disconnect fuel pump fuse (1) to avoid fuel injection during meaC
surement.
: Vehicle front

D

E

PBIA9861J

4.
5.
6.
7.

Remove engine cover. Refer to EM-120, «INTAKE MANIFOLD» .
Remove ignition coil and spark plug from each cylinder. Refer to EM-132, «IGNITION COIL» and EM-133,
«SPARK PLUG (PLATINUM-TIPPED TYPE)» .
Connect an engine tachometer (not required in use of CONSULT-II).
Install a compression tester (B) with an adapter (commercial
service tool) (A) onto spark plug hole.

F

G

H

I

J

PBIC3730E

●

Use the adapter whose picking up end inserted to spark plug
hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it
may be caught by cylinder head during removal.

K

L

M

SBIA0533E

8.

With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each
cylinder.
Compression pressure:
Unit: kPa (bar, kg/cm2 , psi) /rpm
Standard

Minimum

1,510 (15.1, 15.4, 219) / 200

1,265 (12.65, 12.9, 183) / 200

Differential limit between cylinders

CAUTION:
Always use fully a changed battery to obtain the specified engine speed.

EM-173

981 (9.81, 10.0, 142) / 200

CYLINDER HEAD
[HR]
If the engine speed is out of the specified range, check battery liquid for proper gravity. Check engine
speed again with normal battery gravity.
● If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure the compression pressure again.
● If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole
of the cylinder to re-check it for compression.
– If the added engine oil improves the compression, piston rings may be worn out or damaged. Check
piston rings and replace if necessary.
– If the compression pressure remains at low level despite the addition of engine oil, valves may be malfunctioning. Check valves for damage. Replace valve or valve seat accordingly.
● If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, cylinder head gasket is leaking. In such a case, replace cylinder head gasket.
9. After inspection is completed, install removed parts.
10. Start the engine, and confirm that the engine runs smoothly.
11. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-863, «TROUBLE DIAGNOSIS» (with
EURO-models) or EC-1284, «TROUBLE DIAGNOSIS» (without EURO-models).
●

Components

BBS002P1

PBIC3731E

1.

Cylinder head assembly

4.

Cylinder head gasket

A.

Refer to EM-176

2.

Cylinder head bolt

3.

Washer

Refer to GI-11 for symbol marks in the figure.

Removal and Installation

BBS002P2

REMOVAL
1.
2.

3.

Release fuel pressure. Refer to EC-860, «FUEL PRESSURE RELEASE» (with EURO-OBD) or EC-1281,
«FUEL PRESSURE RELEASE» (without EURO-OBD).
Drain engine coolant and engine oil. Refer to CO-28, «Changing Engine coolant» and LU-17, «Changing
Engine Oil» .
CAUTION:
Perform this step when the engine is cold.
Remove the following components and related parts.
● Exhaust manifold; Refer to EM-124, «EXHAUST MANIFOLD» .
● Intake manifold; Refer to EM-120, «INTAKE MANIFOLD» .

EM-174

CYLINDER HEAD
[HR]
Fuel tube and fuel injector; Refer to EM-135, «FUEL INJECTOR AND FUEL TUBE» .
Water outlet; Refer to CO-40, «WATER OUTLET» .
● Front fender protector (RH); Refer to EI-14, «FENDER PROTECTOR» .
● Drive belt; Refer to EM-114, «DRIVE BELTS» .
● Front cover; Refer to EM-142, «TIMING CHAIN» .
● Camshaft; Refer to EM-151, «CAMSHAFT» .
Remove cylinder head loosening bolts in reverse order as
shown in the figure with cylinder head wrench (commercial service tool).
●

A

●

4.

A

: EXH side

B

: INT side

EM

C

D

: Engine front

E

PBIC3732E

5.

Remove cylinder head gasket.

INSPECTION AFTER REMOVAL
Cylinder Head Bolts Outer Diameter
●

G

Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between “d1” and “d2”
exceeds the limit, replace them with a new one.

H

Limit (“d1” – “d2”): 0.15 mm (0.0059 in)
●

F

I

If reduction of outer diameter appears in a position other than
“d2”, use it as “d2” point.

J

PBIC3717E

K

Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checking.
Refer to EM-209, «CYLINDER BLOCK DISTORTION» .
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
CAUTION:
Use utmost care not to allow gasket debris to enter passages for engine oil or engine coolant.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions.

Limit
●

A

: Straightedge

B

: Feeler gauge

: 0.1 mm (0.004 in)

If it exceeds the limit, replace cylinder head.

PBIC3207J

EM-175

L

M

CYLINDER HEAD
[HR]
INSTALLATION
1.
2.

Install new cylinder head gasket.
Tighten cylinder head bolts in numerical order as shown in the
figure with the following procedure to install cylinder head.
A

: EXH side

B

: INT side
: Engine front

a.
b.

CAUTION:
If cylinder head bolts are re-used, check their outer diameters before installation. Refer to EM-175, «Cylinder Head
Bolts Outer Diameter» .
Apply new engine oil to threads and seating surfaces of mounting bolts.
Tighten all bolts.

PBIC3732E

: 66.7 N·m (6.8 kg-m, 49 ft-lb)
c.

Completely loosen.
: 0 N·m (0 kg-m, 0 ft-lb)

d.

CAUTION:
In this step, loosen bolts in reverse order of that indicated in the figure.
Tighten all bolts.
: 40.0 N·m (4.1 kg-m, 30 ft-lb)

e.

f.

Turn all bolts 75 degrees clockwise (angle tightening).
CAUTION:
Check and confirm the tightening angle by using the angle
wrench (SST: KV10112100) (A) or protractor. Avoid judgment by visual inspection without the tool.
Turn all bolts 75 degrees clockwise again (angle tightening).

PBIC3733E

3.

Install in the reverse order of removal after this step.

INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
●
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS» .
●
Use procedure below to check for fuel leakage.
–
Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
–
Start engine. With engine speed increased, check again for fuel leakage at connection points.
●
Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises.
●
Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.

EM-176

CYLINDER HEAD
[HR]
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.

●
●

Summary of the inspection items:
Item

EM

Before starting engine

Engine running

After engine stopped

Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Other oils and fluid*

Level

Leakage

Level

Leakage

Leakage

Leakage

—

Leakage

—

Fuel
Exhaust gases

A

C

D

* Transmission/transaxle fluid, power steering fluid, brake fluid, etc.

Components

BBS002P3

E

F

G

H

I

J

K

L

M
PBIC3734E

1.

Spark plug

4.

Valve spring

5.

Valve spring seat

6.

Valve oil seal

7.

Valve guide (EXH)

8.

Valve guide (INT)

9.

Cylinder head

10. Valve seat (EXH)

2.

Valve collet

11. Valve (EXH)

13. Valve (INT)
A.

Refer to EM-180

B.

Refer to EM-181

Refer to GI-11, «Components» for symbol marks in the figure.

EM-177

3.

Valve spring retainer

12. Valve seat (INT)

CYLINDER HEAD
[HR]

Disassembly and Assembly

BBS002P4

DISASSEMBLY
1.
2.
3.

Remove spark plug with a spark plug wrench (commercial service tool).
Remove valve lifter.
● Identify installation positions, and store them without mixing them up.
Remove valve collet.
● Compress valve spring with the valve spring compressor, the
attachment and the adapter (SST: KV10116200) (A). Remove
valve collet with a magnet hand (B).
CAUTION:
When working, be careful not to damage valve lifter holes.

PBIC3727E

4.
5.
6.

Remove valve spring retainer and valve spring.
Push valve stem to combustion chamber side, and remove valve.
● Identify installation positions, and store them without mixing them up.
Remove valve oil seal with the valve oil seal puller (SST:
KV10107902) (A).

PBIC3728E

7.
8.
9.

Remove valve spring seat.
When valve seat must be replaced, refer to EM-181, «VALVE SEAT REPLACEMENT» to removal.
When valve guide must be replaced, refer to EM-180, «VALVE GUIDE REPLACEMENT» to removal.

ASSEMBLY
1.
2.
3.

Install valve guide if removed. Refer to EM-180, «VALVE GUIDE REPLACEMENT» .
Install valve seat if removed. Refer to EM-181, «VALVE SEAT REPLACEMENT» .
Install valve oil seal.
● Install with the valve oil seal drift (SST: KV10115600) (A) to
match dimension in the figure.
Height “H”

: 13.2 — 13.8 mm (0.519 — 0.543 in)

PBIC3211J

4.
5.
6.

Install valve spring seat.
Install valve.
● Install larger diameter to intake side.
Install valve spring.

EM-178

CYLINDER HEAD
[HR]

7.
8.

NOTE:
It can be installed in either direction.
Install valve spring retainer.
Install valve collet.
● Compress valve spring with the valve spring compressor, the
attachment and the adapter (SST: KV10116200) (A). Install
valve collet with a magnet hand (B).
CAUTION:
When working, be careful not to damage valve lifter
holes.
● Tap valve stem edge lightly with a plastic hammer after installation to check its installed condition.

A

EM

C

D

PBIC3727E

9. Install valve lifter.
10. Install spark plug with a spark plug wrench (commercial service tool).

Inspection After Disassembly

F
BBS002P5

VALVE DIMENSIONS
●
●

E

G

Check dimensions of each valve. For dimensions, refer to EM-216, «Valve Dimensions» .
If dimensions are out of the standard, replace valve.

VALVE GUIDE CLEARANCE
Valve Stem Diameter

H

Measure the diameter of valve stem with a micrometer.
Standard
Intake
Exhaust

I

: 4.965 — 4.980 mm (0.1954 — 0.1960 in)
: 4.955 — 4.970 mm (0.1950 — 0.1956 in)

J

K

SEM938C

L

Valve Guide Inner Diameter
Measure the inner diameter of valve guide with a bore gauge.
Standard
Intake and Exhaust
: 5.000 — 5.018 mm (0.1968 — 0.1975 in)

Valve Guide Clearance
(Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).
Valve guide clearance:
Standard
Intake
: 0.020 — 0.053 mm (0.0008 — 0.0021 in)
Exhaust : 0.030 — 0.063 mm (0.0012 — 0.0025 in)
Limit
Intake
: 0.1 mm (0.004 in)
Exhaust : 0.1 mm (0.004 in)
●

If it exceeds the limit, replace valve guide and/or valve. When valve guide must be replaced, refer to EM180, «VALVE GUIDE REPLACEMENT» .

EM-179

M

CYLINDER HEAD
[HR]
VALVE GUIDE REPLACEMENT
When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide.
1. To remove valve guide, heat cylinder head to 110 to 130°C (230
to 266°F) by soaking in heated oil.

SEM008A

2.

Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US
ton, 2.0 lmp ton) force] or hammer and valve guide drift (commercial service tool).
CAUTION:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.

SEM931C

3.

Ream cylinder head valve guide hole with a valve guide reamer
(commercial service tool).
Valve guide hole diameter (for service parts):
Intake and exhaust
: 9.175 — 9.196 mm (0.3612 — 0.3620 in)

SEM932C

4.

Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.

SEM008A

EM-180

CYLINDER HEAD
[HR]
5.

Using a valve guide drift (commercial service tool), press valve
guide (1) from camshaft side to dimensions as shown in the figure.
Projection “H”:

A

: 11.4 — 11.8 mm (0.448 — 0.464 in)
EM

CAUTION:
Cylinder head (2) contains heat, when working, wear protective equipment to avoid getting burned.

C
PBIC3217J

D

6.

Apply reamer finish to valve guide with a valve guide reamer
(commercial service tool).
E

Standard
5.000 — 5.018 mm (0.1968 — 0.1975 in)

F

G
SEM932C

VALVE SEAT CONTACT
●

●

●

●

After confirming that the dimensions of valve guides and valves are within specifications, perform this procedure.
Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the
valve contact on the surface.
Check if the contact area band is continuous all around the circumference.
If not, grind to adjust valve fitting and check again. If the contacting surface still has NG conditions even after the re-check,
replace valve seat. Refer to EM-181, «VALVE SEAT REPLACEMENT» .

H

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SBIA0322E

VALVE SEAT REPLACEMENT

M

When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-219, «Valve Seat» .
CAUTION:
Prevent to scratch cylinder head by excessive boring.
2. Ream cylinder head recess diameter for service valve seat.
Oversize [0.5 mm (0.020 in)]
Intake
: 31.900 — 31.916 mm (1.2559 — 1.2565 in)
Exhaust : 26.400 — 26.416 mm (1.0393 — 1.0399 in)
●

Be sure to ream in circles concentric to the valve guide center.
This will enable valve seat to fit correctly.

SEM795A

EM-181

CYLINDER HEAD
[HR]
3.

Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.

SEM008A

4.

Provide valve seats cooled well with a dry ice. Press-fit valve seats into cylinder head.
CAUTION:
● Avoid directly to touching cold valve seats.
● Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.

5.

Using a valve seat cutter set (commercial service tool) or a valve
seat grinder, finish valve seat to the specified dimensions. For
dimensions, refer to EM-219, «Valve Seat» .
CAUTION:
When using a valve seat cutter, firmly grip the cutter handle
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with the cutter or cutting many different times
may result in stage valve seat.
SEM934C

6.
7.

Using compound, grind to adjust valve fitting.
Check again for normal contact. Refer to EM-181, «VALVE SEAT CONTACT» .

VALVE SPRING SQUARENESS
●

Set a try square along the side of valve spring and rotate valve
spring. Measure the maximum clearance between the top of
valve spring and try square.
Limit

●

: 1.8 mm (0.070 in)

If it exceeds the limit, replace valve spring.

PBIC0080E

VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD
●

Check valve spring pressure with valve spring seat installed at
the specified spring height.

SEM113

EM-182

CYLINDER HEAD
[HR]
Standard:
Free height

42.26 mm (1.6637 in)

Installation height

32.40 mm (1.2755 in)

Installation load

136 — 154 N (13.9 — 15.7 kg, 31 — 35 lb)

Height during valve open

EM

23.96 mm (0.9433 in)

Load with valve open
●

A

262 — 296 N (26.7 — 30.2 kg, 59 — 67 lb)

If the installation load or load with valve open is out of the standard, replace valve spring.

C

D

E

F

G

H

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M

EM-183

ENGINE ASSEMBLY
[HR]

ENGINE ASSEMBLY
Components

PFP:10001
BBS002P6

MBIB1379E

1.

Engine mounting insulator (LH)

2.

Engine mounting bracket (LH)

3.

Engine mounting insulator (RH)

4.

Engine mounting stay (RH)

5.

Engine mounting bracket (RH)

6.

Rear engine mounting bracket

7.

Rear torque rod

8.

Washer

9.

Engine mountin bracket (LH)

A.

Front mark

Refer to GI-11, «Components» for symbol marks in the figure.

Removal and Installation

BBS002P7

WARNING:
●
Situate the vehicle on a flat and solid surface.
●
Place chocks at front and back of rear wheels.
●
Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not
equipped.
CAUTION:
●
Always be careful to work safely, avoid forceful or uninstructed operations.
●
Do not start working until exhaust system and coolant are cool enough.

EM-184

ENGINE ASSEMBLY
[HR]
If items or work required are not covered by the engine section, refer to the applicable sections.
A
Always use the support point specified for lifting.
●
Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for
unavoidable reasons, support at the rear axle jacking point with a transmission jack or similar tool
before starting work, in preparation for the backward shift of center of gravity.
EM
●
For supporting points for lifting and jacking point at rear axle, refer to GI-40, «Garage Jack, Safety
Stand and 2-Pole Lift» .
C
REMOVAL
●
●

Outline
Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the
transaxle.

D

Preparation
1.
2.
3.
4.

5.

When engine can be hoisted, remove hood assembly. Refer to BL-8, «Removal and Installation» .
When engine can be hoisted, remove cowl top cover and cowl top extension assembly. Refer to EI-12,
«COWL TOP» .
Release fuel pressure. Refer to EC-860, «FUEL PRESSURE RELEASE» (with EURO-OBD) or EC-1281,
«FUEL PRESSURE RELEASE» (without EURO-OBD).
Drain engine coolant from radiator. Refer to CO-28, «Changing Engine coolant» .
CAUTION:
Perform this step when the engine is cold.
Remove the following parts.
● Engine undercover
● Remove headlamp. Refer to LT-32, «Removal and Installation» or LT-51, «Removal and Installation» .
● Remove cowl top. Refer to EI-12, «COWL TOP»
● Front fender protector (RH and LH); Refer to EI-14, «FENDER PROTECTOR» .
● Front road wheels and tires; Refer toWT-5, «ROAD WHEEL AND TYRE ASSEMBLY» .
● Battery and battery tray; Refer to SC-5, «BATTERY» .
● Drive belt; Refer to EM-114, «DRIVE BELTS» .
● Air duct and air cleaner case assembly; Refer to EM-118, «AIR CLEANER AND AIR DUCT» .
● Radiator hose (upper and lower) A/T fluide cooler and cooling fan assembly; Refer to CO-31, «RADIATOR» .
● Exhaust front tube; Refer to EX-3, «EXHAUST SYSTEM» .

2.
3.
4.
5.

Disconnect all connections of engine harness around the engine mounting insulator (LH), and then temporarily secure the engine harness into the engine side.
CAUTION:
Protect connectors using a resin bag to protect against foreign materials during the operation.
Disconnect fuel feed hose at engine side. Refer to EM-135, «FUEL INJECTOR AND FUEL TUBE» .
Disconnect heater hoses, and install plugs them to prevent engine coolant from draining.
Refer to CO-40, «WATER OUTLET» .
Disconnect control linkage from transaxle. Refer to MT-12, «CONTROL LINKAGE» .
Remove ground cable at transaxle side.

Engine Room RH
1.
2.
3.

F

G

H

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K

L

Engine Room LH
1.

E

Remove ground cable between front cover and vehicle.
Alternator and alternator bracket; Refer to SC-40, «Removal and Installation (HR Engine Models)» .
Remove A/C compressor (with A/C models) with piping connected from the engine. Temporarily secure it
on the vehicle side with a rope to avoid putting load on it. Refer to ATC-140, «Removal and Installation of
Compressor» (with auto A/C models) or MTC-86, «Removal and Installation of Compressor» (with manual
A/C models).

EM-185

M

ENGINE ASSEMBLY
[HR]
Vehicle Underbody
1.
2.
3.
4.

Remove front wheel sensor (LH and RH) for ABS from steering knuckle. Refer to BRC-86, «WHEEL SENSORS» (with ESP models) or BRC-36, «WHEEL SENSORS» (without ESP models).
Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on the
vehicle side with a rope to avoid load on it. Refer to BR-21, «FRONT DISC BRAKE» .
Remove drive shafts (LH and RH) from steering knuckle. Refer to FAX-10, «FRONT DRIVE SHAFT» .
Remove rear torque rod (1).

MBIB1377E

PBIC3737E

5.

Preparation for the separation work of transaxle is as follows:
● Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to MT-7, «REMOVAL
AND INSTALLATION» or AT-356, «TRANSAXLE ASSEMBLY» .

Removal
1.
2.

When engine can be hoisted, remove the intake manifold to prevent the hanging chain from interfering.
Refer to EM-120, «INTAKE MANIFOLD» .
When engine can be hoisted, install engine slinger to cylinder
head front left side (A) and rear right side (B) and support the
engine position with a hoist.
: Engine front

Slinger bolts
: 25.5 N·m (2.6 kg-m, 19 ft-lb)

PBIC3738E

3.

Lift with a hoist and secure the engine in appropriate position.

EM-186

ENGINE ASSEMBLY
[HR]
4.

Use a manual lift table caddy (commercial service tool) (A) or
equivalently rigid tool such as a transmission jack. Securely support bottom of the engine and the transaxle, and simultaneously
adjust hoist tension.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.

A

EM

C
PBIC1454E

D

5.

6.

Remove engine mounting stay (RH) (1), engine mounting insulator (RH) (2) and engine mounting bracket (RH) (3).
4

: Engine mounting insulator (LH)

A

: Engine front side

B

: Transaxle side

E

F

Remove engine mounting through bolt-securing nut (C).

G
MBIB1378E

7.

Remove the engine and the transaxle assembly from the vehicle downward by carefully operating supporting tools.
CAUTION:
● During the operation, make sure that no part interferes with the vehicle side.
● Before and during this lifting, always check if any harnesses are left connected.
● During the removal operation, always be careful to prevent the vehicle from falling off the lift
due to changes in the center of gravity.
● If necessary, support the vehicle by setting jack or suitable tool at the rear.

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Separation
CAUTION:
During operation, securely support the engine by placing a piece of wood under the engine oil pan and
transaxle oil pan. Securely support the engine slingers with a hoist.
1. When the engine hoisting is not performed simultaneously, install engine slinger to cylinder head front left
side and rear right side. Refer to EM-185, «REMOVAL» .
2. Remove starter motor. Refer to SC-51, «Removal and Installation (HR Engine Models)» .
3. Lift with a hoist and position above engine.
4. Separate the engine and the transaxle. Refer to MT-7, «REMOVAL AND INSTALLATION» or AT-356,
«TRANSAXLE ASSEMBLY» .

INSTALLATION
Note the following, and install in the reverse order of removal.
●
Do not allow engine oil to get on engine mounting insulator. Be careful not to damage engine mounting
insulator.
●
When installation directions are specified, install parts according to the direction marks on them referring
to the figure of components. Refer to EM-184, «Components» .
●
Make sure that each mounting insulator is seated properly, and tighten mounting nuts and bolts.

EM-187

K

L

M

ENGINE ASSEMBLY
[HR]
●

Tighten engine mounting insulator (RH) bolts in the numerical
order shown in the figure.
: Vehicle front

MBIB1380E

INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
●
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS» .
●
Use procedure below to check for fuel leakage.
–
Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
–
Start engine. With engine speed increased, check again for fuel leakage at connection points.
●
Run engine to check for unusual noise and vibration.
●
Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
●
Bleed air from lines and hoses of applicable lines, such as in cooling system.
●
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
Before starting engine

Engine running

After engine stopped

Engine coolant

Item

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Other oils and fluid*

Level

Leakage

Level

Leakage

Leakage

Leakage

—

Leakage

—

Fuel
Exhaust gases

* Transmission/transaxle fluid, power steering fluid, brake fluid, etc.

EM-188

CYLINDER BLOCK
[HR]

CYLINDER BLOCK
Components

PFP:11010

A
BBS002P8

EM

C

D

E

F

G

H

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K

L

M

PBIC3770E

EM-189

CYLINDER BLOCK
[HR]
1.

Crank shaft position sensor (POS)
cover

2.

Crankshaft position sensor (POS)

3.

O-ring

4.

Water drain plug

5.

Cylinder block

6.

Oil level gauge

7.

Oil level gauge guide

8.

O-ring

9.

Knock sensor

10. Oil pressure switch

11. Top ring

12. Second ring

13. Oil ring

14. Piston pin

15. Piston

16. Connecting rod

17. Connecting rod bearing (upper)

18. Main bearing (upper)

19. Thrust bearing

20. Crankshaft key

21. Connecting rod bolt

22. Connecting rod cap

23. Connecting rod bearing (lower)

24. Main bearing (lower)

25. Crankshaft

26. Pilot converter (A/T models)

27. Signal plate

28. Rear oil seal

29. Drive plate (A/T models)

30. Reinforcement plate (A/T models)

31. Flywheel (M/T models)

32. Main bearing cap

33. Main bearing cap bolt

A.

B.

Refer to EM-193

Refer to EM-193

Refer to GI-11 for symbol marks in the figure.

Disassembly and Assembly

BBS002P9

DISASSEMBLY
NOTE:
Explained here is how to disassemble with an engine stand supporting mating surface of transaxle. When
using different type of engine stand, note with difference in steps and etc.
1. Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the
engine. Refer to EM-184, «ENGINE ASSEMBLY» .
2. Remove clutch cover and clutch disc. Refer to CL-11, «CLUTCH DISC, CLUTCH COVER AND FLYWHEEL» .
3. Remove flywheel (M/T models) or drive plate (A/T models).
● Secure flywheel or drive plate with a stopper plate (SST:
KV11105210) (A), and remove mounting bolts.
● Using TORX socket (size E20), loosen mounting bolts.
CAUTION:
Be careful not to damage or scratch drive plate (A/T models) and contact surface for clutch disc of flywheel.

MBIB1382E

4.

Lift the engine with a hoist to install it onto widely use engine stand.
CAUTION:
● Use the engine stand that has a load capacity [approximately 150 kg (331 lb) or more] large
enough for supporting the engine weight.
● If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the
potential risk of overturning stand.
– Intake manifolds; Refer to EM-120, «INTAKE MANIFOLD» .
– Exhaust manifold; Refer to EM-124, «EXHAUST MANIFOLD» .
– Rocker cover; Refer to EM-140, «ROCKER COVER» .

EM-190

CYLINDER BLOCK
[HR]
NOTE:
The figure shows an example of widely use engine stand that
can support mating surface of transaxle with flywheel or drive
plate removed.
CAUTION:
Before removing the hanging chains, make sure the engine
stand is stable and there is no risk of overturning.

A

EM

C

PBIC0085E

5.
6.

Drain engine oil. Refer to LU-16, «ENGINE OIL» .
Drain engine coolant by removing water drain plug (1) from
inside of the engine.

D

E

: Engine front

F

G

PBIC3742E

Remove cylinder head. Refer to EM-174, «Removal and Installation» .
Remove oil pan (upper and lower). Refer to EM-127, «OIL PAN AND OIL STRAINER» .
Remove knock sensor.
CAUTION:
Carefully handle knock sensor avoiding shocks.
10. Remove cover, and then crankshaft position sensor (POS).

7.
8.
9.

H

I

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: Engine front
1.

Crank shaft position sensor (POS)

2.

O ring

3.

Cover

A.

Cylinder block LHD side

K

L

CAUTION:
● Avoid impacts such as a dropping.
● Do not disassemble.
● Keep it away from metal particles.
● Do not place the sensor in a location where it is exposed to magnetism.

M
MBIB1383E

11. Remove pilot converter (1) using the pilot bushing puller (SST:
ST16610001) (A) or suitable tool. (A/T models)
NOTE:
M/T models have no pilot bushing.

PBIC3743E

12. Remove piston and connecting rod assembly with the following procedure:

EM-191

CYLINDER BLOCK
[HR]
Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer
to EM-206, «CONNECTING ROD SIDE CLEARANCE» .
Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
Remove connecting rod cap.
Using a hammer handle or similar tool, push piston and connecting rod assembly out to the cylinder head side.
CAUTION:
● Be careful not to damage matching surface with connecting rod cap.
● Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod
big end.
●

a.
b.
c.

KBIA3365J

13. Remove connecting rod bearings.
CAUTION:
Identify installation positions, and store them without mixing them up.
14. Remove piston rings form piston.
● Before removing piston rings, check the piston ring side clearance.
Refer to EM-207, «PISTON RING SIDE CLEARANCE» .
● Use a piston ring expander (commercial service tool).
CAUTION:
● When removing piston rings, be careful not to damage
the piston.
● Be careful not to damage piston rings by expanding
them excessively.

PBIC0087E

15. Remove piston from connecting rod.
● Use a piston pin press stand (SST) and a press to remove the
piston pin.
● For the details of SST, refer to the following.
Press stand
Drift
Center cap

: ST13030020
: KV10109730
: KV10110310

CAUTION:
Be careful not to damage the piston and connecting rod.
NOTE:
The joint between the connecting rod and the piston pin is a press fit.
16. Remove the main bearing cap in the following procedure.
● Measure crankshaft end play before loosening main bearing cap bolts.
Refer to EM-206, «CRANKSHAFT END PLAY» .

EM-192

KBIA3470J

CYLINDER BLOCK
[HR]
a.

Loosen and remove bolts in several steps in reverse of the
numerical order shown in the figure.

A

: Engine front
●

TORX socket (size: E14) can be used.

EM

C
PBIC3744E

D

b.

Remove the main bearing cap from the cylinder block while tapping lightly with a plastic hammer.

17. Remove crankshaft (2).
CAUTION:
● Be careful not damage or deform signal plate (1) mounted
on crankshaft.
● When setting crankshaft on a flat floor surface, use a
block of wood to avoid interference between signal plate
and the floor surface.
● Do not remove signal plate unless it is necessary to do
so.
NOTE:
PBIC3745E
When removing or installing signal plate, use TORX socket (size
T40).
18. Pull rear oil seal out from rear end of crankshaft.
19. Remove main bearing (upper and lower) and thrust bearings from cylinder block and main bearing cap.
CAUTION:
Identify installation positions, and store them without mixing them up.

2.

F

G

H

I

J

ASSEMBLY
1.

E

Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.
CAUTION:
Use a goggles to protect your eye.
Install water drain plug (1) to cylinder block as shown in the figure.

K

L

: Engine front

M

Use Genuine Liquid Gasket or equivalent.
: 9.8 N·m (1.0 kg-m, 87 in-lb)

PBIC3742E

3.
a.

Install main bearings and thrust bearings with the following procedure:
Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block.

EM-193

CYLINDER BLOCK
[HR]
b.

Install thrust bearings to the both sides of the No. 3 journal housing (B) on cylinder block.
: Engine front
●

Install thrust bearings with the oil groove (A) facing crankshaft
arm (outside).

PBIC3258J

c.

Install the main bearings (1) paying attention to the direction.
● Install the one with oil holes (A) onto cylinder block and the
one without oil holes onto main bearing cap.
● Before installing main bearings, apply new engine oil to the
bearing surface (inside). Do not apply engine oil to the back
surface, but thoroughly clean it.
● Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
PBIC3746E

●

Install the main bearing in the position shown in the figure.
1

: Cylinder block

2

: Main bearing (upper)

3

: Main bearing (lower)

4

: Main bearing cap
: Engine front

NOTE:
Install the main bearing in the center position with the following dimension. For service operation, the center position can
be checked visually.
Journal position
L1 [Unit: mm (in)]

L2 [Unit: mm (in)]

4.
a.

c.

No. 1

No. 2

No. 3

No. 4

No. 5

1.65–2.05

1.25–1.65

2.30–2.70

1.25–1.65

1.60–2.00

(0.064-0.080)

(0.049-0.064)

(0.090-0.106)

(0.049-0.064)

(0.062-0.078)

1.30–1.70

1.30–1.70

2.30–2.70

1.30–1.70

1.30–1.70

(0.051-0.066)

(0.051-0.066)

(0.090-0.106)

(0.051-0.066)

(0.051-0.066)

CAUTION:
Dimension L1 of journal No. 3 is the distance from the housing base end surface (bulk) (it is not
the distance from the thrust bearing mounting end surface).
Install signal plate to crankshaft if removed.
Set the signal plate (1) with the flange facing toward the counterweight side (engine front side) to the crankshaft rear surface.
A

b.

PBIC3747E

: Dowel pin hole

After positioning crankshaft and signal plate with positioning
dowel pin, tighten bolt.
NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for
each.
Remove dowel pin.
PBIC3748E

EM-194

CYLINDER BLOCK
[HR]

5.

6.

CAUTION:
Be sure to remove dowel pin.
Install crankshaft to cylinder block.
● While turning crankshaft by hand, make sure that it turns smoothly.
CAUTION:
Do not install rear oil seal yet.
Install main bearing caps.
● Install the main bearing cap while referring to the front mark
(B) and the journal number stamp (A).

A

EM

C

: Engine front

D

NOTE:
Main bearing cap cannot be replaced as a single parts,
because it is machined together with cylinder block.

E

PBIC3749E

7.

Tighten main bearing cap bolts in numerical order shown in the
figure with the following steps.

F

G

: Engine front

a.
b.

H

Apply new engine oil to threads and seat surfaces of the mounting bolts.
Tighten main bearing cap bolts.

I

: 32.4 N·m (3.3 kg-m, 24 ft-lb)
PBIC3744E

c.

J

Turn main bearing cap bolts 60 degrees clockwise (angle tightening) in numerical order shown in the figure.
CAUTION:
Check and confirm the tightening angle by using the angle
wrench (SST: KV10112100) (A) or protractor. Avoid judgment by visual inspection without the tool.

K

L

M
PBIC3750E

●
●

8.
a.

After installing the mounting bolts, make sure that crankshaft can be rotated smoothly by hand.
Check crankshaft end play. Refer to EM-206, «CRANKSHAFT END PLAY» .
Install piston to connecting rod with the following procedure:
Set so that the front mark (A) on the piston head and the cylinder number (C) are in the position shown in the figure.
B

: Oil hole

D

: Connecting rod big end grade

NOTE:
The symbols without notes are for management

PBIC3766E

EM-195

CYLINDER BLOCK
[HR]
b.

Press-fit the piston pin using the piston pin press stand (SST).
● For the details of SST, refer to the following.
Press stand
Spring
Drift
Center shaft
Center cap

: ST13030020
: ST13030030
: KV10109730
: KV10114120
: KV10110310

CAUTION:
Press-fit the piston so as not to damage it.
NOTE:
The joint between the connecting rod and the piston pin is a press fit.
●

KBIA3470J

Press-fit the piston pin (2) from piston surface“A” to the depth
of 2.35 mm (0.092 in).
1

: Connecting rod
: Press-fit direction

●

After finishing work, make sure that the piston (3) moves
freely.

PBIC3751E

9.

Using a piston ring expander (commercial service tool), install piston rings.
CAUTION:
● Be careful not to damage piston.
● Be careful not to damage piston rings by expanding them excessively.
● Position each ring with the gap as shown in the figure referring to the piston front mark (B).

●

A

: Oil ring upper or lower rail gap (either of them)

C

: Second ring and oil ring spacer gap

D

: Top ring gap

Install second ring with the stamped mark (E) facing upward.
Stamped mark:
Second ring

:R
PBIC3752E

10. Install connecting rod bearings to connecting rod and connecting rod cap.
● When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not
apply engine oil to the back surface, but thoroughly clean it.
● Install the bearing in the center position.
NOTE:
There is no stopper tab.
● Make sure that the oil holes on connecting rod and connecting rod bearing are aligned.

EM-196

CYLINDER BLOCK
[HR]
●

Install the connecting rod in the dimension shown in the figure.
A

EM

C

MBIB1429E

1

: Connecting rod

2

4

: Connecting rod cap

: Connecting rod bearing (upper)

3

D

: Connecting rod bearing (lower)

: Engine front

E

NOTE:
Install the connecting rod bearing in the center position with the dimension shown in the figure. For service operation, the center position can be checked visually.
11. Install piston and connecting rod assembly to crankshaft.
● Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
● Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
● Match the cylinder position with the cylinder number on connecting rod to install.
● Using the piston ring compressor (SST: EM03470000) (A) or
suitable tool, install piston with the front mark on the piston
head facing the front of the engine.
CAUTION:
● Be careful not to damage matching surface with connecting rod cap.
● Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.

F

G

H

I

J

K
PBIC3765E

12. Install connecting rod cap.
● Match the stamped cylinder number marks (C) on connecting
rod with those on connecting rod cap to install.
A

: Front mark

B

: Oil hole

D

: Connecting rod big end grade

L

M

PBIC3766E

13. Inspect outer diameter of connecting rod bolts.
Refer to EM-214, «CONNECTING ROD BOLT OUTER DIAMETER» .
14. Tighten connecting rod bolt with the following procedure:
a. Apply new engine oil to the threads and seats of connecting rod bolts.
b. Tighten bolts in several steps.
: 27.5 N·m (2.8 kg-m, 20 ft-lb)
c.

Completely loosen bolts.

EM-197

CYLINDER BLOCK
[HR]
: 0 N·m (0 kg-m, 0 ft-lb)
d.

Tighten bolts in several steps.
: 19.6 N·m (2.0 kg-m, 14 ft-lb)

e.

Then turn all bolts 60 degrees clockwise (angle tightening).
CAUTION:
Check and confirm the tightening angle by using the angle
wrench (SST: KV10112100) (A) or protractor. Avoid judgement by visual inspection without the tool.

PBIC3753E

After tightening connecting rod bolt, make sure that crankshaft rotates smoothly.
Check the connecting rod side clearance. Refer to EM-206, «CONNECTING ROD SIDE CLEARANCE» .
15. Install oil pan (upper). Refer to EM-128, «INSTALLATION» .
NOTE:
Install the rear oil seal after installing the oil pan (upper).
16. Install rear oil seal. Refer to EM-172, «INSTALLATION» .
17. Install flywheel (M/T models) or drive plate (A/T models).
● When installing flywheel (M/T models) or drive plate (A/T models) to crankshaft, make sure that align
crankshaft side dowel pin with flywheel/drive-plate side dowel pin hole correctly.
● Install drive plate (1), reinforcement plate (2) and pilot converter (3) as shown in the figure (A/T models).
●
●

A

: Crankshaft rear end

B

: Rounded

C

: Chamfered

CAUTION:
Be careful about the installing direction (front/back).
● Using a drift of 33 mm (1.30 in) in diameter, press-fit pilot converter into the end of crankshaft until it stops (A/T models).
● Tighten bolts with the following procedure.
– Using a stopper plate (SST: KV11105210), secure and tighten the crankshaft.
– Tighten them diagonally in several steps.

PBIC3259J

18. Install knock sensor (1).
: Engine front

Install connectors so that they are positioned towards the rear
of the engine.
CAUTION:
● Do not tighten mounting bolt while holding the connector.
● If any impact by dropping is applied to knock sensor,
replace it with a new one.
PBIC3754E
NOTE:
● Make sure that there is no foreign material on the cylinder block mating surface and the back surface of
knock sensor.
● Make sure that knock sensor does not interfere with other parts.
19. Install crankshaft position sensor (POS).
●

EM-198

CYLINDER BLOCK
[HR]
● Tighten bolts with it seated completely.
20. For the oil level gauge guide (1), fix the position (B) shown in the
figure to the water inlet clip (A) after inserting to the cylinder
block side.

A

EM

C

PBIC3755E

D

21. Assemble in the reverse order of disassembly after this step.

How to Select Piston and Bearing

BBS002PA

E

DESCRIPTION
Selection points

Selection parts

Between cylinder block and
crankshaft

Between crankshaft and connecting rod

●

●

●

Main bearing

Connecting rod bearing

Selection items

Selection methods

Main bearing grade (bearing
thickness)

Determined by match of cylinder block bearing housing
grade (inner diameter of housing) and crankshaft journal
grade (outer diameter of journal)

Connecting rod bearing grade
(bearing thickness)

Combining service grades for
connecting rod big end diameter and crankshaft pin outer
diameter determine connecting
rod bearing selection.

The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.

HOW TO SELECT CONNECTING ROD BEARING
When New Connecting Rod and Crankshaft Are Used
1.

: Oil hole

B

: Cylinder number

D

: Front mark

H

I

J

K

M

PBIC3756E

EM-199

G

L

Apply connecting rod big end diameter grade stamped (C) on
connecting rod side face to the row in the “Connecting Rod
Bearing Selection Table”.
A

F

CYLINDER BLOCK
[HR]
2.

Apply crankshaft pin journal diameter grade stamped (B) on
crankshaft front side to the column in the “Connecting Rod Bearing Selection Table”.
A

: Main journal diameter grade (No. 1 to 5 from left)

B

: Crankshaft pin journal diameter grade (No. 1 to 4 from left)

PBIC3757E

3.
4.

Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection
Table”.
Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.

When Crankshaft and Connecting Rod Are Reused
1.

2.
3.
4.

Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter individually. Refer to EM-208, «CONNECTING ROD BIG END DIAMETER» and EM-211, «CRANKSHAFT
PIN JOURNAL DIAMETER» .
Apply the measured dimension to the “Connecting Rod Bearing Selection Table”.
Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection
Table”.
Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.

EM-200

CYLINDER BLOCK
[HR]
Connecting Rod Bearing Selection Table
A

EM

C

D

E

F

G

H

I

J

K

L

M

MBIB9024E

EM-201

CYLINDER BLOCK
[HR]
Connecting Rod Bearing Grade Table
Unit: mm (in)
Grade number

Thickness

Identification color

0

1.501 — 1.498 (0.0591 — 0.0590)

Black

1

1.504 — 1.501 (0.0592 — 0.0591)

Brown

2

1.507 — 1.504 (0.0593 — 0.0592)

Green

3

1.510 — 1.507 (0.0594 — 0.0593)

Yellow

4

1.513 — 1.510 (0.0596 — 0.0594)

Blue

UPR

1.501 — 1.498 (0.0591 — 0.0590)

Black

LWR

1.504 — 1.501 (0.0592 — 0.0590)

Brown

UPR

1.504 — 1.501 (0.0592 — 0.0590)

Brown

LWR

1.507 — 1.504 (0.0593 — 0.0592)

Green

UPR

1.507 — 1.504 (0.0593 — 0.0592)

Green

LWR

1.510 — 1.507 (0.0594 — 0.0593)

Yellow

UPR

1.510 — 1.507 (0.0594 — 0.0593)

Yellow

LWR

1.513 — 1.510 (0.0596 — 0.0594)

Blue

01

12

Remarks

Grade and color are the same
for upper and lower bearings.

Grade and color are different
for upper and lower bearings.

23

34

Undersize Bearings Usage Guide
When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod
bearings, use undersize (US) bearings.
●
When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft pin to use undersize bearings, keep the
fillet R (A) [0.8 — 1.2 mm (0.031 — 0.047 in)].
●

PBIC3263J

Bearing undersize table
Unit: mm (in)
Size

Thickness

US 0.25 (0.0098)

1.623 — 1.631 (0.0638 — 0.0642)

HOW TO SELECT MAIN BEARING
When New Cylinder Block and Crankshaft Are Used
1.

“Main Bearing Selection Table” rows correspond to main bearing
housing grade on left side of cylinder block.
A

: Basic stamp mark
: Engine front

●

If there is a corrected stamp mark (B) on cylinder block, use it
as a correct reference.

PBIC3760E

EM-202

CYLINDER BLOCK
[HR]
2.

Apply main journal diameter grade stamped (A) on crankshaft
front side to column in the “Main Bearing Selection Table”.
A

: Main journal diameter grade (No. 1 to 5 from left)

B

: Crankshaft pin journal diameter grade (No. 1 to 4 from left)

A

EM

C

PBIC3757E

3.
4.

Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.
Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE:
Service part is available as a set of both upper and lower.

When Cylinder Block and Crankshaft Are Reused
1.

2.
3.
4.

Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main
journal diameter individually. Refer to EM-209, «MAIN BEARING HOUSING INNER DIAMETER» and EM211, «CRANKSHAFT MAIN JOURNAL DIAMETER» .
Apply the measured dimension to the “Main Bearing Selection Table”.
Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.
Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.

D

E

F

G

H

I

J

K

L

M

EM-203

CYLINDER BLOCK
[HR]
Main Bearing Selection Table

PBIC3759E

EM-204

CYLINDER BLOCK
[HR]
Main Bearing Grade Table
Unit: mm (in)
Grade number

Thickness

Identification color

0

1.996 — 1.999 (0.0785 — 0.0787)

Black

1

1.999 — 2.002 (0.0787 — 0.0788)

Brown

2

2.002 — 2.005 (0.0788 — 0.0789)

Green

3

2.005 — 2.008 (0.0789 — 0.0790)

Yellow

4

2.008 — 2.011 (0.0790 — 0.0791)

Blue

5

2.011 — 2.014 (0.0791 — 0.0792)

Pink

UPR

1.996 — 1.999 (0.0785 — 0.0787)

Black

LWR

1.999 — 2.002 (0.0787 — 0.0788)

Brown

UPR

1.999 — 2.002 (0.0787 — 0.0788)

Brown

LWR

2.002 — 2.005 (0.0788 — 0.0789)

Green

UPR

2.002 — 2.005 (0.0788 — 0.0789)

Green

LWR

2.005 — 2.008 (0.0789 — 0.0790)

Yellow

UPR

2.005 — 2.008 (0.0789 — 0.0790)

Yellow

LWR

2.008 — 2.011 (0.0790 — 0.0791)

Blue

UPR

2.008 — 2.011 (0.0790 — 0.0791)

Blue

LWR

2.011 — 2.014 (0.0791 — 0.0792)

Pink

01

12

23

34

45

A

Remarks

EM
Grade and color are the same
for upper and lower bearings.

C

D

E
Grade and color are different
for upper and lower bearings.

F

G

H

Use Undersize Bearing Usage Guide
When the specified main bearing oil clearance is not obtained with standard size main bearings, use
undersize (US) bearing.
●
When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft main journal to use undersize bearings,
keep fillet R (A) [0.8 — 1.2 mm (0.031 — 0.047 in)].
●

I

J

K

L

PBIC3263J

Bearing undersize table
Unit: mm (in)
Size

Thickness

US 0.25 (0.0098)

2.126 — 2.134 (0.0837 — 0.0840)

EM-205

M

CYLINDER BLOCK
[HR]

Inspection After Disassembly

BBS002PB

CRANKSHAFT END PLAY
●

Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a
dial indicator (A).
Standard
Limit

●

: 0.098 — 0.260 mm (0.0038 — 0.0102 in)
: 0.35 mm (0.0137 in)

If the measured value exceeds the limit, replace thrust bearings,
and measure again. If it still exceeds the limit, replace crankshaft also.
PBIC3762E

CONNECTING ROD SIDE CLEARANCE
●

Measure the side clearance between connecting rod and crankshaft arm with a feeler gauge (A).
Standard

●

: 0.200 — 0.352 mm (0.0079 — 0.0138 in)

If the measured value exceeds the limit, replace connecting rod,
and measure again. If it still exceeds the standard, replace
crankshaft also.

PBIC3763E

PISTON TO PISTON PIN OIL CLEARANCE
Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with an inside
micrometer.
Standard: 19.006 — 19.012 mm (0.7482 — 0.7485 in)

PBIC0116E

Piston Pin Outer Diameter
Measure the outer diameter of piston pin with a micrometer.
Standard: 18.996 — 19.002 mm (0.7478 — 0.7481 in)

PBIC0117E

Piston to Piston Pin Oil Clearance
(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)
Standard: 0.008 — 0.012 mm (0.0003 — 0.0004 in)
●

If oil clearance is out of the standard, replace piston and piston pin assembly.

EM-206

CYLINDER BLOCK
[HR]
PISTON RING SIDE CLEARANCE
●

●

A

Measure the side clearance of piston ring and piston ring groove
with a feeler gauge.
Standard:
Top ring
2nd ring
Oil ring

: 0.040 — 0.080 mm (0.0015 — 0.0031 in)
: 0.030 — 0.070 mm (0.0012 — 0.0028 in)
: 0.045 — 0.125 mm (0.0017 — 0.0049 in)

Limit:
Top ring
2nd ring

: 0.11 mm (0.0043 in)
: 0.10 mm (0.0039 in)

EM

C

SEM024AA

If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
replace piston also.

D

E

PISTON RING END GAP
●

●

Make sure that cylinder bore inner diameter is within the specification. Refer to EM-210, «Cylinder Bore Inner Diameter» .
Lubricate with new engine oil to piston and piston ring, and then
insert piston ring until middle of cylinder with piston, and measure piston ring end gap with a feeler gauge.
Standard:
Top ring
2nd ring
Oil ring (rail ring)

F

G

: 0.20 — 0.30 mm (0.0078 — 0.0118 in)
: 0.35 — 0.50 mm (0.0137 — 0.0196 in)
: 0.20 — 0.60 mm (0.0079 — 0.0236 in)

H

SEM822B

Limit:
Top ring
2nd ring
Oil ring (rail ring)
●

: 0.50 mm (0.0196 in)
: 0.66 mm (0.0259 in)
: 0.92 mm (0.0362 in)

If the measured value exceeds the limit, replace piston ring.

I

J

K

L

M

EM-207

CYLINDER BLOCK
[HR]
CONNECTING ROD BEND AND TORSION
●

Check with a connecting rod aligner.
Bend:
Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
Torsion:
Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length

●

If it exceeds the limit, replace connecting rod assembly.

PBIC2077E

CONNECTING ROD BIG END DIAMETER
●

●

Install connecting rod cap without connecting rod bearing installed, and tightening connecting rod bolts to
the specified torque. Refer to EM-193, «ASSEMBLY» for the tightening procedure.
Measure the inner diameter of connecting rod big end with an
inside micrometer.
Standard: 43.000 — 43.013 mm (1.6929 — 1.6934 in)

●

If out of the standard, replace connecting rod assembly.

PBIC1641E

CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with an inside
micrometer.
Standard: 18.958 — 18.978 mm (0.7463 — 0.7471 in)

PBIC0120E

EM-208

CYLINDER BLOCK
[HR]
Piston Pin Outer Diameter
A

Measure the outer diameter of piston pin with a micrometer.
Standard: 18.996 — 19.002 mm (0.7478 — 0.7481 in)

EM

C

PBIC0117E

D

Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diameter)

E

Standard: –0.018 to –0.044 mm (–0.0007 to –0.0017 in)
●

●

If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin
assembly.
If replacing connecting rod assembly, refer to EM-211, «CONNECTING ROD BEARING OIL CLEARANCE» to select connecting rod bearing.

F

G

CYLINDER BLOCK DISTORTION
●

●

Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon,
or other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
Measure the distortion on the cylinder block upper face at some
different points in six directions with a straight edge and a feeler
gauge.

H

I

J

Limit: 0.1 mm (0.004 in)
●

If it exceeds the limit, replace cylinder block.

K

L
PBIC0121E

MAIN BEARING HOUSING INNER DIAMETER
●

●
●

Install main bearing cap without main bearings installed, and tighten main bearing cap bolts to the specified torque. Refer to EM-193, «ASSEMBLY» for the tightening procedure.
Measure the inner diameter of main bearing housing with a bore gauge.
Measure the position shown in the figure [5 mm (0.196 in) rearward from main bearing housing front side end surface) in the 2
directions as shown in the figure. The smaller one is the measured value.
1

: Cylinder block

2

: Main bearing cap
: Engine front

Standard: 51.997 — 52.017 mm (2.0471 — 2.0479 in)
●

If out of the standard, replace cylinder block and main bearing
caps as an assembly.

EM-209

PBIC3879E

M

CYLINDER BLOCK
[HR]
NOTE:
These components cannot be replaced as a single unit, because they were processed together.

PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
●

Using a bore gauge, measure the cylinder bore for wear, out-ofround and taper at six different points on each cylinder. (“X” and
“Y” directions at “A”, “B” and “C”) (“Y” is in longitudinal direction
of the engine)
A

: Unit: mm (in)

NOTE:
When determining cylinder bore grade, measure cylinder bore at
“B” position.
Standard inner diameter:
78.000 — 78.015 mm (3.0708 — 3.0714 in)
Wear limit:
0.2 mm (0.008 in)
Out-of-round (Difference between “X” and “Y”):
0.015 mm (0.0006 in)
Taper limit (Difference between “A” and “C”):
0.010 mm (0.0004 in)
●

PBIC3767E

If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
replace cylinder block.
NOTE:
There is no service setting for oversized piston.

Piston Skirt Diameter
Measure the outer diameter of piston skirt with a micrometer.
Measure point
: Distance from the top 37.1 mm (1.460 in)
Standard
: 77.965 — 77.980 mm (3.0694 — 3.0700 in)

PBIC0125E

Piston to Cylinder Bore Clearance
Calculate by piston skirt diameter and cylinder bore inner diameter (direction “X”, position “B”).
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter)
Standard : 0.020 — 0.050 mm (0.0007 — 0.0019 in)
Limit
: 0.09 mm (0.0035 in)
●

If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block.

EM-210

CYLINDER BLOCK
[HR]
CRANKSHAFT MAIN JOURNAL DIAMETER
●

A

Measure the outer diameter of crankshaft main journals with a
micrometer (A).
Standard: 47.959 — 47.979 mm (1.8881 — 1.8888 in) dia.

●

EM

If out of the standard, measure the main bearing oil clearance.
Then use undersize bearing. Refer to EM-212, «MAIN BEARING
OIL CLEARANCE» .

C

PBIC3457J

CRANKSHAFT PIN JOURNAL DIAMETER
●

D

E

Measure the outer diameter of crankshaft pin journal with a micrometer.
Standard: 39.953 — 39.971 mm (1.5729-1.5736 in) dia.

●

If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing.
Refer to EM-211, «CONNECTING ROD BEARING OIL CLEARANCE» .

OUT-OF-ROUND AND TAPER OF CRANKSHAFT
●

●

●

●
●

G

Measure the dimensions at four different points as shown in the
figure on each main journal and pin journal with a micrometer.
Out-of-round is indicated by the difference in dimensions
between “X” and “Y” at “A” and “B”.
Taper is indicated by the difference in dimension between “A”
and “B” at “X” and “Y”.
Limit:
Out-of-round (Difference between “X” and “Y”)
: 0.003 mm (0.0001 in)
Taper (Difference between “A” and “B”)
: 0.004 mm (0.0001 in)

F

H

I

J
PBIC2203E

K

If the measured value exceeds the limit, correct or replace crankshaft.
If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then
select main bearing and/or connecting rod bearing. Refer to EM-212, «MAIN BEARING OIL CLEARANCE» and/or EM-211, «CONNECTING ROD BEARING OIL CLEARANCE» .

L

CRANKSHAFT RUNOUT
●

●
●

Limit
●

M

Place a V-block on a precise flat table to support the journals on
the both end of crankshaft.
Place a dial indicator (A) straight up on the No. 3 journal.
While rotating crankshaft, read the movement of the pointer on
the dial indicator. (Total indicator reading)
: 0.10 mm (0.0039 in)

If it exceeds the limit, replace crankshaft.
PBIC3458J

CONNECTING ROD BEARING OIL CLEARANCE
Method by Calculation
●

Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque. Refer to EM-193, «ASSEMBLY» for tightening procedure.

EM-211

CYLINDER BLOCK
[HR]
●

Measure the inner diameter of connecting rod bearing with an
inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter) – (Crankshaft pin journal diameter)
Standard
Limit

●

: 0.037 — 0.047 mm (0.0014 — 0.0018 in)
: 0.10 mm (0.0039 in)

If the clearance exceeds the limit, select proper connecting rod
bearing according to connecting rod big end diameter and
crankshaft pin journal diameter to obtain the specified bearing oil
clearance. Refer to EM-199, «HOW TO SELECT CONNECTING
ROD BEARING» .

PBIC1642E

Method of Using Plastigage
●
●

●

●

Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding
oil holes.
Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque. Refer to EM-193, «ASSEMBLY» for the tightening procedure.
CAUTION:
Do not rotate crankshaft.
Remove connecting rod cap and bearing, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.

PBIC1149E

MAIN BEARING OIL CLEARANCE
Method by Calculation
Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap bolts to the
specified torque. Refer to EM-193, «ASSEMBLY» for the tightening procedure.
●
Measure the inner diameter of main bearing with a bore gauge.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crankshaft main journal diameter)
●

Standard:
: 0.024 — 0.034 mm (0.0009 — 0.0013 in)
●

If the clearance exceeds the limit, select proper main bearing
according to main bearing inner diameter and crankshaft main
journal diameter to obtain the specified bearing oil clearance.
Refer to EM-202, «HOW TO SELECT MAIN BEARING» .
PBIC1644E

Method of Using Plastigage
●
●

●

Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding
oil holes.
Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap bolts to the
specified torque. Refer to EM-193, «ASSEMBLY» for the tightening procedure.
CAUTION:
Do not rotate crankshaft.

EM-212

CYLINDER BLOCK
[HR]
●

Remove main bearing cap and bearings, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.

A

EM

C
PBIC1149E

D

MAIN BEARING CRUSH HEIGHT
●

When main bearing cap is removed after being tightened to the
specified torque with main bearings installed, the tip end of bearing must protrude. Refer toEM-193, «ASSEMBLY» for the tightening procedure.

E

Standard: There must be crush height.
●

F

If the standard is not met, replace main bearings.
G
SEM502G

CONNECTING ROD BEARING CRUSH HEIGHT
●

H

When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings
installed, the tip end of bearing must protrude. Refer to EM-193,
«ASSEMBLY» for the tightening procedure.

I

Standard: There must be crush height.
●

J

If the standard is not met, replace connecting rod bearings.

K
PBIC1646E

MAIN BEARING CAP BOLT OUTER DIAMETER
●

●

L

Measure the outer diameters (“d1 ”, “d2” ) at two positions as
shown in the figure.
If reduction appears in a position other than “d2 ” , regard it as
“d2” .

M

Limit (“d1 ” – “d2 ”): 0.2 mm (0.0078 in)
●

If it exceeds the limit (a large difference in dimensions), replace
main bearing cap bolt with a new one.

PBIC3768E

EM-213

CYLINDER BLOCK
[HR]
CONNECTING ROD BOLT OUTER DIAMETER
●

●

Measure the outer diameter “d” at position as shown in the figure.
If reduction appears in a position other than “d”, regard it as “d”.
Limit: 7.75 mm (0.3051 in)

●

When “d” falls below the limit (when it becomes thinner), replace
connecting rod bolt with a new one.

PBIC3769E

FLYWHEEL DEFLECTION
●

Measure the deflection of flywheel contact surface to clutch with
a dial indicator.
Standard

●

: 0.25 mm (0.0098 in) or less.

If measured value is out of the standard, replace flywheel.

PBIC2646E

EM-214

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR]

SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit

PFP:00030

A
BBS002PC

GENERAL SPECIFICATIONS
Engine type

HR16DE

Cylinder arrangement

In-line 4
cm3 (cu in)

Displacement
Bore and stroke

1,598 (97.51)

mm (in)

C

78.0 x 83.6 (3.070 x 3.291)

Valve arrangement

DOHC

Firing order

1-3-4-2

Number of piston rings

EM

Compression

2

Oil

1

Compression ratio

D

E

9.8

Compression pressure
kPa (bar, kg/cm2 , psi) / 200 rpm

Standard

1,510 (15.1, 15.4, 219)

Minimum

1,265 (12.69, 12.9, 183)

Differential limit between cylinders

F

981 (9.81, 10.0, 142)

DRIVE BELT
G

Belt Deflection:
Deflection adjustment *
Location

Used belt
Limit

Drive belt

Unit: mm (in)
New belt

After adjusted

With A/C models

7.9 (0.31)

4.8 — 5.3 (0.19 — 0.21)

4.2 — 4.5 (0.17 — 0.18)

Without A/C models

7.1 (0.28)

4.3 — 4.7 (0.17 — 0.19)

3.6 — 3.9 (0.14 — 0.15)

Applied pushing force

H

I

98 N (10 kg, 22lb)

*: When engine is cold.

J

EXHAUST MANIFOLD
Unit: mm (in)
Items

K

Limit

Surface distortion

0.3 (0.012)

SPARK PLUG (PLATINUM-TIPPED TYPE)

L
Unit: mm (in)

Make

NGK

Standard type

PLZKAR6A-11

Hot type

PLZKAR5A-11

Cold type
Spark plug gap

M

PLZKAR7A-11
Standard

1.1 (0.043)

CYLINDER HEAD
Unit: mm (in)
Items

Limit

Head surface distortion

0.1 (0.004)

EM-215

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR]
VALVE
Valve Timing
Unit: degree

Valve timing

PBIC0187E

(

a

b

c

d

e

f

208

228

-11 (19)

59 (19)

4

24

): Valve timing control “ON”

Valve Dimensions
Unit: mm (in)

PBIC3878E

Valve head diameter “D”

Valve length “a”

“b”

“c”

Intake

31.0 — 31.3 (1.220 — 1.232)

Exhaust

25.3 — 25.6 (0.996 — 1.007)

Intake

101.65 (4.0019)

Exhaust

102.46 (4.0338)

Intake

1.0 (0.0393)

Exhaust

1.0 (0.0393)

Intake

2.1 — 2.8 (0.0826 — 0.1102)

Exhaust

2.3 — 3.0 (0.0905 — 0.1181)

Intake
“c′ ”

“d ”

3.0 (0.1181)

Exhaust

–

Intake

4.965 — 4.980 (0.1954 — 0.1960 in)

Exhaust

4.955 — 4.970 (0.1950 — 0.1956 in)

Intake
Valve seat angle “α”

45°15′ — 45°45′

Exhaust

Valve Clearance
Unit: mm (in)
Cold

Hot * (reference data)

Intake

0.26 — 0.34 (0.010 — 0.013)

0.304 — 0.416 (0.012 — 0.016)

Exhaust

0.29 — 0.37 (0.011 — 0.014)

0.308 — 0.432 (0.012 — 0.017)

*:Approximately 80°C (176°F)

EM-216

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR]
Available Valve Lifter
Thickness

mm (in)

Identification mark

A

EM

C

D
KBIA0119E

3.00 (0.1181)

300

3.02 (0.1188)

302

3.04 (0.1196)

304

3.06 (0.1204)

306

3.08 (0.1212)

308

3.10 (0.1220)

310

3.12 (0.1228)

312

3.14 (0.1236)

314

3.16 (0.1244)

316

3.18 (0.1251)

318

3.20 (0.1259)

320

3.22 (0.1267)

322

3.24 (0.1275)

324

3.26 (0.1283)

326

3.28 (0.1291)

328

3.30 (0.1299)

330

3.32 (0.1307)

332

3.34 (0.1314)

334

3.36 (0.1322)

336

3.38 (0.1330)

338

3.40 (0.1338)

340

3.42 (0.1346)

342

3.44 (0.1354)

344

3.46 (0.1362)

346

3.48 (0.1370)

348

3.50 (0.1377)

350

EM-217

E

F

G

H

I

J

K

L

M

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR]
Valve Spring
Standard:
Free height

42.26 mm (1.6637 in)

Installation height

32.40 mm (1.2755 in)

Installation load

136 — 154 N (13.9 — 15.7 kg, 31 — 35 lb)

Height during valve open

23.96 mm (0.9433 in)

Load with valve open

262 — 296 N (26.7 — 30.2 kg, 59 — 67 lb)

Valve Lifter
Unit: mm (in)
Items

Standard

Valve lifter outer diameter

29.977 — 29.987 (1.1801 — 1.1805)

Valve lifter hole diameter

30.000 — 30.021 (1.1811 — 1.1819)

Valve lifter clearance

0.013 — 0.044 (0.0005 — 0.0017)

Valve Guide
Unit: mm (in)

PBIC0184E

Items
Valve guide

Outer diameter

Standard part

Service part

9.023 — 9.034 (0.3552 — 0.3556)

9.223 — 9.234 (0.3631 — 0.3635)

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

5.000 — 5.018 (0.1968 — 0.1975)
8.975 — 8.996 (0.3533 — 0.3541)

Interference fit of valve guide

0.027 — 0.059 (0.0011 — 0.0023)

Items
Valve guide clearance

9.175 — 9.196 (0.3612 — 0.3620)

Standard

Limit

Intake

0.020 — 0.053 (0.0008 — 0.0021)

0.1 (0.004)

Exhaust

0.030 — 0.063 (0.0012 — 0.0025)

0.1 (0.004)

Projection length “H”

11.4 — 11.8 (0.448 — 0.464)

EM-218

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR]
Valve Seat
Unit: mm (in)

A

EM

C

D
PBIC2745E

Items
Cylinder head seat recess diameter “D”

Valve seat outer diameter “d”

Valve seat interference fit

Diameter “d1”*1

Diameter “d2”*2

Angle “α1”

Angle “α2”

Angle “α3”

Contacting width “W”*3

Height “h”

Standard

Oversize [0.5 (0.02)] (Service)

Intake

31.400 — 31.416 (1.2362 — 1.2368)

31.900 — 31.916 (1.2559 — 1.2565)

Exhaust

25.900 — 25.916 (1.0196 — 1.0203)

26.400 — 26.416 (1.0393 — 1.0399)

Intake

31.497 — 31.513 (1.2400 — 1.2406)

31.997 — 32.013 (1.2597 — 1.2603)

Exhaust

25.997 — 26.013 (1.0235 — 1.0241)

26.497 — 26.513 (1.0431 — 1.0438)

Intake

0.081 — 0.113 (0.0032 — 0.0044)

Exhaust

0.081 — 0.113 (0.0032 — 0.0044)

Intake

29.0 (1.141)

Exhaust

23.0 (0.905)

Intake

30.6 — 30.8 (1.204 — 1.212)

Exhaust

24.9 — 25.1 (0.980 — 0.988)

Intake

60°

Exhaust

60°

Intake

89°45′ — 90°15′

Exhaust

89°45′ — 90°15′

Intake

120°

Exhaust

120°

J

K

Exhaust

1.25 — 1.55 (0.0492 — 0.0610)

Intake

6.0 (0.236)

5.45 (0.214)

Exhaust

6.0 (0.236)

5.43 (0.213)

*1 : Diameter made by intersection point of conic angles α1 and α2
*2 : Diameter made by intersection point of conic angles α2 and α3
*3 : Machining data

EM-219

G

I

1.05 — 1.35 (0.0413 — 0.0531)

6.0 (0.236)

F

H

Intake

Depth “H”

E

L

M

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR]
CAMSHAFT AND CAMSHAFT BEARING
Unit: mm (in)
Items
Camshaft runout [TIR*]

Standard

Limit

0.02 (0.0008)

0.1 (0.0039)

SEM671

Camshaft cam height “A”

Camshaft journal outer diameter

Camshaft bracket inner diameter

Camshaft journal oil clearance

Intake

41.705 — 41.895 (1.6419 — 1.6494)

—

Exhaust

40.175 — 40.365 (1.5816 — 1.5891)

—

No. 1

27.935 — 27.955 (1.0998 — 1.1006)

—

No. 2, 3, 4, 5

24.950 — 24.970 (0.9822 — 0.9830)

—

No. 1

28.000 — 28.021 (1.1024 — 1.1032)

—

No. 2, 3, 4, 5

25.000 — 25.021 (0.9842 — 0.9850)

—

No. 1

0.045 — 0.086 (0.0018 — 0.0034)

—

No. 2, 3, 4, 5

0.030 — 0.071 (0.0011 — 0.0027)

—

0.075 — 0.153 (0.0029 — 0.0060)

0.2 (0.0078)

—

0.15 (0.0059)

Camshaft end play
Camshaft sprocket runout [TIR*]
*: Total indicator reading

CYLINDER BLOCK
Unit: mm (in)

PBIC3924E

Surface distortion
Cylinder bore

Limit
Inner diameter

0.1 (0.004)

Standard

78.000 — 78.015 (3.0708 — 3.0714)

Wear limit

0.2 (0.008)

Out-of-round (Difference between “X” and “Y”)
Taper (Difference between “A” and “C”)

0.015 (0.0006)
Limit

0.010 (0.0004)

EM-220

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR]
Grade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
Grade No. P
Grade No. R
Grade No. S
Grade No. T
Grade No. U
Grade No. V
Grade No. W

Cylinder block main bearing housing inner diameter grade

Difference in inner diameter between cylinders

51.997 — 51.998 (2.0471 — 2.0472)
51.998 — 51.999 (2.0472 — 2.0472)
51.999 — 52.000 (2.0472 — 2.0472)
52.000 — 52.001 (2.0472 — 2.0472)
52.001 — 52.002 (2.0473 — 2.0473)
52.002 — 52.003 (2.0473 — 2.0473)
52.003 — 52.004 (2.0474 — 2.0474)
52.004 — 52.005 (2.0474 — 2.0474)
52.005 — 52.006 (2.0474 — 2.0474)
52.006 — 52.007 (2.0475 — 2.0475)
52.007 — 52.008 (2.0475 — 2.0475)
52.008 — 52.009 (2.0476 — 2.0476)
52.009 — 52.010 (2.0476 — 2.0476)
52.010 — 52.011 (2.0476 — 2.0476)
52.011 — 52.012 (2.0477 — 2.0477)
52.012 — 52.013 (2.0477 — 2.0477)
52.013 — 52.014 (2.0478 — 2.0478)
52.014 — 52.015 (2.0478 — 2.0478)
52.015 — 52.016 (2.0478 — 2.0478)
52.016 — 52.017 (2.0479 — 2.0479)

Standard

A

EM

C

D

E

F

Less than 0.03 (0.0012)

PISTON, PISTON RING AND PISTON PIN
Available Piston

G
Unit: mm (in)

H

I

J

PBIC0188E

Piston skirt diameter “A”

77.965 — 77.980 (3.0694 — 3.0700)

Piston height “H” dimension

37.1 (1.460)

Piston pin hole diameter

19.006 — 19.012 (0.7482 — 0.7485)

Piston to cylinder bore clearance

Unit: mm (in)

Side clearance

End gap

L

0.020 — 0.050 (0.0007 — 0.0019)

Piston Ring
Items

K

Standard

Limit

Top

0.040 — 0.080 (0.0015 — 0.0031)

0.11 (0.0043)

2nd

0.030 — 0.070 (0.0012 — 0.0028)

0.10 (0.0039)

Oil (rail ring)

0.045 — 0.125 (0.0017 — 0.0049)

—

Top

0.20- 0.30 (0.0078 — 0.0118)

0.50 (0.0196)

2nd

0.35 — 0.50 (0.0137 — 0.0196)

0.66 (0.0259)

Oil (rail ring)

0.20 — 0.60 (0.0079 — 0.0236)

0.92 (0.0362)

Piston Pin
Unit: mm (in)
Piston pin outer diameter

18.996 — 19.002 (0.7478 — 0.7481)

Piston to piston pin oil clearance

Standard

0.008 — 0.012 (0.0003 — 0.0004)

Connecting rod bushing oil clearance

Standard

–0.018 to –0.044 (–0.0007 to –0.0017)

EM-221

M

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR]
CONNECTING ROD
Unit: mm (in)
Center distance

129.84 — 129.94 (5.1118 — 5.1157)

Bend [per 100 (3.94)]

Limit

0.15 (0.0059)

Torsion [per 100 (3.94)]

Limit

0.30 (0.0118)

Connecting rod bushing inner diameter*

18.958 — 18.978 (0.7463 — 0.7471)

Side clearance

Standard

Connecting rod big end diameter

Grade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N

0.200 — 0.352 (0.0079 — 0.0138)
43.000 — 43.001 (1.6929 — 1.6929)
43.001 — 43.002 (1.6929 — 1.6930)
43.002 — 43.003 (1.6930 — 1.6930)
43.003 — 43.004 (1 6930 — 1.6931)
43.004 — 43.005 (1.6931 — 1.6931)
43.005 — 43.006 (1.6931 — 1.6931)
43.006 — 43.007 (1.6931 — 1.6932)
43.007 — 43.008 (1.6932 — 1.6932)
43.008 — 43.009 (1.6932 — 1.6933)
43.009 — 43.010 (1.6933 — 1.6933)
43.010 — 43.011 (1.6933 — 1.6933)
43.011 — 43.012 (1.6933 — 1.6934)
43.012 — 43.013 (1.6934 — 1.6934)

*: After installing in connecting rod

CRANKSHAFT
Unit: mm (in)

SBIA0535E

SEM645

Center distance “r”

41.68 — 41.76 (1.6409 — 1.6440)

Out-of-round (Difference between “X” and “Y”)

Limit

0.003 (0.0001)

Taper (Difference between “A” and “B”)

Limit

0.004 (0.0001)

Runout [TIR*]

Limit

0.10 (0.0039)

Standard
Crankshaft end play

0.098 — 0.260 (0.0038 — 0.0102)

Limit

0.35 (0.0137)

EM-222

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR]

Crankshaft pin journal diameter grade. “DP”

Crankshaft main journal diameter grade. “Dm”

Grade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
Grade No. P
Grade No. R
Grade No. S
Grade No. T
Grade No. U

39.971 — 39.970 (1.5737 — 1.5736)
39.970 — 39.969 (1.5736 — 1.5736)
39.969 — 39.968 (1.5736 — 1.5735)
39.968 — 39.967 (1.5735 — 1.5735)
39.967 — 39.966 (1.5735 — 1.5735)
39.966 — 39.965 (1.5736 — 1.5734)
39.965 — 39.964 (1.5735 — 1.5734)
39.964 — 39.963 (1.5734 — 1.5733)
39.963 — 39.962 (1.5734 — 1.5733)
39.962 — 39.961 (1.5733 — 1.5733)
39.961 — 39.960 (1.5733 — 1.5732)
39.960 — 39.959 (1.5732 — 1.5732)
39.959 — 39.958 (1.5732 — 1.5731)
39.958 — 39.957 (1.5731 — 1.5731)
39.957 — 39.956 (1.5731 — 1.5731)
39.956 — 39.955 (1.5731 — 1.5730)
39.955 — 39.954 (1.5730 — 1.5730)
39.954 — 39.953 (1.5730 — 1.5729)

Grade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
Grade No. P
Grade No. R
Grade No. S
Grade No. T
Grade No. U
Grade No. V
Grade No. W

47.979 — 47.978 (1.8889 — 1.8889)
47.978 — 47.977 (1.8889 — 1.8889)
47.977 — 47.976 (1.8889 — 1.8888)
47.976 — 47.975 (1.8888 — 1.8888)
47.975 — 47.974 (1.8888 — 1.8887)
47.974 — 47.973 (1.8887 — 1.8887)
47.973 — 47.972 (1.8887 — 1.8887)
47.972 — 47.971 (1.8887 — 1.8886)
47.971 — 47.970 (1.8886 — 1.8886)
47.970 — 47.969 (1.8886 — 1.8885)
47.969 — 47.968 (1.8885 — 1.8885)
47.968 — 47.967 (1.8885 — 1.8885)
47.967 — 47.966 (1.8885 — 1.8884)
47.966 — 47.965 (1.8884 — 1.8884)
47.995 — 47.964 (1.8884 — 1.8883)
47.994 — 47.963 (1.8883 — 1.8883)
47.963 — 47.962 (1.8883 — 1.8883)
47.962 — 47.961 (1.8883 — 1.8882)
47.961 — 47.960 (1.8882 — 1.8882)
47.960 — 47.959 (1.8882 — 1.8881)

A

EM

C

D

E

F

G

H

I

J

K

*: Total indicator reading

L

M

EM-223

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR]
MAIN BEARING
Unit: mm (in)

SEM685D

Grade number

Thickness

Identification color

0

1.996 — 1.999 (0.0785 — 0.0787)

Black

1

1.999 — 2.002 (0.0787 — 0.0788)

Brown

2

2.002 — 2.005 (0.0788 — 0.0789)

Green

3

2.005 — 2.008 (0.0789 — 0.0790)

Yellow

4

2.008 — 2.011 (0.0790 — 0.0791)

Blue

5
01

12

23

34

45

2.011 — 2.014 (0.0791 — 0.0792)

Pink

UPR

1.996 — 1.999 (0.0785 — 0.0787)

Black

LWR

1.999 — 2.002 (0.0787 — 0.0788)

Brown

UPR

1.999 — 2.002 (0.0787 — 0.0788)

Brown

LWR

2.002 — 2.005 (0.0788 — 0.0789)

Green

UPR

2.002 — 2.005 (0.0788 — 0.0789)

Green

LWR

2.005 — 2.008 (0.0789 — 0.0790)

Yellow

UPR

2.005 — 2.008 (0.0789 — 0.0790)

Yellow

LWR

2.008 — 2.011 (0.0790 — 0.0791)

Blue

UPR

2.008 — 2.011 (0.0790 — 0.0791)

Blue

LWR

2.011 — 2.014 (0.0791 — 0.0792)

Pink

Remarks

Grade and color are the same
for upper and lower bearings.

Grade and color are different
for upper and lower bearings.

Undersize
Unit: mm (in)
Item

Thickness

Main journal diameter

US 0.25 (0.0098)

2.126 — 2.134 (0.0837 — 0.0840)

Grind so that bearing clearance is the specified value.

Standard

0.024 — 0.034 (0.0009 — 0.0013)

Bearing Oil Clearance
Unit: mm (in)
Main bearing oil clearance

EM-224

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR]
CONNECTING ROD BEARING
Unit: mm (in)
Grade number

Thickness

Identification color

0

1.501 — 1.498 (0.0591 — 0.0590)

Black

1

1.504 — 1.501 (0.0592 — 0.0591)

Brown

2

1.507 — 1.504 (0.0593 — 0.0592)

Green

3

1.510 — 1.507 (0.0594 — 0.0593)

Yellow

4

1.513 — 1.510 (0.0596 — 0.0594)

Blue

UPR

1.501 — 1.498 (0.0591 — 0.0590)

Black

LWR

1.504 — 1.501 (0.0592 — 0.0590)

Brown

UPR

1.504 — 1.501 (0.0592 — 0.0590)

Brown

LWR

1.507 — 1.504 (0.0593 — 0.0592)

Green

UPR

1.507 — 1.504 (0.0593 — 0.0592)

Green

LWR

1.510 — 1.507 (0.0594 — 0.0593)

Yellow

UPR

1.510 — 1.507 (0.0594 — 0.0593)

Yellow

LWR

1.513 — 1.510 (0.0596 — 0.0594)

Blue

01

12

A

Remarks

EM
Grade and color are the same
for upper and lower bearings.

C

D
Grade and color are different
for upper and lower bearings.

E

23

34

F

G

Undersize
Unit: mm (in)
Item

Thickness

Crankshaft pin journal diameter

US 0.25 (0.0098)

1.623 — 1.635 (0.0639 — 0.0644)

Grind so that bearing clearance is the specified value.

H

Bearing Oil Clearance
Unit: mm (in)
Connecting rod bearing oil clearance

Standard

I

0.029 — 0.039 (0.0011 — 0.0015)

Limit

0.10 (0.0039)

J

K

L

M

EM-225

APPLICATION NOTICE
[K9K]

APPLICATION NOTICE
How to Check Vehicle Type
[K9K]

PFP:00000
BBS005AQ

Confirm K9K engine type with Model written on identification plate (refer to GI-45, «IDENTIFICATION INFORMATION» ), then refer to service information in EM section.
Vehicle type

Engine type

xTKxxxxE11xxE

50kW

xTKxxxxE11xxA

63kW

EM-226

PRECAUTIONS
[K9K]

PRECAUTIONS
Precautions for Drain Coolant

PFP:00001

A
BBS002PE

Drain coolant when engine is cooled.

Precautions for Disconnecting Fuel Piping
●
●
●

Before starting work, make sure no fire or spark producing items are in the work area.
Release fuel pressure before disassembly.
After disconnecting pipes, plug openings to stop fuel leakage.

Precautions for Removal and Disassembly
●

●
●
●
●

EM
BBS002PF

C

BBS002PG

When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
Exercise maximum care to avoid damage to mating or sliding surfaces.
Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.

Precautions for Inspection, Repair and Replacement

●
●

●
●

●

●
●

●

–
–
–
–

●
●
●

BBS002PI

Use torque wrench to tighten bolts or nuts to specified value.
When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly same as specified.
Replace with new gasket, packing, oil seal or O-ring.
Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assemble, spread the oil on sliding surfaces well.
Release air within route when refilling after draining coolant.
Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine
stopped). Then make sure that there are no leaks at fuel line connections.
After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage.

F

G

H

I

J

K

L

M

Parts Requiring Angular Tightening
●

E

BBS002PH

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.

Precautions for Assembly and Installation

D

BBS002PJ

Use an angle wrench for the final tightening of the following engine parts.
Cylinder head bolts
Lower cylinder block bolts
Connecting rod cap bolts
Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
Do not use a torque value for final tightening.
The torque value for these parts are for a preliminary step.
Ensure thread and seat surfaces are clean and coated with engine oil.

EM-227

PRECAUTIONS
[K9K]

Precautions For Liquid Gasket

BBS002PK

REMOVAL OF LIQUID GASKET
●

●

After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the liquid gasket.
CAUTION:
Be careful not to damage the mating surfaces.
In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the liquid gasket applied area.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating
surfaces.
PBIC0275E

LIQUID GASKET APPLICATION PROCEDURE
1.

2.

3.

Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
● Remove the liquid gasket completely from the groove of the
gasket application surface, mounting bolts and bolt holes.
Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
PBIC0003E

4.

Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
● If there is a groove for the liquid gasket application, apply the
gasket to the groove.

EMA0622D

As for the bolt holes, normally apply the gasket inside the
holes. If specified, it should be applied outside the holes.
Make sure to read the instruction in this manual.
● Within five minutes of gasket application, install the mating
component.
● If the liquid gasket protrudes, wipe it off immediately.
● Do not retighten after the installation.
● After 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION:
If there are instructions in this manual, observe them.
●

EM-228

SEM159F

PRECAUTIONS
[K9K]

Precautions for Diesel Equipment

BBS0058A

A

CLEANLINESS

CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRESSURE DIRECT INJECTION SYSTEM
Risks relating to contamination
EM
The system is very sensitive to contamination. The risks caused by the introduction of contamination are:
●
Damage or destruction of the high pressure injection system and the engine,
C
●
Seizing or leaking of a component.
All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a few microns in size) get into the system during dismantling or into the circuits via the fuel unions.
D
The cleanliness principle must be applied from the filter to the injectors.
WHAT ARE THE SOURCES OF CONTAMINATION?
Contamination is caused by:
E
●
Metal or plastic chips,
●
Paint,
●
Fibres:
F
–
Boxes,
–
Brushes,
–
Paper,
G
–
Clothing,
–
Cloths,
●
Foreign bodies such as hair,
H
●
Ambient air,
●
Etc.
I
IMPORTANT: It is not possible to clean the engine using a high pressure washer because of the risk of damaging connections. In addition, moisture may collect in the connectors and create electrical connection malfunctions.
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYS- J
TEM
●
Ensure that you have the plugs for the unions to be opened (bag of plugs sold at the Parts Stores — Nissan
part No.: 16830 BN700, Renault part No.: 77 01 206 804). Plugs are to be used once only. After use, they K
must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable).
Unused plugs must be thrown away.
●
Ensure that you have hermetically resealable plastic bags for storing removed parts. Stored parts will
therefore be less subject to the risk of impurities. The bags must be used only once, and after use they L
must be thrown away.
●
Lint-free towelettes to be used for injection pump related service purpose. The use of a normal cloth or
paper for cleaning purposes is forbidden. These are not lint-free and may contaminate the fuel circuit of M
the system. Each lint-free cloth should only be used once.
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
●
For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.
●
For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
●
Use a brush and thinners to clean the connections to be opened.
●
Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and
injection system zone). Check that no bristles remain adhered.
●
Wash your hands before and during the operation if necessary.
●
When wearing leather protective gloves, cover these with latex gloves.
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
●
As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The plugs to be used are available from the Parts Stores — Nissan part No.: 16830 BN700, Renault
part No.: 77 01 206 804. They must not, under any circumstances, be reused.
●
Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries
contamination.

EM-229

PRECAUTIONS
[K9K]
All components of the injection system that are removed must be stored in a hermetically sealed plastic
bag once the plugs have been inserted.
●
The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been
opened. These items are likely to allow impurities to enter the system.
●
A new component replacing an old one must not be removed from its packaging until it is to be fitted to the
vehicle.
Instructions for Fitting the Plugs
Nissan part number: 16830 BN700
(Renault part number: 77 01 206 804)
●

MBIB0321E

CAUTION:
●
The engine must not run with:
–
Diesel containing more than 10% diester
–
Petrol, even in very small amounts.

EM-230

PRECAUTIONS
[K9K]
●

●

The system can inject the diesel into the engine at a pressure of up to 140,000 kPa (1,400 bar,
1,428 kg/cm2 , 20,300 psi). Before carrying out any work, check that the injector rail is no longer A
pressurized and that the fuel temperature is not too high.
You must respect the cleaning and safety advice specified in this document for any work on the
high pressure injection system.
EM

SPECIAL FEATURES
CAUTION:
●
The engine must not operate with:
–
Diesel engine fuel containing more than 10% diester,
–
Petrol, even in tiny quantities.
●
The system can inject the diesel into the engine at a pressure up to 1400 bars. Before carrying out
any work, check that the injector rail is not under pressure and that the fuel temperature is not too
high.
●
You must respect the cleaning and safety advice specified in this document for any work on the
high pressure injection system.
●
Removal of the interior of the pump and injectors is prohibited. Only the flow actuator, the fuel
temperature sensor and the venturi can be replaced.
●
For safety reasons, it is strictly forbidden to slacken a high pressure pipe union when the engine
is running.
●
It is not possible to remove the pressure sensor from the fuel rail because this may cause circuit
contamination malfunctions. If the pressure sensor fails, the pressure sensor, the rail and the five
high pressure pipes must be replaced.
●
It is strictly forbidden to remove any injection pump pulley marked number 070 575. If the pump is
being replaced, the pulley must be replaced.
●
It is forbidden to repair the wiring connecting the knock sensor (accelerometer) and the CKP sensor (engine speed sensor). If the wiring should fail, it has to be replaced with new wiring.
●
Applying 12 volts directly to any component in the system is prohibited.
●
Ultrasonic carbon removal and cleaning are prohibited.
●
Never start the engine without the battery being connected correctly.
●
It is essential to replace all the disconnected air inlet plastic pipes.
There is a 16 digit code on the injectors called individual injector correction. This code is specific to
each injector, and takes into account differences in manufacture and specifies the flow injected by
each of them.
When an injector is replaced, it is necessary to program the code of the new injector into the ECM.
Refer to EC-1625, «Injector Adjustment Value Registration» .
INSTRUCTIONS FOR HIGH PRESSURE PIPES
CAUTION:
All the high pressure pipe removed must be systematically replaced along with the clips.
TIGHTENING THE HIGH PRESSURE PIPES
NOTE:
fit the pump/rail pipe before the rail/injector pipes.
Rail-pump pipe
●
Undo the rail,
●
Grease the threads of the high pressure pipe nuts,
●
Insert the high pressure pipe olive into the taper of the high pressure pump outlet,
●
Insert the high pressure pipe olive into the taper of the high pressure rail inlet.
●
Move the nut into position by hand, on the rail side then the pump side,
●
Tighten the rail,
●
Tighten the high pressure pipe nuts on the rail side then on the pump side.
Rail/injector pipes
●
Undo the rail,
●
Grease the threads of the high pressure pipe nuts,
●
Insert the high pressure pipe olive into the taper of the high pressure injector inlet,

EM-231

C

D

E

F

G

H

I

J

K

L

M

PRECAUTIONS
[K9K]
Insert the high pressure pipe olive into the taper of the high pressure rail outlet,
Move the nuts into position by hand, on the injector side then the rail side,
●
Tighten the rail,
●
Ensure that the new clip, supplied with the new high pressure pipe, is fitted,
●
Tighten the nuts of the high pressure pipes on the injector side first and then on the fuel rail side.
NOTE:
Before fitting a new high pressure pipe, move back the nuts on the pipe then lightly lubricate the nut
threads with the oil from the sachet provided in the parts kit.
CHECKING SEALING AFTER REPAIR
CAUTION:
After any operation, check that there are no diesel leaks.
●
Reprime the circuit using the priming pump.
●
Start the engine and allow to warm up at idle speed, visually inspecting for any fuel leaks.
●
Apply tracing fluid around the high pressure connections of the pipe that has been replaced.
●
Once the engine coolant temperature is above 50°C and provided there are no malfunctions present,
carry out a road test, taking the engine speed up to 4000 rpm at least once to check that there are no
leaks.
●
Perform a visual inspection after the road test to make sure that there are no high pressure leaks.
●
Clean off the tracing fluid.
REPLACING THE INJECTORS
NOTE:
Individual injector correction is a factory calibration carried out on each injector to adjust the flow of
each one precisely, taking into account differences in manufacture.
The correction values are written on a label affixed to each injector then entered in the ECM which can then
control each injector by taking account of their differences in manufacture.
The system can be programmed “WORK SUPPORT” mode with CONSULT-II.
The correction values (16 digit code) must be replaced after replacing an injector. Refer to EC-1625, «Injector
Adjustment Value Registration» .
●
Entering each injector’s individual correction value, when replacing the ECM. Refer to EC-1626,
«Replacing ECM» .
●
●

EM-232

PREPARATION
[K9K]

PREPARATION
Special Service Tools

PFP:00002

A
BBS002PR

NISSAN tool number
(RENAULT tool No.)
Tool name

Description

KV113B0020
(Emb. 880)
Sliding hammer

EM

Inertia extractor

C

D
MBIB0358E

KV113B0030
(Mot. 11)
Crankshaft bearing remover

Crankshaft bearing extractor

E

F
MBIB0359E

KV113B0040
(Mot. 251-01)
Dial gauge stand set

Gauge stand used with KV113B0050 (Mot.
252-01)

G

H

I

MBIB0360E

KV113B0050
(Mot. 252-01)
Dial gauge stand set

Thrust plate for measuring the protrusion of
cylinder liners used with KV113B0040 (Mot.
251-01).

J

K
MBIB0361E

KV113B0060
(Mot. 582-01)
Ring gear stopper

Flywheel immobilizing tool.

L

M
MBIB0363E

KV113B0070
(Mot. 792-03)
Engine sub-attachment

Engine mounting plate for engine stand

MBIB0367E

KV113B0080
(Mot. 799-01)
Camshaft pulley holder

Tool for locking sprockets for toothed timing
belt

MBIB0368E

EM-233

PREPARATION
[K9K]
NISSAN tool number
(RENAULT tool No.)
Tool name

Description

KV113B0090
(Mot. 1335)
Valve seal remover

Tool for removing valve stem seals

MBIB0370E

KV113B0100
(Mot. 1378)
Engine sub-attachment

X and Y engine pins

MBIB0371E

KV113B0110
(Mot. 1430)
TDC set pin

Set of TDC pins

KV113B0120
(Mot. 1485-01)
Oil jet remover

Tool for removing the piston bottom oil jets

MBIB0372E

KV113B0130
(Mot. 1489)
TDC set pin

TDC setting pin

MBIB0373E

KV113B0140
(Mot. 1492)
Bearing assembling set

Tool for installing connecting rod bearing

MBIB0374E

KV113B0150
(Mot. 1492-03)
Bearing assembling adapter

Adaptation kit for installing the detachable
cap connecting rod bearing

MBIB0375E

KV113B0160
(Mot. 1493-01)
Bearing insert

Tool for installing main bearing

MBIB0376E

EM-234

PREPARATION
[K9K]
NISSAN tool number
(RENAULT tool No.)
Tool name

Description

KV113B0170
(Mot. 1494)
Oil jet remover plate

Tool for removing oil jets

KV113B0180
(Mot. 1511-01)
Valve seal drift

Tool for installing valve stem seals

A

EM

C

D
MBIB0378E

KV113E0010
(Mot. 1566)
Fuel spill tube spanner

Spanner for installing and removing high
pressure pipes

E

F
MBIB0379E

KV113B0190
(Mot. 1567)
Clip pliers

Pliers for exhaust gas recycling pipe clips

KV113B0200
(Mot. 1573)
Cylinder head stand

Cylinder head support

G

H

I

MBIB0380E

KV113B0210
(Mot. 1585)
Front oil seal drift

J
Tool for installing crankshaft seals, flywheel
end

K

L

MBIB0381E

KV113B0220
(Mot. 1586)
Front oil seal drift set

Tool for installing crankshaft seals, timing end

KV113B0230
(Mot. 1632)
Camshaft seal insert

Tool for installing inlet camshaft seals

KV113B0240
(Rou. 15-01)
Shaft protector

Internal shaft protector
16 mm (0.63 in) dia.

EM03470000
(
—
)
Piston ring compressor

Installing piston assembly into cylinder bore

M

NT044

EM-235

PREPARATION
[K9K]
NISSAN tool number
(RENAULT tool No.)
Tool name
KV10111100
(
—
Seal cutter

Description
Removing oil pan

)

NT046

WS39930000
(
—
Tube presser

Pressing the tube of liquid gasket
)

NT052

KV10112100
(
—
)
Angle wrench

Tightening bolts for bearing cap, cylinder
head, etc. in angle

NT014

Commercial Service Tools

BBS002PS

(RENAULT tool No.)
Tool name

Description

Manual lift table caddy

Removing and installing engine

ZZA1210D

Piston ring expander

Removing and installing piston ring

NT030

(Mot. 588)

Liner retaining strap

MBIB0364E

EM-236

PREPARATION
[K9K]
(RENAULT tool No.)
Tool name
(664000)
Cylinder head test container

Description

A

Tool for testing the cylinder head, including: a
tray and the various kits suited for each
model of cylinder head (plug, sealing plate,
blanking plate).

EM

C
MBIB0383E

Torx socket

Standard 1/2″ (12.7 mm) square drive 8/12 /
14 female torx socket.

(Mot. 1505)
(Mot. 1715)
Belt tension setting tool

Tool for belt tension checking with frequency

D

E

F
MBIB1423E

Glow plug wrench

Articulated wrench for removing and installing
the glow plugs

G

H
MBIB0387E

Main bearing wrench

Wrench for removing main bearings

I

J
MBIB0388E

(Mot. 1638)
Belt tension gauge

Setting drive belt tension

K

L

MBIB0382E

Engine support bar

M
Using with engine support chain
A: Approx. 12.5 mm (0.492in)

MBIB0961E

Engine support chain

Using with engine support bar

MBIB0962E

EM-237

IDENTIFICATION INFORMATION
[K9K]

IDENTIFICATION INFORMATION
Engine Identification

PFP:00010
BBS002PT

Identification is by means of an engraved plate on the cylinder block
which carries:
●
A: engine type
●
B: engine type approval letter
●
D: code
●
E: engine suffix
●
F: engine serial number
●
G: engine assembly plant
Engine

Compression
ratio

Bore and stroke
mm (in)

K9K

18.25/1

76 x 80.5 (2.992 x
3.169)

Displacement
cm3 (cu in)
1,461 (89.15)

MBIB0322E

EM-238

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
[K9K]

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

PFP:00003

A
BBS002PU

EM

C

D

E

F

G

H

I

J

K

L

M

MBIB0554E

EM-239

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
[K9K]

Use the Chart Below to Help You Find the Cause of the Symptom.

BBS002PV

1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Operating condition of engine
Location
of noise

Type of
noise

Before
warmup

After
warmup

When
starting

When
idling

When
racing

While
driving

Source of
noise

Check item

Reference page

Top of
engine
Rocker
cover
Cylinder
head

Ticking or
clicking

C

A

—

A

B

—

Tappet
noise

Valve clearance

EM-324

Crankshaft pulley
Cylinder
block
(Side of
engine)
Oil pan

Slap or
rap

A

—

—

B

B

A

Piston
slap noise

Piston ring end gap

EM-327

Front of
engine
Timing
belt cover

Tapping or
ticking

B

Timing
belt
tensioner
noise

Timing belt tensioner
operation

EM-272

Drive belts deflection

EM-242

Water pump operation

CO-54

Front of
engine

A

A

—

B

B

Squeaking or fizzing

A

B

—

B

—

C

Drive belts
(Sticking
or slipping)

Squall
Creak

A

B

—

B

A

B

Water
pump
noise

A: Closely related

B: Related

C: Sometimes related

—: Not related

EM-240

ENGINE ROOM COVER
[K9K]

ENGINE ROOM COVER
Removal and Installation

PFP:14049

A
BBS002PW

EM

C

D

E

F

G

H

I
MBIB1412E

1.

Engine room cover

2.

Engine room cover bracket

J

REMOVAL
Remove engine room cover from engine room cover bracket.
CAUTION:
Do not damage or scratch cover when installing or removing.

●

INSTALLATION
●

K

L

Install in the reverse order of removal.
NOTE:
Press engine room cover until hearing the “click”.

EM-241

M

DRIVE BELTS
[K9K]

DRIVE BELTS
Checking Drive Belts

PFP:02117
BBS002PX

WARNING:
Be sure to perform when the engine is stopped.
1. Inspect belts for cracks, fraying, wear and oil. If necessary,
replace.
2. Tighten auto-tensioner lock nut (models with A/C compressor) or
idler pulley lock nut (models without A/C compressor) by hand
and measure deflection or tension without looseness.

MBIB0664E

3.

When measuring deflection, apply 98 N (10 kg, 22 lb) at the
marked point as shown (models without A/C compressor).

MBIB1066E

Tension Adjustment

BBS002PY

MODELS WITH A/C COMPRESSOR
Belt tensioning is not necessary, as it is automatically adjusted by auto-tensioner.

MODELS WITHOUT A/C COMPRESSOR
●

●

Tighten the accessories belt using tool (Mot. 1638) by tightening the nut (both tension wheel mounting bolts are loosened).
Check the belt tension using tools (Mot. 1715) and (Mot. 1505)
.

MBIB1422E

EM-242

DRIVE BELTS
[K9K]
Belt tightening method for adjustment

Adjusting bolt on idler pulley

A
The tension value is 234±10 Hz.
NOTE:
EM
The engine must be turned through two revolutions in order to position the belt correctly.
CAUTION:
●
When checking belt tension immediately after installation, first adjust it to the specified value.
Then, after turning the crankshaft two turns or more, re-adjust to the specified value to avoid vari- C
ation in deflection between pulleys.
●
When installing belt, make sure that it is correctly engaged with pulley groove.
●
Keep oil and water away from belt.
D
●
Do not twist or bend belt excessively.
●

Removal and Installation

BBS002PZ

CAUTION:
●
Replace any belt that has been removed with a new one.
●
Auto-tensioner and idle pulley must be replaced with a new one when the belt is replaced.
●
Do not run the engine without the drive belts to avoid damaging the crankshaft pulley.

E

F

REMOVAL
1.
2.
3.
4.
5.
●

G

Remove engine undercover.
Remove RH front wheel.
Remove right side splash cover.
Remove RH head light assembly.
Remove drive belt.
Turn clockwise adjusting bolt.

H

I

J

K
MBIB0353E

6.

If necessary, remove auto-tensioner (models with A/C compressor) or idler pulley (models without A/C
compressor).

INSTALLATION
1.

Install auto-tensioner mounting bolt (models with A/C compressor) or idler pulley mounting bolt (models
without A/C compressor).
Auto-tensioner mounting bolt
(models with A/C compressor)
Idler pulley mounting bolt
(models without A/C compressor)

:

40 N·m (4.1 kg-m, 30 ft-lb)

:

30 N·m (3.1 kg-m, 22 ft-lb)

EM-243

L

M

DRIVE BELTS
[K9K]
●

The right figure is for example of models with A/C compressor. Align the notch and tighten mounting bolt.

MBIB0558E

2.

Install the drive belt.
CAUTION:
● Make sure belt is correctly engaged with the pulley
groove.
● Check for oil and coolant on belt and each pulley groove.
NOTE:
The drive belt has five teeth as opposed to the pulleys which
have six. It is therefore essential to ensure that tooth (O)
remains free when installing the belt.

MBIB0516E

3.
4.

Adjust belt tension (models without A/C compressor). Refer to EM-242, «Tension Adjustment» .
Make sure that tension of each belt is within the standard.

EM-244

AIR CLEANER AND AIR DUCT
[K9K]

AIR CLEANER AND AIR DUCT
Removal and Installation

PFP:16500

A
BBS002Q1

EM

C

D

E

F

G

H

I
MBIB9017E

1.

Air duct (suction)

2.

Blow-by hose

3.

Air cleaner case

6.

Air mass flow sensor

4.

Air cleaner filter

5.

Air duct (inlet)

7.

O-ring

8.

Grommet

J

K

: To turbocharger

REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.

Disconnect battery ground cable.
Disconnect battery positive cable.
Remove engine room cover. Refer to EM-241, «ENGINE ROOM COVER» .
Disconnect blow-by hose.
Remove air duct (suction) mounting clip and remove air duct (suction).
Remove battery.
Remove air duct (inlet) by loosing clamp clip.
Remove air cleaner case by sliding the air cleaner case frontward.
CAUTION:
Slide the air cleaner case carefully so as not to damage it on the air cleaner case and harness
bracket.

INSTALLATION
●

Install in the reverse order of removal.

EM-245

L

M

AIR CLEANER AND AIR DUCT
[K9K]

Changing Air Cleaner Filter

BBS002Q2

REMOVAL
1.

Open air cleaner case.

MBIB1035E

2.

Remove air cleaner filter.

MBIB9018E

INSTALLATION
Install in the reverse order of removal.

EM-246

CHARGE AIR COOLER
[K9K]

CHARGE AIR COOLER
Removal and Installation (For 50kW)

PFP:14461

A
BBS002Q4

EM

C

D

E

F

G

H

I

J

K

L

M

MBIB9033E

1.

Hose clamp

2.

Inlet pipe assembly

3.

Air inlet hose

4.

Air inlet tube

5.

Charge air cooler

6.

Alternator

7.

Spacer

8.

Cylinder head

9.

Radiator upper core

10. Inlet pipe bracket
: Paint mark
: Mark

REMOVAL
1.
2.
3.

Remove air inlet hose and tube between inlet pipe assembly and charge air cooler.
Remove engine undercover.
Remove bumper undercover. Refer to EI-4, «FRONT BUMPER» .

EM-247

CHARGE AIR COOLER
[K9K]
4.

Liberate the clamp [A] securing charge air cooler (1) to radiator
(2) and pull to release charge air cooler from the radiator lower
core(3).

MBIB9031E

5.
6.

Remove charge air cooler from underbody as shown.
Remove grommet (4) from the radiator lower core.
Arrow: vehicle front direction
CAUTION:
●
Avoid interference between the charge air cooler and radiator.
●
When removing charge air cooler, close opening on turbo
charger and intake manifold with shop cloth or other suitable material.
MBIB9020E

INSPECTION AFTER REMOVAL
1.
2.

Check that the charge air cooler is not full of oil. In that case, clean it with cleaning agent and then let it
dry.
Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler in necessary.
● Be careful not to deform core fins.
● For cleaning procedure of charge air cooler core, refer to CO-53, «Checking Radiator» .

INSTALLATION
Install in the reverse order of removal paying attention to the following points:
●
Apply a neutral detergent (fluid) to the joint between hoses and pipes (oil is not permissible).
●
Pay attention to identification mark and direction.
●
When installing air inlet hoses and tubes. Refer to EM-247, «Removal and Installation (For 50kW)» .

EM-248

CHARGE AIR COOLER
[K9K]

Removal and Installation (For 65kW)

BBS002Q5

A

EM

C

D

E

F

G

H

I

J

K

L

M

MBIB9016E

1.

Hose clamp

2.

Inlet pipe assembly

3.

Air inlet hose

4.

Air inlet tube

5.

Charge air cooler

6.

Alternator

7.

Spacer

8.

Cylinder head

9.

Radiator upper core

: Paint mark
: Mark

REMOVAL
1.
2.
3.

Remove air inlet hose and tube between inlet pipe assembly and charge air cooler.
Remove engine undercover.
Remove bumper undercover. Refer to EI-4, «FRONT BUMPER» .

EM-249

CHARGE AIR COOLER
[K9K]
4.

Liberate the clamp [A] securing charge air cooler (1) to radiator
(2) and pull to release charge air cooler from the radiator lower
core(3).

MBIB9031E

5.
6.

Remove charge air cooler from underbody as shown.
Remove grommet (4) from the radiator lower core.
Arrow: vehicle front direction
CAUTION:
●
Avoid interference between the charge air cooler and radiator.
●
When removing charge air cooler, close opening on turbo
charger and intake manifold with shop cloth or other suitable material.
MBIB9020E

INSPECTION AFTER REMOVAL
1.
2.

Check that the charge air cooler is not full of oil. In that case, clean it with cleaning agent and then let it
dry.
Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler in necessary.
● Be careful not to deform core fins.
● For cleaning procedure of charge air cooler core, refer to CO-53, «Checking Radiator» .

INSTALLATION
Install in the reverse order of removal paying attention to the following points:
●
Apply a neutral detergent (fluid) to the joint between hoses and pipes (oil is not permissible).
●
Pay attention to identification mark and direction.
●
When installing air inlet hoses and tubes. Refer to EM-249, «Removal and Installation (For 65kW)» .

EM-250

EGR UNIT
[K9K]

EGR UNIT
Removal and Installation

PFP:14710

A
BBS002Q7

EM

C

D

E

F

G

H

I
MBIB1414E

1.

Air inlet tube

2.

EGR solenoid valve

3.

Air duct and blow-by unit assembly

4.

Water port

5.

EGR unit housing

6.

EGR tube

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

K

Remove battery ground cable.
Remove engine room cover. Refer to EM-241, «ENGINE ROOM COVER» .
Remove air cleaner case and air duct (inlet). Refer to EM-245, «AIR CLEANER AND AIR DUCT» .
Remove wiper assembly.
Remove bulk head cover.
Disconnect EGR solenoid valve connector.
Remove mounting bolts.
Drain engine coolant and water hose.
Loosen turbocharger inlet tube.
Remove front engine slinger. Refer to EM-280, «REMOVAL» .
Remove air inlet tube.

L

M

MBIB1415E

EM-251

J

EGR UNIT
[K9K]
12. Remove air duct and blow-by unit assembly.
13. Remove EGR tube mounting bolts.
14. Remove EGR unit housing and EGR tube.

MBIB1427E

INSTALLATION
●

Install in the reverse order of removal.

EM-252

EXHAUST MANIFOLD, TURBOCHARGER, CATALYST
[K9K]

EXHAUST MANIFOLD, TURBOCHARGER, CATALYST
Removal and Installation

PFP:14004

A
BBS002QA

EM

C

D

E

F

G

H

I
MBIB1416E

1.

Catalyst

2.

Bracket

3.

Turbocharger assembly

4.

Hose

5.

Exhaust manifold

6.

EGR unit

7.

Gasket

K

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

J

Remove battery ground cable.
Remove engine undercover.
Remove air cleaner case and air duct (inlet). Refer to EM-245, «AIR CLEANER AND AIR DUCT» .
Remove wiper assembly.
Remove bulk head cover.
Remove EGR unit assembly. Refer to EM-251, «EGR UNIT» .
Remove turbocharger assembly as follows:

EM-253

L

M

EXHAUST MANIFOLD, TURBOCHARGER, CATALYST
[K9K]
a.
b.

c.

Remove catalyst mounting bolts and brackets.
Remove exhaust front tube. Refer to EX-3, «Removal and Installation» .
CAUTION:
Temporarily fix on vehicle side with rope or so to avoid putting stress on exhaust center tube.
Remove catalyst.

MBIB1428E

8.
9.

Each wiring and piping (disconnect/move).
Loosen exhaust manifold mounting nuts in the reverse order as
shown.

MBIB1417E

10. Rotate the exhaust manifold and turbocharger assembly so that the rear side (EGR tube mounting side)
faces upward. And then pull out the assembly from between the engine and the air conditioning piping.
CAUTION:
Be careful not to deform each turbocharger piping when pulling out the assembly.

INSTALLATION
1.

Tighten the mounting nuts in numerical order as shown.

MBIB1417E

2.

Install in reverse order of removal after this step.

INSPECTION AFTER INSTALLATION
Start engine and raise engine speed to check no exhaust emission leaks.

EM-254

EXHAUST MANIFOLD, TURBOCHARGER, CATALYST
[K9K]

Disassembly and Assembly

BBS002QB

A

EM

C

D

E

F
MBIB1418E

1.

Washer

2.

4.

Turbocharger

7.

Turbocharger oil outlet pipe

Oil tube

3.

O-ring

5.

Exhaust manifold

6.

Gasket

8.

Gasket

G

H

DISASSEMBLY
●

After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and
then loosen the nuts to remove.
CAUTION:
Do not disassemble or adjust the turbocharger body.

I

J

INSPECTION AFTER DISASSEMBLY
Turbocharger

K

L

M

MBIB1419E

CAUTION:
When the compressor wheel turbine wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary failure:
Suction side
Exhaust side

: Between turbocharger and air cleaner
: Between turbocharger and catalyst

EM-255

EXHAUST MANIFOLD, TURBOCHARGER, CATALYST
[K9K]
ASSEMBLY
Install in the reverse order of removal.
NOTE:
Apply LOCTITE FRENETANCH or equivalent to the threads of the turbocharger oil inlet pipe union to the cylinder head.
●

EM-256

OIL PAN
[K9K]

OIL PAN
Removal and Installation

PFP:11110

A
BBS002QC

EM

C

D

E

F

G

H

I
MBIB0571E

1.

Baffle plate

2.

Gasket

3.

Oil pan

4.

O-ring

5.

Drain plug

6.

Oil level gauge

7.

Crankshaft position sensor (POS)

J

K

CAUTION:
To avoid the danger of being scalded, never drain the engine oil when the engine is hot.

REMOVAL
1.
2.
3.
4.

L

Remove engine undercover.
Remove RH front wheel.
Remove right side splash cover.
Remove center bearing bracket as shown.

M

MBIB1037E

EM-257

OIL PAN
[K9K]
5.

Remove A/C compressor bracket mounting bolt as shown.

MBIB1038E

6.
7.
8.

9.

Remove bolts (3) from the catalyst bracket. Refer to EM-253, «EXHAUST MANIFOLD, TURBOCHARGER, CATALYST» .
Remove oil level gauge guide.
Drain engine oil. Refer to LU-24, «Changing Engine Oil» .
CAUTION:
Perform when engine is cold.
Remove oil pan and transaxle joint bolts.

MBIB1039E

10. Support the engine bottom of the oil pan with a transmission jack
etc.

MBIB0575E

11. Remove oil pan bolt reverse order as shown.

MBIB1257E

EM-258

OIL PAN
[K9K]
●

Insert seal cutter (special service tool) between upper oil pan
and cylinder block. Slide tool by tapping on the side of the tool
with a hammer.
CAUTION:
Exercise care not to damage mating surface.

A

EM

C
SEM365EA

D

12. Remove oil pan and baffle plate.

INSPECTION AFTER REMOVAL
E

Clean oil pump assembly if any object attached.

INSTALLATION
●

1.

Install in the reverse order of removal paying attention to the following.
Apply liquid gasket as shown.
● Use Genuine Liquid Gasket or equivalent.

F

G

H

I
MBIB0593E

J

K

L

MBIB0594E

2.
3.

4.

Install baffle plate.
Install oil pan bolts in numerical order as shown.
● Tighten the bolts in the numerical order shown in the figure to
a torque of 8 N·m (0.8 kg-m, 71 in-lb).
● Tighten the mounting bolts of oil pan on the clutch housing
without locking.
● Tighten the bolts in the numerical order shown in the figure to
a torque of 15 N·m (1.5 kg-m, 11 ft-lb).
● Tighten the mounting bolts of oil pan on the clutch housing to
a torque of 44 N·m (4.5 kg-m, 32 ft-lb).
At least 30 minutes after oil pan is installed, pour engine oil.

INSPECTION AFTER INSTALLATION
●
●

Inspection the engine oil level. Refer to LU-23, «ENGINE OIL» .
Start the engine, and make sure there is no leak of engine oil. Refer to LU-23, «ENGINE OIL» .

EM-259

MBIB1257E

M

GLOW PLUG
[K9K]

GLOW PLUG
Removal and Installation

PFP:22401
BBS002QD

MBIB0576E

1.

Glow plug

REMOVAL
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.
1. Disconnect battery ground cable.
2. Remove engine room cover. Refer to EM-241, «ENGINE ROOM COVER» .
3. Disconnect harness connector from glow plug.
4. Remove glow plug.
CAUTION:
● When removing or installing, do not use such tools as an air impact wrench.
● Handle it carefully without giving any impact, even after removal. [As a guide, if it drops from
height of 10 cm (3.94 in) or higher, always replace it.]

INSTALLATION
1.
2.
3.

Remove adhered carbon from glow plug installation hole with a reamer.
Install glow plug.
Install remaining parts in reverse order of removal.

EM-260

VACUUM PUMP
[K9K]

VACUUM PUMP
Removal and Installation

PFP:41920

A
BBS002QF

EM

C

D

E

F
MBIB1420E

1.

Vacuum pump

2.

Gasket

3.

Vacuum hose

G

INSPECTION BEFORE REMOVAL
1.

2.

Disconnect vacuum hose, and connect a vacuum gauge via 3-way connector.
● Disconnect point where vacuum from vacuum pump can be measured directly and install 3-way connector.
Start engine and measure generated vacuum at idle speed.
Standard

J

Remove engine room cover. Refer to EM-241, «ENGINE ROOM COVER» .
Remove battery.
Remove air duct (suction). Refer to EM-245, «AIR CLEANER AND AIR DUCT» .
Remove EGR inlet tube. Refer to EM-251, «EGR UNIT» .
Disconnect vacuum hose from vacuum pump side.
Remove vacuum pump.

INSTALLATION
●

I

: – 86.6 to – 101.3 kPa (– 866 to – 1,013 mbar, – 650 to – 760 mmHg, – 25.59 to –
29.92 inHg)

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

H

K

L

M

Install in the reverse order of removal.

EM-261

HIGH PRESSURE PIPES
[K9K]

HIGH PRESSURE PIPES
Removal and Installation

PFP:16680
BBS0058E

MBIB9025E

1.

High pressure pipe

2.

Dipstick guide

3.

High pressure pipes protection
cover

REMOVAL
CAUTION:
●
Be sure to read “Precautions for Diesel Equipment”. Refer to EM-229, «Precautions for Diesel
Equipment» .
●
Wait until the fuel temperature drops before carrying out any work.
●
Order the special high pressure injection circuit plug kit.
NOTE:
It is possible to replace a single high pressure pipe.
1. Disconnect the battery.
2. Remove charge air cooler hose and pipes. Refer to EM-247, «Removal and Installation (For 50kW)» and
EM-249, «Removal and Installation (For 65kW)» .
3. Remove engine cover. Refer to EM-241, «ENGINE ROOM COVER» .
4. Remove the dipstick guide and plug the hole.
5. Remove high pressure pipes protection cover.
6. Remove the neck located on the fuel rail,
7. Remove the clips connecting the high pressure pipes.

EM-262

HIGH PRESSURE PIPES
[K9K]
8.

Undo the mounting nut of the rail a few turns.
A

EM

C
MBIB9026E

D

CAUTION:
● When undoing the high pressure pipes, it is essential to
maintain the central union of the injector (2).
● Do not damage the injector’s leak return duct (1).

E

F

G
MBIB9027E

H

NOTE:
Undo the nut on the pump side or the injector side, then the
nut located on the rail side. Undo the nuts for each pipe in
turn. Move the nut along the pipe keeping the olive in contact with the taper.
9. Remove all the high pressure pipes.
10. Plug all the holes in the injection circuit.
11. Remove the rail.

I

J

K
MBIB9026E

L

INSTALLATION
CAUTION:
All the high pressure pipes removed must be systematically replaced.
1. Finger tightens the nuts.
2. Before fitting the new high pressure pipes, lightly lubricate the nut threads with the oil from the sachet provided in the new parts kit.
NOTE:
Fit the pump/rail pipe before the rail/injector pipes.
3. Fit the pump-rail high pressure pipe as follow:
● Remove the protective plugs from the high pressure pump outlet, the high pressure rail inlet and the
pipe.
● Insert the high pressure pipe olive into the taper of the high pressure pump outlet,
● Insert the high pressure pipe olive into the taper of the high pressure rail inlet.
● Finger tighten the nuts of the high pressure pipe starting with the one located on the rail side.
4. Fit the rail-injector high pressure pipe as follow:

EM-263

M

HIGH PRESSURE PIPES
[K9K]

5.

6.

7.

CAUTION:
When tightening the high pressure pipes, it is essential to
maintain the central union of the injector (2).
● Remove the protective plugs from the high pressure rail outlet, the injector high pressure inlet and the pipe.
● Insert the high pressure pipe olive into the taper of the high
pressure injector inlet,
● Insert the high pressure pipe olive into the taper of the high
pressure rail outlet.
● Finger tighten the nuts of the high pressure pipe starting with
the one located on the injector side.
Fit the remaining high pressure pipes as you did previously.
NOTE:
The order in which the pipes are installed is not important.
Fit a new clips supplied with the new pipes onto the high pressure pipes:
● Insert the first half of the clip using adjustable pliers
● Insert the second half of the clip using adjustable pliers.
CAUTION:
Pay attention to the direction of installation of the second
clip. The tabs located in the centre of the clip will only fit
together in one position.
Tighten the rail nuts to the torque.

MBIB9027E

: 28 N·m (2.9 kg-m, 21 ft-lb)
CAUTION:
● Do not touch the pipes with the wrench when torque
tightening.
● Follow the order and tightening torque of the high pressure pipes.
8.

MBIB9028E

Using the recommended tools, tighten the nuts on the rail pump high pressure pipe:
● Tighten the nut on the rail side to the torque
: 38 N·m (3.9 kg-m, 28 ft-lb)
●

Tighten the nut on the pump side to a torque of
: 38 N·m (3.9 kg-m, 28 ft-lb)
MBIB9037E

9.

Using the recommended tools, tighten the nuts on the rail — injector high pressure pipes:
Tool number: KV113E0010 (Mot.1566)
●

Tighten the nut on the injector side to a torque of
: 38 N·m (3.9 kg-m, 28 ft-lb)

●

T tighten the nut on the rail side to a torque of
: 38 N·m (3.9 kg-m, 28 ft-lb)
MBIB9029E

EM-264

HIGH PRESSURE PIPES
[K9K]
CAUTION:
● When undoing the high pressure pipes, it is essential to
maintain the central union of the injector (2).
● Do not damage the injector’s leak return duct (1).
NOTE:
Tighten one pipe fully before moving on to the next pipe.
10. Tighten the rail nut to the torque. Refer to EM-267, «INJECTOR
RAIL» .
11. Refit in the reverse order to removal for the other refitting operations.
12. Test the sealing of the high pressure after it has been repaired
(refer to EM-231, «SPECIAL FEATURES» ).

A

EM

C

MBIB9027E

D

E

F

G

H

I

J

K

L

M

EM-265

FUEL INJECTOR
[K9K]

FUEL INJECTOR
Removal and Installation

PFP:16600
BBS0058B

REMOVAL
CAUTION:
●
Be sure to read “Precautions for Diesel Equipment”. Refer to EM-229, «Precautions for Diesel
Equipment» .
●
Wait until the fuel temperature drops before carrying out any work.
●
Order the special high pressure injection circuit plug kit.
●
It is forbidden to open an injector. If you open an injector by mistake, you will have to change it.
This is because of the manufacturing and installation tolerances and because there is a risk of
contaminating the inside of the injector.
●
The rod filter of the injector must not be removed.
NOTE:
It is possible to replace a single high pressure pipe.
1. Disconnect fuel return pipe. Refer to EM-268, «HIGH PRESSURE PUMP» .
2. Remove high pressure pipe of the injector. Refer to EM-262, «HIGH PRESSURE PIPES» .
3. Disconnect the diesel return pipe on the injector.
4. Plug all the holes of the injection circuit.
5. Disconnect the injector electrical connector (1).
6. Unscrew the injector bracket (2).
7. Remove the injector.
8. Pull off the flame shield washer.

MBIB9030E

INSTALLATION
NOTE:
Read the 16 digit code on the new injector before refitting it and
programming the code into he ECM using the CONSULT-II (see
section “Special features, Replacing injectors”). The codes
unique to each injector, it specifies the flow.
CAUTION:
All the high pressure pipes removed must be systematically
replaced.
1. Clean the injector sockets and the injector bodies, as well as
their brackets using a lint-free cloth (use the wipes recommended for this purpose, dipped in clean solvent.
2. Dry off using a different new wipe.
3. Replace the flame shield washer with a new one.
4. Position the injector.
5. Tighten its mounting clamp to the torque.
: 28 N·m (2.9 kg-m, 21 ft-lb)
6.

Reinstall high pressures pipes. Refer to EM-262, «HIGH PRESSURE PIPES» .

EM-266

MBIB9027E

INJECTOR RAIL
[K9K]

INJECTOR RAIL
Removal and Installation

PFP:00018

A
BBS0058C

REMOVAL
CAUTION:
EM
●
Be sure to read “Precautions for Diesel Equipment”. Refer to EM-229, «Precautions for Diesel
Equipment» .
●
Wait until the fuel temperature drops before carrying out any work.
C
●
Order the special high pressure injection circuit plug kit.
1. Disconnect the battery.
2. Remove charge air cooler hose and pipes. Refer to EM-247, «Removal and Installation (For 50kW)» and D
EM-249, «Removal and Installation (For 65kW)» .
3. Remove engine cover. Refer to EM-241, «ENGINE ROOM COVER» .
4. Remove the neck located on the fuel rail.
E
5. Remove the dipstick guide and plug the hole.
6. Remove fuel pipes cover. Refer to EM-262, «HIGH PRESSURE PIPES» .
F
7. Disconnect the pressure sensor connector from the rail.
8. Remove all high pressure pipes connecting injectors to the rail.
Refer to EM-262, «HIGH PRESSURE PIPES» .
G
9. Remove all high pressure pipes connecting high pressure pump
to the rail. Refer to EM-262, «HIGH PRESSURE PIPES» .
10. Plug all the holes of the injection circuit.
H
11. Remove injector rail mounting nuts and remove the injector rail.

I
MBIB9026E

INSTALLATION
1.
2.

Refit in the reverse order to removal for the other refitting operations.
Test the sealing of the high pressure after it has been repaired (refer to EM-231, «SPECIAL FEATURES» ).

J

K

L

M

EM-267

HIGH PRESSURE PUMP
[K9K]

HIGH PRESSURE PUMP
Removal and Installation

PFP:17082
BBS0058D

MBIB9035E

1.

Flow actuator

2.

Fuel temperature sensor

3.

Injector connector

4.

Fuel supply

5.

Fuel return pipe

6.

Fuel return pipe (injector)

7.

Fuel rail neck

8.

Pressure sensor

REMOVAL
CAUTION:
●
Be sure to read “Precautions for Diesel Equipment”. Refer to EM-229, «Precautions for Diesel
Equipment» .
●
Wait until the fuel temperature drops before carrying out any work.
●
Order the special high pressure injection circuit plug kit.
●
It is strictly forbidden to remove any injection pump pulley
marked number 070 575 (see diagram). If the pump is being
replaced, the pulley must be replaced.
1. Disconnect the battery.
2. Remove charge air cooler hose and pipes. Refer to EM-247,
«Removal and Installation (For 50kW)» and EM-249, «Removal
and Installation (For 65kW)» .
3. Remove engine cover. Refer to EM-241, «ENGINE ROOM
COVER» .
4. Remove the timing belt. Refer to EM-272, «TIMING BELT» .
MBIB9036E
5. Remove the neck located on the fuel rail,
6. Remove the dipstick guide and plug the hole.

EM-268

HIGH PRESSURE PUMP
[K9K]
7.
8.

Remove fuel pipes cover. Refer to EM-262, «HIGH PRESSURE PIPES» .
A
Carefully disconnect:
● The connectors from the flow actuator,
● The connectors from the fuel temperature sensor,
EM
● The injector connectors,
● The pre-heater (glow)
● On the pump, the fuel supply and return pipes.
C
● The return pipe connecting the injectors with the pump.
9. Remove the high pressure pipe connecting the pump to the rail. Refer to EM-262, «HIGH PRESSURE
PIPES» .
D
10. Plug all the holes of the injection circuit.
11. Remove the three mounting bolts from the injection pump then remove it.
E
INSTALLATION
1.
2.
3.

4.
5.

Fit the pump then position the mounting bolts without tightening them.
Before fitting the new high pressure pipe, lightly lubricate the nut threads with the oil from the sachet provided in the new parts kit.
Refit the high pressure pipe, to do this:
● remove the protective plugs,
● insert the high pressure pipe olive into the taper of the high pressure pump outlet,
● insert the high pressure pipe olive into the taper of the high pressure rail inlet.
Finger tighten the nuts of the high pressure pipe starting with the one located on the rail side.
Tighten the mounting bolts on the high pressure pump to the torque.
: 21 N·m (2.1 kg-m, 15 ft-lb)

6.
7.
8.

F

G

H

I

Tighten the high pressure pipes to the torque. Refer to EM-262, «HIGH PRESSURE PIPES» .
Refit in the reverse order to removal for the other refitting operations.
Test the sealing of the high pressure after it has been repaired (refer to EM-231, «SPECIAL FEATURES» ).

J

K

L

M

EM-269

ROCKER COVER
[K9K]

ROCKER COVER
Removal and Installation

PFP:13264
BBS002QG

MLIA0009E

1.

Oil filler cap

4.

Gasket

2.

Oil catcher

3.

Rocker cover

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

Remove engine room cover. Refer to EM-241, «ENGINE ROOM COVER» .
Remove air duct (suction). Refer to EM-245, «AIR CLEANER AND AIR DUCT» .
Remove inlet pipe assembly and air inlet hose, and inlet pipe bracket. Refer to EM-247, «Removal and
Installation (For 50kW)» or EM-249, «Removal and Installation (For 65kW)» .
Remove rear engine slinger.
Unclip timing belt upper cover.
Remove rocker cover.
● Loosen holding bolts in the reverse order as shown in the figure and remove.

MBIB0580E

EM-270

ROCKER COVER
[K9K]
INSTALLATION
1.

A

Apply liquid gasket on locations shown in the figure.
● Use Genuine Liquid gasket or equivalent.

EM

C

D

E

F

G
MBIB0581E

2.

H

Tighten holding bolts in the numerical order as shown in the figure.
: 10 N·m (1.02 kg-m, 7.4 ft-lb)

3.

I

Install in the reverse order of removal after this steps.
J

K
MBIB0580E

L

M

EM-271

TIMING BELT
[K9K]

TIMING BELT
Removal and Installation

PFP:13028
BBS002QH

MBIB1258E

1.

Timing belt inner cover

4.

Timing belt tensioner

5.

Timing belt upper cover

6.

Camshaft position sensor

7.

Timing belt lower cover

8.

Cylinder head suspended bracket

9.

Crankshaft pulley

10. Crankshaft sprocket

2.

Timing belt

11. Rear oil seal

3.

Camshaft sprocket

12. Rear oil seal retainer

13. Gasket

CAUTION:
●
Apply new engine oil to parts marked in illustration before installation.
●
Replace any belt that has been removed.
●
Never turn the engine in the direction opposite to that of normal operation.
●
When replacing the timing belt, be sure to replace the timing belt tensioner.
●
Do not run the engine without the drive belts to avoid damaging the crankshaft pulley.

REMOVAL
1.

2.
3.
4.
5.

Remove the following parts.
● Battery ground cable
● Undercover
● RH front wheel
● RH head light assembly
Remove right side splash cover.
Remove engine room cover. Refer to EM-241, «ENGINE ROOM COVER» .
Remove drive belt. Refer to EM-242, «DRIVE BELTS» .
Install engine slingers. Refer to EM-280, «REMOVAL» .

EM-272

TIMING BELT
[K9K]
6.

Set the engine support bar (commercial service tool) or suitable
tool, and secure the engine in position.

A

EM

C
MBIB1046E

D

7.
8.

Remove RH engine torque rod.
Remove RH engine mounting.
E

F

G
MBIB1041E

H

9. Remove RH engine mounting support bracket, RH engine mounting insulator and reservoir tank.
10. Remove upper timing cover, camshaft position sensor and cylinder head suspended mounting bracket.

I

J

K
MLIA0003E

L

11. Remove timing belt lower cover.
12. Remove the TDC pin bolt.

M

MBIB0392E

EM-273

TIMING BELT
[K9K]
13. Rotate the crankshaft clockwise, until the position (A) of the
came shaft pulley becomes opposite of the position (B) on the
cylinder head.

MBIB0393E

14. Screw in the TDC pin (special service tool).

MBIB0394E

15. Turn the engine clockwise (timing side) until the crankshaft
touches the TDC pin (special service tool).

MBIB0395E

16. The pin (special service tool) must engage in the camshaft pulley and cylinder head holes.

MBIB0396E

17. Remove crankshaft pulley:
CAUTION:
Do not remove fixing bolts. Keep loosened fixing bolts in
place to protect removed crankshaft pulley from dropping.

MBIB0591E

EM-274

TIMING BELT
[K9K]
18. Slacken the timing belt by loosening the bolt of tensioner, then
remove timing belt.

A

EM

C
MBIB0592E

D

INSTALLATION
●

Install in the reverse order of removal paying attention to the following.
E

Timing Belt
Refer to EM-316, «TIMING ADJUSTMENT» .

F

G

H

I

J

K

L

M

EM-275

CYLINDER HEAD
[K9K]

CYLINDER HEAD
Removal and Installation

PFP:11041
BBS002QI

MBIB0596E

1.

Front engine slinger

4.

Camshaft sprocket

7.

Valve rotator

2.

Camshaft bracket

3.

Camshaft

5.

Cylinder head suspended bracket

6.

Shim

8.

Valve spring retainer

9.

Valve spring

10. Valve cotter

11. Exhaust valve

12. Intake valve

13. Rear engine slinger

14. Cap

15. Cylinder head gasket

16. Cylinder head

CAUTION:
Apply new engine oil to parts marked in illustration before installation.

REMOVAL
1.

2.
3.
4.

5.
6.
7.
8.

Remove the following parts.
● Battery ground cable
● Undercover
● RH front wheel
● RH head light assembly
Remove right side splash cover.
Remove engine room cover. Refer to EM-241, «ENGINE ROOM COVER» .
Drain engine coolant. Refer to CO-49, «DRAINING ENGINE COOLANT» .
CAUTION:
Perform when engine is cold.
Remove air cleaner case and air duct (suction). Refer to EM-245, «AIR CLEANER AND AIR DUCT» .
Remove radiator upper hose. Refer to CO-51, «RADIATOR» .
Disconnect fuel feed tube and return tube from fuel injection pump. Refer to EM-268, «HIGH PRESSURE
PUMP» .
Remove oil level gauge guide.

EM-276

CYLINDER HEAD
[K9K]
9. Remove harnesses and connectors.
A
10. Remove heater hoses.
11. Remove turbocharger assembly. Refer to EM-253, «EXHAUST MANIFOLD, TURBOCHARGER, CATALYST» .
EM
12. Remove drive belt. Refer to EM-242, «DRIVE BELTS» .
13. Remove rocker cover. Refer to EM-270, «ROCKER COVER» .
14. Support underneath of engine by setting a manual lift table caddy (commercial service tool) or equivalent
C
tool.
CAUTION:
Put a piece of wood or something similar as supporting surface, secure a completely stable condiD
tion.
15. Remove timing belt. Refer to EM-272, «TIMING BELT» .
16. Remove engine support bar.
E
CAUTION:
During the removal operation, always be careful to prevent engine moves downward from the
vehicle.
F
17. Remove cylinder head bolt in the reverse order as shown.

G

H

MBIB0323E

I

18. Remove cylinder head assembly.
J

INSTALLATION
●

Install in the reverse order of removal paying attention to the following.

Cylinder Head Bolts

K

NOTE:
Use a syringe to remove any oil which may have entered the cylinder head mounting bolt holes to achieve correct tightening of the bolts.
CAUTION:
All bolts must always be changed after removal. Do not oil the new bolts.
●
Tighten all the bolts in the numerical order as shown.

L

: 25 N·m (2.6 kg-m, 18 ft-lb)
●

Check that all the bolts are correctly tightened to 25 N·m (2.6 kgm, 18 ft-lb), then angle tightening of 245 to 265 degrees.
CAUTION:
● Use an angle wrench (special service tool) to check tightening angle.
● Do not retighten the cylinder head bolts after preforming
this procedure.
MBIB0323E

Disassembly and Assembly

BBS002QJ

DISASSEMBLY
●

Refer to EM-288, «DISASSEMBLY OF THE CYLINDER HEAD» .

INSPECTION AFTER DISASSEMBLY
●

Refer to EM-291, «Inspection» .

EM-277

M

CYLINDER HEAD
[K9K]
●
●

Refer to EM-292, «Valve Clearance» .
Refer to EM-321, «Cylinder Head» .

ASSEMBLY
●

Refer toEM-301, «Assembly» .

EM-278

ENGINE ASSEMBLY
[K9K]

ENGINE ASSEMBLY
Removal and Installation

PFP:10001

A
BBS002QL

EM

C

D

E

F

G

H

I
MBIB9019E

1.

Transaxle mounting insulator

2.

Transaxle mounting upper bracket

3.

Transaxle mounting stay

4.

Engine torque rod

5.

Engine mounting insulator

6.

Engine mounting stay

7.

Engine mounting bracket

8.

Transaxle mounting lower bracket

9.

Transaxle torque rod

WARNING:
●
Situate vehicle on a flat and solid surface.
●
Place chocks at front and back of rear wheels.
●
For engines not equipped with engine slingers, attach proper slingers and bolts described in
PARTS CATALOG.
CAUTION:
●
Always be careful to work safely, avoid forceful or uninstructed operations.
●
Do not start working until exhaust system and coolant are cool enough.
●
If items or work required are not covered by the engine main body section, refer to the applicable
sections.
●
Always use the support point specified for lifting.
●
Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for
unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool
before starting work, in preparation for the backward shift of center of gravity.
●
For supporting points for lifting and jacking point at rear axle, refer to GI-40, «LIFTING POINT» .

EM-279

J

K

L

M

ENGINE ASSEMBLY
[K9K]
REMOVAL
Description of work
Remove engine and transaxle assembly from vehicle down ward. Separate engine and transaxle.
Preparation
1. Remove the following parts.
● Battery ground cable
● Undercover
● Right side splash cover
● LH/RH front wheel
● RH head light assembly
Engine room
2. Drain engine coolant. Refer to LU-24, «Changing Engine Oil» .
CAUTION:
Perform when engine is cold.
3. Remove engine room cover. Refer to EM-241, «ENGINE ROOM COVER» .
4. Remove air cleaner case and air duct (suction). Refer to EM-245, «AIR CLEANER AND AIR DUCT» .
5. Remove radiator upper hose. Refer to CO-51, «RADIATOR» .
6. Remove reservoir tank and hoses. Refer to CO-51, «RADIATOR» .
7. Remove fuel feed and return tubes. Refer to EM-268, «HIGH PRESSURE PUMP» .
8. Remove vacuum hose. Refer to EM-261, «VACUUM PUMP» .
9. Remove turbocharger air duct. Refer to EM-253, «EXHAUST MANIFOLD, TURBOCHARGER, CATALYST» .
10. Disconnect heater hoses.
11. Disconnect engine room harness from the engine side and set it aside for easier work.
12. Disconnect transaxle side harness and clutch hose.
13. Disconnect drain hose transaxle side.
14. Disconnect shift cable and select cable. Refer to MT-12, «CONTROL LINKAGE» .
15. Loosen wire bracket.
16. Disconnect all the body-side vacuum hoses and air hoses at engine side.
17. Disconnect fuel feed and return hoses, and plug it to prevent fuel from draining.
Vehicle underbody
18. Remove drive shaft lock pin and lock nut. Refer to FAX-10, «FRONT DRIVE SHAFT» .
19. Remove ABS sensor from brake caliper.
20. Remove strut lower bolts.
21. Remove drive shaft assembly RH and LH.
22. Remove drive belt. Refer to EM-242, «DRIVE BELTS» .
23. Remove A/C compressor with piping connected from engine (with A/C compressor models). Temporarily
secure it on body with a rope to avoid putting load on it.
24. Remove exhaust front tube. Refer to EX-3, «Removal and Installation» .
25. Remove engine rear mounting bracket.

MBIB1044E

Removal

EM-280

ENGINE ASSEMBLY
[K9K]
26. Install engine slingers (1) into front right of cylinder head and
engine slinger (2) into rear left of cylinder head.

A

Slinger bolts:
: 21 N·m (2.14 kg-m, 15.5 ft-lb)

EM

C
MBIB9022E

27. Set the engine support bar (commercial service tool) or suitable tool, and secure the engine in position.
● Use a manual lift table caddy (commercial service tool) or
equivalently rigid tool such as a jack or trestle. Securely support bottom of engine and transaxle.
CAUTION:
Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
28. Remove RH and LH engine mounting bolts.
29. Remove engine and transaxle assembly from vehicle downward
by carefully operating supporting tools.
CAUTION:
MBIB1045E
● During the operation, make sure that no part interferes
with body side.
● Before and during this lifting, always check if any harnesses are left connected.
● During the removal operation, always be careful to prevent vehicle from falling off the lift due to
changes in the center of gravity.
● If necessary, support vehicle by setting a jack or equivalent tool at the rear.
Separation Work
CAUTION:
During the operation, secure support the engine by placing a piece of wood under the engine oil pan,
transaxle oil pan and suspended the engine slinger by baby crane (movable hoist) etc.
30. Remove starter motor.
31. Separate engine and transaxle.

D

E

F

G

H

I

J

K

INSTALLATION

L

Install in the reverse order of removal.
●
Do not allow oil to get on mounting insulator. Be careful not to damage mounting insulator.
●
When installation directions are specified, install parts according to the direction marks on them referring
to components illustration.
●
Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.

M

INSPECTION AFTER INSTALLATION
●

●
●
●

●

Before starting engine check the levels of coolant, lubrications and working oils. If less than required
quantity, fill to the specified level.
Before starting engine, bleed air from fuel piping. Refer to FL-28, «Bleeding Fuel Filter» .
Run engine to check for unusual noise and vibration.
Warm up engine thoroughly to make sure there is no leakage of coolant, lubricants, working oil, fuel and
exhaust gas.
Bleed air from passages in pipes and tubes of applicable lines.

EM-281

OVERHAUL
[K9K]

OVERHAUL
Tightening Torques

PFP:00000
BBS002QM

UPPER ENGINE
Unit: N·m (kg-m, in-lb)*2 Unit: N·m (kg-m, ft-lb)
Tightening torque

Cylinder head

: *1

Camshaft bearing

: 10 (1.0, 7)

Vacuum pump

: 21 (2.1, 15)

Cylinder head coolant outlet unit

: 10 (1.0, 7)

Exhaust manifold

: 26 (2.7, 19)

Glow plug

: 15 (1.5, 11)

Rocker cover

: 10 (1.0, 7)

Turbocharger-manifold mounting

: 26 (2.7, 19)

Turbocharger oil return pipe

: 9 (0.9, 80)*2

Turbocharger oil delivery pipe

: 23 (2.3, 17)

Timing tensioner

: 25 (2.6, 18)

TDC cap

: 20 (2.0, 15)

Cylinder head suspended mounting bracket

: 21 (2.1, 15)

*1: Refer to tightening procedure in the text.

BOTTOM ENGINE
Unit: N·m (kg-m, in-lb)*2 Unit: N·m (kg-m, ft-lb)
Tightening torque

Oil cooler connector bolt

: 45 (4.6, 33)

Oil filter bracket

: 45 (4.6, 33)

Main bearing cap

: 27 (2.8, 20) + 47°±5° (Angle tightening)

Connecting rod

: 20 (2.0, 15) + 45°±6° (Angle tightening)

Knock sensor

: 20 (2.0, 15)

Oil level sensor

: 25 (2.6, 18)

Oil pump

: 25 (2.6, 18)

Oil pan

: *1

Water pump

: 11 (1.1,

Flywheel

: 50 — 55 (5.1 — 5.6, 37 — 40)

Crankshaft pulley

: 20 (2.0, 15) + 130°±15° (Angle tightening)

Water pump inlet pipe

: 20 (2.0, 15)

Alternator bracket

: 44 (4.5, 32)

Alternator

: 25 (2.6, 18)

A/C compressor

: 21 (2.1, 15)

*1: Refer to tightening procedure in the text.

EM-282

OVERHAUL
[K9K]

Standard Replacement

BBS002QN

A

PREPARING USED ENGINE
The engine should be cleaned and drained (oil and water).
Leave on the used engine or include in the return box:
●
Oil filter
●
Oil pressure switch
●
Water pump
●
Fuel injection pump
●
Rail
●
Injectors
●
Glow plugs
●
Oil level gauge
●
Vacuum pump
●
Flywheel
Remember to remove:
●
All coolant pipes
●
Exhaust manifold
●
Alternator
●
Power steering pump
●
A/C compressor
●
Alternator bracket
●
Oil level sensor
●
Cylinder head coolant outlet unit
The used engine should be secured to the base under the same conditions as the overhauled engine:
●
Plastic plugs and covers fitted
●
Cardboard cover over the assembly

EM

C

D

E

F

G

H

I

J

K

L

M

EM-283

OVERHAUL
[K9K]

Disassembly

BBS002QO

REMOVING THE UPPER ENGINE
1.

Remove the upper timing cover by unclipping the two tabs (A).

MLIA0004E

2.

Remove the lower timing cover by unclipping the three tabs (B)
and pulling out the plastic bolt (C).

MBIB0390E

EM-284

OVERHAUL
[K9K]
3.

Remove the cylinder head suspended mounting bracket.
A

EM

C

D

E

F

G
MBIB0391E

4.

Remove the TDC pin cap.

H

I

J

MBIB0392E

POSITIONING THE BELT AT THE TIMING POINT
1.

Position the hole (A) of the camshaft pulley almost opposite the
hole (B) of the cylinder head.

K

L

M

MBIB0393E

2.

Screw in the Tool KV113B0130 (Mot. 1489).

MBIB0394E

EM-285

OVERHAUL
[K9K]
3.

Turn the engine clockwise (timing side) until the crankshaft
touches the Tool KV113B0130 (Mot. 1489).

MBIB0395E

4.
5.

The Tool KV113B110 (Mot. 1430) must engage in the camshaft
pulley and cylinder head holes.
Remove Tool KV113B0130 (Mot. 1489).

MBIB0396E

6.

Install the Tool KV113B0060 (Mot. 582-01).

MBIB0397E

7.

Remove the crankshaft pulley.

MBIB0398E

EM-286

OVERHAUL
[K9K]
8.

Slacken the timing belt by loosening the bolt of the tensioner,
then remove the timing belt.

A

EM

C

D

E

F

G
MBIB0399E

9.

Remove the timing belt tensioner and inner timing cover.

H

I

J

MBIB0400E

10. Remove air cleaner case. Refer to EM-245, «AIR CLEANER AND AIR DUCT» .
11. Remove the clamp, oil vapor rebreathing pipe and turbocharger
oil supply pipe on the cylinder head side.

K

L

M

MBIB0402E

EM-287

OVERHAUL
[K9K]
12. Remove the turbocharger oil supply pipe on the turbocharger
side, nuts (A) and the torx bolt of the turbocharger flange, bolts
(B) of the catalytic converter bracket, and turbocharger oil return
pipe (C).

MBIB0403E

13. Unclip the fuel return pipe from the cylinder head cover at the
fuel spill tube, then remove the rocker cover.

MBIB0404E

14. Remove the oil level gauge guide and cylinder head.

MBIB0405E

DISASSEMBLY OF THE CYLINDER HEAD
1.

Place the cylinder head on Tool KV113B0200 (Mot. 1573).
CAUTION:
Pay strict attention to the rules regarding cleanliness. Refer
to EM-227, «PRECAUTIONS» .

MBIB0406E

2.

Remove fuel injection pump and related parts. Refer to EM-262, «Removal and Installation» , EM-268,
«Removal and Installation» .

EM-288

OVERHAUL
[K9K]
3.

Remove the injectors (by marking them in relation to their cylinder), glow plugs using Tool KV113E0010 (Mot. 1566), and rear
engine slinger.

A

EM

C
MBIB0410E

D

4.

Remove the vacuum pump and water outlet.
E

F

G
MBIB0411E

5.

Remove the front engine slinger, EGR unit, air inlet pipe and
exhaust manifold.

H

I

J

MBIB0412E

6.

K

Remove the camshaft pulley using Tool KV113B0080 (Mot. 79901).
L

M

MBIB0413E

7.

Remove the camshaft brackets.

MBIB0414E

EM-289

OVERHAUL
[K9K]
8.

Remove the tappets, noting their position.

MBIB0415E

9.

Compress the valve springs using the valve lifter.
Remove the keys, upper cups and springs.

MBIB0416E

NOTE:
Before removing the valves and the valve stem seals, it is
vital to measure position “H” of one of the old seals in relation to the cylinder head using Tool KV113B0180 (Mot. 151101) or suitable tool.

MBIB0417E

10. Install the push rod (A) of Tool KV113B0180 (Mot. 1511-01) on
the valve stem seal.
NOTE:
The inner diameter of the push rod must be identical to that
of the valve. In addition, the bottom of the push rod must
come into contact with the metal upper section of the valve
stem seal.

MBIB0418E

EM-290

OVERHAUL
[K9K]
11. Install the guide tube (B) over the push rod until the guide tube
comes into contact with the cylinder head, locking the push rod
with the knurled wheel.
12. Remove the guide tube assembly plus push rod, being careful
not to loosen the knurled wheel.
13. Remove the valves and valve guide seals using the Tool
KV113B0090 (Mot. 1335).

A

EM

C
MBIB0419E

D

Cleaning
●
●
●

●
●
●

●

BBS002QP

It is very important not to scratch the gasket faces of any aluminium components.
Use suitable tool to dissolve any part of the seal which remains stuck to the metal surface.
Apply the dissolving product to the part to be cleaned, wait approximately 10 minutes, then remove it
using a wooden spatula.
Wear gloves while carrying out this operation.
Do not allow this dissolving product to drip on to the paintwork.
Great care should be taken when performing this operation, to prevent foreign objects from entering the pipes taking oil under pressure to the camshafts (pipes in both the cylinder head and its
cover) and the oil return pipes.
Failure to follow these instructions could lead to the blocking of the oilways, resulting in rapid and
serious damage to the engine.

Inspection

●

J

K

CAMSHAFT END PLAY
NOTE:
Set the dial gauge to the cylinder head and inspect following dimensions:

1.
2.

H

: 0.05 mm (0.0020 in)

Test the cylinder head to detect possible cracks using the cylinder head test tools (comprising a tray and a
kit suited to the cylinder head, plug, sealing plate and blanking plate). The approval number of the cylinder
head test container (commercial service tool) is 664000.

Outer diameter
Height

G

I

Inspect mating surface bow using a ruler and a set of shims.
Maximum bow

F

BBS002QQ

GASKET FACE
●

E

L

: 18 mm (0.71 in)
: 15 mm (0.59 in)

M

Install the camshaft.
Install the camshaft brackets (positioning them correctly with
bracket 1 on the flywheel end), then tighten the bolts to a torque
of 10 N·m (1.0 kg-m, 7 ft-lb).
Check the end play, which must be between 0.08 mm (0.0031
in) and 0.178 mm (0.0070 in).
Remove the camshaft brackets and the camshaft.

MBIB0420E

EM-291

OVERHAUL
[K9K]

Valve Clearance

BBS002QR

CHECKING AND ADJUSTING THE VALVE CLEARANCE
1.
2.
3.

Install the tappet.
Install the camshaft.
Install the camshaft brackets.
: 10 N·m (1.0 kg-m, 7 ft-lb)

4.

Place the valves of the cylinder concerned at the “end of
exhaust — beginning of inlet” position and check the clearance
(X).
NOTE:
Dimension (Y) corresponds to the tappet thickness sizes (there
are 25 sizes at the service parts).
1
3
4
2

5.

MBIB0333E

4
2
1
3

Compare the values recorded with the values specified, then replace the tappets which are not within tolerance.
Clearance, under cold condition:
Intake
: 0.125 — 0.25 mm (0.0049 — 0.0098 in)
Exhaust
: 0.325 — 0.45 mm (0.0128 — 0.0177 in)

6.
7.
8.

Remove the camshaft brackets.
Remove the camshaft.
Remove the tappet not within tolerance.
Determining dimension Y.
Set up the following assembly using KV113B0050 (Mot. 252-01)
and dial gauge, then calibrate the gauge.

MBIB0334E

9.

10.
11.
12.
13.

Raise the gauge extension (without modifying the position of the
magnetic support/gauge assembly), then slide in the tappet to
be measured.
● Note dimension (Y) and repeat the operation for the tappets
where the valve clearance is not within tolerance.
● Refer to the Replacement Parts Catalogue for the vehicle
concerned to select the various thicknesses of the tappet(s).
Check the valve clearance again.
Remove the camshaft brackets.
Remove the camshaft.
Remove the tappet(s) not within tolerance.

EM-292

MBIB0335E

OVERHAUL
[K9K]
14. Grease the underside of the tappets and the camshaft brackets.
15. Degrease the gasket faces (of the cylinder head and brackets 1
and 6). They should be clean, dry and free from grease (in particular, remove finger marks).
16. Lay four beads of Loctite with a width of 1 mm (0.04 in) on
brackets 1 and 6 of the cylinder head.
17. Install the camshaft.
18. Install the camshaft brackets (these are numbered from 1 to 6
and bearing (1) should be positioned on the flywheel end).
: 10 N·m (1.0 kg-m, 7 ft-lb)

A

EM

C
MBIB0427E

D

Assembly

BBS002QS

ASSEMBLY OF THE CYLINDER HEAD
1.

E

Install new valves and grind them gently into their respective
seats. Clean all the parts thoroughly, mark them for identification
purposes, then carry out the refitting operation.
Lubricate the inside of the valve guide.
● It is imperative to fit the valve stem seals using Tool
KV113B0180 (Mot. 1511-01) or suitable tool.
NOTE:
Do not lubricate the valve stem seals before fitting them.

F

G

MBIB0421E

H

New Valve Stem Seals
1.
2.

Place the valve in the cylinder head.
Place the barrel of Tool KV113B0180 (Mot. 1511-01) over the
valve stem (the inner diameter of the barrel must be identical to
the diameter of the valve stem).

I

J

K

L
MBIB0422E

3.
4.

Keep the valve pressed against its seat.
Place the valve stem seal (not lubricated) over the tool barrel.

M

MBIB0423E

EM-293

OVERHAUL
[K9K]
5.

Push the valve stem seal past the tool barrel, then withdraw the
barrel.

MBIB0424E

6.
7.

8.

Place the guide tube plus push rod assembly on the valve stem
seal.
Push the valve stem seal down by tapping the top of the sleeve
with the palm of your hand until the guide tube touches the cylinder head.
Repeat these operations for all the valves.

MBIB0425E

9.

Install the valve springs and upper cups using valve spring compressor.
10. Install the keys using tweezers.

MBIB0416E

EM-294

OVERHAUL
[K9K]
11. Check the valve protrusion using KV113B0040 (Mot. 251-01)
and KV113B0050 (Mot. 252-01) as shown.
Valve protrusion

A

: −0.07 to 0.07 mm (−0.0028 to
0.0028 in)

EM

C
MBIB0426E

D

Camshaft Seal
●

1.

This engine can be fitted with two different types of seals.
Old and new seals are easily recognized.
The old rubber seal is installed with a spring (A) and has a “V”shaped sealing lip (B).

E

F

G
MBIB0428E

2.

H

The new rubber seal has a flat sealing lip (C) and a protector (D)
which also assists in installing the seal to the engine.

I

J

K
MBIB0429E

3.
4.

Screw the shouldered rod of Tool KV113B0230 (Mot. 1632) onto
the stud of the camshaft.
Install the old seal on the camshaft.

L

M

MBIB0430E

EM-295

OVERHAUL
[K9K]
5.

For the new seal, put the protector with the seal on the camshaft, taking care not to touch the seal.

MBIB0431E

6.

Install the cover (E) and the collar nut (F) of Tool KV113B0230
(Mot. 1632).

MBIB0432E

7.

Screw the collar nut until the cover touches the cylinder head.

MBIB0433E

8.
9.

Remove the nut, the cover, the protector and the shouldered
rod.
Install the camshaft pulley. Tighten the new nut to a torque of 30
N·m (3.1 kg-m, 22 ft-lb) plus an angle tightening of 84°.

MBIB0434E

EM-296

OVERHAUL
[K9K]
10. Install the vacuum pump with a new gasket. Tighten the bolts to
a torque of 21 N·m (2.1 kg-m, 15 ft-lb).
11. Install water outlet unit with a new gasket. Tighten the bolts to a
torque of 26 N·m (2.7 kg-m, 19 ft-lb).

A

EM

C
MBIB0411E

D

12. Install the exhaust manifold with new gasket. Tighten the bolts to
a torque of 26 N·m (2.7 kg-m, 19 ft-lb) in the numerical order as
shown.
13. Install the EGR unit with new clips. Tighten the mounting bolts of
the valve to a torque of 21 N·m (2.1 kg-m, 15 ft-lb), then tighten
the clips of the pipe using Tool KV113B0190 (Mot. 1567).
14. Install the air inlet pipe with a new seal.
15. Install the front engine slinger.

E

F

G
MBIB0435E

16. Clean the injector sockets and the injector bodies, as well as
their brackets using a lint-free cloth (use the wipes recommended for this purpose) dipped in clean solvent.
Dry off using a different new wipe.
Replace the compression washer with a new washer.
17. Install the injectors (using the marks made during removal).
Tighten the mounting flanges to a torque of 28 N·m (2.9 kg-m,
21 ft-lb).
18. Install the glow plugs. Tighten them to a torque of 15 N·m (1.5
kg-m, 11 ft-lb).
19. Install the rear engine slinger.
20. Install fuel injection pump and related parts. Refer to EM-268, «HIGH PRESSURE PUMP» .

Disassembly of The Bottom Engine

H

I

J

K
MBIB0410E

BBS002QT

L

REMOVAL
1.

Install the Tool KV113B0060 (Mot. 582-01).
M

MBIB0397E

EM-297

OVERHAUL
[K9K]
2.
3.

Remove the clutch housing.
Remove the flywheel.

MBIB0439E

4.

Remove the oil pan bolt in reverse order as shown.

MBIB1257E

5.

Remove the baffle plate.

MBIB0441E

6.
7.

Remove the oil level sensor.
Remove the oil pump.

MBIB0442E

8.
9.

Remove the rear oil seal retainer.
Remove the water pump.

MBIB0443E

EM-298

OVERHAUL
[K9K]
10. Remove the oil pump chain.
11. Remove the oil pump drive sprocket.

A

EM

C

MBIB0444E

WARNING:
Do not use a sharp point to mark the bearing caps in relation to their connecting rods to avoid starting a crack in the
rod. Use a permanent marker pen.
12. Remove the big end cap bolts and the connecting rod/piston
assemblies.
NOTE:
It is essential to mark the position of the main bearing cap,
as the category may be different for each bearing.
13. Remove the main bearing caps.
14. Remove the crankshaft.

D

E

F

G

MBIB0341E

H

15. Remove the oil pressure switch, the knock sensor and oil filter
bracket connecting bolt.
I

J

K
MBIB0445E

16. Remove the oil cooler connecting bolt.

L

M

MBIB0446E

EM-299

OVERHAUL
[K9K]
REPLACEMENT OF THE OIL JETS
Removal
1. To remove the oil jets (A), they must be drilled with a 7 mm (0.28
in) diameter drill. This is necessary in order to remove the spring
stop (B) and the spring (C).

MBIB0447E

NOTE:
Do not remove the ball (D) to prevent from entering the
cooling circuit.

MBIB0448E

2.

Remove the using a suitable brush.

MBIB0449E

3.

Screw Tool KV113B0120 (Mot. 1485-01) in the drilled out jets
using a 6 mm (0.24 in) Allen key which must slide into the tool.

MBIB0450E

EM-300

OVERHAUL
[K9K]
4.

Screw Tool KV113B0020 (Emb. 880) onto KV113B0120 (Mot.
1485-01) and remove the oil jet.

A

EM

C
MBIB0451E

D

Assembly

BBS002QU

INSTALLATION OF OIL JETS
●

The oil jets must be installed using Tool KV113B0170 (Mot. 1494).

E

Installation of The Oil Jets For No. 1 and No. 3 Cylinders
1.

2.
3.
4.

Install plate (A) of Tool KV113B0170 (Mot. 1494) onto the cylinder block (as shown in the figure) without tightening the two
bolts (C).
Position the guide rod (B) in the plate (A) and the end of the
guide rod in the hole of the oil jet to center the plate (A).
Tighten the two bolts (C).
Remove the guide rod.

F

G

H
MBIB0452E

I

5.

Install the push rod instead of the guide rod, then insert the oil jet
into the push rod.
NOTE:
Check that the oil jet is correctly oriented with the end of
the jet (D) directed towards the center of the cylinder.

J

K

L
MBIB0453E

6.

M

With a hammer, tap the push rod until the shoulder (E) of the
push rod comes into contact with the plate (A).

MBIB0454E

EM-301

OVERHAUL
[K9K]
Installation of The Oil Jets For No. 1 and No. 4 Cylinders
1.

2.
3.
4.

Fit plate (A) of Tool KV113B0170 (Mot. 1494) onto the cylinder
block (as shown in the figure) without tightening the two bolts
(C).
Position the guide rod (B) in the plate (A) and the end of the
guide rod in the hole of the oil jet to center the plate (A).
Tighten the two bolts (C).
Remove the guide rod.

MBIB0455E

5.

Position the push rod instead of the guide rod, then insert the oil
jet into the push rod.
NOTE:
Check that the oil jet is correctly oriented with the end of
the jet (D) directed towards the center of the cylinder.

MBIB0453E

6.

With a hammer, tap the push rod until the shoulder (E) of the
push rod comes into contact with the plate (A).

MBIB0456E

Orientation Of The Oil Jets (See Diagram Below)
A

Orientation of the oil jets of No. 2 and No. 4 cylinders

B

Orientation of the oil jets of No. 1 and No. 3 cylinders

1.

Clean the cylinder block and crankshaft by passing a wire
through the lubrication channels.

MBIB0457E

METHOD FOR INSTALLING THE OIL COOLER AND OIL FILTER
1.
2.

Install oil cooler. Refer to LU-27, «OIL COOLER» .
Install oil filter. Refer to LU-25, «OIL FILTER» .

Removing The Piston Pins

BBS002QV

NOTE:
It is imperative to mark the connecting rod to match it to its piston, because the piston height classes
in the same engine may be different (see Technical Specifications section).
To remove the piston pin, remove the snap ring using a screwdriver, then release the pin.

EM-302

OVERHAUL
[K9K]
CONNECTING ROD BEARING
1.

A

The connecting rod bearing are installed using Tool
KV113B0140 (Mot. 1492) and Tool KV113B0150 (Mot. 1492-03).

EM

C

MBIB0461E

D

E

F

G

MBIB0352E

H

ON THE CONNECTING ROD BODY
1.

Slide the connecting rod bearing support (A) of Tool
KV113B0150 [Mot. 1492-03 (positioning the engraved mark (B)
as shown in the figure)] into the groove (C) of the base of Tool
KV113B0140 (Mot. 1492).

I

J

K

MBIB0462E

L

2.

Install the guide (D) of Tool KV113B0150 (Mot. 1492-03) onto
the base (as shown in the figure).
M

MBIB0463E

EM-303

OVERHAUL
[K9K]
3.

Lay the body of the connecting rod on the base of the tool (as
shown in the diagram). Check that the lower part (E) of the small
end is touching the centering pin and push the guide (G) in the
direction of the arrow.

MBIB0464E

4.

Lay the connecting rod bearing [with a width of 20.625 mm
(0.8120 in)] (F) on the connecting rod bearing support, then
push it in the direction of the arrow (as shown in the figure).

MBIB0465E

5.
6.

Bring the connecting rod support up against the base of the connecting rod body.
Remove the connecting rod body support and repeat the operation for the remaining connecting rod bodies.

MBIB0466E

ON THE CONNECTING ROD CAP
1.

2.

Position the connecting rod bearing support either on the
engraved mark (C) if the width of the connecting rod bearing is
equal to 20.625 mm (0.8120 in).
Position the connecting rod bearing support either on the
engraved mark (D) if the width of the connecting rod bearing is
equal to 17.625 mm (0.6939 in).

MBIB0467E

EM-304

OVERHAUL
[K9K]
3.

Install the connecting rod cap as shown in the figure.
A

EM

C
MBIB0468E

D

4.

Push the guide (in the direction of the arrow) until the connecting
rod cap is in contact with the pins (I) on the base of the tool.
E

F

G
MBIB0469E

5.

Install the connecting rod bearing (H) on the bearing support,
then push it in the direction of the arrow (as shown in the figure).

H

I

J

MBIB0470E

6.
7.

Bring the connecting rod bearing support up against the base of
the connecting rod cap.
Remove the connecting rod bearing support and repeat the
operation for the remaining connecting rod caps.

K

L

M

MBIB0471E

EM-305

OVERHAUL
[K9K]
INSTALLATION OF MAIN BEARING
1.

Position the grooved main bearing on the cylinder block.

MBIB0348E

2.

Install the smooth bearing cap on the bearings.

MBIB0349E

ON THE CYLINDER BLOCK
1.

Position tool KV113B0160 (Mot. 1493-01) on the cylinder block.

MBIB0472E

2.

Install the bearing cap in Tool KV113B0160 (Mot. 1493-01), then
press at (A) until the bearing cap is touching at (B) with
KV113B0160 (Mot. 1493-01).

MBIB0473E

EM-306

OVERHAUL
[K9K]
ON THE BEARING CAPS
1.

A

Position Tool KV113B0160 (Mot. 1493-01) on the bearing cap.

EM

C

MBIB0474E

2.

Install the main bearing in Tool KV113B0160 (Mot. 1493-01),
then press at (A) until the main bearing is touching at (B) with
Tool KV113B0160 (Mot. 1493-01).

D

E

F

G
MBIB0475E

3.
4.
5.
6.

H

Oil the main bearing.
Install the crankshaft.
Install the lateral shims on bearing No. 3, putting the grooves on
the crankshaft side.
Install the main bearing caps on bearing cap No. 1 (these are
numbered from 1 — 5 and these numbers should be positioned
opposite the water pump). Then tighten the bolts to a torque of
27 N·m (2.8 kg-m, 20 ft-lb) plus an angle tightening of 47°±5°.

I

J

K
MBIB0476E

7.

8.

Check the lateral clearance of the crankshaft which should be
without wear on lateral shims: 0.045 — 0.252 mm (0.0018 0.0099 in)
Check the lateral clearance of the crankshaft which should be
with wear on the lateral shims: 0.045 — 0.852 mm (0.0018 0.0335 in)

L

M

MBIB0477E

EM-307

OVERHAUL
[K9K]
INSTALLATION OF NO. 1 BEARING
1.

2.

Degrease the gasket faces (of the cylinder block and bearing No. 1). They should be clean, dry and free from grease
(in particular, remove finger marks).
Lay two beads of liquid sealant with a width of 1 mm (0.04 in) on
bearing No. 1 of the cylinder block.
Tighten the bolts of bearing cap No. 1 to a torque of 27 N·m (2.8
kg-m, 20 ft-lb) plus an angle tightening of 47°±5°.

MBIB0478E

CONNECTING RODS / PISTON ASSEMBLY
●

1.
2.

The pistons have a mark engraved on their heads indicating the engine rear side.
Oil the piston pin.
Check that the piston pins rotate correctly in the new piston and in the matching connecting rod.

Direction Of Installation Of The Connecting Rod In Relation To The Piston
●

Point the mark (A) engraved on the top of the piston upwards
and the flat (B) of the big end downwards as shown in the figure.

MBIB0342E

DIRECTION FOR INSTALLATION THE SNAP RINGS ON THE PISTON
●

Position the opening (C) of the snap rings opposite the removal
and fitting channel (D).

MBIB0343E

INSTALLATION OF THE SNAP RINGS
1.
2.

Rings set to their original adjustment must be free within their channels.
Ensure the snap rings are fitted the correct way, with the word TOP pointing upwards.

EM-308

OVERHAUL
[K9K]
Orientation Of The Piston Rings In The Piston
1.

A

Ensure the break in each piston ring is correctly oriented as
shown in the figure.

EM

C

MBIB0339E

2.
3.

4.
5.
6.
7.

Apply new engine oil to the pistons.
Install the connecting rod/piston assemblies into the cylinder
block using the ring, being careful to fit them the right way round
(mark towards the flywheel).
Install the connecting rods onto the oiled crankshaft pins of the
crankshaft.
Install the connecting rod caps, ensuring they are correctly
matched.
Tighten the big end cap bolts to a torque of 20 N·m (2.0 kg-m, 15
ft-lb), plus an angle tightening of 45°±6°.
Inspect that the big ends have the correct lateral clearance of
0.205 to 0.467 mm (0.0081 to 0.0184 in).

D

E

F

G
MBIB0479E

H

CHECKING PISTON PROTRUSION
1.
2.
3.
4.

5.

Clean the piston head.
Turn the crankshaft one turn in its operating direction to bring
piston No. 1 close to TDC.
Install Tool KV113B0050 (Mot. 252-01) on the piston.
Install Tool KV113B0040 (Mot. 251-01) equipped with a gauge
on support plate KV113B0050 (Mot. 252-01), and find TDC.
NOTE:
All measurements must be carried out along the longitudinal
axis of the engine, in order to eliminate any errors due to tilting
of the piston.
WARNING:
The gauge follower must not be in the valve clearance.

I

J

K

MBIB0480E

M

Inspect the piston protrusion which must be 0.099 to 0.285 mm
(0.0039 to 0.0112 in).

MBIB0325E

EM-309

L

OVERHAUL
[K9K]
INSTALLATION OF REAR OIL SEAL RETAINER AND OIL PUMP
1.
2.
3.

Tighten the knock sensor to a torque of 20 N·m (2.0 kg-m, 15 ftlb).
Tighten the oil pressure switch to a torque of 22 N·m (2.2 kg-m,
16 ft-lb).
Install the oil pump sprocket and chain to a torque of 25 N·m (2.6
kg-m, 18 ft-lb).

MBIB0442E

NOTE:
The gasket faces (cylinder block, rear oil seal retainer and
water pump) must be clean, dry and free from grease (in
particular, remove finger marks).
The rear oil seal retainer should be applied with liquid gasket. The bead (A) must be 1.5 to 2 mm (0.059 to 0.079 in)
wide and be applied in accordance with the figure.
● Use Genuine Liquid Gasket or equivalent.

MBIB0481E

4.

5.

6.
7.

Install the rear oil seal retainer.
● Tighten bolts 1 and 6 to a torque of 8 N·m (0.8 kg-m, 71 in-lb).
● Tighten bolts 2, 3, 4 and 5 to a torque of 12 N·m (1.2 kg-m, 9
ft-lb).
● Tighten bolts 1 and 6 to a torque of 12 N·m (1.2 kg-m, 9 ft-lb).
Put a new gasket to water pump face and install the water
pump. Put a drop of locking sealant on the bolts, then tighten
them to a torque of 11 N·m (1.1 kg-m, 8 ft-lb) in the numerical
order.
● Use Genuine thread locking sealant or equivalent.

MBIB0482E

NOTE:
The gasket faces (cylinder block and rear oil seal retainer)
must be clean, dry and free from grease (in particular,
remove finger marks).
Apply four beads (B) of liquid gasket, with a diameter of 5 mm
(0.20 in).
Apply two drops (C) of liquid gasket, with a diameter of 7 mm
(0.28 in) at the intersection of the rear oil seal retainer and the
cylinder block.
● Use Genuine Liquid Gasket or equivalent.
MBIB0483E

EM-310

OVERHAUL
[K9K]
A

EM

C
MBIB0484E

D

8.

When installing the oil pan, ensure that the tabs (D) of the baffle
plate are correctly positioned in the slots (E).
9. When installing the oil pan, ensure that the cylinder block and
the oil pan are correctly aligned on the flywheel side, to prevent
the clutch housing from being damaged when installing the
transaxle.
10. Install the baffle plate.

E

F

G
MBIB0485E

11. Install the oil pan and tighten the bolts as follows:
● Tighten the bolts in the numerical order shown in the figure to
a torque of 8 N·m (0.8 kg-m, 71 in-lb).
● Tighten the mounting bolts of oil pan on the clutch housing
without locking.
● Tighten the bolts in the numerical order shown in the figure to
a torque of 15 N·m (1.5 kg-m, 11 ft-lb).
● Tighten the mounting bolts of oil pan on the clutch housing to
a torque of 44 N·m (4.5 kg-m, 32 ft-lb).

H

I

J
MBIB1257E

K

INSTALLATION OF THE CRANKSHAFT SEAL GASKETS
1.
2.

Crankshaft elastomer seal, timing side.
Screw the threaded rod (A) of Tool KV113B0220 (Mot. 1586)
into the crankshaft.

L

M

MBIB0487E

3.

Position the spacer (B) of Tool KV113B0220 (Mot. 1586) on the
crankshaft.

MBIB0488E

EM-311

OVERHAUL
[K9K]
4.

Install the protector complete with the seal onto the spacer, taking care not to touch the seal.

MBIB0489E

5.

Install the cover (A) and the nut (B) (putting the threaded part
(C) of the nut on the side away from the engine) of Tool
KV113B0220 (Mot. 1586).

MBIB0490E

6.

Tighten the nut until the cover touches the spacer.

MBIB0491E

MBIB0492E

EM-312

OVERHAUL
[K9K]
7.

Remove the nut, the cover, the protector and the threaded rod.
A

EM

C
MBIB0493E

D

8.
9.

Crankshaft elastomer seal, flywheel side.
Install Tool KV113B0210 (Mot. 1585) on the crankshaft, securing
it with bolts (F).

E

F

G
MBIB0494E

10. Put the protector complete with the seal on Tool KV113B0210
(Mot. 1585), being careful not to touch the seal.

H

I

J

MBIB0495E

11. Install the cover (G) and nut (H) (putting the threaded part (I) of
the nut on the side away from the engine) of Tool KV113B0210
(Mot. 1585).

K

L

M

MBIB0496E

12. Tighten the nut until the cover touches the cylinder block.

MBIB0497E

EM-313

OVERHAUL
[K9K]

MBIB0498E

13. Remove the nut, the cover, the protector and the threaded rod.

MBIB0499E

14. Install Tool KV113B0060 (Mot. 582-01) and tighten the new bolts
to a torque of 50 to 55 N·m (5.1 to 5.6 kg-m, 37 to 40 ft-lb).

MBIB0500E

15. Install the clutch housing, tightening the bolts to a torque of 8
N·m (0.8 kg-m, 71 in-lb).
16. Remove Tool KV113B0060 (Mot. 582-01).

MBIB0501E

EM-314

OVERHAUL
[K9K]
INSTALLATION OF THE CYLINDER HEAD
1.
2.
3.

4.

5.

Position the pistons at mid-stroke.
Install the cylinder head gasket using the centering dowels of
the cylinder block.
Tighten the cylinder head, Refer to EM-293, «ASSEMBLY OF
THE CYLINDER HEAD» .
NOTE:
The gasket faces (cylinder head and rocker cover) must be
clean, dry and free from grease (in particular, remove finger
marks).
Lay four beads (A) of liquid gasket, with a diameter of 2 mm
(0.08 in).
● Use Genuine Liquid Gasket or equivalent.

A

EM

C

MBIB0502E

D

E

Install the rocker cover, tightening the bolts to a torque of 10 N·m
(1.0 kg-m, 7 ft-lb) in the numerical order as shown.

F

G

H
MBIB0503E

6.
7.
8.
9.

Put new seals on the pipe ends and install the turbocharger oil
return pipe.
Install the turbocharger, tightening the nuts and the torx bolt to a
torque of 26 N·m (2.7 kg-m, 19 ft-lb).
Install the catalytic converter bracket.
Install the turbocharger oil supply pipe.

I

J

K

MBIB0504E

10. Tighten the bolts of the turbocharger oil return pipe to a torque of
9 N·m (0.9 kg-m, 80 in-lb).
11. Tighten the nut and the bolt of the turbocharger oil supply pipe to
a torque of 23 N·m (2.3 kg-m, 17 ft-lb).
12. Install the oil vapor rebreathing pipe.
13. Install the new turbocharger air ducts.

M

MBIB0505E

EM-315

L

OVERHAUL
[K9K]
14. Install the inner timing cover.
15. Install the timing tensioner.

MBIB0400E

TIMING ADJUSTMENT
CAUTION:
It is essential to degrease the end of the crankshaft, the bore of
the crankshaft sprocket and the bearing faces of the accessories pulley to prevent any slip between the timing and the crankshaft which would risk destroying the engine.
Ensure that the peg (A) of the tension wheel is correctly positioned in the groove (B).
1. Insert Tool KV113B0110 (Mot. 1430) in the camshaft pulley and
cylinder head holes.
2. Check that the mark on the high pressure pump pulley (C) is
opposite the bolt head (D).
3. Check that the crankshaft is touching Tool KV113B0130 (Mot.
1489) (the crankshaft groove (E) must be facing upwards).

MBIB0507E

MBIB0395E

EM-316

OVERHAUL
[K9K]
4.

Install the timing belt, aligning the marks on the belt with those
on the camshaft and fuel injection pump sprockets (19 teeth
spaces on the belt between the marks on the camshaft and
pump sprockets).

A

EM

C
MBIB0508E

D

5.

Using a 6 mm (0.24 in) Allen key, move the movable index (F) of
the tension wheel into the position shown below, by turning the
key counterclockwise.

E

F

G
MBIB0509E

6.

Tighten the tension wheel bolt to a torque of 25 N·m (2.6 kg-m,
18 ft-lb).
7. Install the crankshaft pulley, tightening the M12 bolt to a torque
of 60 N·m (6.1 kg-m, 44 ft-lb), then angle tighten to 100°±10°, or
M14 bolt to a torque of 120 N·m (12 kg-m, 89 ft-lb), then angle
tighten to 95°±15°.
8. Remove Tool KV113B0130 (Mot. 1489) and Tool KV113B0110
(Mot. 1430).
9. Turn the crankshaft two full turns in a clockwise direction (timing
side). Just before the hole (G) of the camshaft pulley is opposite
the cylinder head hole (H), insert tool KV113B0130 (Mot. 1489)
into the cylinder block.
10. Then turn the crankshaft slowly and without jolting it until it is resting on the pin.

H

I

J

MBIB0583E

L

11. Check that Tool KV113B0110 (Mot. 1430) is correctly inserted in
the holes of the camshaft pulley and cylinder head and that
there are 19 teeth spaces between the marks on the camshaft
(I) and the fuel pump (J) sprockets.
12. Remove Tool KV113B0130 (Mot. 1489) and Tool KV113B0110
(Mot. 1430).

M

MBIB0510E

EM-317

K

OVERHAUL
[K9K]
13. Undo the tension wheel bolt by a maximum of one turn while
holding it using a 6 mm (0.24 in) Allen key, then gradually bring
the movable index (K) (by turning the key clockwise) to the center of the timing window (L) and tighten the nut to a torque of 25
N·m (2.6 kg-m, 18 ft-lb).
14. Install the cap of the TDC bolt, apply liquid gasket to the thread
and tighten to a torque of 20 N·m (2.0 kg-m, 15 ft-lb).

MBIB0511E

15. Install the cylinder head suspended bracket. Tighten the bolts to
a torque of 21 N·m (2.1 kg-m, 15 ft-lb).

MBIB0512E

16. Install the lower timing cover by positioning the tab (M) into the
hole (N) on the inner timing cover.

MBIB0513E

EM-318

OVERHAUL
[K9K]
A

EM

C
MBIB0514E

D

17. Install the upper timing cover.
18. Remove the engine from the Tool KV113B0070 (Mot. 792-03).

E

F

G

H

I

J
MBIB0515E

K

19. Install the water pipe. Tighten the bolt to a torque of 22 N·m (2.2
kg-m, 16 ft-lb).
20. Install the two water hoses.

L

M

MBIB0356E

21. Install the alternator bracket. Tighten the bolts to a torque of 44
N·m (4.5 kg-m, 32 ft-lb).

MBIB0355E

EM-319

OVERHAUL
[K9K]
22. Install the alternator. Tighten the bolts to a torque of 21 N·m (2.1
kg-m, 15 ft-lb).
23. Install the A/C compressor. Tighten the bolts to a torque of 21
N·m (2.1 kg-m, 15 ft-lb).
24. Install the power steering pump or the washer which replaces
the pulley (if the engine has one). Tighten the bolts to a torque of
21 N·m (2.1 kg-m, 15 ft-lb).

MBIB0354E

25. Install the drive belt.
NOTE:
The accessories belt has five teeth as opposed to the pulleys which have six. It is therefore essential to ensure that
tooth “O” remains free when installing the belt.

MBIB0516E

Models With A/C Compressor
NOTE:
The engine must be turned through two revolutions in order to
position the belt correctly.

MBIB0353E

Models Without A/C Compressor
1.

2.

The belt is tensioned using tool belt tension gauge (commercial
service tool) (with the two mounting bolts of the tensioner
undone).
The tension value is 233±5 Hz.
NOTE:
The engine must be turned through two revolutions in order
to position the belt correctly.

MBIB1066E

EM-320

BASIC INSPECTION
[K9K]

BASIC INSPECTION
Cylinder Head

PFP:00013

A
BBS002QW

CYLINDER HEAD TIGHTENING PROCEDURE
NOTE:
Use a syringe to remove any oil which may have entered the cylinder
head mounting bolt holes to achieve correct tightening of the bolts.
1. All bolts must always be changed after removal. Do not oil the
new bolts.
2. Tighten all the bolts in the numerical order as shown.

EM

C

: 25 N·m (2.6 kg-m, 18 ft-lb)

D

3.

Check that all the bolts are correctly tightened to 25 N·m (2.6 kgm, 18 ft-lb) then angle tightening of 245 to 265 degrees.
Do not retighten the cylinder head bolts after performing this
procedure.

E
MBIB0323E

THICKNESS OF THE CYLINDER HEAD GASKET
●

F

The thickness of the cylinder head gasket is measured at (A):
Thickness

: 0.75 — 0.81 mm (0.0295 — 0.0319 in)
G

H

I
MBIB0324E

INSPECTION OF THE PISTON PROTRUSION
Clean the piston heads in order to eliminate any traces of
deposits.
2. Turn the crankshaft one turn in its operating direction to bring
piston No. 1 close to TDC.
3. Install Tool KV113B0040 (Mot. 251-01) equipped with a gauge
on its base plate KV113B0050 (Mot. 252-01), and find TDC of
the piston.
NOTE:
All measurements must be carried out along the longitudinal axis of
the engine, in order to eliminate any errors due to tilting of the piston.
WARNING:
The gauge follower must not be in the valve clearance.
Measure the piston protrusion.
The protrusion must be: 0.099 — 0.285 mm (0.0039 — 0.0112 in).

J

1.

K

L

MBIB0325E

Height of the cylinder head:
H = 127 mm (5.00 in)
Gasket face bow:
Cylinder head
Cylinder
block

: 0.05 mm (0.0020 in)
: 0.03 mm (0.0012 in)

NO REGRINDING IS AUTHORIZED
Test the cylinder head to detect possible cracks using the cylinder
head test container (comprising a tray and a kit suited to the cylinder
head, plug, sealing plate and blanking plate).

EM-321

MBIB0326E

M

BASIC INSPECTION
[K9K]
VALVE
Valve Dimensions
Stem diameter:
Intake
: 5.969 — 5.985 mm (0.2350 — 0.2356 in)
Exhaust
: 5.955 — 5.971 mm (0.2344 — 0.2351 in)
Face angle:
Intake and
: 90°
exhaust
Head diameter:
Intake
: 33.38 — 33.62 mm (1.3142 — 1.3236 in)
Exhaust
: 28.88 — 29.12 mm (1.1370 — 1.1465 in)
Valve length:
Intake
: 100.73 — 101.17 mm (3.9657 — 3.9831 in)
Exhaust
: 100.53 — 100.97 mm (3.9579 — 3.9752 in)
Max. valve lift:
Intake
: 8.015 mm (0.3156 in)
Exhaust
: 8.595 mm (0.3384 in)
Protrusion of valves in relation to the cylinder head gasket face:
Intake and
: −0.7 to 0.7 mm (−0.028 to 0.028 in)
exhaust

VALVE SEAT
Seat angle (α):
Intake
: 89°30′
and
exhaust
Contacting width (X):
Intake
: 1.8 mm (0.071 in)
and
exhaust
Seat outer diameter (D):
Intake
: 34.444 — 34.460 mm (1.3561 — 1.3567 in)
Exhaust
: 30.034 — 30.050 mm (1.1824 — 1.1831 in)
Diameter of the housing in the cylinder head:
Intake
: 34.444 — 34.474 mm (1.3561 — 1.3572 in)
Exhaust
: 29.955 — 29.985 mm (1.1793 — 1.1805 in)

VALVE GUIDE
Length:
Intake and : 40.35 — 40.65 mm (1.5886 — 1.6004 in)
exhaust
Guide outer diameter:
Standard
: 11.044 — 11.062 mm (0.4348 — 0.4355 in)
Guide inner diameter:
Intake and exhaust
Not
: 5.50 — 5.62 mm (0.2165 — 0.2213 in)
machined
Machined* : 6.000 — 6.018 mm (0.2362 — 0.2369 in)

EM-322

MBIB0327E

BASIC INSPECTION
[K9K]
* This dimension is measured with the guide fitted in the cylinder head.
Diameter of the housing in the cylinder head:
Standard
: 10.9925 — 11.0075 mm (0.4328 — 0.4334 in)

A

The intake and exhaust guides have valve stem seals which must be changed each time the valves are EM
removed.
It is imperative to fit the valve stem seals using Tool
KV113B0180 (Mot. 1511-01) or suitable tool.
C
NOTE:
Do not lubricate the valve stem seals before fitting them.
D

E
MBIB0328E

F

G

H

I
MBIB0329E

J

Angle of the intake and exhaust guides (in degrees)
Intake and exhaust
: α = 90

K

L

M
MBIB0330E

Position of the intake and exhaust valve guides
Intake
: A = 14 mm (0.55 in)
Exhaust
: A = 14.2 mm (0.559 in)

MBIB0331E

EM-323

BASIC INSPECTION
[K9K]
VALVE SPRING
The valve springs are tapered (ensure the correct direction of fitting).
Free height:
Length under a load of
230 N (23.5 kg, 51.7 lb)
500 N (51.0 kg, 112.4 lb)
Joined spires:
Wire diameter:
Inner diameter:
Bottom
Top
Outer diameter:
Bottom
Top

: 43.31 mm (1.7051 in)
: 33.80 mm (1.3307 in)
: 24.80 mm (0.9764 in)
: 23.40 mm (0.9213 in)
: 3.45 mm (0.1358 in)
: 18.78 — 18.82 mm
(0.7394 — 0.7409 in)
: 13.90 — 14.30 mm
(0.5472 — 0.5630 in)

MBIB0332E

: 25.50 — 25.90 mm
(1.0039 — 1.0197 in)
: 20.8 — 21.2 mm
(0.819 — 0.835 in)

WARNING:
This engine does not have any valve spring lower washers.

PISTON
Piston outer diameter
Diameter of the housing in the cylinder head

: 34.965 — 34.985 mm (1.3766 — 1.3774 in)
: 35.00 — 35.04 mm (1.3780 — 1.3795 in)

INSPECTION OF VALVE CLEARANCE
1.

Place the valves of the cylinder concerned at the “end of
exhaust — beginning of intake” position and inspect the clearance
(X).
NOTE:
Dimension (Y) corresponds to the tappet thickness sizes (there
are 25 sizes at the service parts).
1
3
4
2

2.

4
2
1
3

Compare the values recorded with the values specified, then
replace the tappets which are not within tolerance.

MBIB0333E

Clearance, when the engine is cold:
Intake
: 0.125 — 0.25 mm (0.0049 — 0.0098 in)
Exhaust : 0.325 — 0.45 mm (0.0128 — 0.0177 in)
3.
4.

The camshaft must be removed to replace the tappets.
Determining dimension “Y”.
Set up the following assembly using Tool KV113B0050 (Mot.
252-01) and dial gauge, then calibrate the gauge.

MBIB0334E

EM-324

BASIC INSPECTION
[K9K]
5.

Raise the gauge extension (without modifying the position of the
magnetic support/gauge assembly), then slide in the tappet to
be measured.
Note dimension (Y) and repeat the operation for the tappets
where the valve clearance is not within tolerance.
Refer to the Replacement Parts Catalogue for the vehicle concerned to select the various thicknesses of the tappet(s). The
service parts supplies 25 sizes of single-piece tappets.

A

EM

C

MBIB0335E

D

CAMSHAFT
End play
Number of bearings
Diameter of the camshaft bearings
On the camshaft:
Bearings 1, 2, 3, 4, 5
Bearing 6
On the cylinder head:
Bearings 1, 2, 3, 4, 5
Bearing 6
Timing diagram
Intake opening retard *
Intake closing retard
Exhaust opening advance
Exhaust closing advance **

: 0.08 — 0.178 mm (0.0031 — 0.0070 in)
:6

E

F

: 24.979 — 24.999 mm (0.9834 — 0.9842 in)
: 27.979 — 27.999 mm (1.1015 — 1.1023 in)

G

: 25.04 — 25.06 mm (0.9858 — 0.9866 in)
: 28.04 — 28.06 mm (1.1039 — 1.1047 in)

H

: −9
: 20
: 27
: −7

I

J

* As the intake opening retard is negative, the valve is opened after TDC.
** As the exhaust closing advance is negative, the valve is closed before TDC.
K

1

Cylinder block TDC fixed mark

2

Flywheel TDC moving mark

3

Flywheel BDC moving mark

4

Intake Opening Retard

5

Exhaust Closing Advance

6

Intake Closing Retard

7

Exhaust Opening Advance

8

Direction of engine rotation (flywheel end).

L

M

EM-325

MBIB0336E

BASIC INSPECTION
[K9K]

Piston
●
●

BBS002QX

Install the piston pin in the connecting rod and in the piston.
The piston pin is retained by circlips.

PISTON MARKING
1

Direction of fitting of the piston mark towards the flywheel

2

Height between the piston pin and the top of the piston (see
table below).

3

Used by the supplier only

4

Used by the supplier only

5

Used by the supplier only

6

Piston axis of symmetry

7

Piston pin hole axis

8

Offset between the hole axis (7) and the piston’s axis of symmetry (6) is 0.3 mm (0.012 in)

MBIB0337E

TABLE OF PISTON PIN HEIGHT
Unit: mm (in)
* Mark on piston

Piston pin height

K

41.667 (1.6404)

L

41.709 (1.6421)

M

41.751 (1.6437)

N

41.793 (1.6454)

P

41.835 (1.6470)

The tolerance on the piston pin heights is ±0.02 mm (±0.0008).
* The different piston pin heights are exclusively reserved for the engine assembly plant.
The service parts will only supply piston classes (height) L, M, N.
NOTE:
●
If the engine is installed with a K class piston, an L class piston must be installed as a replacement.
●
If the engine is installed with a P class piston, an N class piston must be installed as a replacement.

MEASURING THE PISTON DIAMETER
The piston diameter must be measured at height A = 56 mm (2.20
in).
Piston diameter
Piston pin:
Length
Outer diameter
Inner diameter

: 75.933 — 75.947 mm (2.9895 2.9900 in)
: 59.7 — 60.3 mm (2.350 — 2.374
in)
: 24.8 — 25.2 mm (0.976 — 0.992
in)
: 13.55 — 13.95 mm (0.5335 0.5492 in)

EM-326

MBIB0338E

BASIC INSPECTION
[K9K]
PISTON RING
Thickness:
Top ring
2nd ring
Oil ring

A

: 1.97 — 1.99 mm (0.0776 — 0.0783 in)
: 1.97 — 1.99 mm (0.0776 — 0.0783 in)
: 2.47 — 2.49 mm (0.0972 — 0.0980 in)

EM

The piston rings are supplied ready adjusted.

C

MBIB0339E

D

PISTON RING END GAP
Top ring
2nd ring
Oil ring

E

: 0.20 — 0.35 mm (0.0079 — 0.0138 in)
: 0.70 — 0.90 mm (0.0276 — 0.0354 in)
: 0.25 — 0.50 mm (0.0098 — 0.0197 in)

Connecting Rod

F
BBS002QY

The connecting rod is of the detachable cap type.
WARNING:
●
The bolts must be coated with engine oil under the heads
and on the threads when the connecting rods are installed
in the engine.
●
The big end caps are positioned on the connecting rod by
irregularities on the parting line.
●
The occurrence of impacts or a foreign body between the
body — cap mating surfaces will lead to rapid rupture of the
connecting rod.

G

H

I

MBIB0340E

Lateral big end play
Diametrical big end play
Center distance between
the big end and small end
Diameter of the big end
Diameter of the small end
(without ring)
(with ring)

: 0.205 — 0.467 mm (0.0081 0.0184 in)
: 0.035 — 0.045 mm (0.0014 0.0018 in)
: 133.75 mm (5.2657 in)
: 47.610 — 47.628 mm (1.8744
— 1.8751 in)

J

K

L

M

: 27.24 — 27.26 mm (1.0724 1.0732 in)
: 25.013 — 25.025 mm (0.9848
— 0.9852 in)

NOTE:
The connecting rod small end rings cannot be replaced.

EM-327

BASIC INSPECTION
[K9K]
The maximum weight difference for the connecting rod, piston and
piston pin assemblies for the same engine must be 0.245 N (25 g,
0.88 oz).
WARNING:
●
To avoid initiating a crack in the connecting rod, do not use
a sharp point to mark the big end caps in relation to their
connecting rod.
●
Use a permanent marker pen.

MBIB0341E

DIRECTION OF INSTALLATION OF THE CONNECTING ROD IN RELATION TO THE PISTON
●

Point the mark (A) engraved on the top of the piston upwards
and the machined flat (B) of the big end downwards as shown in
the figure.

MBIB0342E

DIRECTION FOR INSTALLATION THE SNAP RINGS ON THE PISTON
●

Position the opening (C) of the snap rings opposite of the
removal and installation channel (D).

MBIB0343E

Crankshaft
Number of main journals
Crankshaft side clearance:
Without wear on side shims
With wear on side shims
Crankshaft diametrical clearance:
Journals
Crankshaft pins
Journal diameter:
Crankshaft pin diameter:
●
●

BBS002QZ

:5
: 0.045 — 0.252 mm (0.0018 — 0.0099 in)
: 0.045 — 0.852 mm (0.0018 — 0.0335 in)
: 0.027 — 0.054 mm (0.0011 — 0.0021 in)
: 0.035 — 0.045 mm (0.0014 — 0.0018 in)
: 47.99 — 48.01 mm (1.8894 — 1.8902 in)
: 43.96 — 43.98 mm (1.7307 — 1.7315 in)

The lateral shims are located on bearing No. 3.
No rectifications are allowed.

EM-328

BASIC INSPECTION
[K9K]
WORKING OUT THE CLASS OF MAIN BEARING (ORIGINAL FITMENT)
Marking (A) On The Crankshaft

A

Detail of the marking (A):
Number of journals
EM
1*

2

3

4

5

B

B

C

C

B

Classes of
journal
diameters
A = D1
B = D2
C = D3

C

D

* Flywheel end.
MBIB0344E

Table Of Journal Diameter Classes

E
Unit: mm (in)

Journal class mark on the crankshaft

Journal diameter

A = D1

47.990 — 47.996 (1.8894 — 1.8896)

B = D2

47.997 — 48.003 (1.8896 — 1.8899)

C = D3

48.004 — 48.010 (1.8899 — 1.8902)

Cylinder Block

F

G
BBS002R0

The diameters of the bearings (A) of the cylinder block are marked
by a hole on the block (B) located above the oil filter.

H

I

J

MBIB0345E

K

L

M

MBIB0346E

TABLE OF CYLINDER BLOCK MAIN BEARING HOUSING INNER DIAMETERS
Hole position (B)

Class reference

Cylinder block main bearing housing inner
diameter

X = 33 mm (1.30 in)

1 or blue

51.936 — 51.942 mm
(2.0447 — 2.0450 in)

Y = 43 mm (1.69 in)

2 or red

51.942 — 51.949 mm
(2.0450 — 2.0452 in)

NOTE:
The marking zone includes:

EM-329

BASIC INSPECTION
[K9K]
●

X — Y gives the diameter class of bearings A or B.

MATCHING THE MAIN BEARING
Journal diameter class
D1

D2

D3

1*

C1
1.949 — 1.955 mm
(0.0767 — 0.0770 in)
yellow

C2
1.946 — 1.952 mm
(0.0766 — 0.0769 in)
blue

C3
1.943 — 1.949 mm
(0.0765 — 0.0767 in)
black

2*

C4
1.953 — 1.959 mm
(0.0769 — 0.0771 in)
red

C1
1.949 — 1.955 mm
(0.0767 — 0.0770 in)
yellow

C2
1.946 — 1.952 mm
(0.0766 — 0.0769 in)
blue

Bearing thickness and class
* Cylinder block main bearing diameter class.

NOTE:
The service parts will only supply class C2 (blue).

Main Bearing and Cap

BBS002R1

MAIN BEARING
●

1.

The engine is installed with main bearing without a locator
notch.
The main bearings are installed on the cylinder block and on the
bearings using Tool KV113B0160 (Mot. 1493-01).

MBIB0347E

2.

For direction of installation on the cylinder block, install grooved
main bearing on all the bearings.

MBIB0348E

3.

For direction of installation on the bearing caps, install nongrooved main bearing.

MBIB0349E

EM-330

BASIC INSPECTION
[K9K]
CONNECTING ROD BEARING
●

A

The engine is installed with connecting rod bearing without
a locator notch.
NOTE:
The upper and lower connecting rod bearing are not the
same width.

EM

Connecting rod bearing width:
Upper bearing
: 20.625 mm (0.8120 in)
Lower bearing
: 17.625 mm (0.6939 in)

C

MBIB0350E

●

The connecting rod bearing are installed using Tool
KV113B0140 (Mot. 1492) and Tool KV113B0150 (Mot. 1492-03).

D

E

F

G
MBIB0351E

H

I

J

K
MBIB0352E

Preparing the engine to be on the stand

BBS002R2

Before the engine is mounted on the Tool KV113B0070 (Mot. 792-03), the engine’s electrical harness must be
removed and the engine oil drained.
1. Remove the drive belt.

MBIB0353E

EM-331

L

M

BASIC INSPECTION
[K9K]
2.

Remove the alternator.

MBIB0354E

3.
4.

Remove the air conditioning compressor or idler pulley.
Remove the multifunction support.

MBIB0355E

5.

Remove the coolant inlet pipe on the water pump.

MBIB0356E

6.

Place the rods (A ), (X ), (Y ) or Tool KV113B0100 (Mot. 1378)
on the cylinder block so that they fit into the holes (20, 32, 33 )
on the plate of Tool KV113B0070 (Mot. 792-03).

MBIB0357E

Parts To Be Replaced After Removal
●
●
●
●
●
●
●
●

All gaskets
Flywheel bolts
Crankshaft bearing bolts
Camshaft pulley bolt
Crankshaft pulley bolts
Big end cap bolts
Injector holder copper washers
Fuel injection tubes

EM-332

BBS002R3

BASIC INSPECTION
[K9K]
●
●
●
●
●

Pipe plugs
Belts
Timing belt tension wheel
Oil jets
Turbocharger plastic pipes

A

EM

Installation of Thread Inserts

BBS002R4

Threaded holes on all engine component parts can be repaired by using thread inserts.

C

D

E

F

G

H

I

J

K

L

M

EM-333

BASIC INSPECTION
[K9K]

EM-334

EXHAUST SYSTEM

B ENGINE

SECTION

EX

EXHAUST SYSTEM

A

EX

C

D

CONTENTS
PREPARATION ………………………………………………….. 2
Special Service Tool …………………………………………. 2
EXHAUST SYSTEM …………………………………………… 3
Checking Exhaust System ………………………………… 3
Removal and Installation …………………………………… 3
CR ENGINE …………………………………………………. 3
HR ENGINE …………………………………………………. 4
K9K ENGINE ………………………………………………… 5
REMOVAL ……………………………………………………. 5

INSTALLATION (CR, HR ENGINE) ………………….. 6
INSTALLATION (K9K ENGINE) ………………………. 7
Inspection After Installation ……………………………….. 7
SERVICE DATA AND SPECIFICATIONS (SDS) …….. 8
Tightening Torque …………………………………………….. 8
CR ENGINE …………………………………………………. 8
HR ENGINE …………………………………………………. 8
K9K ENGINE ………………………………………………… 8

E

F

G

H

I

J

K

L

M

EX-1

PREPARATION
PREPARATION
Special Service Tool

PFP:00002
BBS003Z4

Tool number
Tool name

Description

KV10117200
Heated oxygen sensor wrench

Loosening or tightening heated oxygen
sensors
a: 22 mm (0.87 in)

S-NT636

EX-2

EXHAUST SYSTEM
EXHAUST SYSTEM
Checking Exhaust System

PFP:20100

A
BBS003Z5

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

EX

C

D
SMA211A

E

Removal and Installation

BBS003Z6

CAUTION:
●
Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat
resistance, corrosion resistance and shape.
●
Perform the operation with the exhaust system fully cooled down because the system is still hot
just after the engine stops.
●
Be careful not to cut your hand on the insulator edge.

F

G

CR ENGINE
H

I

J

K

L

M

MBIB9012E

1.

Main muffler

2.

Mounting rubber

3.

Clamp

4.

Mounting rubber

5.

Center muffler

6.

Mounting bracket

7.

Heated oxygen sensor 2

8.

Seal bearing

9.

Spring

10. Exhaust front tube

11. Seal bearing

EX-3

12. Spring

EXHAUST SYSTEM
HR ENGINE

MBIB9013E

1.

Main muffler

2.

Mounting rubber

3.

Clamp

4.

Center muffler

5.

Mounting rubber

6.

Spring

7.

Seal bearing

8.

Heated oxygen sensor 2

9.

Exhaust front tube

10. Seal bearing

11. Stud bolt

12. Spring

EX-4

EXHAUST SYSTEM
K9K ENGINE
A

EX

C

D

E

F

G

H

MBIB9014E

1.

Main muffler

2.

Mounting rubber

3.

Clamp

4.

Mounting rubber

5.

Exhaust center tube

6.

Exhaust front tube

7.

Bolt

8.

Spring

9.

Seal bearing

I

J

REMOVAL
●

K

Disconnect each joint and mounting.

Heated Oxygen Sensor 2 (CR, HR Engine)
●

1.
2.

When removing heated oxygen sensor 2 on vehicle, perform following procedure.
Disconnect harness connector.
Use a heated oxygen sensor wrench (special service tool) for
removal of heated oxygen sensor 2.
CAUTION:
● Do not apply impact while handling.

L

M

PBIC1511E

EX-5

EXHAUST SYSTEM
Exhaust Front Tube (CR, HR Engine)
1.
2.
3.
4.

Disconnect center muffler connecting points.
Remove the ground cable on vehicle.
Remove mount bracket mounting nuts on suspension member.
Disconnect three way catalyst connecting points to remove
exhaust front tube.

PBIC1512E

INSTALLATION (CR, HR ENGINE)
Install in the reverse order of removal paying attention to the following.
●
Remove all deposits, such as old gasket, from the sealing surfaces of each connection. Connect firmly
without any leaks.
●
When installing exhaust pipe assembly, temporarily tighten nuts on the exhaust manifold side mounting
bolts and vehicle side mounting nuts. After making sure there is no unusual tension on each part, tighten
nuts and bolts to the specified torque.
●
Be careful not to twist or apply excess tension in any direction when installing mounting rubbers.
●
Because thickness is different between center muffler rear side mounting rubber and main muffler side
mounting rubbers, install thick mount rubber at main muffler side.
●
Install seal bearing unit in the following procedures.
●
When installing heated oxygen sensor 2, use heated oxygen sensor wrench (special service tool:
KV10117200).
CAUTION:
● Do not apply impact while handing.
● Do not use heated oxygen sensor 2 after being dropped on a solid concrete floor, from a height
of 0.5 m (1.6 ft) or higher. Replace it with a new one.
● Do not tighten heated oxygen sensor 2 to a torque larger than specified. Excess tightening may
result in damage of heated oxygen sensor 2, causing MI to turn ON.
● when using heated oxygen sensor wrench (special service tool: KV10117200), tighten to the
middle of specified torque because length of tool may induce slight indication increase. Do not
tighten to the maximum specified torque.

Three Way Catalyst to Exhaust Front Tube
1.

2.

Securely insert seal bearing into three way catalyst side in the
direction shown in figure.
CAUTION:
Be careful not to damage seal bearing surface when installing.
With spring large diameter side facing to exhaust front tube
flange, tighten mounting bolt.
● Be careful that mounting bolt does not interfere with flanged
area, and tighten it.
PBIC1513E

EX-6

EXHAUST SYSTEM
Exhaust Front Tube to Center Muffler
1.

2.

A

Securely insert seal bearing into exhaust front tube side in the
direction shown in figure.
CAUTION:
Be careful not to damage seal bearing surface when installing.
With spring large diameter side facing to center muffler flange,
tighten mounting bolt.
● Be careful that mounting bolt does not interfere with flanged
area, and tighten it.

EX

C

PBIC1514E

D

INSTALLATION (K9K ENGINE)
Install in the reverse order of removal.
CAUTION:
●
Always replace exhaust gaskets with new ones when reassembling.
●
If the insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the insulator, remove them.
●
When installing the insulator avoid large gaps or interference between the insulator and each
exhaust pipe.
●
Remove deposits from the sealing surface of each connection. Connect them securely to avoid
gas leakage.
●
Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehicle side. Check each part for unusual interference, and then tighten them to the specified torque.
●
When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/
left directions.
●

Inspection After Installation
●
●

E

F

G

H

I

BBS003Z7

With the engine running, check exhaust tube joints for gas leakage and unusual noises.
Check to ensure that mounting brackets and mounting insulators are installed properly and free from
undue stress. Improper installation could result in excessive noise and vibration.

J

K

L

M

EX-7

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Tightening Torque

PFP:00030
BBS003Z8

CR ENGINE
Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)*
Exhaust system connecting parts
Three way catalyst to Exhaust front tube

43.1 — 54.9 (4.4 — 5.6, 32 — 40)

Exhaust front tube to Center muffler

43.1 — 54.9 (4.4 — 5.6, 32 — 40)

Center muffler to Main muffler

30.4 — 39.2 (3.1 — 3.9, 23 — 28)

Heated oxygen sensor 2

40 — 60 (4.1 — 6.1, 30 — 44)

Exhaust front tube mounting bracket

16.4 — 20.7 (1.7 — 2.1, 12 — 15)

Ground cable

2.9 — 4.9 (0.3 — 0.49, 26 — 43)*

HR ENGINE
Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)*
Exhaust system connecting parts
Three way catalyst to Exhaust front tube

49.0 (5.0, 36)

Exhaust front tube to Center muffler

49.0 (5.0, 36)

Center muffler to Main muffler

34.8 (3.5, 26)

Heated oxygen sensor 2

50 (5.1, 37)

Ground cable

3.9 (0.4, 35)*

K9K ENGINE
Unit: N·m (kg-m, ft-lb)
Exhaust system connecting parts
Catalyst to Exhaust front tube

17.9 — 24.2 (1.9 — 2.4, 14 — 17)

Exhaust front tube to Exhaust center tube

30.4 — 39.2 (3.1 — 3.9, 23 — 28)

Exhaust center tube to Main muffler

30.4 — 39.2 (3.1 — 3.9, 23 — 28)

EX-8

EXTERIOR & INTERIOR

I BODY

SECTION

EI

EXTERIOR & INTERIOR

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 2
PrecautionsforProcedureswithoutCowlTopCover….. 2
Precautions …………………………………………………….. 2
CLIP AND FASTENER ……………………………………….. 3
Clip and Fastener …………………………………………….. 3
FRONT BUMPER ………………………………………………. 4
Removal and Installation …………………………………… 4
REMOVAL ……………………………………………………. 6
INSTALLATION …………………………………………….. 7
REAR BUMPER ………………………………………………… 8
Removal and Installation …………………………………… 8
REMOVAL ……………………………………………………. 9
INSTALLATION …………………………………………….. 9
FRONT GRILLE ……………………………………………….. 10
Removal and Installation …………………………………. 10
REMOVAL ………………………………………………….. 10
INSTALLATION …………………………………………… 10
FRONT DEFLECTOR …………………………………………11
Removal and Installation …………………………………..11
REMOVAL ……………………………………………………11
INSTALLATION …………………………………………….11
COWL TOP ……………………………………………………… 12
Removal and Installation …………………………………. 12
REMOVAL ………………………………………………….. 12
INSTALLATION …………………………………………… 13
FENDER PROTECTOR …………………………………….. 14
Removal and Installation …………………………………. 14
MUDGUARD ……………………………………………………. 15
Removal and Installation …………………………………. 15
ROOF SIDE MOLDING …………………………………….. 16
Removal and Installation …………………………………. 16
REMOVAL ………………………………………………….. 16
INSTALLATION …………………………………………… 16

WINDSHIELD MOLDING …………………………………… 17
Removal and Installation …………………………………. 17
REMOVAL ………………………………………………….. 17
INSTALLATION …………………………………………… 18
DOOR OUTSIDE MOLDING ………………………………. 19
Removal and Installation …………………………………. 19
REMOVAL ………………………………………………….. 19
INSTALLATION …………………………………………… 19
DOOR FINISHER ……………………………………………… 20
Removal and Installation …………………………………. 20
REMOVAL ………………………………………………….. 21
INSTALLATION …………………………………………… 21
BACK DOOR TRIM …………………………………………… 22
Removal and Installation …………………………………. 22
REMOVAL ………………………………………………….. 22
INSTALLATION …………………………………………… 23
LICENSE PLATE FINISHER ………………………………. 24
Removal and Installation …………………………………. 24
REMOVAL ………………………………………………….. 24
INSTALLATION …………………………………………… 25
BODY SIDE TRIM …………………………………………….. 26
Removal and Installation …………………………………. 26
REMOVAL ………………………………………………….. 26
INSTALLATION …………………………………………… 27
REAR PARCEL SHELF FINISHER …………………….. 28
Component Parts Location ………………………………. 28
FLOOR TRIM …………………………………………………… 29
Removal and Installation …………………………………. 29
REMOVAL ………………………………………………….. 29
INSTALLATION …………………………………………… 29
HEADLINER …………………………………………………….. 30
Removal and Installation …………………………………. 30
REMOVAL ………………………………………………….. 30
INSTALLATION …………………………………………… 31
LUGGAGE FLOOR TRIM ………………………………….. 32
Removal and Installation …………………………………. 32
REMOVAL ………………………………………………….. 33
INSTALLATION …………………………………………… 33

EI-1

E

F

G

H

EI

J

K

L

M

PRECAUTIONS
PFP:00001
PRECAUTIONS
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

BIS000T5

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Precautions for Procedures without Cowl Top Cover

BIS000T6

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

PIIB3706J

Precautions

BIS000T7

When removing or disassembling any part, be careful not to damage or deform it. Protect parts, which
may get in the way with cloth.
●
When removing parts with a screwdriver or other tool, protect parts by wrapping them with vinyl or tape.
●
Keep removed parts protected with cloth.
●
If a clip is deformed or damaged, replace it.
●
If an unreusable part is removed, replace it with a new one.
●
Tighten bolts and nuts firmly to the specified torque.
●
After re-assembly has been completed, make sure each part functions correctly.
●
Remove stains in the following way.
Water-soluble stains:
Dip a soft cloth in warm water, and then squeeze it tightly. After wiping the stain, wipe with a soft dry cloth.
Oil stain:
Dissolve a synthetic detergent in warm water (density of 2 to 3% or less), dip the cloth, then clean off the stain
with the cloth. Next, dip the cloth in fresh water and squeeze it tightly. Then clean off the detergent completely.
Then wipe the area with a soft dry cloth.
●
Do not use any organic solvent, such as thinner or benzine.
●

EI-2

CLIP AND FASTENER
CLIP AND FASTENER
Clip and Fastener

PFP:76906

A
BIS000T8

B

C

D

E

F

G

H

EI

J

K

L

M

SIIA0315E

EI-3

FRONT BUMPER
FRONT BUMPER
Removal and Installation
●

PFP:F2022
BIS000T9

Bumper fascia is made of plastic. Do not use excessive force and be sure to protect it from exposure to
oil.

EI-4

FRONT BUMPER
A

B

C

D

E

F

G

H

EI

J

K

L

M

MIIB9318E

1.

Bumper fascia

2.

Front emblem

3.

Front deflector

4.

Towing cover

5.

Bumper stay RH

6.

Bumper side bracket RH

7.

Bumper energy absorber

8.

Bumper reinforcement

9.

Bumper stay LH

EI-5

FRONT BUMPER
10. Grommet

11. Bumper side bracket LH

12. Front air guide

13. Hook lock support stay

14. Radiator core upper support

15. Radiator core lower support

16. Front grille

17. Bumper under cover

18. Guide

19. Front fog lamp (if equipped)

20. Fog lamp finisher (if equipped)

21. Bumper fascia finisher
(model without front fog lamp)

: Pawl
: Refer to text

REMOVAL
1.
2.
3.
4.

5.

Remove front mud guard (if equipped). Refer to EI-15, «MUDGUARD» .
Remove fender protector fixing bolts. Remove partially fender protectors (right, left) to access to bumper
fascia mountings bolts. Refer to EI-14, «FENDER PROTECTOR» .
Remove front bumper lowers clips.
Squeeze the front grille fasteners LH and RH to the outside
direction (arrow direction 1) and push forward to release (arrow
direction 2).
Remove mountings bolts from both side of front bumper.

PIIB5089J

6.

Raise the front bumper and pull to release it from the front
fender on both sides.

PIIB2537J

7.

Disconnect front fog lamps harness connectors (if equipped) on
both sides.
8. Remove the front bumper assembly from the vehicle.
NOTE:
This operation requires two workers
9. Remove front fog lamp finisher (if equipped). Refer to LT-87,
«Removal and Installation» .
10. Remove front fog lamp (if equipped). Refer to LT-87, «Removal
and Installation» .
11. Remove the front bumper energy absorber.

EI-6

PIIB2538J

FRONT BUMPER
12. Remove clip from bumper reinforcement on both sides.
A

B

C
PIIB2539J

D

13. Remove bolts from hook lock support stay.
E

F

G
PIIB5569J

14. Remove four mountings nuts on the LH and two mountings nuts on the RH of bumper reinforcement, and
remove the bumper reinforcement from the body.
15. Remove bumper stay LH and RH, bumper side brackets LH and RH, front air guide LH and RH.

INSTALLATION

H

EI

Install in the reverse order of removal.
NOTE:
After installation, adjust the clearance.

J
Portion

Clearance mm (in)

Front grille — Hood

A-A

6.5 ± 2.0 (0.256 ± 0.079)

Front grille — Hood

B-B

6.5 ± 2.0 (0.256 ± 0.079)

Front grille — Head lamp

C-C

2.5 ± 1.5 (0.098 ± 0.059)

Front bumper — Head lamp

D-D

2.0 ± 1.6 (0.079 ± 0.063)

Front bumper — Front fender

E-E

0.0 + 1.0 (0.000 + 0.039)

K

L

M

EI-7

REAR BUMPER
REAR BUMPER
Removal and Installation

PFP:H5022
BIS000TA

Bumper fascia is made of plastic. Do not use excessive force and be sure to protect it from exposure to oil.

MIIB9319E

1.

Reflector LH

2.

Rear fog lamp

3.

Reflector RH

4.

Bumper fascia

5.

Rear combination lamp LH

6.

Rear combination lamp RH

7.

Rear fender cover LH

8.

Bumper fascia protector LH

9.

Bumper fascia energy absorber

10. Bumper fascia protector RH

11. Bumper fascia stay LH

12. Grommet

13. Bumper fascia stay RH

14. Rear fender cover RH

15. Rear panel (lower)

16. Bumper fascia retainer

17. Air extractor LH

18. Air extractor RH

19. Bumper fascia bracket LH

20. Bumper fascia bracket RH

21. Grommet

: Pawl

EI-8

REAR BUMPER
REMOVAL
1.
2.
3.

A

Remove lower fixing bolts from rear combination lamp LH and
RH.
Remove rear bumper lowers clips.
Remove rear bumper mountings bolts LH and RH on the rear
fender.

B

C

MIIB9320E

4.
5.
6.
7.

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

D

Pull the rear bumper fascia to outside vehicle direction and disengage the fascia from the side of the vehicle.
E
Remove bumper fascia mountings bolts LH and RH on the rear
gate.
Remove rear mudguard LH and RH (if equipped). Refer to EIF
15, «MUDGUARD» .
Remove partially the bumper fascia to disconnect the rear fog
lamp harness connector.
G
NOTE:
This operation requires two workers.
PIIB2547J
Remove the bumper fascia from the rear side of the vehicle.
H
Disengage clip securing the rear fender cover LH and RH to the rear fender.
Remove the rear fog lamp. Refer to LT-97, «Removal and Installation» .
Remove the reflex reflector LH and RH.
EI
Remove fascia bumper energy absorber.
Remove rear panel (lower), bumper fascia protector LH and RH, bumper fascia stay LH and RH, bumper
J
fascia bracket LH and RH, air extractor LH and RH.

INSTALLATION
Install in the reverse order of removal.
NOTE:
Before installation check bumper fascia bracket LH and RH for
break.

K

L

M

MIIB9323E

NOTE:
After installation, adjust the clearance.
Portion

Clearance mm (in)

Rear fender — Rear bumper

A-A

0.0 + 1.0 (0.000 + 0.039)

Rear fender cover — Rear bumper

B-B

0.0 + 1.0 (0.000 + 0.039)

Back door — Rear bumper

C-C

6.0 ± 2.0 (0.236 ± 0.079)

EI-9

FRONT GRILLE
FRONT GRILLE
Removal and Installation

PFP:62310
BIS000TB

REMOVAL
1.
2.

Remove front grille mounting clips. Refer to EI-4, «FRONT BUMPER» .
Squeeze the front grille fasteners LH and RH to the outside
direction (arrow direction 1) and push forward to release (arrow
direction 2).

PIIB5089J

3.

Push the front grille from back side to disengage pawls from the front bumper.

INSTALLATION
Install in the reverse order of removal.

EI-10

FRONT DEFLECTOR
FRONT DEFLECTOR
Removal and Installation

PFP:96015

A
BIS000TC

B

C

D

E

F

G

H

EI
MIIB9327E

1.

J

Front deflector

REMOVAL
1.
2.

Remove mountings clips from the front bumper.
Remove the front deflector.

K

INSTALLATION
L

Install in the reverse order of removal.

M

EI-11

COWL TOP
COWL TOP
Removal and Installation

PFP:66100
BIS000TD

PIIB4890J

1.

Front fender cover

2.

Side seal rubber and foam

3.

Front washer hose

4.

Plastic retainer*

5.

Cowl top

6.

Cowl top seal rubber

7.

Vehicle identification cover

8.

Cowl top sealing

9.

Front wiper motor and link

10. Cowl top extension

11. Dash insulator

12. Plastic nuts

*: Refer to text
: Pawl
: Plastic clip
: Always replace after every disassembly

REMOVAL
1.
2.
3.

Remove front wiper motor rand link (LH and RH). Refer to WW-43, «Removal and Installation of Front
Wiper Drive Assembly» .
Disconnect the Front washer hose.
Remove front fender cover (LH and RH).

PIIB2555J

EI-12

COWL TOP
4.

5.
6.

Remove plastic retainer as follow.
● Expand and maintain the central clip to upper and lower direction.
● Pull the plastic clip to vehicle front direction to release the clip.
Remove plastic clips from cowl top on left and right side.
Remove side seal rubber (LH and RH) and foams.

A

B

C
PIIB2815J

D

7.
8.

Separate front wiper harness from the cowl top extension.
Remove plastic nuts and fixing screws from the cowl top extension and remove cowl top extension.

E

F

G
PIIB2556J

INSTALLATION
Install in the reverse order of removal.
NOTE:
If the cowl top is reused, discard and replace the cowl top sealing by a new one.

H

EI

J

K

L

M

EI-13

FENDER PROTECTOR
FENDER PROTECTOR
Removal and Installation

PFP:63840
BIS000TE

MIIB9333E

1.

Fender protector

2.

Spring nut

: Front bumper fascia
: Front mud guard (if equipped)

EI-14

MUDGUARD
MUDGUARD
Removal and Installation

PFP:63854

A
BIS0014Z

B

C

D

E

F

G

H

EI
MIIB9337E

1.

Front mudguard (if fitted)

2.

Rear mudguard (if fitted)

J

K

L

M

EI-15

ROOF SIDE MOLDING
ROOF SIDE MOLDING
Removal and Installation

PFP:73854
BIS000TF

MIIB9335E

1.

Roof side molding

2.

Ended cap

3.

Double sided tape

4.

Roof panel flange

5.

Roof panel

6.

Body side outer panel

: Always replace after every disassembly

REMOVAL
1.

2.

Use a plastic knife, etc., and lift up the end of roof side molding
(back end), remove clip, and peel off double-sided tape to
remove it.
Remove the double-sided tape remaining on roof side molding
back and vehicle body.
NOTE:
Double-sided tape can be easily removed using double-sided
tape removal agent.

PIIB4893J

INSTALLATION
NOTE:
When only installing roof side molding, conduct the following procedure from Step 3.
1. Clean the roof side molding clip attachment surface (body side).
2. Bond roof side molding clip (body side) to vehicle body and let sit for 40 min.
3. Apply primer (Sumitomo3M N200 or comparable product) to roof side molding back double-sided tape
application area.
4. Apply double-sided tape to roof side molding back (position in figure).
5. After butting roof side molding front end against window seal molding, push in molding from front to back
end, and then affix to body using double-sided tape.

EI-16

WINDSHIELD MOLDING
WINDSHIELD MOLDING
Removal and Installation

PFP:72750

A
BIS000TG

B

C

D

E

F

G
MIIB0062E

CAUTION:
Be careful when handling adhesive and primer.

H

REMOVAL
1.
2.

Remove cowl top cover. Refer to EI-12, «COWL TOP» .
Peel off double-sided tape and remove front fender covers (LH/
RH) from front fenders (LH/RH).

EI

J

K

MIIB9073E

3.
4.
5.

Apply protective tape along the contour of windshield molding
and cut molding lip with cutter knife.
Tear off excess molding from end of molding to glass.
With pliers, draw out all the remaining molding left in flanged
area of body to remove it completely from adhering surface on
glass.

M

MIIB0064E

EI-17

L

WINDSHIELD MOLDING
INSTALLATION
1.

Apply primer between glass and panel then apply enough adhesive to allow molding adhesion.
NOTE:
●
The essential function of primers is to strengthen adhesion
between glass and painted surface.
●
There are 2 types of primer. Never confuse the application methods.
Primer M ··· for painted surfaces
Primer G ··· for glass
●
If primer M overflows onto a painted surface other than bonding
area, quickly remove it with white gasoline.
2. Apply primer to entire perimeter of molding area shown in the
figure.
3. Align molding positioning mark (center of molding: white) with
glass top edge center spacer positioning mark, push in so that
molding’s lower chin hooks onto glass, then continuing pushing
toward the outside.
CAUTION:
After installing molding, make sure there are no non-standard conditions, such as a lip sticking out or wave in molding.

MIIB0065E

MIIB0066E

4.
5.

Remove protective tape.
Remove double-sided tape from front fender cover and apply
primer (Sumitomo 3M K520) to double-sided tape application
position shown in the figure. Then apply new double-sided tape
and install front fender.

MIIB9074E

6.

Install cowl top cover. Refer to EI-12, «COWL TOP» .

EI-18

DOOR OUTSIDE MOLDING
DOOR OUTSIDE MOLDING
Removal and Installation

PFP:82820

A
BIS000TH

B

C

D

E

F

G

H

EI
PIIB4894J

1.

Front door outside molding

4.

Grommet

2.

Rear door outside molding

3.

J

Front fender finisher

: Plastic clip

K

REMOVAL
1.
2.

Fully open the door glass.
Take the door outside molding end by fingers and pull to disengage the plastic clip from the door outer panel. Insert a clip
remover between the door outer panel and outside molding end
if there is a risk to deform the door outside molding.
3. Pull upward to remove the door outside molding from the door
outer panel.
CAUTION:
After removal, visually inspect molding, and if it is deformed,
replace it with a new one.

L

M

PIIB3386J

INSTALLATION
Install in the reverse order of removal.

EI-19

DOOR FINISHER
DOOR FINISHER
Removal and Installation

PFP:80900
BIS000TJ

MIIB9329E

1.

Power door switch finisher
(front door)

2.

Front door finisher

3.

Inside handle escutcheon

4.

Pull handle

5.

Pull handle cap

6.

Power door switch finisher
(rear door)

7.

Rear door finisher

8.

Rear door corner cover

9.

Front door corner cover*

10. Dust cover*
*: Refer to GW section
: Pawl
: molded clip
: Metal clip

EI-20

DOOR FINISHER
REMOVAL
1.
2.
3.

A

Fully open door glass.
Pull up inside handle lever, and then spread inside handle
escutcheon top and bottom to release top and bottom hooks.
Slide inside handle escutcheon backwards, disengage bottom,
and remove from door finisher.

B

C

D
MIIB0070E

4.

5.
6.

Insert a clip remover wrapped with tape into back of power window switch finisher, hold up the back end, and disengage metal
clips.
Hold up front side, remove inserted area, and remove. Pull back
rear side, remove inserted area, and remove.
Separate the power window switch finisher back harness connector and remove it.

E

F

G

PIIB4900J

7.
8.
9.

Remove door pull handle cap and screw.
Remove front door corner cover. Refer to GW-101, «Removal and Installation» .
Insert clip driver or clip clamp remover into door finisher back clip and remove clip.
NOTE:
Insert a clip driver or clip clamp remover into the part shown by
the arrow (between the body side panel and the clips). Remove
finisher.

H

EI

J

K

L

MIIB0072E

10. Pull door finisher upwards to remove it from door panel.

INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
When installing finisher, confirm clips are accurately aligned with the holes on body side panel, then
press in.

EI-21

M

BACK DOOR TRIM
BACK DOOR TRIM
Removal and Installation

PFP:90900
BIS000TK

MIIB9326E

1.

Back door side finisher LH

2.

Back door side finisher RH

3.

Back door finisher

: Metal clip

REMOVAL
1.
2.
3.

Insert a suitable tool between the back door inner panel and
back door finisher, to access to mountings clips.
Using a clip remover, remove clips from the back door panel.
Disengage metal clips from the back door panel and remove
back door finisher, and separate back door finisher from back
door side finisher LH and RH.

MIIB9324E

4.
5.

Insert a suitable tool between the back door inner panel and
back door side finisher and to disengage metal clips.
Remove back door side finisher.

MIIB9325E

EI-22

BACK DOOR TRIM
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
When installing, confirm clips are accurately aligned with the holes on body side panel, then press in.

A

B

C

D

E

F

G

H

EI

J

K

L

M

EI-23

LICENSE PLATE FINISHER
LICENSE PLATE FINISHER
Removal and Installation

PFP:84810
BIS00150

MIIB9328E

1.

License plate finisher

2.

License plate lamp and back door
switch actuator harness

REMOVAL
1.
2.
3.

Remove the back door finisher. Refer to EI-22, «BACK DOOR TRIM» .
Remove nuts securing the license plate finisher to the back door panel.
Pull the license plate finisher to downward direction to disengage fixing clips from the back door panel.

MIIB9321E

EI-24

LICENSE PLATE FINISHER
4.
5.
6.

Release license plate lamp LH (1) and RH (2) from holder (3),
and disconnect harness connector.
Remove screws securing the holder to the license plate finisher
(5) and disconnect back door lock switch actuator (4).
Separate license plate lamp and back door switch actuator harness from the holder.
NOTE:
For easier installation, locate the position of harness and component.

A

B

C
MIIB9322E

D

INSTALLATION
Install in the reverse order of removal, paying attention to following points:
●
Before installation of back door finisher, close the back door and check the correct operation of back door
lock switch actuator.
●
Check the correct operation of license plate lamp LH and RH.

E

F

G

H

EI

J

K

L

M

EI-25

BODY SIDE TRIM
BODY SIDE TRIM
Removal and Installation

PFP:76913
BIS000TN

MIIB9332E

1.

Front pillar garnish

2.

Front body side welt

3.

Dashboard side finisher

4.

Rear parcel shelf holder

5.

Center pillar lower garnish

6.

Rear pillar garnish

7.

Rear body side welt

8.

Center pillar upper garnish

9.

Ledge

: Insertion
: Pawl
: Plastic clip
: Metal clip
: Refer to text

REMOVAL
Front Body Side Welt
Remove front body side welt from vehicle.

Dashboard Side Finisher
1.
2.

Remove front body side welt from vehicle.
Pull dash side finisher slanted backwards to remove it.

Front Pillar Garnish
1.
2.

Remove partially front body side welt.
Remove the mounting clips, pull the front pillar garnish from inside the passenger room, and remove it.

EI-26

BODY SIDE TRIM
Center Pillar Lower Garnish
1.
2.

Remove partially front and rear body side welt.
Spread the area engaged in the center pillar flange, remove front side first and then remove rear side in
the same manner.

B

Center Pillar Upper Garnish
1.
2.
3.
4.

A

Remove partially front and rear body side welt.
Remove center pillar lower garnish.
Remove front seat belt shoulder anchor. Refer to SB-3, «Removal and Installation of Front Seat Belt» .
Pull center pillar upper garnish from inside passenger room, disengage clips as instructed in the figure,
and remove garnish from vehicle.

C

D

E

F

G
MIIB0074E

Rear Pillar Garnish
1.
2.
3.
4.

Remove partially rear body side welt.
Remove Luggage side finisher. Refer to EI-33, «Luggage Side Finisher» .
Remove rear seat belt upper anchor. Refer to SB-4, «Removal and Installation of Rear Seat Belt» .
Release clips and remove rear pillar garnish.

H

EI

INSTALLATION
Install in the reverse order of removal.

J

K

L

M

EI-27

REAR PARCEL SHELF FINISHER
REAR PARCEL SHELF FINISHER
Component Parts Location

PFP:79910
BIS0015D

MIIB9334E

1.

Rear parcel shelf finisher

EI-28

FLOOR TRIM
FLOOR TRIM
Removal and Installation

PFP:74902

A
BIS000TQ

B

C

D

E

F

G

H

EI
MIIB9330E

1.

Floor carpet

2.

Steering column shaft cover

3.

Front floor spacer LH

4.

Front floor spacer RH

5.

Front floor center LH

6.

Front floor center RH

7.

Rear floor spacer LH

8.

Rear floor spacer RH

J

K

: Clip

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

Remove front seats (LH/RH) and rear seat cushion. Refer to SE-7, «FRONT SEAT» and SE-12, «REAR
SEAT» in SE section.
Remove center console. Refer to IP-13, «Removal And Installation» in IP section.
Remove air bag sensor unit harness connector and harness clips. Refer to SRS-48, «DIAGNOSIS SENSOR UNIT» in SRS section.
Remove instrument panel stay cover. Refer to IP-5, «Removal and Installation» in IP section.
Remove center pillar lower garnish (LH/RH). Refer to EI-26, «Removal and Installation» in EI section.
Remove partially body side welts (LH/RH).
Remove dash side finishers (LH/RH). Refer to EI-26, «BODY SIDE TRIM» in EI section.
Remove carpet hook.
Remove floor carpet from vehicle.

INSTALLATION
Install in the reverse order of removal.

EI-29

L

M

HEADLINER
HEADLINER
Removal and Installation

PFP:73910
BIS000TR

MIIB9336E

1.

Headliner

2.

Assist grip

3.

Room lamp

4.

Room harness

5.

Sunvisor holder

6.

Harness

7.

Room lamp

8.

Sunvisor

9.

Cap

10. Assist grip

11. Adhesive

12. Microphone spacer (if equipped)

13. Spacer
: Pawl
: Plastic clip
: Metal clip
: Always replace after every disassembly

REMOVAL
1.
2.
3.
4.

Remove front pillar garnish. Refer to EI-26, «BODY SIDE TRIM» in EI section.
Remove back door weatherstrip.
Remove luggage side upper finishers (LH/RH). Refer to EI-32, «LUGGAGE FLOOR TRIM» in EI section.
Remove center pillar upper garnish (5-door vehicles) and lock pillar upper garnish (3-door vehicles). Refer
to EI-26, «BODY SIDE TRIM» in EI section.

EI-30

HEADLINER
5.

Remove assist grip.
NOTE:
When removing assist grip, insert a thin screwdriver, etc., into
the clip and move the clip outside.

A

B

C
MIIB0078E

D

6.
7.
8.

Remove sunvisors (LH/RH).
Remove room lamp (with map lamp function). Refer to LT-171, «MAP LAMP, PERSONAL LAMP» .
Remove sunvisor holder.
NOTE:
Insert a screwdriver into the cutout and rotate 90° to remove.

E

F

G

SIIA0224J

9. Remove vehicle rear clips.
10. Peel off headliner adhesive and remove headliner from back
door opening.
CAUTION:
The roof panel could be deformed, so do not strongly pull
the headliner.

H

EI

J

K
MIIB0079E

L

INSTALLATION
1.
2.

Remove any adhesive left on the vehicle side.
Apply adhesive to headliner.
Adhesive:

3.
4.
5.

M

Yokohama Rubber Hammer Tight
YM-21, or BETAMATE 7138

Move front seats (LH/RH) toward front of vehicle, and fix headrests (LH/RH) in top position.
Place the headliner front section on the headrest and fasten the
headliner rear section with the clips.
After installing sunvisor holder, install in the reverse order of
removal.

MIIB9106E

EI-31

LUGGAGE FLOOR TRIM
LUGGAGE FLOOR TRIM
Removal and Installation

PFP:84999
BIS000TW

MIIB9331E

1.

Luggage floor lid RR

2.

Luggage floor lid FR

3.

4.

Luggage floor carpet

5.

Trunk room lamp

6.

Rope hook

7.

Cap

8.

Luggage side finisher

9.

Mask

10. Hook
: Pawl
: Plastic clip
: Metal clip

EI-32

Luggage rear kick plate

LUGGAGE FLOOR TRIM
REMOVAL
Luggage Side Finisher
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

A

Remove rear parcel shelf. Refer to EI-28, «REAR PARCEL SHELF FINISHER» .
Remove luggage floor lid FR and RR.
Remove luggage floor carpet.
Remove luggage rear plate. Refer to EI-33, «Luggage Rear Kickplate» .
Remove cigar lighter (if equipped) and disconnect harness connector.
Remove Trunk room lamp. Refer to LT-172, «LUGGAGE ROOM LAMP» .
Remove cap and remove bolts securing the luggage side finisher to the rear fender inner panel.
Remove hook and rope hook.
Remove plastic clips securing the luggage side finisher to rear fender inner panel.
Remove metal clips securing the luggage side finisher to rear fender inner panel.
Separate the luggage side finisher from the rear pillar garnish.
Remove luggage side finisher.

Luggage Rear Kickplate
1.
2.
3.
4.
5.

B

C

D

E

F

Remove rear parcel shelf finisher.
Remove luggage floor lid FR and RR.
Remove partially back door weather strip.
Remove luggage side finisher.
Remove luggage rear kickplate.

G

H

INSTALLATION
Install in the reverse order of removal.

EI

J

K

L

M

EI-33

LUGGAGE FLOOR TRIM

EI-34

QUICK REFERENCE INDEX
A GENERAL INFORMATION

GI

General Information

B ENGINE

EM

Engine Mechanical

LU

Engine Lubrication System

CO

Engine Cooling System

EC

Engine Control System

FL

Fuel System

EX

Exhaust System

ACC
C TRANSMISSION/
TRANSAXLE

CL

Clutch

MT

Manual Transaxle

AT
D DRIVELINE/AXLE

E SUSPENSION

F BRAKES

MODEL E11 SERIES

G STEERING

H RESTRAINTS

BODY

J AIR CONDITIONER

K ELECTRICAL

Automatic Transaxle

FAX

Front Axle

RAX

Rear Axle

FSU

Front Suspension

RSU

Rear Suspension

WT

Road Wheels & Tires

BR

Brake System

PB

Parking Brake System

BRC

Brake Control System

PS

Power Steering System

STC

Steering Control System

SB
SRS

I

Accelerator Control System

Seat Belts
Supplemental Restraint System (SRS)

BL

Body, Lock & Security System

GW

Glasses, Window System & Mirrors

EI

Exterior & Interior

IP

Instrument Panel

SE

Seat

ATC

Automatic Air Conditioner

MTC

Manual Air Conditioner

SC

Starting & Charging System

LT

Lighting System

DI

Driver Information System

WW

Wiper, Washer & Horn

BCS

Body Control System

LAN

LAN System

AV

Audio, Visual & Telephone System

PG

Power Supply, Ground & Circuit Elements

L MAINTENANCE

MA

Maintenance

M INDEX

IDX

Alphabetical Index

© 2006 NISSAN EUROPE S.A.S.
All rights reserved. No part of this Electronic Service Manual may be reproduced or stored in a retrieval system, or transmitted in any
form, or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Nissan
Europe S.A.S., Paris, France.

A
B
C
D
E
F
G
H
I
J
K
L
M

FOREWORD
This manual contains maintenance and repair procedures for the NISSAN
NOTE, model E11 series.
In order to assure your safety and the efficient functioning of the vehicle,
this manual should be read thoroughly. It is especially important that the
PRECAUTIONS in the GI section be completely understood before starting
any repair task.
All information in this manual is based on the latest product information
at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.

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

NISSAN EUROPE S.A.S.
Service Engineering Section
Paris, France

FRONT AXLE

D DRIVELINE/AXLE

SECTION

FAX

FRONT AXLE

A

B

C

FAX

CONTENTS
PRECAUTIONS …………………………………………………. 2
Cautions …………………………………………………………. 2
Precautions for Brake System ……………………………. 2
PREPARATION ………………………………………………….. 3
Special Service Tools ……………………………………….. 3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ………………………………………… 5
NVH Troubleshooting Chart ………………………………. 5
FRONT WHEEL HUB AND KNUCKLE …………………. 6
On-Vehicle Inspection ………………………………………. 6
FRONT WHEEL BEARING …………………………….. 6
Removal and Installation …………………………………… 6
REMOVAL ……………………………………………………. 6
INSTALLATION …………………………………………….. 7
Disassembly and Assembly ………………………………. 7
DISASSEMBLY …………………………………………….. 7
INSPECTION AFTER DISASSEMBLY …………….. 8
ASSEMBLY ………………………………………………….. 8
INSPECTION AFTER ASSEMBLY ………………….. 9
FRONT DRIVE SHAFT ……………………………………… 10
On-Vehicle Inspection and Service …………………… 10

DRIVE SHAFT BOOT ………………………………….. 10
Removal and Installation …………………………………. 13
REMOVAL ………………………………………………….. 14
INSPECTION AFTER REMOVAL ………………….. 14
INSTALLATION …………………………………………… 15
Disassembly and Assembly ……………………………… 16
INSPECTION BEFORE DISASSEMBLY …………. 16
DISASSEMBLY (CR AND HR16 ENGINE MODELS) ………………………………………………………….. 16
DISASSEMBLY (K9K ENGINE MODELS) ………. 18
INSPECTION AFTER DISASSEMBLY (CR AND
HR16 ENGINE MODELS) …………………………….. 20
INSPECTION AFTER DISASSEMBLY (K9K
ENGINE MODELS) ……………………………………… 20
ASSEMBLY (CR AND HR16 ENGINE MODELS)… 21
ASSEMBLY (K9K ENGINE MODELS) ……………. 23
SERVICE DATA AND SPECIFICATIONS (SDS) …… 27
Wheel Bearing ……………………………………………….. 27
Drive shaft …………………………………………………….. 27
Dynamic Damper ……………………………………………. 27
Tightening Torque …………………………………………… 27

E

F

G

H

I

J

K

L

M

FAX-1

PRECAUTIONS
PRECAUTIONS
Cautions

PFP:00001
BDS0006R

Observe the following precautions when disassembling and servicing drive shaft.
●
The joint of drive shaft cannot be disassembled. Do not attempt to disassemble it.
●
Perform work in a location which is as dust-free and dirt-free as possible.
●
Before disassembling and servicing, clean the outside of parts.
●
The disassembly and service location must be clean. Care must be taken to prevent parts from becoming
dirty and to prevent the entry of foreign objects.
●
Disassembled parts must be carefully reassembled in the correct order. If work is interrupted, a clean
cover must be placed over parts.
●
Paper shop cloths must be used. Fabric shop cloths must not be used because of the danger of lint adhering to parts.
●
Disassembled parts (except for rubber parts) should be cleaned with kerosene which shall be removed by
blowing with air or wiping with paper shop cloths.

Precautions for Brake System
●

●
●

●

BDS0006S

When installing rubber parts, final tightening must be carried out
under unladen condition* with tyres on ground.
*: Fuel, radiator coolant and engine oil full. Spare tyre, jack,
hand tools and mats in designated positions.
Use flare nut wrench when removing or installing brake tubes.
After installing removed suspension parts, check wheel alignment and adjust if necessary.
Always tighten brake lines to the specified torque when installing.
SBR820BA

FAX-2

PREPARATION
PREPARATION
Special Service Tools

PFP:00002

A
BDS0006T

Description

Application

B
Hub lock nut wrench
KV40104000
a: 85 mm (3.35 in) dia.
b: 65 mm (2.56 in) dia.

●

Removing and installing hub lock nuts

●

Removing and installing drive shaft

C

FAX

ZZA0802D

E

Protector
KV38107900
a: 32 mm (1.26 in) dia.

Installing drive shaft

F
ZZA0835D

G

Drift
ST35271000
a: 72 mm (2.83 in) dia.
b: 63 mm (2.48 in) dia.

Installing wheel bearing

H
ZZA0837D

I
Drift
ST33710000
a: 30 mm (1.18 in) dia.
b: 23 mm (0.91 in) dia.

●

Removing wheel hub

●

Removing inner race (outside) of wheel
bearing

J

ZZA1233D

K

Bearing replacer
ST30031000

Removing inner race (outside) of wheel
bearing

M

ZZA0700D

Drift
ST35321000
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.
ST30621000
a: 79 mm (3.11 in) dia.
b: 59 mm (2.32 in) dia.

●

Removing wheel bearing

●

Installing wheel hub

ZZA1051D

Drift
ST27863000
a: 74 mm (2.91 in) dia.
b: 62 mm (2.44 in) dia.

Installing wheel bearing

ZZA0936D

FAX-3

L

PREPARATION
Description

Application

Boot band crimping tool
KV40107300

Installing boot band

ZZA1229D

Flare nut torque wrench
GG94310000
a: 10 mm (0.39 in)

Removing and installing brake lines

NT406

FAX-4

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

PFP:00003

A
BDS0006U

NVH in PS section.
STEERING

NVH in WT section.
ROAD WHEEL

NVH in WT section.

E

TYRES

Refer to FAX-6, «FRONT WHEEL HUB AND KNUCKLE»

FAX

Parts interference

FRONT AXLE

C

Noise

×

×

×

×

×

Shake

×

×

×

×

×

Vibration

×

×

×

Shimmy

×

×

×

×

×

Judder

×

×

×

×

Poor quality ride or handling

×

×

×

×: Applicable

FAX-5

F

G

H

×

Wheel bearing damage

Possible cause and SUSPECTED PARTS

Symptom

B

Improper installation, looseness

Reference page

—

Refer to FAX-6, «FRONT WHEEL HUB AND KNUCKLE»

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

×

I

J

K

×

L

M

FRONT WHEEL HUB AND KNUCKLE
FRONT WHEEL HUB AND KNUCKLE
On-Vehicle Inspection

PFP:40202
BDS0006V

Inspect to check that there is no excessive play, cracking, wear, or
other damage to front axle.
●
Turn front wheels (left/right) and check the play.
●
Check that no nails or other foreign objects are embedded.
●
Retighten all axle nuts and bolts to the specified torque.

SMA525A

FRONT WHEEL BEARING
With the vehicle raised, inspect the following:
●
Move wheel hub in the axial direction by hand. Check if there is no looseness of front wheel bearings.
Axial end play
●

: 0.05 mm (0.0020 in)

Rotate wheel hub and Make sure there is no unusual noise or other non-standard condition. If there are
any non-standard conditions, replace the wheel bearing.

Removal and Installation

BDS0006W

MDIA0032E

1.

Steering knuckle

2.

Sensor housing

3.

Wheel bearing

4.

Snap rings

5.

Wheel hub

6.

Front drive shaft

REMOVAL
1.
2.
3.
4.

5.
6.

Lift up the vehicle and remove tyre from the vehicle.
Disconnect ABS wheel sensor harness connector. Refer to BRC-36, «WHEEL SENSORS» .
Disconnect brake hose from strut. Refer to BR-11, «BRAKE PIPING AND HOSE» .
Remove brake caliper from steering knuckle. Hang it in a place where it does not interfere with work.
Refer to BR-23, «Removal and Installation of Brake Caliper Assembly» .
CAUTION:
Avoid depressing the brake pedal with the brake caliper removed.
Remove disc rotor from wheel hub. Refer to BR-21, «FRONT DISC BRAKE» .
Pull out ABS wheel sensor from steering knuckle. Refer to BRC-36, «WHEEL SENSORS» .

FAX-6

FRONT WHEEL HUB AND KNUCKLE
CAUTION:
Do not pull on ABS wheel sensor harness.
A
7. Use wheel hub lock nut wrench (SST) to remove lock nut from
drive shaft.
8. Remove tie-rod from steering knuckle. If tie-rod is not easily
B
removed, use ball joint remover (commercial service tool).
CAUTION:
To prevent damage to threads and to prevent ball joint
C
remover (commercial service tool) from sudden coming off,
temporarily tighten lock nuts.
9. Remove steering knuckle from strut.
FAX
CAUTION:
MDIA0033E
Do not place drive shaft joint at an extreme angle (22° or
more). Also, hold steering knuckle tightly and do not overextend slide joint.
E
10. Remove drive shaft from steering knuckle.
CAUTION:
When removing drive shaft, do not place drive shaft joint at an extreme angle (22° or more). Also
F
be careful not to overextend slide joint.
● Do not lift drive shaft with axle attached by grasping countershaft only.
● Do not allow drive shaft, with transaxle inserted, to hang down without support for countershaft,
G
wheel joints, and other parts.
11. Remove transverse link ball joint mounting bolt and nut. Then, remove transverse link from steering
knuckle.
H

INSTALLATION
For tightening torque and other details, FAX-6, «FRONT WHEEL BEARING» , BRC-36, «WHEEL SENSORS» ,
FSU-5, «FRONT SUSPENSION ASSEMBLY» and tighten in the reverse order of removal.

Disassembly and Assembly

I

BDS0006X

DISASSEMBLY
1.

J

Press the wheel bearing out with a drift (SST) to remove.

K

L

SDIA0758J

2.

Insert a screwdriver into cutout of snap ring and remove it from
steering knuckle.
CAUTION:
Be careful not to scratch the steering knuckle.

MDIA0034E

FAX-7

M

FRONT WHEEL HUB AND KNUCKLE
3.

Use a puller (commercial service tool), drift (SST), and bearing
replacer (SST) to remove inner race of outer wheel bearing from
wheel hub.

SDIA0759J

4.

Press the wheel bearing and sensor housing out of the steering
knuckle with a drift (SST).

SDIA0760J

INSPECTION AFTER DISASSEMBLY
Wheel Hub
●

Check wheel hub for cracks (with magnetic exploration or dye testing). Replace if necessary.

Steering Knuckle
●

Check steering knuckle for deformation, cracks, and other damage. Replace if any non-standard conditions are found.

Snap Rings
●

Check snap ring for wear or cracks. Replace if necessary.

ASSEMBLY
1.

Temporarily put sensor housing on steering knuckle.
CAUTION:
Protrusion of sensor housing ABS sensor mounting should
fit in cutout of steering knuckle (as shown in figure).

MDIA0035E

FAX-8

FRONT WHEEL HUB AND KNUCKLE
2.

Press-fit a wheel bearing into the steering knuckle with a drift
(SST) from steering knuckle outer side.
CAUTION:
● Be sure that wheel bearing is completely press-fit until
sensor housing contacts the body tightly.
● Be sure that protrusion of ABS sensor mounting does
not roll onto steering knuckle.
● Be sure to mount so that sensor rotor (rubber side) side
comes to steering knuckle inner side.
● Do not press and weigh on wheel bearing inner lace and
sealing part.
NOTE:
Final press-loading guideline [49,000 N (5,000 kg, 11,015 lb)]

A

B

C
MDIA0037E

FAX

E

3.

Install snap ring onto steering knuckle.

4.

Press-fit a wheel bearing into the steering knuckle with a drift
(SST) from steering knuckle outer side.
NOTE:
Final press-loading guideline [49,000 N (5,000 kg, 11,015 lb)]
CAUTION:
Drift (special tool) which touches wheel bearing inner lace
shall not touch sensor housing.

F

G

H

MDIA0037E

I

INSPECTION AFTER ASSEMBLY
1.
2.

Apply a load of 34,300 to 49,000 N (3,500 to 5,000 kg, 7,710 — 11,015 lb). In this condition, rotate in forward and reverse directions 10 times each to insure a good fit.
Set a spring balance on strut mounting hole (upper). Measure
rotating torque at an rpm of 8 — 12 rpm.
Rotating torque
Spring balance
measurement

K

: 0.30 — 1.43 N·m (0.03 — 0.14 kg-m)
: 6.0 — 28.6 N (0.61 — 2.92 kg)

L

NOTE:
In case the above loading is not possible
●
Assemble drive shaft and tighten wheel hub lock nuts to specified torque. Then rotate in forward and reverse direction 10
times each to insure a good fit.
●
At a rotating speed of 8 — 12 rpm, place a spring balance on hub bolt to measure torque.
Rotating torque
Spring balance
measurement

J

: 0.23 N·m (0.02 kg-m) or less
: 15.9 N (1.62 kg) or less

FAX-9

M
SDIA0762J

FRONT DRIVE SHAFT
FRONT DRIVE SHAFT
On-Vehicle Inspection and Service

PFP:39100
BDS0006Y

DRIVE SHAFT BOOT
Replacement
CAUTION:
When noise or vibration occur from drive shaft, replace entire drive shaft assembly.
1. Lift up the vehicle and remove the wheel from the vehicle.
2. Disconnect ABS wheel sensor harness connector. BRC-36, «WHEEL SENSORS» .
3. Disconnect brake hose from strut. Refer to BR-11, «BRAKE PIPING AND HOSE» .
4. Remove the ABS wheel sensor from the steering knuckle. Refer to BRC-36, «WHEEL SENSORS» .
CAUTION:
Do not pull on ABS wheel sensor harness.
5. Remove brake caliper assembly from brake rotor and hand cylinder body with a wire. Refer to BR-22,
«Removal and Installation of Brake Pad» .
6. Use a hub lock nut wrench (SST), remove lock nuts.
7. Remove steering knuckle and strut installation bolt.
CAUTION:
Do not place drive shaft joint at an extreme angle (22° or
more). Also, hold steering knuckle tightly and do not overextend slide joint.
8. Using a puller (commercial service tool), remove the drive shaft
from the steering knuckle.
CAUTION:
When removing drive shaft, do not place drive shaft joint at
MDIA0038E
an extreme angle (22° or more). Also be careful not to overextend slide joint.
● Do not lift drive shaft with axle attached by grasping barshaft only.
● Do not allow the wheel-side joint and/or barshaft to hang from the transmission without support.
9. Remove boot bands and remove boot from the joint subassembly.
10. Screw drive shaft puller (commercial service tool) into joint subassembly screw part in depth of 30 mm (1.18in) or more. Fix
drive shaft by one hand and pull out joint subassembly with sliding hammer (commercial service tool) from shaft.
CAUTION:
● For K9K engines: before separating joint subassembly
put matching marks on drive shaft and joint subassembly.
● Align sliding hammer and drive shaft and remove them
by pulling firmly and uniformly.
● When joint subassembly is not able to be pulled out, try
after removing drive shaft from the vehicle.
11. Remove boot from shaft.

FAX-10

SDIA0881J

FRONT DRIVE SHAFT
12. Remove circlip from the shaft.
A

B

C
MDIA0039E

FAX

13. While rotating ball cage, remove old grease on joint subassembly with paper towels.
CAUTION:
Visually check joint subassembly for compression scar,
cracks, fractures. Also check the grease for contamination
by road debris and metal fragments. If any non-standard
condition is detected, replace entire joint subassembly.
14. Inject Genuine Nissan Grease (see parts catalog) into the joint
subassembly serration hole until the grease begins to ooze from
the ball groove and serration hole.
MDIA0040E
After injecting the grease, wipe off the old grease that has oozed
out with towel.
15. Cover drive shaft splines with tape so as not to damage boot during installation. Install new boot and boot
bands to the shaft.
NOTE:
Install small band first.
CAUTION:
Do not reuse the boot bands and boot.
16. Remove the tape wrapped around the serration on the shaft.
17. Mount circlip on circlip groove at the shaft edge. Do not over extend the circlip. Align the shaft edge and
joint subassembly center axle. Then, assemble on the circlip groove, holding circlip with screwdriver tip.
Drive joint inserter (commercial service tool) is recommended as an assisting tool when mounting circlip.
For K9K engines: install joint subassembly securely, ensuring
marks which were made during disassembly are properly
aligned.
CAUTION:
Do not reuse the circlip.

E

F

G

H

I

J

K

L

M

MDIA0041E

18. Press joint subassembly into shaft with plastic hammer.
CAUTION:
Confirm that joint subassembly is correctly engaged while
rotating.
19. Working from the big end of the boot, add enough Genuine
Nissan Grease (refer to the part catalog) to the boot to equal the
quantity mentioned below.
Grease
quantity

: For CR and HR16 engines: 45 — 55 g (1.59 1.94 oz)
For K9K engines: 40 — 50 g (1.41 — 1.76 oz)

FAX-11

MDIA0042E

FRONT DRIVE SHAFT
20. Remove grease from the boot and joint mating surfaces.
21. Mount boot firmly on the groove shown in the figure (with * mark)
and confirm the length of the boot (L) is same as shown below.
Hold the boot band at the opposite side to the clip to prevent
misalignment. Fit the small boot band as shown in the figure.
Insert a screwdriver or fitting tool from the large-diameter side.
Bleed air out of the inside boot (to adjust pressure outside and
inside of boot) to prevent deformation of boot.
Boot
mounting
length

:Wheel side

Transaxle side

: AC1700i: 88.0 mm (3.46 in)
AC2000i: 91.0 mm (3.58 in)
AC2300i: 94.0 mm (3.70 in)
: GI1700i: 89.4 mm (3.52 in)
GI2000i: 90.45 mm (3.56 in)
GI2300i: 91.5 mm (3.60 in)

MDIA0043E

CAUTION:
If boot mounting length is outside the standard, it may cause breakage in the boot.
● Be careful not to damage the inside of the boot with the tip of a screwdriver.
●

22. Hold the boot band at the opposite side to the clip to prevent
misalignment. As shown in the figure, secure the big end of the
boot with new boot band.

SDIA0876J

23. Confirm that the mounting position of the boot band does not deviate around the circumference of the
joint. When it deviates, mount a new boot band again.
CAUTION:
When fixing boot band, fix so that the M gap on the drawing becomes as follows.
Large-diameter side
Small-diameter side

: 5 mm (0.20 in)
: 5 mm (0.20 in)

YAX006

24. Confirm that the driveshaft is still engaged in the differential.
25. Insert the drive shaft to the steering knuckle, and tighten the lock nut.
26. Install bolts securing steering knuckle to the strut. For tightening torque, refer to FSU-5, «FRONT SUSPENSION ASSEMBLY» .
27. Fix the brake hose onto the strut with the lock plate.
28. Install tie-rod to steering knuckle. For tightening torque, refer to FSU-5, «FRONT SUSPENSION ASSEMBLY» .
29. Install ABS wheel sensor. Refer to BRC-36, «WHEEL SENSORS» .

FAX-12

FRONT DRIVE SHAFT
30. Using a hub lock nut wrench (SST), tighten lock nut to the specified torque.
Tightening torque

A

: 280 N·m (29 kg-m, 207 ft-lb)

31. Mount the wheel and lower lift.

B

C
MDIA0044E

FAX

Removal and Installation

BDS0006Z

FOR CR AND HR16 ENGINES:
E

F

G

H

I

J
MDIB9062E

1.

Damper (RH side)

2.

Damper (LH side)

K

FOR K9K ENGINES:
L

M

MDIB9022E

FAX-13

FRONT DRIVE SHAFT
REMOVAL
1.
2.
3.

4.
5.

6.

7.

8.

Lift up the vehicle and remove the wheel from the vehicle.
Remove lock plate from strut. Disconnect brake hose from strut. Refer to BR-11, «BRAKE PIPING AND
HOSE» .
Remove the ABS wheel sensor from the steering knuckle. Refer to BRC-36, «WHEEL SENSORS» .
CAUTION:
Do not pull on ABS wheel sensor harness.
Use a hub lock nut wrench (SST), remove lock nuts.
Remove tie-rod from steering knuckle. If tie-rod is not easily
removed, use ball joint remover (commercial service tool).
CAUTION:
To prevent damage to threads and to prevent ball joint
remover (commercial service tool) from sudden coming off,
temporarily fix lock nuts.
Remove steering knuckle and strut installation bolt.
CAUTION:
Do not place drive shaft joint at an extreme angle (22° or
MDIA0038E
more). Also, hold steering knuckle tightly and do not overextend slide joint.
Using a puller (commercial service tool), remove the drive shaft from the steering knuckle.
CAUTION:
When removing drive shaft, do not place drive shaft joint at an extreme angle (22° or more). Also
be careful not to overextend slide joint.
● Do not lift drive shaft with axle attached by grasping barshaft only.
● Do not allow the wheel-side joint and/or barshaft to hang from the transmission without support.
Remove driveshaft from transaxle with a wheel wrench or equivalent, as shown in figure.
CAUTION:
When removing drive shaft from vehicle, be careful to avoid
interfering with brake hose, ABS wheel sensor harness, and
other parts. Take care not to damage the dust shield.
● Confirm that the circlip is attached to the driveshaft.

MAA0384D

INSPECTION AFTER REMOVAL
●

●
●

Move joint in up/down, left/right, and axial directions. Check for
motion that is not smooth and for significant looseness. Listen
for air or grease leakage from the boot.
Check the boot for cracks, damage, and leakage of grease.
Check the boot band for damage.

SDIA1029J

FAX-14

FRONT DRIVE SHAFT
INSTALLATION
1.
2.
3.

Protector SST (special
service tool) No.
4.

5.

A

In order to prevent damage to differential side oil seal, first fit a
protector (SST) onto oil seal before inserting drive shaft.
Align the driveshaft splines with the splines in the transmission.
Holding the barshaft and wheel-side joint, apply a shock force to
drive the slide joint stem into the differential.
CAUTION:
Make sure the circlip is fully engaged.

B

C

: KV38107900
MDIA0046E

For vehicles equipped with support bearing, fix drive shaft with
support bearing retainer.
WARNING:
Before tightening the support bearing retainer bolts, ensure that the driveshaft support bearing is
fully inserted into the support bracket. Also ensure that rubber o-ring is fitted between the support
bearing and the support bracket.
Tighten support bearing retainer bolts in numerical order as
shown in the figure.
Tightening torque: 21 N·m (2.1 kg-m, 15 ft-lb)

6.

FAX

E

F

G

Retighten support bearing retainer bolts in numerical order as
shown in the figure.
H

Tightening torque: 21 N·m (2.1 kg-m, 15 ft-lb)
NOTE:
The second tightening operation should be performed with a
manual torque wrench.
MDIB9043E
7. Insert the drive shaft to the steering knuckle, and tighten the lock
nut.
8. Install bolts securing steering knuckle to the strut. For tightening torque, refer to FSU-5, «FRONT SUSPENSION ASSEMBLY» .
9. Fix the brake hose onto the strut with the lock plate.
10. Install tie-rod to steering knuckle. For tightening torque, refer to FSU-5, «FRONT SUSPENSION ASSEMBLY» .
11. Install ABS wheel sensor. Refer to BRC-36, «WHEEL SENSORS» .
12. Using a hub lock nut wrench (SST), tighten lock nut to the specified torque.
Tightening torque

: 280 N·m (29 kg·m, 207 ft-lb)

J

K

L

M

13. Mount tyre and lower lift.

MDIA0044E

FAX-15

I

FRONT DRIVE SHAFT
Disassembly and Assembly

BDS00070

INSPECTION BEFORE DISASSEMBLY
●

●

Move joint in up/down, left/right, and axial directions. Check for motion that is not smooth and for significant looseness.
Check the boot for cracks, damage, and leakage of grease.

DISASSEMBLY (CR AND HR16 ENGINE MODELS)

MDIA0047E

1.

Boot

2.

Circlip

3.

Joint subassembly (fixed joint)

4.

Boot band

5.

Dynamic damper (right side only)

6.

Band

7.

Shaft

8.

Boot band

9.

Spider assembly

10. Boot

11. Snap rings

12. Housing (slide joint)

13. Circlip

Transaxle Side
1.
2.

3.

4.

5.

Remove the boot bands.
Fix shaft in a vice. Remove housing.
CAUTION:
When securing in a vice, use aluminum plates, copper plates or something similar to protect the
shaft. Do not clamp onto the damper.
Put mating marks onto the shaft and spider assembly.
CAUTION:
Use paint or similar substance for alignment marks. Do not
scratch the surface.
Remove the snap ring, and remove the spider assembly from
the shaft. Use a bar to apply the load directly to the body of the
spider assembly. Do not apply load to the rollers.
Remove boot from shaft.
MDIA0048E

Wheel Side
1.

2.

Using a vice, secure the shaft.
CAUTION:
When securing in a vice, use aluminum plates, copper plates or something similar to protect the
shaft. Do not clamp onto the damper.
Remove boot bands and remove boot from the joint subassembly.

FAX-16

FRONT DRIVE SHAFT
3.

4.
5.
6.

Screw the drive shaft puller (commercial service tool) 30 mm
(1.18 in) or more over the thread on joint subassembly, and pull
the joint subassembly out of the shaft.
CAUTION:
● Align sliding hammer and drive shaft and remove them
by pulling firmly and uniformly.
● If joint subassembly cannot be removed after five or
more unsuccessful attempts, replace entire drive shaft
assembly.
Remove boot from shaft.
Remove circlip from the shaft.

A

B

C
MDIA0049E

FAX

While rotating ball cage, remove old grease on joint subassembly with paper towels.
CAUTION:
Visually check joint subassembly for compression scar,
cracks, fractures. Also check the grease for contamination
by road debris and metal fragments. If any non-standard
condition is detected, replace entire joint subassembly.

E

F

G
MDIA0040E

H

Dynamic Damper
●

Make the damper’s position by applying paint to the barshaft. Remove band. Then, remove dynamic
damper from shaft.
I

J

K

L

M

FAX-17

FRONT DRIVE SHAFT
DISASSEMBLY (K9K ENGINE MODELS)

MDIB9044E

1.

Joint assembly

2.

Boot

3.

Boot band

4.

Circular clip

5.

Drive shaft

6.

Dynamic damper band

7.

Dynamic damper

8.

Boot

9.

Boot band

10. Spider assembly

11. Snap ring

12. Slide joint housing

13. Circular clip

14. Slide joint housing with extension shaft

15. Dust shield

16. Support bearing

17. Support bearing retainer

18. Bracket

19. Snap ring

20. Dust shield

21. Dust shield

22. O-ring

Transaxle Side
1.
2.
3.
4.

Remove the boot bands.
Put matching marks on slide joint housing and drive shaft before
separating joint assembly.
Put matching marks on spider assembly and drive shaft.
Remove slide joint housing.

SFA963

FAX-18

FRONT DRIVE SHAFT
5.

6.

Pry off snap ring, then remove spider assembly.
CAUTION:
Do not disassemble spider assembly.
Draw out boot.
CAUTION:
Cover drive shaft serration with tape to prevent damage to
the boot.

A

B

C
SFA612

FAX

Wheel Side
CAUTION:
The joint on the wheel side cannot be disassembled.
1. Before separating joint assembly, put matching marks on drive
shaft and joint assembly.
2. Separate joint assembly with a suitable tool.
CAUTION:
Be careful not to damage threads on drive shaft.
3. Remove boot bands.
4. Draw out boot.

E

F

G

H
SFA092A

Dynamic Damper
I

Remove bands. Then, remove dynamic damper from drive shaft.

Support Bearing
1.

Remove dust shield.

J

K

L

YAX002

2.

Remove dust shield. Then, remove snap ring.

YAX003

FAX-19

M

FRONT DRIVE SHAFT
3.
4.

Press support bearing assembly off of drive shaft.
Remove dust shield.

YAX004

INSPECTION AFTER DISASSEMBLY (CR AND HR16 ENGINE MODELS)
Shaft
●

If the shaft has runout, cracks, or damage, replace the shaft.

Joint Subassembly (Fixed Joint)
●
●

Check the joint for rough rotation and abnormal axial looseness.
Check if there is any compression scar, cracks, or fractures.
CAUTION:
If there are any non-standard conditions of joint assembly component parts, replace the joint
assembly. Also check the grease for contamination by road debris and metal fragments.

Joint Assembly (Sliding Joint)
●

●
●

If there is scratching or wear of housing roller contact surface or spider roller contact surface, replace joint
assembly.
If there is circumferential looseness or rough rotation of spider roller, replace joint assembly.
If there are any non-standard conditions of joint assembly component parts, replace the joint assembly.

Housing (Slide Joint)
●
●
●

Check the ball rolling surface for damage and abnormal wear.
Check the shaft thread for damage.
Check the boot mount for deformation.

Dynamic Damper
●

Check for cracks, wear, and damage. Replace if necessary.

INSPECTION AFTER DISASSEMBLY (K9K ENGINE MODELS)
Thoroughly clean all parts in cleaning solvent, and dry with compressed air. Check parts for evidence
of deformation or other damage.

Drive Shaft
Replace drive shaft if it is twisted or cracked.

Boot
Check boot for fatigue, cracks or wear. Replace boot with new boot bands.

Joint Assembly (Transaxle side)
●
●
●
●

Check spider assembly for needle bearing and washer damage. Replace if necessary.
Check roller surfaces for scratches, wear or other damage. Replace if necessary.
Check serration for deformation. Replace if necessary.
Check slide joint housing for any damage. Replace if necessary.

Joint Assembly (Wheel side)
Replace joint assembly if it is deformed or damaged.

Support Bearing
Make sure wheel bearing rolls freely and is free from noise, cracks, pitting or wear.

FAX-20

FRONT DRIVE SHAFT
Support Bearing Bracket
A

Check support bearing bracket for cracks with a magnetic exploration or dyeing test.

Dynamic Damper
Check dynamic damper for cracks, wear, and damage. Replace if necessary.

B

ASSEMBLY (CR AND HR16 ENGINE MODELS)
Wheel Side
For mounting, perform steps 13 to 22 of On-Vehicle Inspection and Service, FAX-10, «On-Vehicle Inspection
and Service» .

Dynamic Damper (Right Drive Shaft)
●

FAX

When dynamic damper has been removed, secure with bands
as shown in figure so that measurements from fixed-joint side
are as listed below.
CAUTION:
Do not reuse dynamic damper bands.
Dimension A
Dimension B

C

E

: RH (1) – 434 — 440 mm (17.09 — 17.32 in)
LH (2) – 235 — 241 mm (9.25 — 9.49 in)
: 70 mm (2.76 in)

F

G
MDIB9063E

H

I

J
MDIB9064E

K

Transaxle Side
1.

Cover drive shaft serration with tape so as not to damage boot
during installation. Install new boot and boot bands to the shaft.
CAUTION:
Do not reuse the boot bands and boot.

L

M

MDIA0051E

2.

Remove the tape wrapped around the serration on the shaft.

FAX-21

FRONT DRIVE SHAFT
3.

4.

5.

Align mating marks painted when spider assembly was
removed. Install spider assembly with serrated mounting surface
facing drive shaft.
Secure the spider assembly with a snap ring.
CAUTION:
Do not reuse the snap ring.
Apply all of the Genuine Nissan Grease into the joint housing.
Grease quantity:

95 — 105 g

6.

Assemble the sliding joint housing onto spider assembly.

7.

Install boot securely into grooves (indicated by * marks) shown
in figure.
CAUTION:
If grease adheres to the boot mounting surface (with *
mark) on the joint, the boot may come off. Remove all
grease from the surface.

MDIA0052E

MDIB9023E

8.

Secure big end of boot with new boot band as shown in the figure. Plunge the joint fully to envelope the spider assembly with
grease. Pull the joint back to the indicated length. Insert a
screwdriver or similar tool into the small-diameter side of the
boot. Bleed air out of the inside boot (to adjust pressure outside
and inside of boot) to prevent deformation of boot.
Boot mounting length

: GI1700i: 89.4 mm (3.52 in)
GI2000i: 90.45 mm (3.56 in)

CAUTION:
If boot mounting length is outside the standard, it may
cause breakage in the boot.
● Be careful not to damage the inside of the boot with the tip of the screwdriver.
Secure the small end of boot with new boot band as shown in
figure.
CAUTION:
Rotate housing and check if boot installation position does
not change. If position changes, reinstall boot bands.
●

9.

MDIA0043E

MDIA0054E

FAX-22

FRONT DRIVE SHAFT
ASSEMBLY (K9K ENGINE MODELS)
●

●

After drive shaft has been assembled, ensure that it moves smoothly over its entire range without
binding.
Use NISSAN GENUINE GREASE or equivalent after every overhaul.

B

Wheel Side
1.

A

Install boot and new small boot band on drive shaft.
CAUTION:
Cover drive shaft serration with tape so as not to damage
boot during installation.

C

FAX

E
SFA800

2.

F

Set joint assembly onto drive shaft by lightly tapping it. Install
joint assembly securely, ensuring marks which were made during disassembly are properly aligned.

G

H

I
SFA942A

3.

Pack drive shaft with specified amount of grease.

J

Specified amount of grease : 40 — 50 g (1.41 — 1.76 oz)
4.

Make sure that boot is properly installed on the drive shaft
groove.
Set boot so that it does not swell and deform when its length is
“L1 ”.
Length “L1 ”

K

L

: AC2000i: 91.0 mm (3.58 in)
AC2300i: 94.0 mm (3.70 in)
SFA592B

5.

Secure the big and small ends of the boot with new boot bands.

SDIA0876J

FAX-23

M

FRONT DRIVE SHAFT
6.

Rotate joint part and confirm that mounting position of boot does
not deviate. When it deviates, mount a new boot band again.
CAUTION:
When fixing boot band, fix so that the M gap on the drawing
becomes as follows.
M gap
Large diameter side: 5 mm (0.20 in)
Small diameter side: 5 mm (0.20 in)
YAX006

Dynamic Damper
1.
2.

Use new damper bands when installing.
Install dynamic damper from stationary-joint side while holding it
securely.
Dimension A
Dimension B

: 50kW: 207 — 213 mm (8.15 — 8.39 in)
63kW: 235 — 241 mm (9.25 — 9.49 in)
: 70 mm (2.76 in)

MDIA0077E

Transaxle Side
1.

2.
3.
4.

Install boot and new small boot band on drive shaft.
CAUTION:
Cover drive shaft serration with tape so as not to damage
boot during installation.
Install spider assembly as a unit, making sure the marks which
were made during disassembly are properly aligned.
Install new snap ring.
Pack drive shaft with specified amount of grease.
Specified amount of grease : 113 — 123 g (3.98 — 4.34 oz)
MDIA0051E

5.
6.

Install slide joint housing.
Make sure that boot is properly installed on the drive shaft.
Set boot so that it does not swell and deform when its length is
“L2 ”.
Length “L2 ”

: GI2000i: 90.45 mm (3.56 in)
GI2300i: 91.5 mm (3.60 in)

MDIA0078E

FAX-24

FRONT DRIVE SHAFT
7.

Lock new larger boot band securely with a suitable tool.
A

B

C
SFA395

FAX

8.

Secure the smaller end of the boot with new boot band.
E

F

G
SDIA0876J

9.

Rotate joint part of smaller end boot band and confirm that
mounting position of boot does not deviate. When it deviates,
mount a new boot band again.
CAUTION:
When fixing boot band, fix so that the M gap on the drawing
becomes as follows.

H

I

M gap
Small diameter side: 5 mm (0.20 in)

J

YAX006

K

Support Bearing
●
●

Install new dust shield on drive shaft.
Press drive shaft into bearing.

L

M

YAX007

FAX-25

FRONT DRIVE SHAFT
●
●

Install new snap ring.
Install new dust shields.

YAX008

FAX-26

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Wheel Bearing

PFP:00030

A
BDS00071

Drive type

2WD

Axial end play

B

0.05 mm (0.0020 in)

Rotating torque

0.30 — 1.43 N·m (0.03 — 0.14 kg-m)

Spring balance measurement

6.0 — 28.6 N (0.61 — 2.92 kg)

C

FAX

Spring balance mounting position (Strut mounting hole upper
side)

E

SDIA0833J

Drive shaft

BDS00072

Engine
Joint type

Amount of grease g (oz)

Boot length mm (in)

CR

HR16

K9K 50 kW

K9K 63 kW

Wheel side

AC1700i

AC2000i

AC2000i

AC2300i

Transaxle side

GI1700i

GI2000i

GI2000i

GI2300i

Wheel side

45 — 55
(1.59 — 1.94)

45 — 55
(1.59 — 1.94)

40 — 50
(1.41 — 1.76)

40 — 50
(1.41 — 1.76)

Transaxle side

95 — 105
(3.35 — 3.70)

95 — 105
(3.35 — 3.70)

113 — 123
(3.99 — 4.34)

113 — 123
(3.99 — 4.34)

88 (3.46)

91 (3.58)

91 (3.58)

94 (3.70)

89.4 (3.52)

90.45 (3.56)

90.45 (3.56)

91.5 (3.60)

Wheel side
Transaxle side

Dynamic Damper
Engine

F

G

H

I

BDS00073

Type

Drive type

Specification

Dimension A mm (in)

Dimension B mm (in)

Illustration

CR/HR16

AC1700i/ GI1700i
AC2000i/ GI2000i

2WD

RH

434 — 440 (17.09 — 17.32)

70 (2.76)

(1)

CR/HR16

AC1700i/ GI1700i
AC2000i/ GI2000i

2WD

LH

235 — 241 (9.25 — 9.49)

70 (2.76)

(2)

K9K 50kW

AC2000i/ GI2000i

2WD

RH, LH

207 — 213 (8.15 — 8.39)

70 (2.76)

(1)

K9K 63kW

AC2300i/ GI2300i

2WD

RH, LH

235 — 241 (9.25 — 9.49)

70 (2.76)

(1)

J

K

L

M

MDIB9063E

MDIB9064E

Tightening Torque

BDS00074

Unit: N·m (kg-m, ft-lb)
Hub lock nut

280 N·m (29 kg-m, 207 ft-lb)

FAX-27

SERVICE DATA AND SPECIFICATIONS (SDS)

FAX-28

FRONT SUSPENSION

E SUSPENSION

SECTION

FSU

FRONT SUSPENSION

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 2
PrecautionsforProcedureswithoutCowlTopCover….. 2
Precautions for Brake System ……………………………. 2
Cautions …………………………………………………………. 2
PREPARATION ………………………………………………….. 3
Special Service Tools ……………………………………….. 3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ………………………………………… 4
NVH Troubleshooting Chart ………………………………. 4
FRONT SUSPENSION ASSEMBLY ……………………… 5
Components ……………………………………………………. 5
On-Vehicle Inspection and Service …………………….. 6
LOOSENESS, BACKLASH, AND DAMAGE OF
MOUNTING PARTS AND CONNECTIONS ………. 6
Wheel Alignment ……………………………………………… 6
DESCRIPTION ……………………………………………… 6
PRELIMINARY INSPECTION …………………………. 6
INSPECTION OF CAMBER, CASTER, AND
KINGPIN INCLINATION ANGLES …………………… 6
STEERING ANGLE INSPECTION …………………… 7
COIL SPRING AND SHOCK ABSORBER …………….. 8
Removal and Installation …………………………………… 8
REMOVAL ……………………………………………………. 8

INSTALLATION …………………………………………….. 8
Disassembly and Assembly ……………………………….. 8
DISASSEMBLY …………………………………………….. 8
INSPECTION AFTER DISASSEMBLY ……………… 9
ASSEMBLY ………………………………………………….. 9
TRANSVERSE LINK …………………………………………. 10
Removal and Installation …………………………………. 10
REMOVAL ………………………………………………….. 10
INSPECTION AFTER REMOVAL ………………….. 10
INSTALLATION …………………………………………… 10
STABILIZER BAR …………………………………………….. 11
Removal and Installation …………………………………. 11
REMOVAL ………………………………………………….. 11
INSPECTION AFTER REMOVAL ………………….. 12
INSTALLATION …………………………………………… 12
FRONT SUSPENSION MEMBER ……………………….. 13
Removal and Installation …………………………………. 13
REMOVAL ………………………………………………….. 13
INSPECTION AFTER REMOVAL ………………….. 13
INSTALLATION …………………………………………… 14
SERVICE DATA AND SPECIFICATIONS (SDS) …… 15
Wheel Alignment ……………………………………………. 15
Ball Joint ……………………………………………………….. 15
Tightening Torque …………………………………………… 15

FSU-1

FSU

F

G

H

I

J

K

L

M

PRECAUTIONS
PRECAUTIONS
Precautions for Procedures without Cowl Top Cover

PFP:00001
BES0002E

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

PIIB3706J

Precautions for Brake System
●

●
●

●

●

BES0002F

Recommended fluid is brake fluid “Nissan Genuine Brake Fluid
or DOT 3 or DOT4 (US FMVSS No.116)”.
Never reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted areas,
wash it away with water immediately.
Use flare nut wrench when removing flare nuts, and use a flare
nut torque wrench when tighten flare nuts.
Always tighten brake lines to the specified torque when installing.

Cautions
●

●

●
●

SBR820BA

BES0002G

When installing rubber bushings, final tightening must be carried out under unladen conditions with tyres
on flat, level ground. Oil will shorten the life of rubber bushings. Be sure to wipe off any spilled oil.
“Unladen condition” means that fuel, coolant and lubricant are full and ready for drive. However, spare
tyre, jack, and hand tools should be unloaded.
After installing the removed suspension parts, always check wheel alignment and adjust if necessary.
Replace the caulking nut with a new one. Install a new nut without wiping the oil off before tightening.

FSU-2

PREPARATION
PREPARATION
Special Service Tools

PFP:00002

A
BES0002H

Description

Application

B

CCK gauge attachment
KV991040S1
1 KV99104020 Adapter A
2 KV99104030 Adapter B
3 KV99104040 Adapter C
4 KV99104050 Adapter D
5 KV99104060 Plate
6 KV99104070 Guide bolt
7 KV99104080 Spring
8 KV99104090 Center plate

C
Measuring wheel alignment

D
ZZA1167D

FSU
Strut attachment
ST35652000

Disassembling and assembling strut

F

ZZA0807D

G

GG94310000
Flare nut torque wrench
a: 10 mm (0.39 in)

H
Removing and installing brake lines

NT406

I

J

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M

FSU-3

Symptom

×

×

Judder

×

×

×

Poor quality ride or handling

×

×

×

×: Applicable

FSU-4

×

NVH in PS section.

×
STEERING

×

NVH in BR section.

Shimmy
BRAKES

×

NVH in FAX section.

×
DRIVE SHAFT

×

NVH in WT section.

×
ROAD WEEL

Vibration
NVH in WT section.

×
TYRES

×

NVH in RAX and RSU section.

×
REAR AXLE AND REAR SUSPENSION

×

Refer to FSU-11, «STABILIZER BAR»

Shake
Stabilizer bar fatigue

×

Refer to FSU-6, «Wheel Alignment»

×
Incorrect wheel alignment

—

×

Refer to FSU-5, «FRONT SUSPENSION ASSEMBLY»

—

Parts interference

×
Suspension looseness

—

Bushing or mounting deterioration

Noise
Spring fatigue

Refer to FSU-8, «COIL SPRING AND SHOCK ABSORBER»

FRONT SUSPENSION
Shock absorber deformation, damage or deflection

Possible cause and SUSPECTED PARTS
Refer to FSU-5, «FRONT SUSPENSION ASSEMBLY»

Reference page

Improper installation, looseness

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

×

×

×

×

×

PFP:00003
BES0002I

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

×
×
×
×
×
×
×
×

×
×
×
×
×
×
×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

FRONT SUSPENSION ASSEMBLY
FRONT SUSPENSION ASSEMBLY
Components

PFP:54010

A
BES0002J

B

C

D

FSU

F

G

H

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J

K

L

M

MEIB9026E

FSU-5

FRONT SUSPENSION ASSEMBLY
1.

Strut mounting insulator

2.

Strut mounting bearing

3.

Coil spring

4.

Bound bumper

5.

Strut

6.

Knuckle

7.

Clamp

8.

Bushing

9.

Connecting rod

10. Transverse link

11. Stabilizer

12. Rear upper link (A/T models only)

13. Upper link

14. Suspension member

15. Suspension member stay

On-Vehicle Inspection and Service

BES0002K

LOOSENESS, BACKLASH, AND DAMAGE OF MOUNTING PARTS AND CONNECTIONS
Lift the vehicle, and inspect as follows:
●
Check mounting point of each component for looseness, backlash, and damage.
●
Check end play of the lower ball joint.
1. Attach a dial gauge so that the contact rests on the brake caliper.
2. Set front wheels in a straight-ahead position. Do not depress brake pedal.
3. Measure axial end play by placing an iron pry bar or something similar between transverse link and steering knuckle.
Standard
Axial end play

4.

: 0 mm (0 in)

CAUTION:
Be careful not to damage ball joint boot.
If axial end play is outside the standard, remove transverse link and check lower ball joint.

Wheel Alignment

BES0002L

DESCRIPTION
●

Measure wheel alignment under unladen conditions. “Unladen conditions” means that fuel, coolant, and
lubricant are full. However, spare tyre, jack, and hand tools should be unloaded.

PRELIMINARY INSPECTION
1.
2.
3.
4.
5.
6.
7.
8.

Check the tyres for improper air pressure and wear.
Check road wheels for runout.
Check wheel bearing axial end play.
Check lower ball joint axial end play.
Check strut operation.
Check each mounting point of axle and suspension for looseness and deformation.
Check each link and arm for cracks, deformation, and other damage.
Check the vehicle posture.

INSPECTION OF CAMBER, CASTER, AND KINGPIN INCLINATION ANGLES
●
●

1.

2.

Camber, caster, and kingpin inclination angles cannot be adjusted.
Before inspection, mount front wheels onto turning radius gauge. Mount rear wheels onto a stand that has
same height so the vehicle will remain horizontal.
Measure camber, caster and kingpin inclination of both right and
left wheels with a suitable alignment gauge.
Camber:
Caster:

-0°48′ — 0°42′ (-0.80° — 0.70°)
3°45′ — 5°15′ (3.75° — 5.25°)

Kingpin offset:

9°00′ — 10°30′ (9.00° — 10.50°)

If camber, caster or kingpin inclination is not within specification,
inspect front suspension parts. Replace dam-aged or worn out
parts.

FSU-6

SRA096A

FRONT SUSPENSION ASSEMBLY
Toe-in
A

Measure toe-in using the following procedure.
WARNING:
●
Always perform the following procedure on a flat surface.
●
Make sure that no person is in front of the vehicle before
pushing it.
1. Bounce front of vehicle up and down to stabilize the posture.
2. Push the vehicle straight ahead about 5 m (16 ft).
3. Put a mark on base line of tread (rear side) of both tyres at the
same height as hub center. These are measuring points.

B

C

AFA050

4.
5.

Measure distance “A” (rear side).
Push the vehicle slowly ahead to rotate the wheels 180degrees
(1/2 turn).
If the wheels have rotated more than 180 degrees (1/2 turn), try the
above procedure again from the beginning. Never push vehicle
backward.
6. Measure distance “B” (front side).

FSU

F

G

Total toe-in: In 2 — 0 mm (0.08 — 0 in)
SFA234AC

STEERING ANGLE INSPECTION
1.
2.

D

Set wheels in straight-ahead position. Move vehicle to set front wheels on turning radius gauge.
Turn steering wheel fully to right and left, and measure steering angle. Refer to PS-13, «SERVICE DATA
AND SPECIFICATIONS (SDS)» .

H

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FSU-7

COIL SPRING AND SHOCK ABSORBER
COIL SPRING AND SHOCK ABSORBER
Removal and Installation

PFP:54302
BES0002M

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

Raise vehicle and remove tyre.
Remove cowl top cover. Refer to EI-12, «COWL TOP» .
Remove electrical wires of ABS wheel sensor from strut. Refer to BRC-36, «WHEEL SENSORS» .
Remove brake hose lock plate. Refer to BR-11, «BRAKE PIPING AND HOSE» .
Remove stabilizer connecting rod.
Remove nuts and bolts securing steering knuckle to strut.
Remove upper bolts of the strut and remove strut from the vehicle.

MEIA0013E

INSTALLATION
●

●

Refer to FSU-5, «FRONT SUSPENSION ASSEMBLY» for tightening torque. Tighten in the reverse order
of removal.
Make sure the identification letters on strut mounting insulator
face toward vehicle front. Then install strut.

MEIA0014E

Disassembly and Assembly

BES0002N

DISASSEMBLY
1.

2.

3.

4.
5.

Install strut attachment (SST) to strut and fix it in a vise.
CAUTION:
When installing strut attachment (SST), wrap a shop cloth
around strut to protect it from damage.
Slightly loosen piston rod lock nut.
CAUTION:
Do not remove piston rod lock nut completely. If it is
removed completely, coil spring jumps out and may cause
serious damage or injury.
Compress coil spring using a spring compressor (commercial
MEIA0015E
service tool).
CAUTION:
Start compressing the coil spring after making sure that the spring compressor is completely
attached to the coil spring.
After making sure coil spring is free between strut mounting bearing and lower seats at the end of Step 3,
remove piston rod lock nut.
Remove small parts on strut.
● Remove strut mounting insulator and strut mounting bearing. Remove coil spring from strut.

FSU-8

COIL SPRING AND SHOCK ABSORBER
6.
7.

Remove bound bumper.
Gradually release spring compressor (commercial service tool), and remove coil spring.

A

INSPECTION AFTER DISASSEMBLY
Strut Inspection
●
●
●

B

Check the strut for deformation, cracks, and damage, and replace if necessary.
Check piston rod for damage, uneven wear, and distortion, and replace if necessary.
Check connections and packing for oil leakage, and replace if necessary.

C

Insulator and Rubber Parts Inspection
Check strut mounting insulator for cracks and rubber parts for wear. Replace them if necessary.

D

Coil Spring Inspection
Check coil spring for cracks, wear, and damage. Replace if necessary.

FSU

ASSEMBLY
1.

2.
3.

4.
5.
6.

Compress coil spring using a spring compressor (commercial
service tool), and install it onto the strut.
CAUTION:
● Face the small diameter side (there is identification mark
in 1.25 rotations) of coil spring downward. Align lower
end to spring seat as shown in the figure.
● Start compressing the coil spring after making sure that
the spring compressor is completely attached to the coil
spring.
Connect bound bumper to strut piston rod.
Install small parts to the strut.
● Attach strut mounting insulator, strut mounting bearing. Position piston rod lock nut.
CAUTION:
Do not reuse piston rod lock nut.
Be sure the identification letters on strut mounting insulator are
positioned as shown.
Be sure coil spring is properly set in strut mounting bearing.
Gradually release spring compressor (commercial service tool).
Tighten piston rod lock nut to the specified torque.
Tightening torque

F

G

H
MEIA0016E

I

J

K

: 67.5 N·m (6.9 kg-m, 50 ft-lb)

L

MEIA0014E

7.

Remove strut attachment (SST).

MEIA0015E

FSU-9

M

TRANSVERSE LINK
TRANSVERSE LINK
Removal and Installation

PFP:54500
BES0002O

REMOVAL
1.
2.
3.

a.
b.

Raise vehicle and remove tyre.
Remove nuts and bolts of transverse link ball joint, and remove transverse link from steering knuckle.
Remove transverse link nuts and bolts, and remove transverse
link from suspension member.
NOTE:
When removing LH transverse link (A/T models), lower the suspension member in order to remove bolts to avoid contacting
and releasing the mounting bolts on vehicle front. Remove suspension member. Refer to FSU-13, «FRONT SUSPENSION
MEMBER» .
Set jack under suspension member.
Loosen RH upper link mounting bolt, LH upper link mounting
MEIA0017E
bolt (suspension member side), suspension member mounting
bolts (left/right). Lower the suspension member in order to
remove transverse link mounting bolts.

INSPECTION AFTER REMOVAL
Visual Inspection
Check transverse link and bushing for deformation, cracks, and other damage, and replace entire transverse
link assembly if necessary.

Ball Joint Inspection
●

Manually move ball stud to confirm it moves smoothly with no binding.

Oscillating Torque Inspection
CAUTION:
Before measuring, move the ball joint at least ten times by hand to check for smooth movement.
●
Hook the spring scale at the cutout on ball stud, and make sure
the spring scale measurement value is within the standard when
ball stud begins moving.
Tensile force
Spring balance
measurement
●

: 0.5 — 4.9 N·m (0.05 — 0.5 kg-m, 5 — 43
in-lb)
: 15.4 — 150.8 N (1.6 — 15.4 kg, 3.5 33.9 lb)

If value is outside the standard, replace transverse link.
MEIA0018E

Axial End Play Inspection
●

Move the tip of the ball joint in the axial direction to check for looseness.
Axial end play

●

: 0 mm (0 in)

If any looseness is noted, replace transverse link assembly as a single unit.

INSTALLATION
●

●
●

Refer to FSU-5, «FRONT SUSPENSION ASSEMBLY» for tightening torque. Tighten in the reverse order
of removal.
Fully tighten transverse link mounting nuts and bolts under unladen condition with tyres on level ground.
After installation, check wheel alignment. Refer to FSU-6, «Wheel Alignment» .

FSU-10

STABILIZER BAR
STABILIZER BAR
Removal and Installation

PFP:54611

A
BES0002P

REMOVAL
1.
2.
3.

4.

Raise vehicle and remove tyre.
Remove the attachment nut on the stabilizer connecting rod and remove the stabilizer connecting rod.
Remove tie-rod from steering knuckle. If it is difficult to remove tie-rod, remove it with a ball joint remover
(commercial service tool).
CAUTION:
To prevent damage to threads and to prevent ball joint remover (commercial service tool) from
coming off, temporarily tighten lock nuts.
Remove exhaust tube mount (models with CR engine). Refer to
EX-3, «Removal and Installation» .

B

C

D

FSU

F

G
MEIA0019E

5.

6.
7.
8.

Remove transaxle rear torque rod (1) (A/T models) or (2) (M/T
models). Refer to MT-7, «REMOVAL AND INSTALLATION»
(with JH3 transaxle) or MT-37, «REMOVAL AND INSTALLATION» (with JR5 transaxle) for M/T models, AT-356, «Removal
and Installation» for A/T models.
Remove rear side bolt of suspension member stay.
Set jack under suspension member.
Remove bolts of suspension member and suspension member
stay.

H

I

J

K

L

M

MEIB9028E

9.

Lower suspension member in order to remove stabilizer mounting bolts. Refer to FSU-13, «FRONT SUSPENSION MEMBER» .
CAUTION:
Be careful not to lower it too far. (Do not overload the links.)

SEIA0161J

FSU-11

STABILIZER BAR
10. Remove stabilizer bolt and remove clamp and bushing.
11. Remove stabilizer from the vehicle.

MEIA0023E

MEIA0021E

INSPECTION AFTER REMOVAL
Check stabilizer, connecting rod, bushing and clamp for deformation, cracks and damage. Replace if necessary.

INSTALLATION
●

Refer to FSU-5, «FRONT SUSPENSION ASSEMBLY» for tightening torque. Tighten in the reverse order
of removal.
CAUTION:
When installing suspension member stay, tighten bolts in
numerical order as shown in the figure.

MEIB9029E

●

Because the stabilizer uses the pillow ball type connecting rod,
position the ball joint with the case on the pillow ball head parallel to the stabilizer.

MEIA0022E

FSU-12

FRONT SUSPENSION MEMBER
FRONT SUSPENSION MEMBER
Removal and Installation

PFP:54401

A
BES0002Q

REMOVAL
1.
2.
3.
4.

Raise vehicle and remove tyre.
Remove stabilizer connecting rod.
Remove nuts and bolts of transverse link ball joint, and remove transverse link from steering knuckle.
Remove steering gear mounting nuts and bolts. Separate steering gear from suspension member.

B

C

D

FSU

SEIA0168J

5.

Remove transaxle rear torque rod (1) (A/T models) or (2) (M/T
models). Refer to MT-7, «REMOVAL AND INSTALLATION»
(with JH3 transaxle) or MT-37, «REMOVAL AND INSTALLATION» (with JR5 transaxle) for M/T models, AT-356, «Removal
and Installation» for A/T models.

F

G

H

I

J

K

L

M
MEIB9028E

6.
7.
8.

9.

Remove exhaust tube mount (models with CR engine). Refer to
EX-3, «Removal and Installation» .
Remove body side bolt of upper link.
Set a jack under suspension member, and remove suspension
member mounting bolts. Remove upper link, transverse link and
stabilizer as a set.
Remove upper link, transverse link and stabilizer from the suspension member.
MEIA0019E

INSPECTION AFTER REMOVAL
Check suspension member for deformed parts, cracks, or any other damage. Replace if necessary.

FSU-13

FRONT SUSPENSION MEMBER
INSTALLATION
●

●

Refer to FSU-5, «FRONT SUSPENSION ASSEMBLY» for tightening torque. Tighten in the reverse order
of removal.
After finishing work, perform final tightening of each part under unladen condition with tyres on level
ground. Check wheel alignment. Refer to FSU-6, «Wheel Alignment» .

FSU-14

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Wheel Alignment

PFP:00030

A
BES0002R

Drive type

2WD

Camber

B

-0°48’ — 0°42’ (-0.80° — 0.70°)

Caster

3°45’ — 5°15’ (3.75° — 5.25°)

Kingpin offset

9°00’ — 10°30’ (9.00° — 10.50°)

Toe-in

C

In 2 — 0 mm (0.08 — 0 in)

Ball Joint

BES0002S

Axial end play

0mm (0 in)

Sliding torque

0.5 — 4.9 N·m (0.05 — 0.5 kg-m, 5 — 43 in-lb)

Spring scale measurement (ball stud cutout)

15.4 — 150.8 N (1.6 — 15.4 kg, 3.5 — 33.9 lb)

Tightening Torque

FSU
BES0002T

Unit: N·m (kg-m, ft-lb)
Front
Transverse link to suspension member

M/T

98.5 (10, 73)

A/T

137.5 (14, 101)

Rear
Steering knuckle to Transverse link

137.5 (14, 101)

F

G

37.1 (3.8, 27)

Stabilizer connecting rod to Strut

44 (4.5, 32)

Strut mounting insulator to Body

17.2 (1.8, 13)

Strut piston rod lock nut

67.5 (6.9, 50)

Strut to Steering knuckle

116 (12, 86)

Upper link to Body
Upper link to Suspension member

D

H

I

64.5 (6.6, 48)
M/T

98.5 (10, 73)

A/T

137.5 (14, 101)

Rear Upper link to Suspension member
(A/T models)

75.5 (7.7, 56)

Suspension member to Body

117.5 (12, 87)

J

K

Suspension member stay to Body (rear)

65 (6.6, 48)

Suspension member to Stabilizer clamp

31.5 (3.2, 23)

L

M

FSU-15

SERVICE DATA AND SPECIFICATIONS (SDS)

FSU-16

FUEL SYSTEM

B ENGINE

SECTION

FL

FUEL SYSTEM

A

FL

C

D

E

CONTENTS
CR
PREPARATION ………………………………………………….. 2
Special Service Tools ……………………………………….. 2
FUEL SYSTEM ………………………………………………….. 3
Checking Fuel Lines …………………………………………. 3
General Precautions ………………………………………… 3
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND
FUEL PUMP ASSEMBLY ……………………………………. 4
Removal and Installation …………………………………… 4
REMOVAL ……………………………………………………. 4
INSTALLATION …………………………………………….. 6
INSPECTION AFTER INSTALLATION …………….. 7
FUEL TANK ………………………………………………………. 8
Removal and Installation …………………………………… 8
REMOVAL ……………………………………………………. 8
INSTALLATION …………………………………………… 10
INSPECTION AFTER INSTALLATION …………….11
SERVICE DATA AND SPECIFICATIONS (SDS) …… 12
Standard and Limit …………………………………………. 12
Tightening Torque …………………………………………… 12

HR
PREPARATION ………………………………………………… 13
Special Service Tools ……………………………………… 13
FUEL SYSTEM ………………………………………………… 14
Checking Fuel Lines ……………………………………….. 14
General Precautions ………………………………………. 14
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND
FUEL PUMP ASSEMBLY ………………………………….. 15
Removal and Installation …………………………………. 15
REMOVAL ………………………………………………….. 15
INSTALLATION …………………………………………… 17
INSPECTION AFTER INSTALLATION …………… 18

FUEL TANK …………………………………………………….. 19
Removal and Installation …………………………………. 19
REMOVAL ………………………………………………….. 19
INSTALLATION …………………………………………… 21
INSPECTION AFTER INSTALLATION ……………. 22
SERVICE DATA AND SPECIFICATIONS (SDS) …… 23
Standard and Limit ………………………………………….. 23
Tightening Torque …………………………………………… 23

K9K
PREPARATION ………………………………………………… 24
Special Service Tool ……………………………………….. 24
FUEL SYSTEM ………………………………………………… 25
Checking Fuel Lines ……………………………………….. 25
FUEL FILTER …………………………………………………… 26
Removal and Installation …………………………………. 26
Water Draining from Fuel Filter ………………………… 26
DRAINING WATER (RHD) ……………………………. 26
DRAINING WATER (LHD) …………………………….. 27
FUEL FILTER CHECK ………………………………….. 27
Changing Fuel Filter ……………………………………….. 27
REMOVAL (RHD) ………………………………………… 27
REMOVAL (LHD) …………………………………………. 27
INSTALLATION …………………………………………… 27
Bleeding Fuel Filter …………………………………………. 28
FUEL LEVEL SENSOR UNIT …………………………….. 29
Removal and Installation …………………………………. 29
REMOVAL ………………………………………………….. 29
INSTALLATION …………………………………………… 30
FUEL TANK …………………………………………………….. 31
Removal and Installation …………………………………. 31
REMOVAL ………………………………………………….. 31
INSTALLATION …………………………………………… 32
INSPECTION AFTER INSTALLATION ……………. 33
SERVICE DATA AND SPECIFICATIONS (SDS) …… 34
Standard and Limit ………………………………………….. 34
Tightening Torque …………………………………………… 34

FL-1

F

G

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M

PREPARATION
[CR]

PREPARATION
Special Service Tools
[CR]

PFP:00002
BBS003YH

Tool number
(RENAULT tool number)
Tool name

Description

KV993G0010
(Mot. 1397)
Lock ring wrench

Removing and Installing lock ring

PBIC1627E

FL-2

FUEL SYSTEM
[CR]

FUEL SYSTEM
Checking Fuel Lines

PFP:17503

A
BBS003YI

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

FL

C

D
SMA803A

E

General Precautions

BBS003YJ

WARNING:
when replacing fuel line parts, be sure to observe the following.
●
Put a “CAUTION: IN FLAMMABLE” sign in workshop.
●
Be sure to work in a well-ventilated area and furnish workshop with a CO2 fire extinguisher.
●
Do not smoke while servicing fuel system, keep open flames and spark away from work area.
CAUTION:
●
Use gasoline required by the regulation for octane number. Refer to GI-5, «Precautions for Fuel»
●
Before removing fuel line parts, carry out the following procedures.
–
Put drained fuel in an explosion-proof container and put the lid on securely, keep the container in
safe area.
–
Release fuel pressure from fuel line. Refer to EC-71, «FUEL PRESSURE RELEASE» (with EUROOBD), refer to EC-488, «FUEL PRESSURE RELEASE» (without EURO-OBD).
–
Disconnect battery negtive cable.
●
Always replace O-ring and clamps with new ones.
●
Do not tighten hose clamps excessively to avoid damaging hoses.
●
Do not kink or twist tubes when they are being installed.
●
Perform work on level place.
●
Do not tighten hose clamps excessively to avoid damaging hoses.
Tighten high-pressure rubber hose clamp so that clamp
end is 3 mm (0.12 in) from hose end.
Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that screw does not contact adjacent parts.
●
After installing tubes, run engine and check for fuel leaks at
connections.
●
For servicing “Evaporative Emission System” parts, refer to
EC-40, «EVAPORATIVE EMISSION SYSTEM» (with EUROOBD), EC-469, «EVAPORATIVE EMISSION SYSTEM» (withMMA104A
out EURO-OBD).

FL-3

F

G

H

I

J

K

L

M

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[CR]

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
Removal and Installation

PFP:17042
BBS003YK

MBIB1354E

1.

Lock ring

2.

Fuel filter and fuel pump assembly

4.

O-ring

5.

Fuel tank

3.

Fuel level sensor unit

REMOVAL
WARNING:
Read “General Precautions” before working on the fuel system.
Refer to FL-3, «General Precautions» .
1. Check fuel level. If gauge indicates more than the level shown in
figure (full or almost full), drain fuel from fuel tank until gauge
indicates the level in figure or below.
When fuel pump malfunctions, insert hose with outer diameter of
25 mm (0.98 in) or less from fuel filler port. Drain fuel in fuel filler
tube. Disconnect connections of fuel filler tube and fuel filler
hose to drain fuel from fuel filler hose.
● As guide, fuel amount becomes the level shown in figure or
below when approximately 7 liter (1-1/2 lmp gal) of fuel are
drained from full.
PBIC1495E
NOTE:
Adjusting fuel level is to prevent fuel from spilling, when fuel
level sensor unit, fuel filter and fuel pump assembly are removed.
2. Release fuel pressure. Refer to EC-71, «Fuel Pressure Check» (with EURO-OBD), EC-488, «Fuel Pressure Check» (without EURO-OBD).
a. Refer to steps 5 to 7. Remove harness connectors from fuel level sensor unit, fuel filter and fuel pump
assembly.
b. Start the engine. After stopping the engine, crank it two or three times to consume the fuel in the fuel line.
3. Open fuel filler lid.
4. Open the filler cap and release the pressure inside the fuel tank.
5. Remove rear seat. Refer to SE-12, «REAR SEAT» .
6. Remove inspection hole cover.
● Using a screwdriver, remove it by turning clips clockwise by 90°.

FL-4

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[CR]
7.

Remove harness connector and fuel feed hose from sender unit.
NOTE:
● Connections of harness connector and fuel feed hose are
called sender unit.

A

FL

C
PBIC1496E

D
●
–

–

●

Remove quick connector in the following procedures.
Pinch quick connector square-parts with your fingers, and pull
out the quick connector by hand.
If quick connector and tube on sender unit are stuck, push
and pull several times until they move, and pull out.
CAUTION:
● The tube can be removed when the tabs are completely
depressed. Do not twist it more than necessary.
● Do not use any tools to remove the quick connector.
● Keep the resin tube away from heat. Be especially
careful when welding near the tube.
● Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube.
● Do not bend or twist the tube during installation and removal.
To keep clean the connecting portion and to avoid damage
and foreign materials, cover them completely with plastic
bags or something similar.
CAUTION:
Do not insert plug, preventing damage on O-ring in quick
connector.

E

F

G
PBIC1497E

H

I

J

K

PBIC0713E

8.

9.

Using lock ring wrench [SST: KV993G0010], remove lock ring.
CAUTION:
Rotate SST while pressing fuel level sensor unit, fuel filter and fuel pump assembly as spring reaction force is applied from fuel tank inside to upward.
Remove fuel level sensor unit, fuel filter and fuel pump assembly.
CAUTION:
● Be careful not to bend the float arm when removing.
● Handle them carefully without subjecting them to impacts
such as dropping.

PBIC1498E

FL-5

L

M

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[CR]
10. Install lock ring temporally by hand tightening until it stops with
maximum force.
● Direct arrow mark on lock ring to vehicle rear. Then turn clockwise to tighten lock ring.
CAUTION:
Do not remove lock ring until fuel level sensor unit, fuel filter and fuel pump assembly is installed.
11. Remove fuel level sensor unit in the following procedures.
a. Remove harness connector (brown).
● Hold connector with your fingers, because there is no tab for
releasing stopper. Pull it out straight downward.
b. Insert a screwdriver into the gap between fuel level sensor unit
left side and mounting part. Pry the screwdriver in the direction
shown by arrow.
CAUTION:
Be careful not to damage anything.
c. When fixing tab comes off, slide fuel level sensor unit in the
direction indicated by arrow to remove.
CAUTION:
● Do not reuse removed fuel level sensor unit.
● Do not disassemble fuel filter and fuel tank pump assembly.

PBIC1573E

PBIC1500E

INSTALLATION
Install in the reverse order of removal which being careful of the following.

Installation of Fuel Level Sensor Unit
Install it in the following procedures.
1. Check fuel gauge mounting part of fuel filter and fuel pump assembly side for damage.
2. Slide fuel level sensor unit along with mounting groove. Insert new fuel level sensor unit until it contacts
the face.
● After inserting, apply force to the reverse direction (removal direction). Make sure fuel level sensor unit
does not come off.
3. Connect harness connector.
● Insert harness connector securely until it contacts the face.

Installation of Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly
Install it in the following procedures.
1. Remove lock ring.
2. Install O-ring to fuel tank without any twist.

PBIC1501E

FL-6

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[CR]
3.

Install fuel level sensor unit, fuel filter and fuel pump assembly,
aligning the sender unit rear side protrusion with the fuel tank
opening rear side cutout.
CAUTION:
● Do not allow O-ring to drop.
● Maintain closely jointed status by pressing fuel level sensor unit, fuel filter and fuel pump assembly at an opening
of the tank until the end of step 5, in order to prevent the
fallout of O-ring (To maintain the O-ring installed status of
view A in the figure at step 2).

A

FL

C
PBIC1502E

D

4.

5.

Direct arrow mark on lock ring to vehicle rear. Then turn lock ring
clockwise by hand until it steps with maximum force.
CAUTION:
Install lock ring horizontally.
Tighten lock ring to the specification with lock ring wrench [SST:
KV993G0010].

E

F

G
PBIC1573E

Fuel Feed Hose Installation
●

1.
2.
3.

H

Connect quick connector in the following procedures.
Check connections for damage or foreign material.
Align the mating side connection part with the center of shaft on
the sender unit, and insert quick connector straight until it clicks.
After connecting, pull out quick connector by hand. Make sure
connections are secure.

I

J

K
PBIC1503E

INSPECTION AFTER INSTALLATION
●

1.
2.

Check for fuel leak in the following procedures.
Turn the ignition switch to ON (do not start engine), and with fuel pressure applied in the fuel line, check to
make sure there are no fuel leaks from the connection.
Start the engine, and at increased speed, check again to see if there any fuel leaks from the connection.

FL-7

L

M

FUEL TANK
[CR]

FUEL TANK
Removal and Installation

PFP:17202
BBS003YL

MBIB9039E

1.

Fuel tank

2.

Vent hose

4.

Fuel filler cap

5.

7.

Vent hose

8.

10. Mounting band

3.

EVAP tube

Grommet

6.

Fuel filler tube

Clamp

9.

Fuel filler hose

11. EVAP hose

12. Evap canister mounting screw

13. Evap canister

14. Evap canister hose*

15. Evap canister hose**

16. Evap air inlet hose

17. Evap air inlet hose

*: To fuel tank
**: To EVAP canister purge volume control solenoid valve
: Air inlet

REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system.
Refer to FL-3, «General Precautions» .
1. Remove RH rear wheel.
2. Perform steps 1 to 7 of FL-4, «REMOVAL» in “FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL
PUMP ASSEMBLY”.
CAUTION:
If fuel tank bottom face is not level, and remaining fuel level is high, tank position becomes unstable, causing a danger. Drain fuel further than that in step 1 of the referenced procedure until tank
can be held by hand even if the balance is lost.
3. Remove center muffler and main muffler. Refer to EX-3, «EXHAUST SYSTEM» .
4. Remove vehicle side insulator on upper center muffler and main muffler.
5. Move parking brake cable from the lower face of fuel tank. Then remove clips for parking brake cable.

FL-8

FUEL TANK
[CR]
6.

7.

Disconnect fuel filler hose on fuel tank side.
CAUTION:
Do not remove fuel filler hose at fuel filler tube side, preventing to interfere with suspension due to dislocation
when installing. When removing at fuel filler tube side necessarily, put mating marks, and remove.
Remove vent hose at RH rear wheelwell side.

A

FL

C
PBIC1505E

D

8.

Remove EVAP hose at front side of fuel tank.
E

F

G
PBIC1507E

●
–

–

●

Remove quick connector in the following procedures.
Pinch quick connector square-parts with your fingers, and pull
out the quick connector by hand.
If quick connector and tube on vehicle are stuck, push and
pull several times until they move, and pull out.
CAUTION:
● The tube can be removed when the tabs are completely
depressed. Do not twist it more than necessary.
● Do not use any tools to remove the quick connector.
● Keep the resin tube away from heat. Be especially
careful when welding near the tube.
● Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube.
● Do not bend or twist the tube during installation and removal.
To keep clean the connecting portion and to avoid damage
and foreign materials, cover them completely with plastic
bags or something similar.
CAUTION:
Do not insert plug, preventing damage on O-ring in quick
connector.

H

I

J

K
PBIC1509E

L

M

PBIC0713E

FL-9

FUEL TANK
[CR]
9.

If necessary, remove mounting screw and quick connectors and
slide the EVAP canister rearward to remove it from the fuel tank.
NOTE:
For servicing “Evaporative Emission System” parts, refer to EC41, «EVAPORATIVE EMISSION LINE DRAWING» (with EUROOBD), EC-470, «EVAPORATIVE EMISSION LINE DRAWING»
(without EURO-OBD).

MBIB9040E

10. Support center of fuel tank with suitable transmission jack.
CAUTION:
Securely support the fuel tank with a piece of wood.
11. Remove RH/LH mounting band.
12. Lower suitable transmission jack carefully to remove fuel tank
while holding it by hand. Perform the following works at the
same time.
● Pull out vent hose from through hole of vehicle.
● Avoid interference with tank by pulling parking brake cable by
hand.
PBIC1508E
CAUTION:
Tank may be in an unstable condition because of the shape of fuel tank bottom. Do not rely on jack
too much. Be sure to hold tank securely.

INSTALLATION
Install in the reverse order of removal which being careful of the following.

Installation of Fuel Tank Mounting Band
●

Install it by referring to the identification stamp mark “R” and “L” on the end.

Installation of fuel Filler Hose
●

Install fuel filler hose to fuel tank, paying attention to install mark.
Marking faces downward.

MBIB9043E

●

●

●

●

Install fuel filler hose (2) to fuel filler tube (1), paying attention to
install mark. Marking faces rightward.
Insert filler hose into mating side part by 35 mm (1.38 in), and
secure it with clamp.
When installing clamp, do not allow clamp to contact the bulge
(bump) part of the tube.
Tighten the clamp of filler hose so that the remaining length
becomes 5 — 9 mm (0.20 — 0.35 in) [or tightening torque: 1.3 — 3.7
N·m (0.13 — 0.38 kg-m, 12 — 32 in-lb].
MBIB9041E

FL-10

FUEL TANK
[CR]
Installation of EVAP Hose
●

1.
2.
3.

A

Connect quick connector in the following procedures.
Check connections for damage or foreign material.
Align the mating side connection part with the center of shaft,
and insert connector straight until it clicks.
After connecting, pull out quick connector by hand. Make sure
connections are secure.

FL

C

PBIC1509E

D

INSPECTION AFTER INSTALLATION
●

1.
2.

Check for fuel leak in the following procedures.
Turn the ignition switch to ON (do not start engine), and with fuel pressure applied in the fuel line, check to
make sure there are no fuel leaks from the connection.
Start the engine, and at increased speed, check again to see if there any fuel leaks from the connection.

E

F

G

H

I

J

K

L

M

FL-11

SERVICE DATA AND SPECIFICATIONS (SDS)
[CR]

SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit
Fuel tank capacity

PFP:00030
BBS003YM

Approx. 46

(10-1/8 Imp gal)

Tightening Torque

BBS003YN

Fuel tank mounting band

Unit: N·m (kg-m, ft-lb)
21.0 — 29.0 (2.1 — 3.0, 15 — 21)

Fuel filler tube

15.8 — 24.2 (1.7 — 2.4, 12 — 17)

Lock ring

65.0 — 75.0 (6. — 7.7, 48 — 55)

FL-12

PREPARATION
[HR]

PREPARATION
Special Service Tools
[HR]

PFP:00002

A
BBS003YO

Tool number
(RENAULT tool number)
Tool name

Description

KV993G0010
(Mot. 1397)
Lock ring wrench

FL

Removing and Installing lock ring

C

D
PBIC1627E

E

F

G

H

I

J

K

L

M

FL-13

FUEL SYSTEM
[HR]

FUEL SYSTEM
Checking Fuel Lines

PFP:17503
BBS003YP

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

SMA803A

General Precautions

BBS003YQ

WARNING:
When replacing fuel line parts, be sure to observe the following.
●
Put a “CAUTION: INFLAMMABLE” sign in the workshop.
●
Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
●
Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
●
Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
CAUTION:
●
Use gasoline required by the regulations for octane number.
Refer to GI-5, «Precautions for Fuel» .
●
Before removing fuel line parts, perform the following procedures:
–
Release fuel pressure from the fuel lines. Refer to EC-860, «FUEL PRESSURE RELEASE» (with
EURO-OBD) or EC-1281, «FUEL PRESSURE RELEASE» (without EURO-OBD).
–
Disconnect the battery cable from the negative cable.
●
Always replace O-rings and clamps with new ones.
●
Do not kink or twist tubes when they are being installed.
●
Perform work on level place.
●
Do not tighten hose clamps excessively to avoid damaging hoses.
●
After connecting fuel tube quick connectors, make sure quick connectors are secure.
Ensure that connector and resin tube do not contact any adjacent parts.
●
After installing tubes, make sure there is no fuel leakage at connections in the following steps.
–
Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then check
for fuel leaks at connections.
–
Start engine and rev it up and check for fuel leaks at connections.
●
Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used,
the “MIL” may come on.
●
For servicing “Evaporative Emission System” parts, refer to EC-823, «EVAPORATIVE EMISSION
SYSTEM» (with EURO-OBD) or EC-1257, «EVAPORATIVE EMISSION SYSTEM» (without EUROOBD).

FL-14

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[HR]

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
Removal and Installation

PFP:17042

A
BBS003YR

FL

C

D

E

F

MBIB1354E

1.

Lock ring

2.

Fuel filter and fuel pump assembly

4.

O-ring

5.

Fuel tank

3.

G

Fuel level sensor unit

H

REMOVAL
WARNING:
Read “General Precautions” before working on the fuel system.
Refer to FL-14, «General Precautions» .
1. Check fuel level. If gauge indicates more than the level shown in
figure (full or almost full), drain fuel from fuel tank until gauge
indicates the level in figure or below.
When fuel pump malfunctions, insert hose with outer diameter of
25 mm (0.98 in) or less from fuel filler port. Drain fuel in fuel filler
tube. Disconnect connections of fuel filler tube and fuel filler
hose to drain fuel from fuel filler hose.
● As guide, fuel amount becomes the level shown in figure or
below when approximately 7 liter (1-1/2 lmp gal) of fuel are
drained from full.
PBIC1495E
NOTE:
Adjusting fuel level is to prevent fuel from spilling, when fuel
level sensor unit, fuel filter and fuel pump assembly are removed.
2. Release fuel pressure. Refer to EC-860, «FUEL PRESSURE RELEASE» (with EURO-OBD), EC-1281,
«FUEL PRESSURE RELEASE» (without EURO-OBD).
a. Refer to steps 5 to 7. Remove harness connectors from fuel level sensor unit, fuel filter and fuel pump
assembly.
b. Start the engine. After stopping the engine, crank it two or three times to consume the fuel in the fuel line.
3. Open fuel filler lid.
4. Open the filler cap and release the pressure inside the fuel tank.
5. Remove rear seat. Refer to SE-12, «REAR SEAT» .
6. Remove inspection hole cover.
● Using a screwdriver, remove it by turning clips clockwise by 90°.

FL-15

I

J

K

L

M

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[HR]
7.

Remove harness connector and fuel feed hose from sender unit.
NOTE:
● Connections of harness connector and fuel feed hose are
called sender unit.

PBIC1496E

●
–

–

●

Remove quick connector in the following procedures.
Pinch quick connector square-parts with your fingers, and pull
out the quick connector by hand.
If quick connector and tube on sender unit are stuck, push
and pull several times until they move, and pull out.
CAUTION:
● The tube can be removed when the tabs are completely
depressed. Do not twist it more than necessary.
● Do not use any tools to remove the quick connector.
● Keep the resin tube away from heat. Be especially
careful when welding near the tube.
● Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube.
● Do not bend or twist the tube during installation and removal.
To keep clean the connecting portion and to avoid damage
and foreign materials, cover them completely with plastic
bags or something similar.
CAUTION:
Do not insert plug, preventing damage on O-ring in quick
connector.

PBIC1497E

PBIC0713E

8.

9.

Using lock ring wrench [SST: KV993G0010], remove lock ring.
CAUTION:
Rotate SST while pressing fuel level sensor unit, fuel filter and fuel pump assembly as spring reaction force is applied from fuel tank inside to upward.
Remove fuel level sensor unit, fuel filter and fuel pump assembly.
CAUTION:
● Be careful not to bend the float arm when removing.
● Handle them carefully without subjecting them to impacts
such as dropping.

PBIC1498E

FL-16

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[HR]
10. Install lock ring temporally by hand tightening until it stops with
maximum force.
● Direct arrow mark on lock ring to vehicle rear. Then turn clockwise to tighten lock ring.
CAUTION:
Do not remove lock ring until fuel level sensor unit, fuel filter and fuel pump assembly is installed.
11. Remove fuel level sensor unit in the following procedures.
a. Remove harness connector (brown).
● Hold connector with your fingers, because there is no tab for
releasing stopper. Pull it out straight downward.
b. Insert a screwdriver into the gap between fuel level sensor unit
left side and mounting part. Pry the screwdriver in the direction
shown by arrow.
CAUTION:
Be careful not to damage anything.
c. When fixing tab comes off, slide fuel level sensor unit in the
direction indicated by arrow to remove.
CAUTION:
● Do not reuse removed fuel level sensor unit.
● Do not disassemble fuel filter and fuel tank pump assembly.

A

FL

C
PBIC1573E

D

E

F

G
PBIC1500E

INSTALLATION

H

Install in the reverse order of removal which being careful of the following.

Installation of Fuel Level Sensor Unit
Install it in the following procedures.
1. Check fuel gauge mounting part of fuel filter and fuel pump assembly side for damage.
2. Slide fuel level sensor unit along with mounting groove. Insert new fuel level sensor unit until it contacts
the face.
● After inserting, apply force to the reverse direction (removal direction). Make sure fuel level sensor unit
does not come off.
3. Connect harness connector.
● Insert harness connector securely until it contacts the face.

I

J

K

L

Installation of Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly
Install it in the following procedures.
1. Remove lock ring.
2. Install O-ring to fuel tank without any twist.

M

PBIC1501E

FL-17

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[HR]
3.

Install fuel level sensor unit, fuel filter and fuel pump assembly,
aligning the sender unit rear side protrusion with the fuel tank
opening rear side cutout.
CAUTION:
● Do not allow O-ring to drop.
● Maintain closely jointed status by pressing fuel level sensor unit, fuel filter and fuel pump assembly at an opening
of the tank until the end of step 5, in order to prevent the
fallout of O-ring (To maintain the O-ring installed status of
view A in the figure at step 2).
PBIC1502E

4.

5.

Direct arrow mark on lock ring to vehicle rear. Then turn lock ring
clockwise by hand until it steps with maximum force.
CAUTION:
Install lock ring horizontally.
Tighten lock ring to the specification with lock ring wrench [SST:
KV993G0010].

PBIC1573E

Fuel Feed Hose Installation
●

1.
2.
3.

Connect quick connector in the following procedures.
Check connections for damage or foreign material.
Align the mating side connection part with the center of shaft on
the sender unit, and insert quick connector straight until it clicks.
After connecting, pull out quick connector by hand. Make sure
connections are secure.

PBIC1503E

INSPECTION AFTER INSTALLATION
●

1.
2.

Check for fuel leak in the following procedures.
Turn the ignition switch to ON (do not start engine), and with fuel pressure applied in the fuel line, check to
make sure there are no fuel leaks from the connection.
Start the engine, and at increased speed, check again to see if there any fuel leaks from the connection.

FL-18

FUEL TANK
[HR]

FUEL TANK
Removal and Installation

PFP:17202

A
BBS003YS

FL

C

D

E

F

G

H

I
MBIB9039E

1.

Fuel tank

2.

Vent hose

3.

EVAP tube

4.

Fuel filler cap

5.

Grommet

6.

Fuel filler tube

7.

Vent hose

8.

Clamp

9.

Fuel filler hose

10. Mounting band

11. EVAP hose

12. Evap canister mounting screw

13. Evap canister

14. Evap canister hose*

15. Evap canister hose**

16. Evap air inlet hose

17. Evap air inlet hose

J

K

L

*: To fuel tank
**: To EVAP canister purge volume control solenoid valve
: Air inlet

M

REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system.
Refer to FL-14, «General Precautions» .
1. Remove RH rear wheel.
2. Perform steps 1 to 7 of FL-15, «REMOVAL» in “FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL
PUMP ASSEMBLY”.
CAUTION:
If fuel tank bottom face is not level, and remaining fuel level is high, tank position becomes unstable, causing a danger. Drain fuel further than that in step 1 of the referenced procedure until tank
can be held by hand even if the balance is lost.
3. Remove center muffler and main muffler. Refer to EX-3, «EXHAUST SYSTEM» .
4. Remove vehicle side insulator on upper center muffler and main muffler.
5. Move parking brake cable from the lower face of fuel tank. Then remove clips for parking brake cable.

FL-19

FUEL TANK
[HR]
6.

7.

Disconnect fuel filler hose on fuel tank side.
CAUTION:
Do not remove fuel filler hose at fuel filler tube side, preventing to interfere with suspension due to dislocation
when installing. When removing at fuel filler tube side necessarily, put mating marks, and remove.
Remove vent hose at RH rear wheelwell side.

PBIC1505E

8.

Remove EVAP hose at front side of fuel tank.

PBIC1507E

●
–

–

●

Remove quick connector in the following procedures.
Pinch quick connector square-parts with your fingers, and pull
out the quick connector by hand.
If quick connector and tube on vehicle are stuck, push and
pull several times until they move, and pull out.
CAUTION:
● The tube can be removed when the tabs are completely
depressed. Do not twist it more than necessary.
● Do not use any tools to remove the quick connector.
● Keep the resin tube away from heat. Be especially
careful when welding near the tube.
● Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube.
● Do not bend or twist the tube during installation and removal.
To keep clean the connecting portion and to avoid damage
and foreign materials, cover them completely with plastic
bags or something similar.
CAUTION:
Do not insert plug, preventing damage on O-ring in quick
connector.

PBIC1509E

PBIC0713E

FL-20

FUEL TANK
[HR]
9.

If necessary, remove mounting screw and quick connectors and
slide the EVAP canister rearward to remove it from the fuel tank.
NOTE:
For servicing “Evaporative Emission System” parts, refer to EC824, «EVAPORATIVE EMISSION LINE DRAWING»
(with
EURO-OBD), EC-1258, «EVAPORATIVE EMISSION LINE
DRAWING» (without EURO-OBD).

A

FL

C
MBIB9040E

D

10. Support center of fuel tank with suitable transmission jack.
CAUTION:
Securely support the fuel tank with a piece of wood.
11. Remove RH/LH mounting band.
12. Lower suitable transmission jack carefully to remove fuel tank
while holding it by hand. Perform the following works at the
same time.
● Pull out vent hose from through hole of vehicle.
● Avoid interference with tank by pulling parking brake cable by
hand.
PBIC1508E
CAUTION:
Tank may be in an unstable condition because of the shape of fuel tank bottom. Do not rely on jack
too much. Be sure to hold tank securely.

INSTALLATION

E

F

G

H

I

Install in the reverse order of removal which being careful of the following.

Installation of Fuel Tank Mounting Band
●

Install it by referring to the identification stamp mark “R” and “L” on the end.

J

Installation of fuel Filler Hose
●

Install fuel filler hose to fuel tank, paying attention to install mark.
Marking faces downward.

K

L

M

MBIB9043E

●

●

●

●

Install fuel filler hose (2) to fuel filler tube (1), paying attention to
install mark. Marking faces rightward.
Insert filler hose into mating side part by 35 mm (1.38 in), and
secure it with clamp.
When installing clamp, do not allow clamp to contact the bulge
(bump) part of the tube.
Tighten the clamp of filler hose so that the remaining length
becomes 5 — 9 mm (0.20 — 0.35 in) [or tightening torque: 1.3 — 3.7
N·m (0.13 — 0.38 kg-m, 12 — 32 in-lb].
MBIB9041E

FL-21

FUEL TANK
[HR]
Installation of EVAP Hose
●

1.
2.
3.

Connect quick connector in the following procedures.
Check connections for damage or foreign material.
Align the mating side connection part with the center of shaft,
and insert connector straight until it clicks.
After connecting, pull out quick connector by hand. Make sure
connections are secure.

PBIC1509E

INSPECTION AFTER INSTALLATION
●

1.
2.

Check for fuel leak in the following procedures.
Turn the ignition switch to ON (do not start engine), and with fuel pressure applied in the fuel line, check to
make sure there are no fuel leaks from the connection.
Start the engine, and at increased speed, check again to see if there any fuel leaks from the connection.

FL-22

SERVICE DATA AND SPECIFICATIONS (SDS)
[HR]

SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit
Fuel tank capacity

PFP:00030

A
BBS003YT

Approx. 46

(10-1/8 Imp gal)

FL

Tightening Torque

BBS003YU

Fuel tank mounting band

Unit: N·m (kg-m, ft-lb)
21.0 — 29.0 (2.1 — 3.0, 15 — 21)

Fuel filler tube

15.8 — 24.2 (1.7 — 2.4, 12 — 17)

Lock ring

65.0 — 75.0 (6.6 — 7.7, 48 — 55)

C

D

E

F

G

H

I

J

K

L

M

FL-23

PREPARATION
[K9K]

PREPARATION
Special Service Tool
[K9K]

PFP:00002
BBS003YV

Tool number
(RENAULT tool number)
Tool name

Description

KV993G0010
(Mot. 1397)
Lock ring wrench

Removing and Installing lock ring

PBIC1627E

FL-24

FUEL SYSTEM
[K9K]

FUEL SYSTEM
Checking Fuel Lines

PFP:17503

A
BBS003YW

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

FL

C

D
SMA803A

E

F

G

H

I

J

K

L

M

FL-25

FUEL FILTER
[K9K]

FUEL FILTER
Removal and Installation

PFP:16400
BBS003YX

MBIB1064E

MBIB1065E

Water Draining from Fuel Filter

BBS003YY

DRAINING WATER (RHD)
CAUTION:
Before carrying out any work, wait for the fuel temperature is dropped.
Open drain valve at the bottom of fuel filter.

MBIB0530E

FL-26

FUEL FILTER
[K9K]
DRAINING WATER (LHD)
A

Refer to EM-227, «PRECAUTIONS» , EC-1625, «WATER DRAINING» .
1. Remove right fender protector. Refer to EI-14, «FENDER PROTECTOR» .
2. Remove foam insulator.
3. Open drain valve at the bottom of fuel filter.
CAUTION:
Put a shop cloth under the drain valve, to avoid the water and fuel spill on ABS actuator.

FL

C

FUEL FILTER CHECK
Check fuel filter for fuel leakage, damage and other abnormal signs.

Changing Fuel Filter

BBS003YZ

D

REMOVAL (RHD)
1.

Remove quick connectors in the following procedures.
● Pinch quick connector square-parts with your fingers, and pull
out the quick connector by hand.
● If quick connector and tube on vehicle are stuck, push and
pull several times until they move, and pull out.

E

F

G

MBIB1048E

2.

Remove fuel filter from fuel filter bracket.
CAUTION:
Do not spill the fuel during removal. If the fuel is spill,
immediately wipe it off. Be especially careful to prevent the
fuel from adhering to the insulators of the engine mounts.

H

I

J

K
MBIB1049E

REMOVAL (LHD)
1.
2.
3.

Remove priming bulb from priming bulb bracket.
Remove fuel filter from fuel filter bracket.
Remove quick connectors as above.
CAUTION:
Put a shop cloth under the drain valve, to avoid the water and fuel spill on ABS actuator. Be especially careful to prevent any damage.

INSTALLATION
Install in the reverse order of removal, paying attention to the following points:
●
To install fuel filter connectors, respect paint marks on fuel filter
as shown.
●
After installation, operate the priming bulb vertically, if it is possible, to perform air bleeding.
Refer to FL-28, «Bleeding Fuel Filter» .
CAUTION:
Do not bend or twist the tube during installation and
removal.

MBIA0095E

FL-27

L

M

FUEL FILTER
[K9K]

Bleeding Fuel Filter
1.
2.

BBS003Z0

Prime the circuit using the priming bulb.
Perform engine cranking with repeating several times until
engine starting.

MBIB9045E

3.

4.

If the engine does not start, use a flat bladed screwdriver to lift
up the button on the fuel return pipe and perform engine cranking.
When the bleeding is completed, push the button, and check
absence of leakage.
: Bleeding position
: Normal position

MBIB9038E

FL-28

FUEL LEVEL SENSOR UNIT
[K9K]

FUEL LEVEL SENSOR UNIT
Removal and Installation

PFP:17042

A
BBS003Z1

FL

C

D

E

F

MBIB9042E

1.

Rock ring

4.

Float arm

2. O-ring

3.

G

Fuel level sensor unit

H

: Always replace after every disassembly

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

I

Disconnect battery ground cable.
Open fuel filler lid and filler cap to release the pressure inside the fuel tank.
Remove rear seat cushion. Refer to SE-12, «REAR SEAT» .
Remove inspection hole cover under the rear seat.
Disconnect electrical connector.
Disconnect the quick connectors.

J

K

L

M

MBIB1051E

●

Hold the connector while pushing in tabs, and pull out the
tube.

MBIB1052E

FL-29

FUEL LEVEL SENSOR UNIT
[K9K]

JFE628A

CAUTION:
● The tube can be removed when the tabs are completely depressed. Do not twist it more than
necessary.
● Do not use any tools to remove the quick connector.
● Keep the resin tube away from heat. Be especially careful when welding near the tube.
● Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube.
● Do not bend or twist the tube during installation and removal.
● Only when the tube is replaced, remove the remaining retainer.
● When the tube is replaced, also replace the retainer with a new one.
Retainer color:
Red (Feed hose side)
White (Return hose side)
7.

8.

Using lock ring wrench [SST: KV993G0010], remove lock ring.
CAUTION:
Rotate SST while pressing fuel level sensor unit as spring reaction force is applied from fuel tank
inside to up ward.
Remove fuel level sensor unit.
CAUTION:
● Be careful not to bend the float arm when removing.
● Handle them carefully without subjecting them to impacts
such as dropping.

MBIB1231E

INSTALLATION
Install in the reverse order of removal.

FL-30

FUEL TANK
[K9K]

FUEL TANK
Removal and Installation

PFP:17202

A
BBS003Z2

FL

C

D

E

F

G

H

I
MBIB9044E

1.

Fuel tank

2.

Vent hose

4.

Fuel filler cap

5.

Grommet

6.

Fuel filler tube

7.

Vent hose

8.

Clamp

9.

Fuel filler hose

10. Mounting band

3.

J

EVAP tube

K

11. EVAP hose

REMOVAL
1.
2.

3.
4.
5.
6.

Remove RH rear wheel.
Perform steps 1 to 7 of FL-29, «REMOVAL» in “FUEL LEVEL SENSOR UNIT”.
CAUTION:
If fuel tank bottom face is not level, and remaining fuel level is high, tank position becomes unstable, causing a danger. Drain fuel further than that in step 1 of the referenced procedure until tank
can be held by hand even if the balance is lost.
Remove center muffler and main muffler. Refer to EX-3, «EXHAUST SYSTEM» .
Remove vehicle side insulator on upper center muffler and main muffler.
Move parking brake cable from the lower face of fuel tank. Then remove clips for parking brake cable.
Disconnect fuel filler hose on fuel tank side.
CAUTION:
Do not remove fuel filler hose at fuel filler tube side, preventing to interfere with suspension due to dislocation
when installing. When removing at fuel filler tube side necessarily, put mating marks, and remove.

PBIC1505E

FL-31

L

M

FUEL TANK
[K9K]
7.
8.

Remove vent hose at RH rear wheelwell side.
Remove EVAP hose at front side of fuel tank.

PBIC1507E

●
–

–

●

Remove quick connector in the following procedures.
Pinch quick connector square-parts with your fingers, and pull
out the quick connector by hand.
If quick connector and tube on vehicle are stuck, push and
pull several times until they move, and pull out.
CAUTION:
● The tube can be removed when the tabs are completely
depressed. Do not twist it more than necessary.
● Do not use any tools to remove the quick connector.
● Keep the resin tube away from heat. Be especially
careful when welding near the tube.
● Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube.
● Do not bend or twist the tube during installation and removal.
To keep clean the connecting portion and to avoid damage
and foreign materials, cover them completely with plastic
bags or something similar.
CAUTION:
Do not insert plug, preventing damage on O-ring in quick
connector.

PBIC1509E

PBIC0713E

9.

Support center of fuel tank with suitable transmission jack.
CAUTION:
Securely support the fuel tank with a piece of wood.
10. Remove RH/LH mounting band.
11. Lower suitable transmission jack carefully to remove fuel tank
while holding it by hand. Perform the following works at the
same time.
● Pull out vent hose from through hole of vehicle.
● Avoid interference with tank by pulling parking brake cable by
hand.
PBIC1508E
CAUTION:
Tank may be in an unstable condition because of the shape of fuel tank bottom. Do not rely on jack
too much. Be sure to hold tank securely.

INSTALLATION
Install in the reverse order of removal which being careful of the following.

FL-32

FUEL TANK
[K9K]
Installation of Fuel Tank Mounting Band
●

A

Install it by referring to the identification stamp mark “R” and “L” on the end.

Installation of fuel Filler Hose
●
●
●

Insert filler hose into mating side part by 35 mm (1.38 in), and secure it with clamp.
FL
When installing clamp, do not allow clamp to contact the bulge (bump) part of the tube.
Tighten the clamp of filler hose so that the remaining length becomes 5 — 9 mm (0.20 — 0.35 in) [or tightening torque: 1.3 — 3.7 N·m (0.13 — 0.38 kg-m, 12 — 32 in-lb].
C

Installation of EVAP Hose
●

1.
2.
3.

Connect quick connector in the following procedures.
Check connections for damage or foreign material.
Align the mating side connection part with the center of shaft,
and insert connector straight until it clicks.
After connecting, pull out quick connector by hand. Make sure
connections are secure.

D

E

F
PBIC1509E

G

Installation of Vent Hose
●
●

Push vent hose into through hole of vehicle.
Insert vent hose into vent rubber hose, and secure it with clamp.

H

INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following procedure.
●
Start engine, rev it up and make sure there is no fuel leakage at connections.

I

J

K

L

M

FL-33

SERVICE DATA AND SPECIFICATIONS (SDS)
[K9K]

SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit
Fuel tank capacity

PFP:00030
BBS0058F

Approx. 46

(10-1/8 Imp gal)

Tightening Torque

BBS0058G

Unit: N·m (kg-m, ft-lb)
Fuel tank mounting band

25.0 (2.6, 18)

Fuel filler tube

15.8 — 24.2 (1.7 — 2.4, 12 — 17)

Lock ring

65.0 — 75.0 (6.6 — 7.7, 48 — 55)

FL-34

GENERAL INFORMATION

A GENERAL INFORMATION

SECTION

GI

GENERAL INFORMATION

GI

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 3
Description ……………………………………………………… 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 3
Precautions for NATS (NISSAN ANTI-THEFT SYSTEM) ……………………………………………………………… 3
Maintenance Information …………………………………… 3
RHD MODELS ……………………………………………… 3
LHD MODELS ………………………………………………. 4
PrecautionsforProcedureswithoutCowlTopCover….. 4
General Precautions ………………………………………… 4
Precautions for Three Way Catalyst ……………………. 5
Precautions for Fuel …………………………………………. 5
GASOLINE ENGINE (REGULAR GASOLINE)….. 5
GASOLINE ENGINE (PREMIUM GASOLINE) ….. 6
DIESEL ENGINE …………………………………………… 6
Precautions for Multiport Fuel Injection System or
Engine Control System …………………………………….. 6
Precautions for Turbocharger (If Equipped) …………. 6
Precautions for Hoses ………………………………………. 7
HOSE REMOVAL AND INSTALLATION …………… 7
HOSE CLAMPING ………………………………………… 7
Precautions for Engine Oils ……………………………….. 7
HEALTH PROTECTION PRECAUTIONS ………… 7
ENVIRONMENTAL PROTECTION PRECAUTIONS …………………………………………………………. 8
Precautions for Air Conditioning …………………………. 8
HOW TO USE THIS MANUAL …………………………….. 9
Description ……………………………………………………… 9
Terms …………………………………………………………….. 9
Units ………………………………………………………………. 9
Contents …………………………………………………………. 9
Relation between Illustrations and Descriptions … 10
Components ……………………………………………………11
RHD MODELS ……………………………………………… 3
How to Follow Trouble Diagnoses …………………….. 12
DESCRIPTION ……………………………………………. 12
HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES ……………………………………….. 12

HARNESS WIRE COLOR AND CONNECTOR
NUMBER INDICATION ………………………………… 13
KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES …………………………. 14
How to Read Wiring Diagrams …………………………. 16
CONNECTOR SYMBOLS …………………………….. 16
SAMPLE/WIRING DIAGRAM — EXAMPL — ………. 17
DESCRIPTION ……………………………………………. 18
Abbreviations …………………………………………………. 23
SERVICE INFORMATION FOR ELECTRICAL INCIDENT ………………………………………………………………. 25
How to Perform Efficient Diagnosis for an Electrical
Incident …………………………………………………………. 25
WORK FLOW ……………………………………………… 25
INCIDENT SIMULATION TESTS …………………… 25
CIRCUIT INSPECTION ………………………………… 28
Control Units and Electrical Parts ……………………… 33
PRECAUTIONS ………………………………………….. 33
SMJ INSTALLATION ……………………………………. 34
CONSULT-II CHECKING SYSTEM …………………….. 35
Description …………………………………………………….. 35
Function and System Application ……………………… 35
Nickel Metal Hydride Battery Replacement ………… 35
Checking Equipment ………………………………………. 36
CONSULT-II Start Procedure ……………………………. 36
CONSULT-II Data Link Connector (DLC) Circuit … 38
INSPECTION PROCEDURE ………………………… 39
LIFTING POINT ………………………………………………… 40
Commercial Service Tools ……………………………….. 40
Garage Jack, Safety Stand and 2-Pole Lift …………. 40
Board-On Lift …………………………………………………. 41
TOW TRUCK TOWING ……………………………………… 42
Tow Truck Towing …………………………………………… 42
TOWING AN AUTOMATIC TRANSAXLE
MODEL WITH FOUR WHEELS ON GROUND… 42
Vehicle Recovery (Freeing a Stuck Vehicle) ……….. 42
FRONT ………………………………………………………. 42
REAR ………………………………………………………… 43
TIGHTENING TORQUE OF STANDARD BOLTS … 44
Tightening Torque Table ………………………………….. 44

GI-1

E

F

G

H

I

J

K

L

M

IDENTIFICATION INFORMATION ………………………. 45
Model Variation ………………………………………………. 45
IDENTIFICATION NUMBER ………………………….. 46
IDENTIFICATION PLATE ……………………………… 47
ENGINE SERIAL NUMBER (CR ENGINE) ……… 47
ENGINE SERIAL NUMBER (HR ENGINE) ……… 47

ENGINE IDENTIFICATION (K9K ENGINE) ………48
AUTOMATIC TRANSAXLE NUMBER ……………..48
Dimensions …………………………………………………….48
Wheels & Tyres ……………………………………………….48
TERMINOLOGY ………………………………………………..49
ISO 15031-2 Terminology List ……………………………49

GI-2

PRECAUTIONS
PRECAUTIONS
Description

PFP:00001

GI
BAS0002D

Observe the following precautions to ensure safe and proper servicing. These precautions are not
described in each individual section.

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

B

BAS0002E

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Precautions for NATS (NISSAN ANTI-THEFT SYSTEM)

BAS0004J

If any of following part is replaced, always replace with new* one.
If it’s not (or fail to do so), the electrical system may not be operated properly.
*: New one means a virgin control unit that has never been energized on-board.

RHD MODELS
●
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM
IPDM E/R

GI-3

D

E

F

G

BAS0002F

NATS will immobilize the engine if someone tries to start it without the registered key of NATS.
Both of the originally supplied ignition key IDs have been NATS registered.
The security indicator is located on the instrument panel. The indicator blinks when the immobilizer system is
functioning.
Therefore, NATS warns outsiders that the vehicle is equipped with the anti-theft system.
●
When NATS detects trouble, the security indicator lamp lights up while ignition switch is in «ON» position.
This lighting up indicates that the anti-theft is not functioning, so prompt service is required.
●
When servicing NATS (trouble diagnoses, system initialization and additional registration of other NATS
ignition key IDs), CONSULT-II hardware and CONSULT-II NATS software is necessary.
Regarding the procedures of NATS initialization and NATS ignition key ID registration, refer to CONSULTII operation manual, NATS.
Therefore, CONSULT-II NATS software (program card and operation manual) must be kept strictly confidential to maintain the integrity of the anti-theft function.
●
When servicing NATS (trouble diagnoses, system initialization and additional registration of other NATS
ignition key IDs), it may be necessary to re-register original key identification. Therefore, be sure to
receive all keys from vehicle owner. A maximum of four or five key IDs can be registered into NATS.
●
When failing to start the engine first time using the key of NATS, start as follows.
1. Leave the ignition key in «ON» position for approximately 5 seconds.
2. Turn ignition key to «OFF» or «LOCK» position and wait approximately 5 seconds.
3. Repeat step 1 and 2 again.
4. Restart the engine while keeping the key separate from any others on key-chain.

Maintenance Information

C

H

I

J

K

L

M

PRECAUTIONS
●
●

Combination meter
EPS control unit

LHD MODELS
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM

Precautions for Procedures without Cowl Top Cover

BAS0002G

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

PIIB3706J

General Precautions
●

BAS0002H

Do not operate the engine for an extended period of time without
proper exhaust ventilation.
Keep the work area well ventilated and free of any inflammable
materials. Special care should be taken when handling any
inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be
sure to properly ventilate the area before working with hazardous materials.
Do not smoke while working on the vehicle.
SGI285

●

●

Before jacking up the vehicle, apply wheel chocks or other tire
blocks to the wheels to prevent the vehicle from moving. After
jacking up the vehicle, support the vehicle weight with safety
stands at the points designated for proper lifting before working
on the vehicle.
These operations should be done on a level surface.
When removing a heavy component such as the engine or
transaxle/transmission, be careful not to lose your balance and
drop them. Also, do not allow them to strike adjacent parts,
especially the brake tubes and master cylinder.
SGI231

●

●

Before starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.
If the battery terminals are disconnected, recorded memory of
radio and each control unit is erased.

SEF289H

GI-4

PRECAUTIONS
●

●

●

●

●

●
●
●

●
●
●
●
●
●

To prevent serious burns:
Avoid contact with hot metal parts.
GI
Do not remove the radiator cap when the engine is hot.
Dispose of drained oil or the solvent used for cleaning parts in
an appropriate manner.
B
Do not attempt to top off the fuel tank after the fuel pump nozzle
shuts off automatically.
Continued refueling may cause fuel overflow, resulting in fuel
C
spray and possibly a fire.
Clean all disassembled parts in the designated liquid or solvent
SGI233
prior to inspection or assembly.
D
Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new
ones.
Replace inner and outer races of tapered roller bearings and needle bearings as a set.
E
Arrange the disassembled parts in accordance with their assembled locations and sequence.
Do not touch the terminals of electrical components which use microcomputers (such as ECM).
Static electricity may damage internal electronic components.
F
After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.
Use only the fluids and lubricants specified in this manual.
Use approved bonding agent, sealants or their equivalents when required.
G
Use tools and recommended special tools where specified for safe and efficient service repairs.
When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks.
H
Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate covers.
Take caution that keys, buckles or buttons do not scratch paint.
I

J

SGI234

WARNING:
To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness
connectors which are related to the engine control system and TCM (transmission control module)
system. The connectors should be disconnected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC and AT sections.

Precautions for Three Way Catalyst

BAS0002I

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

Precautions for Fuel

BAS0002J

GASOLINE ENGINE (REGULAR GASOLINE)
●

Three way catalyst equipped models … use unleaded gasoline with an octane rating of at least 91 RON
(research octane number).

GI-5

K

L

M

PRECAUTIONS

●

CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst.
Except for the above models … use unleaded or leaded gasoline with an octane rating of at least 88 RON
(research octane number).
Use unleaded gasoline if instructed on the fuel filler lid.

GASOLINE ENGINE (PREMIUM GASOLINE)
Use premium unleaded gasoline with an octane rating of at least 95 RON (research octane number). If premium unleaded gasoline is not available, regular unleaded gasoline with an octane rating of at least 91 RON
(research octane number) can be used. However, for maximum vehicle performance, the use of premium
unleaded gasoline is recommended.
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel
other than that specified could adversely affect the emission control devices and systems, and could
also affect the warranty coverage validity.

DIESEL ENGINE
For Europe model; use diesel fuel of at least 50 cetane.
●
Except for Europe model; use diesel fuel of at least 45 cetane.
If two types of diesel fuel are available, use summer or winter fuel properly according to the following temperature conditions.
●
Above -7°C (20°F) ··· Summer type diesel fuel.
●
Below -7°C (20°F) ··· Winter type diesel fuel.
CAUTION:
●
Do not use home heating oil, gasoline or other alternate fuels in your diesel engine. The use of
those can cause engine damage.
●
Do not use summer fuel at temperature below -7°C (20°F). The cold temperature will cause wax to
form in the fuel. As a result, it may prevent the engine from running smoothly.
●
Do not add gasoline or other alternate fuels to diesel fuel.
●

Precautions for Multiport Fuel Injection System or Engine Control System
●

●

●

BAS0002K

Before connecting or disconnecting any harness connector for
the multiport fuel injection system or ECM:
Turn ignition switch to “OFF” position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
Before disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure.
Be careful not to jar components such as ECM and mass air
flow sensor.
SGI787

Precautions for Turbocharger (If Equipped)

BAS0002L

The turbocharger turbine revolves at extremely high speeds and
becomes very hot. Therefore, it is essential to maintain a clean supply of oil flowing through the turbocharger and to follow all required
maintenance instructions and operating procedures.
●
Always use the recommended oil. Follow the instructions for
proper time to change the oil and proper oil level.
●
Avoid accelerating engine to a high rpm immediately after starting.
●
If engine had been operating at high rpm for an extended period
of time, let it idle for a few minutes prior to shutting if off.
SGI292

GI-6

PRECAUTIONS
Precautions for Hoses

BAS0002M

GI

HOSE REMOVAL AND INSTALLATION
●

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

C

D
SMA019D

●

E

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

F

G

H
SMA020D

HOSE CLAMPING
●

●

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

I

J

K

SMA021D

●

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

M

SMA022D

Precautions for Engine Oils

BAS0002N

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

HEALTH PROTECTION PRECAUTIONS
●

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

GI-7

L

PRECAUTIONS
●
●
●
●

●
●
●

●
●
●
●

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

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

Precautions for Air Conditioning

BAS0002O

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

GI-8

HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
Description

PFP:00008

GI
BAS0002P

This volume explains “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diagnoses”.

Terms
●

BAS0002Q

The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal
injury and/or damage to some part of the vehicle.
WARNING indicates the possibility of personal injury if instructions are not followed.
CAUTION indicates the possibility of component damage if instructions are not followed.
BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information.
Standard value:Tolerance at inspection and adjustment.
Limit value:The maximum or minimum limit value that should not be exceeded at inspection and adjustment.

Units
●

The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit),
and alternatively expressed in the metric system and in the yard/pound system.
“Example”
: 59 — 78 N-m (6.0 — 8.0 kg-m, 43 — 58 ft-lb)

Contents

●

A QUICK REFERENCE INDEX, a black tab (e.g.
) is provided on the first page. You can quickly find
the first page of each section by matching it to the section’s black tab.
THE CONTENTS are listed on the first page of each section.
THE TITLE is indicated on the upper portion of each page and shows the part or system.
THE PAGE NUMBER of each section consists of two or three letters which designate the particular section and a number (e.g. “BR-5”).
THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks
of work and hidden or tricky steps which are not shown in the previous large illustrations.
Assembly, inspection and adjustment procedures for the complicated units such as the automatic
transaxle or transmission, etc. are presented in a step-by-step format where necessary.

●

E

F

BAS0002S

ALPHABETICAL INDEX is provided at the end of this manual so that you can rapidly find the item and
page you are searching for.

●

D

G

●

●

C

BAS0002R

Outer Socket Lock Nut

●

B

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HOW TO USE THIS MANUAL
Relation between Illustrations and Descriptions

BAS0004K

The following sample explains the ralationship between the part description in an illustration, the part name in
the text and the service procedures.

SAIA0519E

GI-10

HOW TO USE THIS MANUAL
Components
●

BAS0002T

THE LARGE ILLUSTRATIONS are exploded views (see the following) and contain tightening torques,
lubrication points, section number of the PARTS CATALOG (e.g. SEC. 440) and other information necessary to perform repairs.
The illustrations should be used in reference to service matters only. When ordering parts, refer to the
appropriate PARTS CATALOG .
Components shown in an illustration may be identified by a circled number. When this style of illustration
is used, the text description of the components will follow the illustration.

GI

B

C

D

E

F

G

H

SFIA2959E

1.

Union bolt

2.

Copper washer

3.

Brake hose

4.

Cap

5.

Bleed valve

6.

Sliding pin bolt

7.

Piston seal

8.

Piston

9.

Piston boot

10.

Cylinder body

11.

Sliding pin

12.

Torque member mounting bolt

13.

Washer

14.

Sliding pin boot

15.

Bushing

16.

Torque member

17.

Inner shim cover

18.

Inner shim

19.

Inner pad

20.

Pad retainer

21.

Pad wear sensor

22.

Outer pad

23.

Outer shim

24.

Outer shim cover

1: PBC (Poly Butyl Cuprysil) grease
or silicone-based grease

2: Rubber grease

I

J

K

L

: Brake fluid

Refer to GI section for additional symbol definitions.

M

SYMBOLS

SAIA0749E

GI-11

HOW TO USE THIS MANUAL
How to Follow Trouble Diagnoses

BAS0002U

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

HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES

SAIA0256E

1.
2.

Work and diagnostic procedure
Start to diagnose a problem using procedures indicated in enclosed test groups.
Questions and required results
Questions and required results are indicated in bold type in test group.
The meaning of are as follows:

GI-12

HOW TO USE THIS MANUAL
a. Battery voltage → 11 — 14V or approximately 12V
b. Voltage
: Approximately 0V → Less than 1V
3.

4.

GI

Symbol used in illustration
Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem,
familiarize yourself with each symbol. Refer to «Connector Symbols» in GI Section and «KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES» below.
Action items
Next action for each test group is indicated based on result of each question. Test group number is shown
in the left upper portion of each test group.

HARNESS WIRE COLOR AND CONNECTOR NUMBER INDICATION

B

C

D

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

TYPE 1: Harness Wire Color and Connector Number are Shown in Illustration
●

●

●

E

Letter designations next to test meter probe indicate harness
wire color.
Connector numbers in a single circle (e.g. M33) indicate harness connectors.
Connector numbers in a double circle (e.g. F211) indicate component connectors.

F

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AGI070

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HOW TO USE THIS MANUAL
TYPE 2: Harness Wire Color and Connector Number are Shown in Text

SGI144A

KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES

SAIA0750E

GI-14

HOW TO USE THIS MANUAL
GI

B

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SAIA0751E

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HOW TO USE THIS MANUAL
How to Read Wiring Diagrams

BAS0002V

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

SAIA0257E

●

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

SGI363

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HOW TO USE THIS MANUAL
SAMPLE/WIRING DIAGRAM — EXAMPL ●

GI

For detail, refer to following “DESCRIPTION”.

B

C

D

E

F

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SGI091A

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HOW TO USE THIS MANUAL
Optional Splice

SGI942

DESCRIPTION
Number

Item

1

Power condition

2

Fusible link

3

Fusible link/fuse location

4

Fuse

5

6

Current rating

Connectors

Description
●

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

●

The double line shows that this is a fusible link.

●

The open circle shows current flow in, and the shaded circle shows current flow out.

●

This shows the location of the fusible link or fuse in the fusible link or fuse box. For arrangement, refer to PG section, POWER SUPPLY ROUTING.

●

The single line shows that this is a fuse.

●

The open circle shows current flow in, and the shaded circle shows current flow out.

●

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

●

This shows that connector E3 is female and connector M1 is male.

●

The G/R wire is located in the 1A terminal of both connectors.

●

Terminal number with an alphabet (1A, 5B, etc.) indicates that the connector is SMJ connector. Refer to PG section, SMJ (SUPER MULTIPLE JUNCTION).

7

Optional splice

●

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

8

Splice

●

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

●

9

Page crossing

This arrow shows that the circuit continues to an adjacent page.

●

The A will match with the A on the preceding or next page.

10

Common connector

●

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

11

Option abbreviation

●

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

12

Relay

●

This shows an internal representation of the relay. For details, refer to PG section, STANDARDIZED RELAY.

13

Connectors

●

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

GI-18

HOW TO USE THIS MANUAL
Number

Item

Description
●

14

Wire color

This shows a code for the color of the wire.
BR = Brown
OR or O = Orange
P = Pink
PU or V (Violet) = Purple
GY or GR = Gray
SB = Sky Blue
CH = Dark Brown
DG = Dark Green

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

When the wire color is striped, the base color is given first, followed by the stripe color as shown
below:
Example: L/W = Blue with White Stripe
15

Option description

16

Switch

17

Assembly parts

18

19

20

Cell code

●

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

●

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

●

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

●

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

●

Arrow indicates electric current flow, especially where the direction of standard flow (vertically
downward or horizontally from left to right) is difficult to follow.

●

A double arrow “
cuit operation.

Current flow arrow

System branch

●

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

●

This arrow shows that the circuit continues to another page identified by cell code.

●

The C will match with the C on another page within the system other than the next or preceding pages.

22

Shielded line

●

The line enclosed by broken line circle shows shield wire.

23

Component box in
wave line

●

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

24

Component name

●

This shows the name of a component.

●

This shows the connector number.

●

The letter shows which harness the connector is located in.

●

Example: M : main harness. For detail and to locate the connector, refer to PG section «Main
Harness», “Harness Layout”. A coordinate grid is included for complex harnesses to aid in
locating connectors.

●

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

●

This shows the ground connection. For detailed ground distribution information, refer to
«Ground Distribution» in PG section.

●

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

●

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

●

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

●

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

●

This shows that more information on the Super Multiple Junction (SMJ) and Joint Connectors
(J/C) exists on the PG section. Refer to «Reference Area» for details.

26

Ground (GND)

27

Ground (GND)

28

Connector views

29

Common component

30

Connector color

31

Fusible link and fuse
box

32

Reference area

C

D

E

F

G

H

Page crossing

Connector number

B

” shows that current can flow in either direction depending on cir-

21

25

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HOW TO USE THIS MANUAL
Harness Indication
●

●

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

AGI070

Component Indication
Connector numbers in a double circle F211 indicate component connectors.

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

SGI860

GI-20

HOW TO USE THIS MANUAL
Detectable Lines and Non-Detectable Lines
GI

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

B

C

D

E

F

G

SGI862-B

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HOW TO USE THIS MANUAL
Multiple Switch
The continuity of multiple switch is described in two ways as shown below.
●
The switch chart is used in schematic diagrams.
●
The switch diagram is used in wiring diagrams.

SGI875

GI-22

HOW TO USE THIS MANUAL
Reference Area
The Reference Area of the wiring diagram contains references to additional electrical reference pages at the GI
end of the manual. If connector numbers and titles are shown in the Reference Area of the wiring diagram,
these connector symbols are not shown in the Connector Area.
B

C

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F

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SGI092A

Abbreviations

BAS0002W

The following ABBREVIATIONS are used:
ABBREVIATION

DESCRIPTION

A/C

Air Conditioner

A/T

Automatic Transaxle/Transmission

ATF

Automatic Transmission Fluid

D1

Drive range 1st gear

D2

Drive range 2nd gear

GI-23

HOW TO USE THIS MANUAL
ABBREVIATION

DESCRIPTION

D3

Drive range 3rd gear

D4

Drive range 4th gear

FR, RR

Front, Rear

LH, RH

Left-Hand, Right-Hand

M/T

Manual Transaxle/Transmission

OD

Overdrive

P/S

Power Steering

SAE

Society of Automotive Engineers, Inc.

SDS

Service Data and Specifications

SST

Special Service Tools

2WD

2-Wheel Drive

22

2nd range 2nd gear

21

2nd range 1st gear

12

1st range 2nd gear

11

1st range 1st gear

GI-24

SERVICE INFORMATION FOR ELECTRICAL INCIDENT
SERVICE INFORMATION FOR ELECTRICAL INCIDENT
How to Perform Efficient Diagnosis for an Electrical Incident

PFP:00000

GI
BAS0002X

WORK FLOW
B

C

D

E

F

G
SGI838

STEP

DESCRIPTION

H

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

STEP 1

STEP 2

WHAT

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

WHEN

Date, Time of Day, Weather Conditions, Frequency.

WHERE

Road Conditions, Altitude and Traffic Situation.

HOW

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

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

I

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K

Get the proper diagnosis materials together including:
●

Power Supply Routing

●

System Operation Descriptions

●

Applicable Service Manual Sections

●

Check for any Service Bulletins

STEP 3

L

M

Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments.
STEP 4

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

STEP 5

Repair or replace the incident circuit or component.

STEP 6

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

INCIDENT SIMULATION TESTS
Introduction
Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create the
conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The following section illustrates ways to simulate the conditions/environment under which the owner experiences an
electrical incident.
The section is broken into the six following topics:
●
Vehicle vibration

GI-25

SERVICE INFORMATION FOR ELECTRICAL INCIDENT
Heat sensitive
Freezing
●
Water intrusion
●
Electrical load
●
Cold or hot start up
Get a thorough description of the incident from the customer. It is important for simulating the conditions of the
problem.
●
●

Vehicle Vibration
The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with
A/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustration.
CONNECTORS & HARNESS
Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently
shake each connector and harness while monitoring the system for the incident you are trying to duplicate.
This test may indicate a loose or poor electrical connection.
HINT
Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector terminals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs intermittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the
terminals on related connectors in the system.
SENSORS & RELAYS
Gently apply a slight vibration to sensors and relays in the system you are inspecting.
This test may indicate a loose or poorly mounted sensor or relay.

SGI839

ENGINE COMPARTMENT
There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the
things to check for are:
●
Connectors not fully seated.
●
Wiring harness not long enough and is being stressed due to engine vibrations or rocking.
●
Wires laying across brackets or moving components.
●
Loose, dirty or corroded ground wires.
●
Wires routed too close to hot components.
To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to Ground
Inspection described later.) First check that the system is properly grounded. Then check for loose connection
by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the
wiring for continuity.
BEHIND THE INSTRUMENT PANEL
An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehicle vibration can aggravate a harness which is routed along a bracket or near a screw.

GI-26

SERVICE INFORMATION FOR ELECTRICAL INCIDENT
UNDER SEATING AREAS
GI
An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides)
during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage or
pinching.
B

Heat Sensitive

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

C

D

E
SGI842

F

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

G

H

I
SGI843

Water Intrusion

J

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

K

L

M
SGI844

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

SGI845

GI-27

SERVICE INFORMATION FOR ELECTRICAL INCIDENT
Cold or Hot Start Up
On some occasions an electrical incident may occur only when the car is started cold, or it may occur when
the car is restarted hot shortly after being turned off. In these cases you may have to keep the car overnight to
make a proper diagnosis.

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

A circuit is open when there is no continuity through a section of the circuit.
There are two types of shorts.

SHORT

●

SHORT CIRCUIT

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

●

SHORT TO GROUND

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

NOTE:
Refer to “How to Check Terminal” to probe or check terminal.

Testing for “Opens” in the Circuit
Before you begin to diagnose and test the system, you should rough sketch a schematic of the system. This
will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your working knowledge of the system.

SGI846-A

CONTINUITY CHECK METHOD
The continuity check is used to find an open in the circuit. The digital multimeter (DMM) set on the resistance
function will indicate an open circuit as over limit (no beep tone or no ohms symbol). Make sure to always start
with the DMM at the highest resistance level.
To help in understanding the diagnosis of open circuits, please refer to the previous schematic.
●
Disconnect the battery negative cable.
●
Start at one end of the circuit and work your way to the other end. (At the fuse block in this example)
●
Connect one probe of the DMM to the fuse block terminal on the load side.
●
Connect the other probe to the fuse block (power) side of SW1. Little or no resistance will indicate that
portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an
over limit or infinite resistance condition. (point A)
●
Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point B)
●
Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of
the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or
infinite resistance condition. (point C)
Any circuit can be diagnosed using the approach in the previous example.

GI-28

SERVICE INFORMATION FOR ELECTRICAL INCIDENT
VOLTAGE CHECK METHOD
To help in understanding the diagnosis of open circuits please refer to the previous schematic.
GI
In any powered circuit, an open can be found by methodically checking the system for the presence of voltage.
This is done by switching the DMM to the voltage function.
●
Connect one probe of the DMM to a known good ground.
B
●
Begin probing at one end of the circuit and work your way to the other end.
●
With SW1 open, probe at SW1 to check for voltage.
voltage; open is further down the circuit than SW1.
C
no voltage; open is between fuse block and SW1 (point A).
●
Close SW1 and probe at relay.
voltage; open is further down the circuit than the relay.
D
no voltage; open is between SW1 and relay (point B).
●
Close the relay and probe at the solenoid.
voltage; open is further down the circuit than the solenoid.
E
no voltage; open is between relay and solenoid (point C).
Any powered circuit can be diagnosed using the approach in the previous example.

Testing for “Shorts” in the Circuit

F

To simplify the discussion of shorts in the system, please refer to the following schematic.
G

H

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SGI847-A

J

RESISTANCE CHECK METHOD
●
Disconnect the battery negative cable and remove the blown fuse.
●
Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the
fuse.
●
Connect one probe of the DMM to the load side of the fuse terminal. Connect the other probe to a known
good ground.
●
With SW1 open, check for continuity.
continuity; short is between fuse terminal and SW1 (point A).
no continuity; short is further down the circuit than SW1.
●
Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good
ground. Then, check for continuity.
continuity; short is between SW1 and the relay (point B).
no continuity; short is further down the circuit than the relay.
●
Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and
a known good ground. Then, check for continuity.
continuity; short is between relay and solenoid (point C).
no continuity; check solenoid, retrace steps.
VOLTAGE CHECK METHOD
●
Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid disconnected) powered through the fuse.
●
Turn the ignition key to the ON or START position. Verify battery voltage at the battery + side of the fuse
terminal (one lead on the battery + terminal side of the fuse block and one lead on a known good ground).
●
With SW1 open and the DMM leads across both fuse terminals, check for voltage.
voltage; short is between fuse block and SW1 (point A).

GI-29

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

●

●

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

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

SGI853

Voltage Drop Tests
Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage
drop in a circuit is caused by a resistance when the circuit is in operation.
Check the wire in the illustration. When measuring resistance with DMM, contact by a single strand of wire will
give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand of wire
is not able to carry the current. The single strand will have a high resistance to the current. This will be picked
up as a slight voltage drop.
Unwanted resistance can be caused by many situations as follows:
●
Undersized wiring (single strand example)
●
Corrosion on switch contacts
●
Loose wire connections or splices.

GI-30

SERVICE INFORMATION FOR ELECTRICAL INCIDENT
If repairs are needed always use wire that is of the same or larger gauge.
GI

MEASURING VOLTAGE DROP — ACCUMULATED METHOD
●
Connect the DMM across the connector or part of the circuit you want to check. The positive lead of the
DMM should be closer to power and the negative lead closer to ground.
●
Operate the circuit.
●
The DMM will indicate how many volts are being used to “push” current through that part of the circuit.
Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb.

B

C

D

E

F

G

H

SGI974

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

I

J

K

L

M

SAIA0258E

GI-31

SERVICE INFORMATION FOR ELECTRICAL INCIDENT
Control Unit Circuit Test
System Description:When the switch is ON, the control unit lights up the lamp.

MGI034A

INPUT-OUTPUT VOLTAGE CHART
Pin
No.

Item

1

Switch

2

Lamp

Voltage
value [V]

Condition

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

Switch ON

Battery voltage

Lower than battery voltage Approx. 8 (Example)

Switch OFF

Approx. 0

Approx. 0

Switch ON

Battery voltage

Approx. 0 (Inoperative lamp)

Switch OFF

Approx. 0

Approx. 0

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

MGI035A

INPUT-OUTPUT VOLTAGE CHART
Pin
No.
1

2

Item
Lamp

Switch

Condition

Voltage
value [V]

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

Switch ON

Approx. 0

Battery voltage (Inoperative lamp)

Switch OFF

Battery voltage

Battery voltage

Switch ON

Approx. 0

Higher than 0 Approx. 4 (Example)

Switch OFF

Approx. 5

Approx. 5

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

GI-32

SERVICE INFORMATION FOR ELECTRICAL INCIDENT
Control Units and Electrical Parts

BAS0002Y

GI

PRECAUTIONS
●
●
●

●
●

Never reverse polarity of battery terminals.
Install only parts specified for a vehicle.
Before replacing the control unit, check the input and output and
functions of the component parts.
Do not apply excessive force when disconnecting a connector.
If a connector is installed by tightening bolts, loosen bolt mounting it, then take it out by hand.

B

C

D
SAIA0251E

●

E

Before installing a connector, make sure the terminal is not bent
or damaged, and then correctly connect it.
When installing a connector by tightening bolts, fix it by tightening the mounting bolt until the painted projection of the connector becomes even with the surface.

F

G

H
SAIA0252E

●

For removal of the lever type connector, pull the lever up to the
direction pointed to by the arrow A in the figure, and then
remove the connector.

I

J

K

SAIA0253E

●

For installation of the lever type connector, pull down the lever to
the direction pointed by the arrow B in the figure, and then push
the connector until a clicking noise is heard.

M

SAIA0254E

GI-33

L

SERVICE INFORMATION FOR ELECTRICAL INCIDENT
●

●

●
●
●

●

●

Do not apply excessive shock to the control unit by dropping or
hitting it.
Be careful to prevent condensation in the control unit due to
rapid temperature changes and do not let water or rain get on it.
If water is found in the control unit, dry it fully and then install it in
the vehicle.
Be careful not to let oil to get on the control unit connector.
Avoid cleaning the control unit with volatile oil.
Do not disassemble the control unit, and do not remove the
upper and lower covers.

SAIA0255E

When using a DMM, be careful not to let test probes get close to
each other to prevent the power transistor in the control unit
from damaging battery voltage because of short circuiting.
When checking input and output signals of the control unit, use
the specified check adapter.

SEF348N

SMJ INSTALLATION
To install SMJ, tighten bolts until orange “fulltight” mark appears and
then retighten to specified torque as required.
SMJ

:3 — 5 N·m (0.3 — 0.5 kg-m, 26 — 43 in-lb)

CAUTION:
Do not overtighten bolts, otherwise, they may be damaged.

CEL969

GI-34

CONSULT-II CHECKING SYSTEM
CONSULT-II CHECKING SYSTEM
Description
●

●

PFP:00000

GI
BAS0002Z

CONSULT-II is a hand-held type tester. When it is connected with a diagnostic connector equipped on the
vehicle side, it will communicate with the control unit equipped in the vehicle and then enable various
kinds of diagnostic tests.
Refer to “CONSULT-II Software Operation Manual” for more information.

Function and System Application
ABS (Including ESP)

EPS

IPDM E/R

BCM

INTELLIGENT KEY

NATS*1

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

x

x

–

–

–

–

x

x

x

Self-diagnostic results

Self-diagnostic results can be read and erased quickly.

x

x

x

x

x

x

x

x

x

Trouble diagnostic record

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

–

–

x

–

–

–

–

–

–

Data monitor

Input/Output data in the ECU can be read.

x

x

–

x

x

x

–

x

x

Function

A/T

Work support

Diagnostic test
mode

ENGINE

AIR BAG

BAS00030

B

C

D

E

F

G

H

CAN diagnosis support
monitor

Indicates the communication condition of CAN communication line.

x

x

–

x

x

x

x

x

–

Active test

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

x

–

–

x

–

x

x

x

–

DTC & SRT
confirmation

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

x*2

–

–

–

–

–

–

–

–

DTC work support

Select the operating condition to confirm Diagnosis Trouble Codes.

–

x

–

–

–

–

–

–

–

ECU part number

ECU part number can be read.

x

x

–

x

x

–

x

x

–

ECU discriminated No.

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

–

–

x

–

–

–

–

–

–

Function test

Conducted by CONSULT-II instead of a technician to determine
whether each system is “OK” or “NG”.

x*2

x

x

x

–

–

–

–

–

Control unit initialization

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

–

–

–

–

–

–

–

–

x

Self-function
check

ECU checks its own NATS communication interface.

–

–

–

–

–

–

–

–

x

Configuration

The vehicle configuration can be read and written on brand-new
BCM and IPDM E/R

–

–

–

–

–

x

x

–

–

I

J

K

M

x: Applicable
*1: Nissan Anti-Theft System
*2: Petrol engine models

Nickel Metal Hydride Battery Replacement

BAS00031

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

GI-35

L

CONSULT-II CHECKING SYSTEM
Checking Equipment

BAS00032

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

Description

NISSAN CONSULT-II
1. CONSULT-II unit (Tester internal soft: Resident
version 3.3.0) and accessories
2. Program card AED06A and AEN06A (For
NATS)
To confirm the best combination of these
softwares, refer to CONSULT-II Operation
Manual.
3. CONSULT-II CONVERTER
4. “CONSULT-II Pigtail” Cable
SAIA0363E

NOTE:
●
The CONSULT-II must be used in conjunction with a program card.
CONSULT-II does not require loading (Initialization) procedure.
●
Be sure the CONSULT-II is turned off before installing or removing a program card.
CAUTION:
●
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carries out CAN communication.
●
If CONVERTER is not connected with CONSULT-II, vehicle occur the “FAIL-SAFE MODE” which is
“LIGHT UP the HEADLIGHT” and/or “Cooling FAN ROTATING” when CONSULT-II is started.
●
Previous CONSULT-II “I” and “Y” DLC-I and DLC-II cables should NOT be used anymore because
their DDL connector pins can be damaged during cable swapping.

CONSULT-II Start Procedure

BAS00033

NOTE:
Turning ignition switch off when performing CAN diagnosis could cause CAN memory to be erased.
1. Connect CONSULT-II and CONSULT-II CONVERTER to the
data link connector.

PAIA0070E

2.
3.

If necessary, turn on the ignition switch.
Touch “START(NISSAN BASED VECL)” or “System Shortcut”
(e.g.: Engine) on the screen.

BCIA0029E

GI-36

CONSULT-II CHECKING SYSTEM
4.

Touch necessary system on “SELECT SYSTEM” screen.
If necessary system is not indicated, check power supply and
ground of system control unit. If it is normal, refer to GI-38,
«CONSULT-II Data Link Connector (DLC) Circuit» .

GI

B

C
BCIA0030E

D

5.

Select the desired part to be diagnosed on the “SELECT DIAG
MODE” screen.
E

F

G
BCIA0031E

H

I

J

K

L

M

GI-37

CONSULT-II CHECKING SYSTEM
CONSULT-II Data Link Connector (DLC) Circuit

BAS00034

MAWA0021E

GI-38

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

Check item
●

CONSULT-II DLC power supply circuit (Terminal and ground circuit (Terminal 4) (For detailed
circuit, refer to “MIL & Data Link Connectors Wiring Diagram” in EC section.)

●

CONSULT-II DLC cable and CONSULT-II CONVERTER

●

CONSULT-II program card (Check the appropriate CONSULT-II program card for the system.
Refer to “Checking Equipment”.)

●

Power supply and ground circuit for the control unit of the system (For detailed circuit, refer to wiring diagram for each system.)

●

Open or short circuit between the system and CONSULT-II DLC (For detailed circuit, refer to wiring
diagram for each system.)

●

Open or short circuit CAN communication line. Refer to LAN-3, «Precautions When Using CONSULT-II» .

CONSULT-II cannot access
any system.

CONSULT-II cannot access
individual system. (Other systems can be accessed.)

GI

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

B

C

D

E

F

G

H

I

J

K

L

M

GI-39

LIFTING POINT
LIFTING POINT
Commercial Service Tools

PFP:00000
BAS00035

Tool name

Description

Board on lift attachment

S-NT001

Safety stand attachment

S-NT002

CAUTION:
●
Every time the vehicle is lifted up, maintain the complete vehicle curb condition.
●
Since the vehicle’s center of gravity changes when removing main parts on the front side (engine,
transmission, suspension etc.), support a jack up point on the rear side garage jack with a mission
jack or equivalent.
●
Since the vehicle’s center of gravity changes when removing main parts on the rear side (rear axle,
suspension, etc.), support a jack up point on the front side garage jack with a mission jack or
equivalent.
●
Be careful not to smash or do not do anything that would affect piping parts.

Garage Jack, Safety Stand and 2-Pole Lift

BAS00036

WARNING:
●
Park the vehicle on a level surface when using the jack. Make sure to avoid damaging pipes,
tubes, etc. under the vehicle.
●
Never get under the vehicle while it is supported only by the jack. Always use safety stands when
you have to get under the vehicle.
●
Place wheel chocks at both front and back of the wheels on the ground.
●
When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear
of the vehicle are well balanced.
●
When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable, fuel lines
and sill spoiler.

GI-40

LIFTING POINT
GI

B

C

D

E

F
MAIB0076E

1.

Safety stand point and lift up point
(front)

4.

Garage jack point (rear)

2.

Safety stand point and lift up point
(rear)

Board-On Lift

3.

Garage jack point (front)

G

BAS00038

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

H

I

J

K

MAIB0030E

L

M

GI-41

TOW TRUCK TOWING
TOW TRUCK TOWING
Tow Truck Towing

PFP:00000
BAS00039

CAUTION:
●
All applicable local laws regarding the towing operation must be obeyed.
●
It is necessary to use proper towing equipment to avoid possible damage to the vehicle during
towing operation. Towing is in accordance with Towing Procedure Manual at dealer.
●
Always attach safety chains before towing.
●
When towing, make sure that the transmission, steering system and power train are in good order.
If any unit is damaged, dollies must be used.
NISSAN recommends that the vehicle is towed with the driving (front) wheels off the ground as illustrated.

MAIB0077E

TOWING AN AUTOMATIC TRANSAXLE MODEL WITH FOUR WHEELS ON GROUND
CAUTION:
Never tow an automatic transaxle model with four wheels on the ground as this may cause serious
and expensive damage to the transaxle.

Vehicle Recovery (Freeing a Stuck Vehicle)

BAS0003A

FRONT
Use the towing hook only, not other parts of the vehicle. Otherwise, the vehicle body will be damaged.
●
Use the towing hook only to free a vehicle stuck in sand, snow,
mud, etc. Never tow the vehicle for a long distance using only
the towing hook.
●
The towing hook is under tremendous force when used to free a
stuck vehicle. Always pull the cable straight out from the front or
rear of the vehicle. Never pull on the hook at an angle.
●
Stand clear of a stuck vehicle.
WARNING:
MAIB0078E
●
Do not spin the tyres at high speed. This could cause them
to explode and result in serious injury. Parts of the vehicle could also overheat and be damaged.
●
Install removable towing hook securely using wheel nut wrench.
●

GI-42

TOW TRUCK TOWING
REAR
GI

Recovery hook is not available.

B

C

MAIB0079E

D

E

F

G

H

I

J

K

L

M

GI-43

TIGHTENING TORQUE OF STANDARD BOLTS
TIGHTENING TORQUE OF STANDARD BOLTS
Tightening Torque Table
Grade

4T

7T

9T

Bolt size

Bolt diameter *
mm

PFP:00000
BAS0003B

Tightening torque (Without lubricant)
Pitch
mm

Hexagon head bolt
N·m

kg-m

Hexagon flange bolt

ft-lb

in-lb

N·m

kg-m

ft-lb

in-lb

M6

6.0

1.0

5.5

0.56

4

49

7

0.71

5

62

M8

8.0

1.25

13.5

1.4

10

—

17

1.7

13

—

1.0

13.5

1.4

10

—

17

1.7

13

—

M10

10.0

1.5

28

2.9

21

—

35

3.6

26

—

1.25

28

2.9

21

—

35

3.6

26

—

M12

12.0

1.75

45

4.6

33

—

55

5.6

41

—

1.25

45

4.6

33

—

65

6.6

48

—

M14

14.0

1.5

80

8.2

59

—

100

10

74

—

M6

6.0

1.0

9

0.92

7

80

11

1.1

8

97

1.25

22

2.2

16

—

28

2.9

21

—

M8

8.0

1.0

22

2.2

16

—

28

2.9

21

—

1.5

45

4.6

33

—

55

5.6

41

—

M10

10.0

1.25

45

4.6

33

—

55

5.6

41

—

1.75

80

8.2

59

—

100

10

74

—

M12

12.0

1.25

80

8.2

59

—

100

10

74

—

M14

14.0

1.5

130

13

96

—

170

17

125

—

M6

6.0

1.0

11

1.1

8

—

13.5

1.4

10

—

1.25

28

2.9

21

—

35

3.6

26

—

M8

8.0

1.0

28

2.9

21

—

35

3.6

26

—

1.5

55

5.6

41

—

80

8.2

59

—

M10

10.0

1.25

55

5.6

41

—

80

8.2

59

—

1.75

100

10

74

—

130

13

96

—

M12

12.0

1.25

100

10

74

—

130

13

96

—

M14

14.0

1.5

170

17

125

—

210

21

155

—

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

MGI044A

GI-44

IDENTIFICATION INFORMATION
IDENTIFICATION INFORMATION
Model Variation
Body

5-door

PFP:00010

GI
BAS0003C

RHD

LHD

Engine

FDLARBF-EEA

FDLALBF-EGA

FDLAREF-EEA

FDLALEF-EGA

FDTARBF-EEA

FDTALBF-EGA

FDTAREF-EEA

FDTALEF-EGA

FDTARTF-EEA

FDTALTF-EGA

Transaxle

Grade

B

Visia
CR14DE

Acenta
JH3

Visia

C

Acenta
Tekna
HR16DE

D

FDTARBA-EEA

FDTALBA-EGA

Visia

FDTAREA-EEA

FDTALEA-EGA

FDTARTA-EEA

FDTALTA-EGA

Tekna

FTKARBF-EEE

FTKALBF-EGE

Visia

FTKAREF-EEE

FTKALEF-EGE

FTKARBF-EEA

FTKALBF-EGA

FTKAREF-EEA

FTKALEF-EGA

FTKARTF-EEA

FTKALTF-EGA

RE4F03B

K9K 50 kW

JH3

Acenta

Acenta

F

Visia
K9K 63 kW

JR5

E

Acenta
Tekna

G

Prefix and suffix designations:
H

I

J

K

L

M

MAIB0073E

GI-45

IDENTIFICATION INFORMATION
IDENTIFICATION NUMBER

MAIB0074E

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT

MAIB0075E

GI-46

IDENTIFICATION INFORMATION
IDENTIFICATION PLATE
GI

B

C

D

E

F
MAIB0019E

G

ENGINE SERIAL NUMBER (CR ENGINE)

H

I

J
MAIA0032E

ENGINE SERIAL NUMBER (HR ENGINE)

K

L

M

STI0429

GI-47

IDENTIFICATION INFORMATION
ENGINE IDENTIFICATION (K9K ENGINE)
Identification is engravFD on the cylinder block which carries:
●
A: engine type,
●
B: engine type approval letter,
●
D: Renault code,
●
E: engine suffix,
●
F: engine fabrication number,
●
G: engine assembly plant.

YGI008

AUTOMATIC TRANSAXLE NUMBER

SGI113A

Dimensions

BAS0003D

Unit: mm (in)
Overall length

4,085 (160.83)

Overall width

1,690 (66.54)

Overall height

1,625 (63.98)

Front tread

1,470 (57.87)

Rear tread

1,460 (57.48)

Wheelbase

2,600 (102.36)

Wheels & Tyres

BAS0003E

Conventional

Spare

Road wheel size/offset mm (in)

15 × 5.5J Steel/45 (1.77)
15 × 5.5J Alminium/45 (1.77)
16 × 6J Aluminum/45 (1.77)

14 × 4T Steel/40 (1.57)
15 × 4T Steel/40 (1.57)

Tyre size

175/65R15
185/65R15
185/55R16

T125/70D14
T125/70D15

GI-48

TERMINOLOGY
TERMINOLOGY
ISO 15031-2 Terminology List

PFP:00011

GI
BAS0003F

All emission related terms used in this publication in accordance with ISO 15031-2 are listed. Accordingly, new
terms, new acronyms/abbreviations and old terms are listed in the following chart.
NEW ACRONYM /
ABBREVIATION

NEW TERM
Air cleaner

ACL

B

OLD TERM
Air cleaner

Barometric pressure

BARO

***

Barometric pressure sensor-BCDD

BAROS-BCDD

BCDD

Camshaft position

CMP

***

Camshaft position sensor

CMPS

Crank angle sensor

Canister

***

Canister

Carburetor

CARB

Carburetor

Charge air cooler

CAC

Intercooler

Closed loop

CL

Closed loop

Closed throttle position switch

CTP switch

Idle switch

Clutch pedal position switch

CPP switch

Clutch switch

Continuous fuel injection system

CFI system

***

Continuous trap oxidizer system

CTOX system

***

Crankshaft position

CKP

***

Crankshaft position sensor

CKPS

***

Data link connector

DLC

***

Data link connector for CONSULT-II

DLC for CONSULT-II

Diagnostic connector for CONSULT-II

Diagnostic test mode

DTM

Diagnostic mode

Diagnostic test mode selector

DTM selector

Diagnostic mode selector

Diagnostic test mode I

DTM I

Mode I

Diagnostic test mode II

DTM II

Mode II

Diagnostic trouble code

DTC

Malfunction code

Direct fuel injection system

DFI system

***

Distributor ignition system

DI system

Ignition timing control

Early fuel evaporation-mixture heater

EFE-mixture heater

Mixture heater

Early fuel evaporation system

EFE system

Mixture heater control

Electrically erasable programmable read
only memory

EEPROM

***

Electronic ignition system

EI system

Ignition timing control

Engine control

EC

***

C

D

E

F

G

H

I

J

K

L

M

Engine control module

ECM

ECCS control unit

Engine coolant temperature

ECT

Engine temperature

Engine coolant temperature sensor

ECTS

Engine temperature sensor

Engine modification

EM

***

Engine speed

RPM

Engine speed

Erasable programmable read only memory

EPROM

***

Evaporative emission canister

EVAP canister

Canister

Evaporative emission system

EVAP system

Canister control solenoid valve

Exhaust gas recirculation valve

EGR valve

EGR valve

GI-49

TERMINOLOGY
NEW ACRONYM /
ABBREVIATION

NEW TERM

OLD TERM

Exhaust gas recirculation control-BPT
valve

EGRC-BPT valve

BPT valve

Exhaust gas recirculation control-solenoid
valve

EGRC-solenoid valve

EGR control solenoid valve

EGRT sensor

Exhaust gas temperature sensor

Flash electrically erasable programmable
read only memory

FEEPROM

***

Flash erasable programmable read only
memory

FEPROM

***

Flexible fuel sensor

FFS

***

Flexible fuel system

FF system

***

Fuel pressure regulator

***

Pressure regulator

Fuel pressure regulator control solenoid
valve

***

PRVR control solenoid valve

Fuel trim

FT

***

Heated Oxygen sensor

HO2S

Exhaust gas sensor

Idle air control system

IAC system

Idle speed control

Idle air control valve-air regulator

IACV-air regulator

Air regulator

Idle air control valve-auxiliary air control
valve

IACV-AAC valve

Auxiliary air control (AAC) valve

Idle air control valve-FICD solenoid valve

IACV-FICD solenoid valve

FICD solenoid valve

Idle air control valve-idle up control solenoid valve

IACV-idle up control solenoid valve

Idle up control solenoid valve

Exhaust gas recirculation temperature sensor
EGR temperature sensor

Idle speed control-FI pot

ISC-FI pot

FI pot

Idle speed control system

ISC system

***

Ignition control

IC

***

Ignition control module

ICM

***

Indirect fuel injection system

IFI system

***

Intake air

IA

Air

Intake air temperature sensor

IAT sensor

Air temperature sensor

Knock

***

Detonation

Knock sensor

KS

Detonation sensor

Malfunction indicator lamp

MIL

Check engine light

Manifold absolute pressure

MAP

***

Manifold absolute pressure sensor

MAPS

***

Manifold differential pressure

MDP

***

Manifold differential pressure sensor

MDPS

***

Manifold surface temperature

MST

***

Manifold surface temperature sensor

MSTS

***

Manifold vacuum zone

MVZ

***

Manifold vacuum zone sensor

MVZS

***

Mass air flow sensor

MAFS

Air flow meter

Mixture control solenoid valve

MC solenoid valve

Air-fuel ratio control solenoid valve

Multiport fuel injection System

MFI system

Fuel injection control

GI-50

TERMINOLOGY
NEW ACRONYM /
ABBREVIATION

NEW TERM

OLD TERM

Nonvolatile random access memory

NVRAM

***

On board diagnostic system

OBD system

Self-diagnosis

Open loop

OL

Open loop

Oxidation catalyst

OC

Catalyst

Oxidation catalytic converter system

OC system

***

Oxygen sensor

O2S

Exhaust gas sensor

Park position switch

***

Park switch

Park/neutral position switch

PNP switch

Park/neutral switch
Inhibitor switch
Neutral position switch

Periodic trap oxidizer system

PTOX system

***

Positive crankcase ventilation

PCV

Positive crankcase ventilation

Positive crankcase ventilation valve

PCV valve

PCV valve

Powertrain control module

PCM

***

Programmable read only memory

PROM

***

Pulsed secondary air injection control solenoid valve

PAIRC solenoid valve

AIV control solenoid valve

Pulsed secondary air injection system

PAIR system

Air induction valve (AIV) control

Pulsed secondary air injection valve

PAIR valve

Air induction valve

Random access memory

RAM

***

Read only memory

ROM

***

Scan tool

ST

***

Secondary air injection pump

AIR pump

***

Secondary air injection system

AIR system

***

Sequential multiport fuel injection system

SFI system

Sequential fuel injection

Service reminder indicator

SRI

***

Simultaneous multiport fuel injection system

***

Simultaneous fuel injection

Smoke puff limiter system

SPL system

***

Supercharger

SC

***

Supercharger bypass

SCB

***

System readiness test

SRT

***

Thermal vacuum valve

TVV

Thermal vacuum valve

Three way catalyst

TWC

Catalyst

Three way catalytic converter system

TWC system

***

Three way + oxidation catalyst

TWC + OC

Catalyst

Three way + oxidation catalytic converter
system

TWC + OC system

***

Throttle body

TB

Throttle chamber
SPI body

Throttle body fuel injection system

TBI system

Fuel injection control

Throttle position

TP

Throttle position

Throttle position sensor

TPS

Throttle sensor

Throttle position switch

TP switch

Throttle switch

Torque converter clutch solenoid valve

TCC solenoid valve

Lock-up cancel solenoid
Lock-up solenoid

GI-51

GI

B

C

D

E

F

G

H

I

J

K

L

M

TERMINOLOGY
NEW ACRONYM /
ABBREVIATION

NEW TERM

OLD TERM

Transmission control module

TCM

A/T control unit

Turbocharger

TC

Turbocharger

Vehicle speed sensor

VSS

Vehicle speed sensor

Volume air flow sensor

VAFS

Air flow meter

Warm up oxidation catalyst

WU-OC

Catalyst

Warm up oxidation catalytic converter system

WU-OC system

***

Warm up three way catalyst

WU-TWC

Catalyst

Warm up three way catalytic converter system

WU-TWC system

***

Wide open throttle position switch

WOTP switch

Full switch

***: Not applicable

GI-52

GLASSES, WINDOW SYSTEM & MIRRORS

I BODY

SECTION

GW

GLASSES, WINDOW SYSTEM & MIRRORS

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 3
Maintenance Information …………………………………… 3
RHD MODELS ……………………………………………… 3
LHD MODELS ………………………………………………. 3
PrecautionsforProcedureswithoutCowlTopCover….. 3
Precautions …………………………………………………….. 3
WINDSHIELD GLASS ………………………………………… 5
Removal and Installation …………………………………… 5
REMOVAL ……………………………………………………. 5
INSTALLATION …………………………………………….. 6
SIDE WINDOW GLASS ………………………………………. 8
Removal and Installation …………………………………… 8
REMOVAL ……………………………………………………. 8
INSTALLATION …………………………………………….. 8
BACK DOOR WINDOW GLASS ………………………… 10
Removal and Installation …………………………………. 10
REMOVAL ………………………………………………….. 10
INSTALLATION …………………………………………….11
REAR WINDOW DEFOGGER ……………………………. 12
Component Parts and Harness Connector Location… 12
System Description ………………………………………… 12
CAN Communication ………………………………………. 14
SYSTEM DESCRIPTION ……………………………… 14
CAN Communication Unit ……………………………….. 14
Schematic …………………………………………………….. 15
Wiring Diagram — DEF — ………………………………. 16
Terminal and Reference Value for BCM …………….. 19
Terminal and Reference Value for IPDM E/R ……… 19
Work Flow …………………………………………………….. 19
CONSULT-II Inspection Procedure …………………… 19
DATA MONITOR …………………………………………. 19
ACTIVE TEST …………………………………………….. 20
Trouble Diagnoses Symptom Chart ………………….. 20
Check BCM Power Supply and Ground Circuit …… 21
Check Rear Window Defogger Switch Circuit / With
Auto A/C ……………………………………………………….. 22
Check Rear Window Defogger Switch Circuit / With-

out Auto A/C ………………………………………………….. 23
Check Rear Window Defogger Power Supply Circuit ……………………………………………………………….. 25
Check Rear Window Defogger Circuit ……………….. 26
Check Door Mirror Defogger Power Supply Circuit… 27
Check Driver Side Door Mirror Defogger Circuit … 28
CheckPassengerSideDoorMirrorDefoggerCircuit
… 29
Filament Check ………………………………………………. 30
Filament Repair ……………………………………………… 31
REPAIR EQUIPMENT ………………………………….. 31
REPAIRING PROCEDURE …………………………… 31
POWER WINDOW SYSTEM ……………………………… 32
Component Parts and Harness Connector Location… 32
System Description (With Front Power Window) … 32
DRIVER DOOR …………………………………………… 32
PASSENGER DOOR [FRONT POWER WINDOW SWITCH (PASSENGER SIDE) OPERATION] …………………………………………………………. 33
PASSENGER DOOR (POWER WINDOW MAIN
SWITCH OPERATION) ………………………………… 33
AUTO OPERATION ……………………………………… 34
POWER WINDOW LOCK …………………………….. 34
ANTI-PINCH SYSTEM …………………………………. 34
INITIALIZATION ………………………………………….. 34
System Description (With Front & Rear Power Window) ……………………………………………………………… 35
DRIVER DOOR …………………………………………… 35
PASSENGER DOOR [FRONT POWER WINDOW SWITCH (PASSENGER SIDE) OPERATION] …………………………………………………………. 36
PASSENGER DOOR (POWER WINDOW MAIN
SWITCH OPERATION) ………………………………… 36
REAR DOOR (RH OR LH) [REAR POWER WINDOW SWITCH (RH OR LH) OPERATION] ……… 37
REAR DOOR (RH OR LH) (POWER WINDOW
MAIN SWITCH OPERATION) ……………………….. 37
AUTO OPERATION ……………………………………… 38
POWER WINDOW LOCK …………………………….. 38
ANTI-PINCH SYSTEM …………………………………. 38

GW-1

E

F

G

H

GW

J

K

L

M

INITIALIZATION ………………………………………….. 38
Schematic/With Front Power Window ……………….. 40
Wiring Diagram — WINDOW —/With Front Power
Window …………………………………………………………. 41
Schematic/With Front & Rear Power Window …….. 44
Wiring Diagram — WINDOW —/With Front & Rear
Power Window ……………………………………………….. 45
Terminal and Reference Value for BCM …………….. 49
Terminal and Reference Value for Power Window
Main Switch/With Front Power Window (For LHD
Models) …………………………………………………………. 49
Terminal and Reference Value for Power Window
Main Switch/With Front Power Window (For RHD
Models) …………………………………………………………. 50
Terminal and Reference Value for Power Window
Main Switch/With Front & Rear Power Window …… 51
Work Flow ……………………………………………………… 52
Trouble Diagnosis Symptom Chart ……………………. 53
Check BCM Power Supply and Ground Circuit …… 54
Check Power Window Main Switch Power Supply
and Ground Circuit …………………………………………. 55
WITH FRONT POWER WINDOW ………………….. 55
WITH FRONT & REAR POWER WINDOW …….. 56
Check Front Power Window Motor (Driver Side) Circuit ……………………………………………………………….. 58
WITH FRONT POWER WINDOW ………………….. 58
WITH FRONT & REAR POWER WINDOW …….. 60
Check Front Power Window Motor (Passenger
Side) Circuit …………………………………………………… 61
WITH FRONT POWER WINDOW ………………….. 61
WITH FRONT & REAR POWER WINDOW …….. 65
Check Rear Power Window Motor RH Circuit …….. 68
Check Rear Power Window Motor LH Circuit ……… 71
Check Limit Switch Circuit (Driver Side) …………….. 75
WITH FRONT POWER WINDOW ………………….. 75
WITH RFONT & REAR POWER WINDOW …….. 78
Check Encoder Circuit (Driver Side) ………………….. 80

WITH FRONT POWER WINDOW …………………..80
WITH FRONT & REAR POWER WINDOW ………85
Check Power Window Lock Switch …………………….88
FRONT DOOR GLASS AND REGULATOR ………….89
Removal and Installation …………………………………..89
DOOR GLASS ……………………………………………..89
REGULATOR ASSENBLY ……………………………..90
Inspection after Installation ……………………………….91
SYSTEM INITIALIZATION ……………………………..91
INSPECT THE FUNCTION OF THE ANTIPINCH SYSTEM. ………………………………………….92
FITTING INSPECTION ………………………………….92
REAR DOOR GLASS AND REGULATOR ……………93
Removal and Installation …………………………………..93
DOOR GLASS ……………………………………………..93
REGULATOR ASSEMBLY ……………………………..94
INSPECTION AFTER INSTALLATION …………….95
DOOR MIRROR …………………………………………………96
Wiring Diagram — MIRROR — LHD Models (With
Retract) ………………………………………………………….96
Wiring Diagram — MIRROR — RHD Models (With
Retract) ………………………………………………………….98
Wiring Diagram — MIRROR — LHD Models (Without Retract) ………………………………………………….. 100
Removal and Installation ………………………………… 101
REMOVAL …………………………………………………. 101
INSTALLATION ………………………………………….. 101
Disassembly and Assembly ……………………………. 102
DISASSEMBLY ………………………………………….. 102
ASSEMBLY ……………………………………………….. 103
INSIDE MIRROR …………………………………………….. 104
Removal and Installation ………………………………… 104
REMOVAL …………………………………………………. 104
INSTALLATION ………………………………………….. 104
Removal and Installation (With Rain Sensor) ……. 104
REMOVAL …………………………………………………. 104
INSTALLATION ………………………………………….. 104

GW-2

PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

A

BIS000MM

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Maintenance Information

B

C

D

E

F

BIS0016I

If any of following part is replaced, always replace with new* one.
If it’s not (or fail to do so), the electrical system may not be operated properly.
*: New one means a virgin control unit that has never been energized on-board.

G

RHD MODELS

H

●
●
●
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM
IPDM E/R
Combination meter
EPS control unit

GW

J

LHD MODELS
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM

Precautions for Procedures without Cowl Top Cover

K

L
BIS000MN

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

M

PIIB3706J

Precautions
●

●
●
●

BIS000MO

When removing or disassembling any part, be careful not to damage or deform it. Protect parts, which
may get in the way with cloth.
When removing parts with a screwdriver or other tool, protect parts by wrapping them with vinyl or tape.
Keep removed parts protected with cloth.
If a clip is deformed or damaged, replace it.

GW-3

PRECAUTIONS
If an unreusable part is removed, replace it with a new one.
Tighten bolts and nuts firmly to the specified torque.
●
After re-assembly has been completed, make sure each part functions correctly.
●
Remove stains in the following way.
Water-soluble stains:
Dip a soft cloth in warm water, and then squeeze it tightly. After wiping the stain, wipe with a soft dry cloth.
Oil stain:
Dissolve a synthetic detergent in warm water (density of 2 to 3% or less), dip the cloth, then clean off the stain
with the cloth. Next, dip the cloth in fresh water and squeeze it tightly. Then clean off the detergent completely.
Then wipe the area with a soft dry cloth.
●
Do not use any organic solvent, such as thinner or benzine.
●
●

GW-4

WINDSHIELD GLASS
WINDSHIELD GLASS
Removal and Installation

PFP:72712

A
BIS000MP

B

C

D

E

F

G

H

GW

J

K

L

M

MIIB1430E

1.

Windshield molding

2.

Windshield glass

4.

Dam sealant

5.

Sealant

6.

3.

Clip
Primer

7.

Mirror base

8.

Roof side outer panel

9.

Body side outer panel

10. Rain sensor base

REMOVAL
1.
2.
3.
4.

Remove inside mirror. Refer to GW-104, «INSIDE MIRROR»
Remove front pillar garnish. Refer to EI-26, «BODY SIDE TRIM»
Remove headlining. Refer to EI-30, «HEADLINER» .
Remove front wiper arm. Refer to WW-42, «Removal and Installation of Front Wiper Arms, Adjustment of
Wiper Arms Stop Location»

GW-5

WINDSHIELD GLASS
5.

Remove cowl top cover. Refer to EI-12, «COWL TOP» .

6. Apply a protective tape around the windshield glass to protect the painted surface from damage.
7. Remove glass using piano wire or power cutting tool A and an inflatable pump bag B.
NOTE:
If a windshield glass will be reused, mark the body and the glass with mating marks.
WARNING:
When cutting the glass from the vehicle, always wear safety glasses and heavy gloves to help prevent
glass splinters from entering your eyes or cutting your hands.
CAUTION:
●
When a windshield glass is reused, do not use a cutting knife or power cutting tool.
●
Be careful not to scratch the glass when removing.
●
Do not set or stand the glass on its edge. Small chips may develop into cracks.

PIIB5779E

8.

Remove the windshield glass, using suction lifter.

INSTALLATION
The dam rubber should be installed in position.
●
Use a genuine Nissan Urethane Adhesive Kit (if available) or equivalent and follow the instructions furnished with it.
●
While the urethane adhesive is curing, open a door window. This will prevent the glass from being forced
out by passenger compartment air pressure when a door is closed.
●
The fastener and the molding must be installed securely so that it is in position and leaves no gap. Install
the moldings in order of lower to upper corner, connect joint, and then corner to center.
●
Inform the customer that the vehicle should remain stationary until the urethane adhesive has completely
cured (preferably 24 hours). Curing time varies with temperature and humidity.
WARNING:
●
Keep heat and open flames away as primers and adhesive are flammable.
●
The materials contained in the kit are harmful if swallowed, and may irritate skin and eyes. Avoid
contact with the skin and eyes.
●
Use in an open, well ventilated location. Avoid breathing the vapors. They can be harmful if
inhaled. If affected by vapor inhalation, immediately move to an area with fresh air.
●
Driving the vehicle before the urethane adhesive has completely cured may affect the performance of the windshield in case of an accident.
CAUTION:
●
Do not use an adhesive which is past its usable term. Shelf life of this product is limited to six
months after the date of manufacture. Carefully adhere to the expiration or manufacture date
printed on the box.
●
Keep primers and adhesive in a cool, dry place. Ideally, they should be stored in a refrigerator.
●
Do not leave primers or adhesive cartridge unattended with their caps open or off.
●
The vehicle should not be driven for at least 24 hours or until the urethane adhesive has completely cured. Curing time varies depending on temperature and humidity. The curing time will
increase under lower temperature and lower humidity.
●

Repairing Water Leaks
Leaks can be repaired without removing and reinstalling glass.

GW-6

WINDSHIELD GLASS
If water is leaking between the urethane adhesive material and body or glass, determine the extent of leakage.
This can be done by applying water to the windshield area while pushing glass outward.
To stop the leak, apply primer (if necessary) and then urethane adhesive to the leak point.

A

B

C

D

E

F

G

H

GW

J

K

L

M

GW-7

SIDE WINDOW GLASS
SIDE WINDOW GLASS
Removal and Installation

PFP:83300
BIS000MQ

MIIB1431E

1.

Side window glass

2.

Sealant

3.

Primer

4.

Body side outer panel

5.

Spacer

6.

Clip

REMOVAL
1. Remove rear pillar finisher. Refer to EI-26, «BODY SIDE TRIM»
2. Apply a protective tape around the side window glass to protect the painted surface from damage.
Remove side window glass using piano wire or power cutting tool and an inflatable pump bag.
WARNING:
When cutting the glass from the vehicle, always wear safety glasses and heavy gloves to help prevent
glass splinters from entering your eyes or cutting your hands.
CAUTION:
●
Be careful not to scratch the glass when removing.
●
Do not set or stand the glass on its edge. Small chips may develop into cracks.

INSTALLATION
●

Use a genuine Nissan Urethane Adhesive Kit (if available) or equivalent and follow the instructions furnished with it.

GW-8

SIDE WINDOW GLASS
While the urethane adhesive is curing, open a door window. This will prevent the glass from being forced
out by passenger room air pressure when a door is closed.
●
The molding must be installed securely so that it is in position and leaves no gap.
●
Inform the customer that the vehicle should remain stationary until the urethane adhesive has completely
cured (preferably 24 hours). Curing time varies with temperature and humidity.
WARNING:
●
Keep heat and open flames away as primers and adhesive are flammable.
●
The materials contained in the kit are harmful if swallowed, and may irritate skin and eyes. Avoid
contact with the skin and eyes.
●
Use in an open, well ventilated location. Avoid breathing the vapors. They can be harmful if
inhaled. If affected by vapor inhalation, immediately move to an area with fresh air.
●
Driving the vehicle before the urethane adhesive has completely cured may affect the performance of the side window in case of an accident.
CAUTION:
●
Do not use an adhesive which is past its usable term. Shelf life of this product is limited to six
months after the date of manufacture. Carefully adhere to the expiration or manufacture date
printed on the box.
●
Keep primers and adhesive in a cool, dry place. Ideally, they should be stored in a refrigerator.
●
Do not leave primers or adhesive cartridge unattended with their caps open or off.
●
The vehicle should not be driven for at least 24 hours or until the urethane adhesive has completely cured. Curing time varies depending on temperature and humidities. The curing time will
increase under lower temperature and lower humidity.
●

Repairing Water Leaks

A

B

C

D

E

F

G

H

Leaks can be repaired without removing and reinstalling glass.
If water is leaking between the urethane adhesive material and body or glass, determine the extent of leakage.
This can be done by applying water to the side window area while pushing glass outward.
GW
To stop the leak, apply primer (if necessary) and then urethane adhesive to the leak point.
J

K

L

M

GW-9

BACK DOOR WINDOW GLASS
BACK DOOR WINDOW GLASS
Removal and Installation

PFP:90300
BIS000MR

MIIB1432E

1.

Back door window molding

2.

Back door window glass

3.

Clip

4.

Spacer

5.

Sealant

6.

Primer

7.

Back door outer panel

REMOVAL
1.
2.
3.

Remove back door finisher inner. Refer to EI-22, «BACK DOOR TRIM» .
Remove rear wiper arm. Refer to WW-69, «Removal and Installation of Rear Wiper Arm, Adjustment of
Wiper Arm Stop Location»
Apply protective tape around windshield glass to protect the painted surface from damage.

GW-10

BACK DOOR WINDOW GLASS
4.

After removing molding, remove glass using cutting knife or power cutting tool and an inflatable pump
bag.

A

B

C

D
PIIB0908E

5.

NOTE:
If a back door window glass is to be reused, mark the body and the glass with mating marks.
WARNING:
When cutting the glass from the vehicle, always wear safety glasses and heavy gloves to help prevent glass splinters from entering your eyes or cutting your hands.
CAUTION:
● When a rear window glass is reused, do not use a cutting knife or power cutting tool.
● Be careful not to scratch the glass when removing.
● Do not set or stand the glass on its edge. Small chips may develop into cracks.
Remove the back door window glass, using suction liter.

E

F

G

H

INSTALLATION

Use a genuine Nissan Urethane Adhesive Kit (if available) or equivalent and follow the instructions furnished with it.
GW
●
While the urethane adhesive is curing, open a door window. This will prevent the glass from being forced
out by passenger room air pressure when a door is closed.
●
The molding must be installed securely so that it is in position and leaves no gap.
J
●
Inform the customer that the vehicle should remain stationary until the urethane adhesive has completely
cured (preferably 24 hours). Curing time varies with temperature and humidity.
WARNING:
K
●
Keep heat and open flames away as primers and adhesive are flammable.
●
The materials contained in the kit are harmful if swallowed, and may irritate skin and eyes. Avoid
contact with the skin and eyes.
L
●
Use in an open, well ventilated location. Avoid breathing the vapors. They can be harmful if
inhaled. If affected by vapor inhalation, immediately move to an area with fresh air.
●
Driving the vehicle before the urethane adhesive has completely cured may affect the perforM
mance of the back door window glass in case of an accident.
CAUTION:
●
Do not use an adhesive which is past its usable term. Shelf life of this product is limited to six
months after the date of manufacture. Carefully adhere to the expiration or manufacture date
printed on the box.
●
Keep primers and adhesive in a cool, dry place. Ideally, they should be stored in a refrigerator.
●
Do not leave primers or adhesive cartridge unattended with their caps open or off.
●
The vehicle should not be driven for at least 24 hours or until the urethane adhesive has completely cured. Curing time varies depending on temperature and humidity. The curing time will
increase under lower temperature and lower humidity.
●

Repairing Water Leaks
Leaks can be repaired without removing and reinstalling glass.
If water is leaking between the urethane adhesive material and body or glass, determine the extent of leakage.
This can be done by applying water to the side window area while pushing glass outward.
To stop the leak, apply primer (if necessary) and then urethane adhesive to the leak point.

GW-11

REAR WINDOW DEFOGGER
REAR WINDOW DEFOGGER
Component Parts and Harness Connector Location

PFP:25350
BIS000MS

MIIB1361E

1.

BCM (Body Control Module)
M57, M59

2.

Rear Window defogger switch
(Built in A/C auto amp.)
M64, M65
(With auto A/C models)

4.

Rear window defogger connector
B49

5.

IPDM E/R E11,E12

System Description

3.

Rear Window defogger switch
(Built in heater control panel)
M62
(Without auto A/C models)

BIS000MT

The rear window defogger system is controlled by BCM (Body Control Module) and IPDM E/R (Intelligent
Power Distribution Module Engine Room).
The rear window defogger operates only for approximately 15 minutes.
Power is at all times supplied
●
through 15A fuse [No. 55, and 56, located in the IPDM E/R]
●
to rear window defogger relay
●
through 20A fuse [No. 61 (with gasoline engine) and 62, located in the fuse block (J/B)]
●
to IPDM E/R
●
through 40A fusible link [letter J , located in the fuse block (J/B)]
●
to BCM terminal 74 and 79
●
through 10A fuse [No. 7, located in the fuse block (J/B)]
●
to A/C auto amp terminal 1.
With the ignition switch turned to ON or START position,
Power is supplied
●
through 10A fuse [No. 5, located in the fuse block (J/B)]
●
to BCM terminal 24
●
to A/C auto amp terminal 17.
Ground is supplied

GW-12

REAR WINDOW DEFOGGER
to BCM terminal 2 and 70
A
through body grounds M21, and M66.
●
to A/C auto amp terminal 10 (with auto A/C)
●
to heater control panel terminal 8 (without auto A/C)
B
●
through body grounds M21 and M66.
●
to internal CPU of IPDM E/R terminal 3 and 54
●
through body grounds E28 and E44.
C
When rear window defogger switch is turned to ON,
Ground is supplied
●
to BCM terminal 4
D
●
through A/C auto amp terminal 14 (with auto A/C)
●
through heater control panel terminal 3 (without auto A/C)
●
through A/C auto amp terminal 10 (with auto A/C)
E
●
through heater control panel terminal 8 (without auto A/C)
●
through body grounds M21 and M66.
F
Then rear window defogger switch is illuminated.
Then BCM recognizes that rear window defogger switch is turned to ON.
Then it sends rear window defogger switch signals to IPDM E/R via DATA LINE (CAN-H, CAN-L).
When IPDM receives rear window defogger switch signals,
G
Ground is supplied
●
to rear window defogger relay terminal
●
through internal CPU of IPDM E/R terminal
H
●
through internal CPU of IPDM E/R and IPDM E/R terminal 54
●
through body grounds E28 and E44.
GW
and then rear window defogger relay is energized.
When rear window defogger relay is turned ON,
Power is supplied,
J
●
through rear window defogger relay terminals
●
through IPDM E/R terminal 8
●
to rear window defogger terminal 1.
K
Rear window defogger is grounded.
With power and ground supplied, rear window defogger filaments heat and defog the rear window.
When rear window defogger relay is turned to ON,
Power is supplied (with mirror defogger)
L
●
through rear window defogger relay terminal
●
through IPDM E/R terminal 8
M
●
through 10A fuse [No. 2, located in the fuse block (J/B)]
●
to door mirror defogger (Driver side and passenger side) terminal 2.
Door mirror defogger (Driver side and passenger side) terminal 3 is grounded through body grounds M21 and
M66.
With power and ground supplied, door mirror defogger filaments heat and defog the mirror.
●
●

GW-13

REAR WINDOW DEFOGGER
CAN Communication

BIS000MU

SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

CAN Communication Unit

BIS000MV

Refer to LAN-27, «CAN Communication Unit» .

GW-14

REAR WINDOW DEFOGGER
Schematic

BIS000MW

A

B

C

D

E

F

G

H

GW

J

K

L

M

MIWA0670E

GW-15

REAR WINDOW DEFOGGER
Wiring Diagram — DEF —

BIS000MX

MIWA0671E

GW-16

REAR WINDOW DEFOGGER
A

B

C

D

E

F

G

H

GW

J

K

L

M

MIWA0672E

GW-17

REAR WINDOW DEFOGGER

MIWA0673E

GW-18

REAR WINDOW DEFOGGER
Terminal and Reference Value for BCM

BIS000MY

A
Terminal

Wire
color

2

B

Ground

W

Rear window defogger
switch signal

4

Item

Signal
Input/
Output

Condition

Voltage (V)
(Approx.)

—

—

0

Input

B
When rear window defogger switch is
pressed.

0

When rear window defogger switch is
OFF.

5

Input/
Output

19

L

CAN- H

24

O

Ignition switch ON or START

39

Y

CAN- L

Input/
Output

—

—

70

B

Ground

—

—

0

74

Y

BAT power supply

Input

—

Battery voltage

79

Y

BAT power supply

Input

—

Battery voltage

Input

—

C

Ignition switch (ON or START position)

Battery voltage

Terminal and Reference Value for IPDM E/R
Condition

Voltage (V)
(Approx.)

—

—

0

When rear window defogger switch is ON.

Battery voltage

When rear window defogger switch is OFF.

0

Input/
Output

—

—

—

—

0

Input/
Output

—

—

Wire
color

3

B

Ground (Power)

8

R

Rear window defogger relay
output signal

Output

52

L

CAN- H

54

B

Ground (Signal)

58

Y

CAN- L

Item

4.
5.

F

H

GW

K
BIS000N0

Check the symptom and customer’s requests.
Understand the outline of system. Refer to GW-12, «System Description» .
According to the trouble diagnosis chart, repair or replace the cause of the malfunction. Refer to GW-20,
«Trouble Diagnoses Symptom Chart» .
Does rear window defogger operate normally? YES: GO TO 5, NO: GO TO 3.
INSPECTION END.

CONSULT-II Inspection Procedure

BIS000N1

Inspection Item, Diagnosis Mode

Description

DATA MONITOR

The input/output data of the BCM is displayed in real time.

ACTIVE TEST

The BCM sends a drive signal to electronic components to check their operation.

Refer to GI-36, «CONSULT-II Start Procedure» .

DATA MONITOR
Display Item List
Monitor item “Operation”
REAR DEF SW

G

J

Work Flow
1.
2.
3.

E

BIS000MZ

Signal
Input/
Output

Terminal

D

—

“ON / OFF”

Content
Displays “Press (ON) / others (OFF)” status determined with the rear window defogger
switch.

GW-19

L

M

REAR WINDOW DEFOGGER
Monitor item “Operation”

Content

IGN ON SW

“ON / OFF”

Displays “IGN SW ON (ON) / OFF (OFF)” status determined with the ignition switch signal.

ENGINE STATUS

“STOP / STALL
/ RUN / CRA ”

Displays “Engine stop (STOP) / engine stall (STALL) / engine running (RUN) / engine
cranking (CRA) ” as judged from engine status.

ACTIVE TEST
Display Item List
Test item

Content

REAR DEFOGGER

Gives a drive signal to the rear window defogger to activate it.

Trouble Diagnoses Symptom Chart
●

BIS000N2

Check that other systems using the signal of the following systems operate normally.
Symptom

Diagnoses / service procedure

Refer to page

1.

Check BCM power supply and ground circuit.

GW-21

2.

Check IPDM E/R auto active test.

PG-22

3.

Check rear window defogger switch circuit (with
auto A/C).

GW-22

3.

Check rear window defogger switch circuit (without
auto A/C).

GW-23

4.

Check rear window defogger power supply circuit.

GW-25

5.

Replace IPDM E/ R.

PG-37

1.

Check BCM power supply and ground circuit.

GW-21

2.

Check IPDM E/R auto active test.

PG-22

3.

Check rear window defogger switch circuit (with
auto A/C).

GW-22

3.

Check rear window defogger switch circuit (without
auto A/C).

GW-23

4.

Check rear window defogger power supply circuit.

GW-25

5.

Check rear window defogger circuit.

GW-26

6.

Check filament.

GW-30

7.

Replace IPDM E/ R.

PG-37

1.

Check rear window defogger circuit.

GW-26

2.

Check filament.

GW-30

Both of door mirror defoggers do not operated but rear
window defogger operate. (With door mirror defogger)

1.

Check door mirror defogger power supply circuit.

GW-27

Driver side door mirror defogger does not operated.
(With door mirror defogger)

1.

Check driver side door mirror defogger circuit.

GW-28

Passenger side door mirror defogger does not operated.
(With door mirror defogger)

1.

Check passenger side door mirror defogger circuit.

GW-29

Rear window defogger and door mirror defogger do not
operate. (With door mirror defogger)

Rear window defogger does not operated.
(without door mirror defogger)

Rear window defogger does not operate but both of door
mirror defoggers operate. (With door mirror defogger)

GW-20

REAR WINDOW DEFOGGER
Check BCM Power Supply and Ground Circuit

BIS000N3

First perform the “SELF-DIAG RESULTS” in “BCM” with CONSULT-II, then perform the each trouble diagnosis of malfunction system indicated “SELF-DIAG RESULTS” of “BCM”, Refer to BCS-9,
«CONSULT-II Function (BCM)» .

1. FUSE INSPECTION
Check 10A fuse [No. 5, located in fuse block (J/B)]
●
Check 40A fusible link (letter J located in the fuse and fusible link box).
NOTE:
Refer to GW-12, «Component Parts and Harness Connector Location» .
OK or NG
OK
>> GO TO 2.
NG
>> If fuse is blown out, be sure to eliminate cause of malfunction before installing new fuse. Refer to
PG-4, «POWER SUPPLY ROUTING CIRCUIT» .

A

B

●

C

D

E

2. CHECK POWER SUPPLY CIRCUIT
1.
2.

F

Turn ignition switch ON.
Check voltage between BCM connector M57, M59 terminal 24, 74, 79 and ground.
24 – Ground
74 – Ground
79 – Ground

G

:Battery voltage.
:Battery voltage.
:Battery voltage.

H

OK or NG
OK
>> GO TO 3.
NG
>> Check BCM power supply circuit for open or short.

GW

MIIB0667E

J

3. CHECK GROUND CIRCUIT
1.
2.
3.

K

Turn ignition switch OFF.
Disconnect BCM connector.
Check continuity between BCM connector M57, M59 terminal 2, 70 and ground.
2 – Ground
70 – Ground

L

:Continuity should exist.
:Continuity should exist.

M

OK or NG
OK
>> Power supply and ground circuit is OK.
NG
>> Check BCM ground circuit for open or short.

MIIB0093E

GW-21

REAR WINDOW DEFOGGER
Check Rear Window Defogger Switch Circuit / With Auto A/C

BIS000N4

1. CHECK REAR WINDOW DEFOGGER SWITCH OPERATION
With CONSULT-II
Check (“REAR DEF SW”, “IGN ON SW”) in DATA MONITOR mode
with CONSULT-II. Refer to GW-19 .
When engine is running
ENGINE STATUS
:RUN
When rear defogger switch is turned to ON
REAR DEF SW
:ON
When ignition switch is turned to ON
IGN ON SW
:ON
MKIB0549E

Without CONSULT-II
1. Turn ignition switch ON.
2. Check voltage between BCM connector ground.
Connector

Terminal (Wire color)
(+)

M57

Voltage (V)
(Approx.)

Condition

(–)

4

Ground

Rear window defogger
switch is pressed.

0

Rear window defogger
switch is OFF.

5

OK or NG
OK
>> Rear window defogger switch check is OK.
NG
>> GO TO 2.

MIIB0094E

2. CHECK REAR WINDOW DEFOGGER SWITCH CIRCUIT HARNESS CONTINUITY
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM and A/C auto amp connector.
Check continuity between BCM connector and A/C auto amp connector.
A

4.

B
Continuity

BCM connector

Terminal

A/C auto amp
connector

Terminal

M57

4

M64

14

Yes

Check continuity between BCM connector and ground.
A

Continuity

BCM connector

Terminal

M57

4

Ground
No

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness between BCM and A/C auto amp.

GW-22

MIIB1362E

REAR WINDOW DEFOGGER

3. CHECK BCM OUTPUT SIGNAL
1.
2.
3.

A

Connect BCM connector.
Turn ignition switch ON.
Check voltage between BCM connector M57 terminal 4 and
ground.
4 – Ground

B

:Approx. 5

C

OK or NG
OK
>> Replace rear window defogger switch. Refer to ATC112, «Removal and Installation of Controller»
NG
>> Replace BCM.

D

MIIB0094E

Check Rear Window Defogger Switch Circuit / Without Auto A/C

E

BIS000N5

1. CHECK REAR WINDOW DEFOGGER SWITCH OPERATION

F

With CONSULT-II
Check (“REAR DEF SW”, “IGN ON SW”) in DATA MONITOR mode
with CONSULT-II. Refer to GW-19 .

G

When engine is running
ENGINE STATUS
:RUN
When rear defogger switch is turned to ON
REAR DEF SW
:ON
When ignition switch is turned to ON
IGN ON SW
:ON

H

GW

MKIB0549E

1.
2.

Without CONSULT-II
Turn ignition switch ON.
Check voltage between BCM connector ground.
Terminal (Wire color)

Connector

M57

(+)

4

(–)

Ground

K

Voltage (V)
(Approx.)

Condition

J

Rear window defogger
switch is pressed.

0

Rear window defogger
switch is OFF.

5

L

M

OK or NG
OK
>> Rear window defogger switch check is OK.
NG
>> GO TO 2.

GW-23

MIIB0094E

REAR WINDOW DEFOGGER

2. CHECK REAR WINDOW DEFOGGER SWITCH CIRCUIT HARNESS CONTINUITY
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM and heater control panel connector.
Check continuity between BCM connector and heater control panel connector.
A

4.

B

BCM connector

Terminal

Heater control
panel connector

Terminal

M57

4

M62

3

Continuity
Yes

Check continuity between BCM connector and ground
A
BCM connector

Terminal

M57

4

Ground

Continuity
No

MIIB1363E

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness between BCM and heater control panel.

3. CHECK BCM OUTPUT SIGNAL
1.
2.
3.

Connect BCM connector.
Turn ignition switch ON.
Check voltage between BCM connector M57 terminal 4 and
ground.
4 – Ground

:Approx. 5

OK or NG
OK
>> Replace heater control panel. Refer to MTC-62,
«Removal and Installation» .
NG
>> Replace BCM.

MIIB0094E

GW-24

REAR WINDOW DEFOGGER
Check Rear Window Defogger Power Supply Circuit

BIS000N6

1. CHECK FUSE

A

Check if any of the following fuses for IPDM E/R are blown.
COMPONENT PARTS

AMPERE

FUSE NO.

15A

#55

15A

#56

20A

#61

20A

#62

IPDM E/R

B

C

D

NOTE:
Refer to GW-12, «Component Parts and Harness Connector Location» .

OK or NG
OK
>> GO TO 2.
NG
>> If fuse is blown, be sure to eliminate cause of malfunction before installing new fuse, refer to GW12, «Component Parts and Harness Connector Location» .

E

F

2. CHECK REAR WINDOW DEFOGGER RELAY
Check rear window defogger relay in “ACTIVE TEST” mode with CONSULT-II. Refer to

G

Do you hear of the operation sound of rear window
defogger relay.
OK or NG
OK
>> GO TO 3.
NG
>> Replace IPDM E/R.

H

GW

PIIA0208E

J

3. CHECK REAR WINDOW DEFOGGER RELAY OUTPUT SIGNAL
1.
2.

K

Turn rear window defogger switch ON.
Check voltage between IPDM E/R connector E11 terminal 8 and ground.
8 – Ground

: Battery voltage

L

OK or NG
OK
>> Rear window defogger power supply circuit check is OK.
NG
>> Check connector for damage and loose connection.

M

MIIB0096E

GW-25

REAR WINDOW DEFOGGER
Check Rear Window Defogger Circuit

BIS000N7

1. CHECK REAR WINDOW DEFOGGER POWER SUPPLY CIRCUIT
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect rear window defogger connector.
Turn ignition switch ON.
Check voltage between rear window defogger connector and ground.
Terminal (Wire color)

Connector

B49

(+)

1

(–)

Condition

Voltage (V)
(Approx.)

Rear window defogger
switch ON.

Battery voltage

Rear window defogger
switch OFF.

0

Ground

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace harness between IPDM E/R and rear
window defogger.

PIIA4234E

2. CHECK HARNESS CONTINUITY
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R connector.
Check continuity between IPDM E/R connector E11 terminal 8 and rear window defogger connector B49
terminal 1.
8–1

4.

:Continuity should exist.

Check continuity between IPDM E/R connector E11 terminal 8
and ground.
8 – Ground

:Continuity should not exist.

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Repair or replace harness.
MIIB0097E

GW-26

REAR WINDOW DEFOGGER
Check Door Mirror Defogger Power Supply Circuit

BIS000N8

1. CHECK FUSE

A

Check if any of the following fuse for Fuse block (J/B) are blown.
COMPONENT PARTS

AMPERE

FUSE NO.

Fuse block (J/B)

10A

#2

B

NOTE:
Refer to GW-12, «Component Parts and Harness Connector Location» .

C

OK or NG
OK
>> GO TO 2.
NG
>> If fuse is blown, be sure to eliminate cause of malfunction before installing new fuse, refer to GW12, «Component Parts and Harness Connector Location» .

D

2. CHECK DOOR MIRROR DEFOGGER POWER SUPPLY CIRCUIT 1

E

1.
2.

F

Turn ignition switch ON.
Check voltage between door mirror connector and ground.
Door mirror
connector
D5
(driver side)

D25
(passenger side)

Terminal
(+)

Voltage (V)
(Approx.)

Condition

(–)

2
Ground
2

Rear window defogger
switch ON

Battery voltage

Rear window defogger
switch OFF

0

OK or NG
OK
>> GO TO 3.
NG
>> Check harness between IPDM E/R and door mirror.

G

H
MIIB1364E

GW

3. CHECK DOOR MIRROR DEFOGGER GROUND CIRCUIT
1.
2.
3.

J

Turn ignition switch OFF.
Disconnect door mirror connector.
Check continuity between door mirror connector and ground.
A
Door mirror connector
D5 (driver side)

K

Continuity
Terminal

L

Ground

3

Yes

D25 (passenger side)

M

OK or NG
OK
>> INSPECTION END.
NG
>> Repair or replace harness.
MIIB1365E

GW-27

REAR WINDOW DEFOGGER
Check Driver Side Door Mirror Defogger Circuit

BIS000N9

1. CHECK DOOR MIRROR DEFOGGER POWER SUPPLY CIRCUIT
1.
2.

Turn ignition switch ON.
Check voltage between door mirror (driver side) connector and ground.
Door mirror
(driver side)
connector

Terminal
(+)

D5

2

Voltage (V)
(Approx.)

Condition

(–)

Ground

Rear window defogger
switch ON

Battery voltage

Rear window defogger
switch OFF

0

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace harness between fuse block (J/B) and
door mirror (driver side).

MIIB1364E

2. CHECK DOOR MIRROR DEFOGGER GROUND CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect door mirror (driver side) connector.
Check continuity between door mirror (driver side) connector and ground.
Door mirror connector

Terminal

D5 (driver side)

3

Ground

Continuity
Yes

OK or NG
OK
>> GO TO 3
NG
>> Repair or replace harness between door mirror (driver
side) and ground.

MIIB1365E

3. CHECK DOOR MIRROR DEFOGGER
Check continuity between each door mirror connector terminal.
Terminal

Door mirror connector
D5 (driver side)

Continuity

(+)

(–)

2

3

Yes

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Replace door mirror (driver side).

MIIB1366E

GW-28

REAR WINDOW DEFOGGER
Check Passenger Side Door Mirror Defogger Circuit

BIS000NA

1. CHECK DOOR MIRROR DEFOGGER POWER SUPPLY CIRCUIT
1.
2.

A

Turn ignition switch ON.
Check voltage between door mirror (passenger side) connector and ground.

Door mirror
(passenger side)
connector

Terminal
(+)

D25

2

Voltage (V)
(Approx.)

Condition

(–)

Ground

B

Rear window defogger
switch ON

Battery voltage

Rear window defogger
switch OFF

0

C

D

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace harness between fuse block (J/B) and
door mirror (passenger side).

E
MIIB1364E

F

2. CHECK DOOR MIRROR DEFOGGER GROUND CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect door mirror (passenger side) connector.
Check continuity between door mirror (passenger side) connector and ground.

G

H
A

Continuity

Door mirror connector

Terminal

D5 (passenger side)

3

Ground

GW

Yes

OK or NG
OK
>> GO TO 3
NG
>> Repair or replace harness between door mirror (passenger side) and ground.

J

MIIB1365E

K

3. CHECK DOOR MIRROR DEFOGGER
L

Check continuity between each door mirror connector terminal.
Terminal

Door mirror connector
D5 (passenger side)

Continuity

(+)

(–)

2

3

M

Yes

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Replace door mirror (passenger side).

MIIB1366E

GW-29

REAR WINDOW DEFOGGER
Filament Check
1.

BIS000NB

When measuring voltage, wrap tin foil around the top of the negative probe. Then press the foil against the wire with your finger.

SEL122R

2.

Attach probe circuit tester (in Volt range) to middle portion of
each filament.

SEL263

3.
4.

If a filament is burned out, circuit tester registers 0 or battery
voltage.
To locate burned out point, move probe to left and right along filament. Test needle will swing abruptly when probe passes the
point.

SEL265

GW-30

REAR WINDOW DEFOGGER
Filament Repair

BIS000NC

A

REPAIR EQUIPMENT
●
●
●
●
●
●

Conductive silver composition (Dupont No. 4817 or equivalent)
Ruler 30 cm (11.8 in) long
Drawing pen
Heat gun
Alcohol
Cloth

B

C

REPAIRING PROCEDURE
1.
2.

3.

D

Wipe broken heat wire and its surrounding area clean with a
cloth dampened in alcohol.
Apply a small amount of conductive silver composition to tip of
drawing pen.
Shake silver composition container before use.
Place ruler on glass along broken line. Deposit conductive silver
composition on break with drawing pen. Slightly overlap existing
heat wire on both sides [preferably 5 mm (0.20 in)] of the break.

E

F

PIIA0215E

4.

After repair has been completed, check repaired wire for continuity. This check should be conducted 10 minutes after silver
composition is deposited.
Do not touch repaired area while test is being conducted.

G

H

GW

J

SEL012D

K

5.

Apply a constant stream of hot air directly to the repaired area
for approximately 20 minutes with a heat gun. A minimum distance of 3 cm (1.2 in) should be kept between repaired area and
hot air outlet.
If a heat gun is not available, let the repaired area dry for 24
hours.

L

M

SEL013D

GW-31

POWER WINDOW SYSTEM
POWER WINDOW SYSTEM
Component Parts and Harness Connector Location

PFP:25401
BIS000UI

MIIB1426E

1.

BCM M57, M59 (View with instrument upper panel removed)

2.

Power window main switch D8, D9

4.

Front power window motor (driver
side) D4

5.

Rear power window motor RH D64

3.

Rear power window switch RH D63

System Description (With Front Power Window)
Power is supplied at all times
●
to BCM terminal 74 and 79
●
through 40A fusible link (letter J , located in the fuse and fusible link box), and
●
to power window main switch terminal 5 (LHD models) or 6 (RHD models)
●
through 40A fusible link (letter J , located in the fuse and fusible link box).
Ground is supplied at all times
●
to BCM terminal 2 and 70
●
through body grounds M21 and M66.
●
to power window main switch terminal 12
●
through body grounds M21 and M66.
With ignition switch in ON or START position, power is supplied
●
to BCM terminal 24
●
through 10A fuse [No. 5, located in the fuse block (J/B)], and
●
to power window main switch terminal 1, front power window switch (passenger side) terminal 1
●
through BCM terminal 78.

DRIVER DOOR
Window Up
When the driver side switch in the power window main switch is operated in the up position,
Power is supplied
●
to front power window motor (driver side) terminal 3
●
through power window main switch terminal 6 (LHD models) or 4 (RHD models)
●
through CPU of power window main switch.
Ground is supplied
●
to front power window motor (driver side) terminal 4
●
through power window main switch terminal 7

GW-32

BIS000UJ

POWER WINDOW SYSTEM
through CPU of power window main switch.
Then, the motor raises the window until the switch is released.

●

A

Window Down
When the driver side switch in the power window main switch is operated in the down position
Power is supplied
●
to front power window motor (driver side) terminal 4
●
through power window main switch terminal 7.
●
through CPU of power window main switch.
Ground is supplied
●
to front power window motor (driver side) terminal 3
●
through power window main switch terminal 6 (LHD models) or 4 (RHD models).
●
through CPU of power window main switch.
Then, the motor lowers the window until the switch is released.

PASSENGER DOOR [FRONT POWER WINDOW SWITCH (PASSENGER SIDE) OPERATION]
Window Up
When the front power window switch (passenger side) is operated in the up position,
Power is supplied
●
to front power window motor (passenger side) terminal 2
●
through front power window switch (passenger side) terminal 5 and 1
●
through BCM terminal 78.
Ground is supplied
●
to front power window motor (passenger side) terminal 1
●
through front power window switch (passenger side) terminal 4 and 3
●
through power window main switch terminal 9 (LHD models) or 5 (RHD models)
●
through power window lock switch
●
through power window main switch terminal 12
●
through body ground M21 and M66.
Then, the motor raises the window until the switch is released.

B

C

D

E

F

G

H

GW

J

K

Window Down
When the front power window switch (passenger side) is operated in the down position,
Power is supplied
●
to front power window motor (passenger side) terminal 1
●
through front power window switch (passenger side) terminal 4 and 1
●
through BCM terminal 78.
Ground is supplied
●
to front power window motor (passenger side) terminal 2
●
through front power window switch (passenger side) terminal 5.
●
through power window main switch terminal 2 (LHD models) or 13 (RHD models)
●
through power window lock switch
●
through power window main switch terminal 12
●
through body ground M21 and M66.
Then, the motor lowers the window until the switch is released.

PASSENGER DOOR (POWER WINDOW MAIN SWITCH OPERATION)
Window Up
When the passenger side switch in the power window main switch is operated in the up position
Power is supplied
●
to front power window motor (passenger side) terminal 2
●
through front power window switch (passenger side) terminal 5 and 2

GW-33

L

M

POWER WINDOW SYSTEM
through power window main switch terminal 1 and 2 (LHD models) or 13 (RHD models)
through BCM terminal 78.
Ground is supplied
●
to front power window motor (passenger side) terminal 1
●
through front power window switch (passenger side) terminal 4 and 3
●
through power window main switch terminal 9 (LHD models) or 5 (RHD models)
●
through power window lock switch
●
through power window main switch terminal 12
●
through body ground M21 and M66.
Then, the motor raises the window until the switch is released.
●
●

Window Down
When the passenger side switch in the power window main switch is operated in the down position,
Power is supplied
●
to front power window motor (passenger side) terminal 1
●
through front power window switch (passenger side) terminal 4 and 3
●
through power window main switch terminal 1 and 9 (LHD models) or 5 (RHD models)
●
through BCM terminal 78.
Ground is supplied
●
to front power window motor (passenger side) terminal 2
●
through front power window switch (passenger side) terminal 5 and 2
●
to power window main switch terminal 2 (LHD models) or 13 (RHD models).
●
through power window lock switch
●
through power window main switch terminal 12
●
through body ground M21 and M66.
Then, the motor raises the window until the switch is released.

AUTO OPERATION
The power window AUTO feature enables the driver to open or close the window without holding the window
switch in the down or up position.

POWER WINDOW LOCK
The power window lock is designed to lock operation of all windows except for driver door window.
When power window lock switch is in LOCK position, ground of passenger and rear power window switches in
the power window main switch are disconnected. This prevents the power window motors from operating.

ANTI-PINCH SYSTEM
Power window main switch monitors the power window motor operation and the power window position (full
closed or other) for driver side power window by the signals from encoder and limit switch in front power window motor (driver side).
When power window main switch detects interruption during the following close operation,
●
automatic close operation when ignition switch is in the “ON” position
power window main switch controls power window motor (driver side) for open and the power window will be
lowered about 150 mm (5.91 in).

INITIALIZATION
Perform the initialization when the following operations are performed or when the auto up operation is not
performed. Refer to GW-91, «SYSTEM INITIALIZATION» .
●
When the power supply to the power window main switch or power window motor is cut off by the removal
of battery terminal or the battery fuse is blown.
●
Disconnection and connection of power window main switch harness connector.
●
Removal and installation of regulator assembly.
●
Removal and installation of motor from regulator assembly.
●
Operation of regulator assembly as an independent unit.

GW-34

POWER WINDOW SYSTEM
●
●

●

Removal and installation of glass.
Removal and installation of door glass run.
CAUTION:
The following operations are not performed under the condition that the initialization is not performed yet.
Auto up operation

System Description (With Front & Rear Power Window)

BIS000V0

Power is supplied at all times
●
to BCM terminal 74 and 79
●
through 40A fusible link (letter J , located in the fuse and fusible link box), and
●
to power window main switch terminal 19
●
through 40A fusible link (letter J , located in the fuse and fusible link box).
Ground is supplied at all times
●
to BCM terminal 2 and 70
●
through body grounds M21 and M66.
●
to power window main switch terminal 17
●
through body grounds M21 and M66.
With ignition switch in ON or START position, power is supplied
●
to BCM terminal 24
●
through 10A fuse [No. 5, located in the fuse block (J/B)], and
●
to power window main switch terminal 10, front power window switch (passenger side) terminal 1 and
rear power window switch (RH and LH) terminal 1.
●
trough BCM terminal 78

A

B

C

D

E

F

G

H

GW

DRIVER DOOR
Window Up
When the driver side switch in the power window main switch is operated in the up position,
Power is supplied
●
to front power window motor (driver side) terminal 3
●
through power window main switch terminal 16
●
through CPU of power window main switch.
Ground is supplied
●
to front power window motor (driver side) terminal 4
●
through power window main switch terminal 12
●
through CPU of power window main switch.
Then, the motor raises the window until the switch is released.

Window Down
When the driver side switch in the power window main switch is operated in the down position
Power is supplied
●
to front power window motor (driver side) terminal 4
●
through power window main switch terminal 12.
●
through CPU of power window main switch.
Ground is supplied
●
to front power window motor (driver side) terminal 3
●
through power window main switch terminal 16.
●
through CPU of power window main switch.
Then, the motor lowers the window until the switch is released.

GW-35

J

K

L

M

POWER WINDOW SYSTEM
PASSENGER DOOR [FRONT POWER WINDOW SWITCH (PASSENGER SIDE) OPERATION]
Window Up
When the front power window switch (passenger side) is operated in the up position,
Power is supplied
●
to front power window motor (passenger side) terminal 2
●
through front power window switch (passenger side) terminal 5 and 1
●
through BCM terminal 78.
Ground is supplied
●
to front power window motor (passenger side) terminal 1
●
through front power window switch (passenger side) terminal 4 and 3
●
through power window main switch terminal 11
●
through power window lock switch
●
through power window main switch terminal 17
●
through body ground M21 and M66.
Then, the motor raises the window until the switch is released.

Window Down
When the front power window switch (passenger side) is operated in the down position,
Power is supplied
●
to front power window motor (passenger side) terminal 1
●
through front power window switch (passenger side) terminal 4 and 1
●
through BCM terminal 78.
Ground is supplied
●
to front power window motor (passenger side) terminal 2
●
through front power window switch (passenger side) terminal 5.
●
through power window main switch terminal 8
●
through power window lock switch
●
through power window main switch terminal 17
●
through body ground M21 and M66.
Then, the motor lowers the window until the switch is released.

PASSENGER DOOR (POWER WINDOW MAIN SWITCH OPERATION)
Window Up
When the passenger side switch in the power window main switch is operated in the up position
Power is supplied
●
to front power window motor (passenger side) terminal 2
●
through front power window switch (passenger side) terminal 5 and 2
●
through power window main switch terminal 8 and 10
●
through BCM terminal 78.
Ground is supplied
●
to front power window motor (passenger side) terminal 1
●
through front power window switch (passenger side) terminal 4 and 3
●
through power window main switch terminal 11
●
through power window lock switch
●
through power window main switch terminal 17
●
through body ground M21 and M66.
Then, the motor raises the window until the switch is released.

Window Down
When the passenger side switch in the power window main switch is operated in the down position,
Power is supplied
●
to front power window motor (passenger side) terminal 1

GW-36

POWER WINDOW SYSTEM
through front power window switch (passenger side) terminal 4 and 3
through power window main switch terminal 11 and 10
●
through BCM terminal 78.
Ground is supplied
●
to front power window motor (passenger side) terminal 2
●
through front power window switch (passenger side) terminal 5 and 2
●
to power window main switch terminal 8.
●
through power window lock switch
●
through power window main switch terminal 17
●
through body ground M21 and M66.
Then, the motor raises the window until the switch is released.
●
●

REAR DOOR (RH OR LH) [REAR POWER WINDOW SWITCH (RH OR LH) OPERATION]
Window Up
When the rear power window switch (RH or LH) is operated in the up position,
Power is supplied
●
to rear power window motor (RH or LH) terminal 2
●
through rear power window switch (RH or LH) terminal 5 and 1
●
through BCM terminal 78.
Ground is supplied
●
to rear power window motor (RH or LH) terminal 1
●
through rear power window switch (RH or LH) terminal 4 and 3
●
through power window main switch terminal 5 (RH) or 3 (LH).
●
through power window lock switch
●
through power window main switch terminal 17
●
through body ground M21 and M66.
Then, the motor raises the window until the switch is released.

A

B

C

D

E

F

G

H

GW

J

Window Down
When the rear power window switch (RH or LH) is operated in the down position,
Power is supplied
●
to rear power window motor (RH or LH) terminal 1
●
through rear power window switch (RH or LH) terminal 4 and 1
●
through BCM terminal 78.
Ground is supplied
●
to rear power window motor (RH or LH) terminal 2
●
through rear power window switch (RH or LH) terminal 5 and 2
●
through power window main switch terminal 7 (RH) or 1 (LH).
●
through power window lock switch
●
through power window main switch terminal 17
●
through body ground M21 and M66.
Then, the motor lowers the window until the switch is released.

REAR DOOR (RH OR LH) (POWER WINDOW MAIN SWITCH OPERATION)
Window Up
When the rear RH or LH switch in the power window main switch is operated in the up position,
Power is supplied
●
to rear power window motor (RH or LH) terminal 2
●
through rear power window switch (RH or LH) terminal 5 and 2
●
through power window main switch terminal 7 (RH) or 1 (LH).
●
through power window main switch terminal 10

GW-37

K

L

M

POWER WINDOW SYSTEM
●
through BCM terminal 78.
Ground is supplied
●
to rear power window motor (RH or LH) terminal 1
●
through rear power window switch (RH or LH) terminal 4 and 3
●
through power window main switch terminal 5 (RH) or 3 (LH)
●
through power window lock switch
●
through power window main switch terminal 17
●
through body ground M21 and M66.
Then, the motor raises the window until the switch is released.

Window Down
When the rear RH or LH switch in the power window main switch is operated in the down position,
Power is supplied
●
to rear power window motor (RH or LH) terminal 1
●
through rear power window switch (RH or LH) terminal 4 and 3
●
through power window main switch terminal 5 (RH) or 3 (LH).
●
through power window main switch terminal 10
●
through BCM terminal 78.
Ground is supplied
●
to rear power window motor (RH or LH) terminal 2
●
through rear power window switch (RH or LH) terminal 5 and 2
●
to power window main switch terminal 7 (RH) or 1 (LH)
●
through power window lock switch
●
through power window main switch terminal 17
●
through body ground M21 and M66.
Then, the motor raises the window until the switch is released.

AUTO OPERATION
The power window AUTO feature enables the driver to open or close the window without holding the window
switch in the down or up position.

POWER WINDOW LOCK
The power window lock is designed to lock operation of all windows except for driver door window.
When power window lock switch is in LOCK position, ground of passenger and rear power window switches in
the power window main switch are disconnected. This prevents the power window motors from operating.

ANTI-PINCH SYSTEM
Power window main switch monitors the power window motor operation and the power window position (full
closed or other) for driver side power window by the signals from encoder and limit switch in front power window motor (driver side).
When power window main switch detects interruption during the following close operation,
●
automatic close operation when ignition switch is in the “ON” position
power window main switch controls power window motor (driver side) for open and the power window will be
lowered about 150 mm (5.91 in).

INITIALIZATION
Perform the initialization when the following operations are performed or when the auto up operation is not
performed. Refer to GW-91, «SYSTEM INITIALIZATION» .
●
When the power supply to the power window main switch or power window motor is cut off by the removal
of battery terminal or the battery fuse is blown.
●
Disconnection and connection of power window main switch harness connector.
●
Removal and installation of regulator assembly.
●
Removal and installation of motor from regulator assembly.
●
Operation of regulator assembly as an independent unit.

GW-38

POWER WINDOW SYSTEM
●
●

●

Removal and installation of glass.
Removal and installation of door glass run.
CAUTION:
The following operations are not performed under the condition that the initialization is not performed yet.
Auto up operation

A

B

C

D

E

F

G

H

GW

J

K

L

M

GW-39

POWER WINDOW SYSTEM
Schematic/With Front Power Window

BIS000UK

MIWA0674E

GW-40

POWER WINDOW SYSTEM
Wiring Diagram — WINDOW —/With Front Power Window

BIS000UL

A

B

C

D

E

F

G

H

GW

J

K

L

M

MIWA0675E

GW-41

POWER WINDOW SYSTEM

MIWA0676E

GW-42

POWER WINDOW SYSTEM
A

B

C

D

E

F

G

H

GW

J

K

L

M

MIWA0677E

GW-43

POWER WINDOW SYSTEM
Schematic/With Front & Rear Power Window

BIS000V1

MIWA0678E

GW-44

POWER WINDOW SYSTEM
Wiring Diagram — WINDOW —/With Front & Rear Power Window

BIS000V2

A

B

C

D

E

F

G

H

GW

J

K

L

M

MIWA0679E

GW-45

POWER WINDOW SYSTEM

MIWA0680E

GW-46

POWER WINDOW SYSTEM
A

B

C

D

E

F

G

H

GW

J

K

L

M

MIWA0681E

GW-47

POWER WINDOW SYSTEM

MIWA0682E

GW-48

POWER WINDOW SYSTEM
Terminal and Reference Value for BCM

BIS000UM

A
Terminal

Wire
color

2

B

Signal
input/output

Item
Ground

—

24

O

Ignition switch (ON or START)

70

B

Ground (power)

74

Y

Battery power supply (BCM)

78

L

Power window power supply (IGN)

Voltage [V]
(Approx.)

Condition
Ignition switch ON
Ignition switch
(ON or START position)

Input
—

0
Battery voltage

Ignition switch ON

Input

—
Ignition switch
(ON or START position)

Output

0

Y

Battery power supply (power window)

Input

—

C

Battery voltage
Battery voltage

Other than above
79

B

D

0
Battery voltage

Terminal and Reference Value for Power Window Main Switch/With Front Power
Window (For LHD Models)

E

BIS000V4

Terminal

Wire
color

1

W

2

3

W

G

Item
Rap signal

Front power window
motor (passenger side)
UP signal

Encoder power supply

Signal
input/output
Input

Condition
Ignition switch ON

Battery voltage

Ignition switch OFF

0

When passenger side switch in
power window main switch is
operated in UP position.
Output

Output

F

Voltage [V]
(Approx.)

G

Battery voltage

Other than above
(Power window lock switch is
unlock position.)

0

Ignition switch ON

10

H

GW

J
4

W

Encoder pulse signal

Input

When power window motor
operates.

K
OCC3383D

5

W

Battery power supply

Input

6

R

Front power window
motor (driver side) UP
signal

Output

When driver side switch in
power window main switch is
operated in UP position.

Battery voltage

Output

When driver side switch in
power window main switch is
operated in DOWN position.

Battery voltage

When passenger side switch in
power window main switch is
operated in DOWN position.

Battery voltage

7

9

11

GR

W

V

Front power window
motor (driver side)
DOWN signal

Front power window
motor (passenger side)
DOWN signal

Limit switch signal

Output

Input

—

Battery voltage

M

Other than above
(Power window lock switch is
unlock position.)

0

Driver side door window is
between fully-open position and
just before fully-closed position
(ON)

0

Driver side door window is
between just before fully-closed
position and fully-closed position
(OFF)

5

GW-49

L

POWER WINDOW SYSTEM
Terminal

Wire
color

12

W

13

LG

Signal
input/output

Condition

Voltage [V]
(Approx.)

Ground

—

—

0

Limit switch and
encoder ground

—

—

0

Item

Terminal and Reference Value for Power Window Main Switch/With Front Power
Window (For RHD Models)

BIS000V3

Terminal

Wire
color

1

W

Rap signal

2

G

Encoder power supply

3

4

5

V

R

W

Item

Limit switch signal

Front power window
motor (driver side) UP
signal

Front power window
motor (passenger side)
DOWN signal

Signal
input/output
Input
Output

Input

Output

Output

6

W

Battery power supply

Input

7

GR

Front power window
motor (driver side)
DOWN signal

Output

9

W

Encoder pulse signal

Input

Condition

Voltage [V]
(Approx.)

Ignition switch ON

Battery voltage

Ignition switch OFF

0

Ignition switch ON

10

Driver side door window is
between fully-open position and
just before fully-closed position
(ON)

0

Driver side door window is
between just before fully-closed
position and fully-closed position
(OFF)

5

When driver side switch in
power window main switch is
operated in UP position.

Battery voltage

When passenger side switch in
power window main switch is
operated in DOWN position.

Battery voltage

Other than above
(Power window lock switch is
unlock position.)
—
When driver side switch in
power window main switch is
operated in DOWN position.

0
Battery voltage
Battery voltage

When power window motor
operates.

OCC3383D

11

LG

Limit switch and
encoder ground

—

—

0

12

W

Ground

—

—

0

13

W

Front power window
motor (passenger side)
UP signal

When passenger side switch in
power window main switch is
operated in UP position.
Output

Other than above
(Power window lock switch is
unlock position.)

GW-50

Battery voltage

0

POWER WINDOW SYSTEM
Terminal and Reference Value for Power Window Main Switch/With Front & Rear
Power Window

BIS000UN

Terminal

1

2

3

5

7

8

9

10

11

12

Wire
color

W

LG

W

W

W

W

V

W

W

GR

Item

Rear power window
motor LH UP signal

Limit switch and
encoder ground

Rear power window
motor LH DOWN signal

Rear power window
motor RH DOWN signal

Rear power window
motor RH UP signal

Front power window
motor (passenger side)
UP signal

Limit switch signal

Rap signal

Front power window
motor (passenger side)
DOWN signal

Front power window
motor (driver side)
DOWN signal

Signal
input/output

Condition
When rear LH switch in
power window main switch is
operated in UP position.

Output

Other than above
(Power window lock switch is
unlock position.)

—

Output

Output

Output

Output

—

Input

Output

Battery voltage

C
0

0

D

Battery voltage

E

Other than above
(Power window lock switch is
unlock position.)

0

F

When rear RH switch in
power window main switch is
operated in DOWN position.

Battery voltage

Other than above
(Power window lock switch is
unlock position.)

0

When rear RH switch in
power window main switch is
operated in UP position.

Battery voltage

Other than above
(Power window lock switch is
unlock position.)

0

When passenger side switch in
power window main switch is
operated in UP position.

GW

J
Battery voltage

K
0

L
0

Driver side door window is
between just before fully-closed
position and fully-closed position
(OFF)

5

M

Ignition switch ON

Battery voltage

Ignition switch OFF

0
Battery voltage

Other than above
(Power window lock switch is
unlock position.)

0

When driver side switch in
power window main switch is
operated in DOWN position.

Battery voltage

GW-51

G

H

Driver side door window is
between fully-open position and
just before fully-closed position
(ON)

When passenger side switch in
power window main switch is
operated in DOWN position.
Output

B

When rear LH switch in
power window main switch is
operated in DOWN position.

Other than above
(Power window lock switch is
unlock position.)

Input

Voltage [V]
(Approx.)

A

POWER WINDOW SYSTEM
Terminal

Wire
color

13

W

Item

Encoder pulse signal

Signal
input/output

Input

Condition

Voltage [V]
(Approx.)

When power window motor
operates.

OCC3383D

15

G

Encoder power supply

Output

Ignition switch ON

16

R

Front power window
motor (driver side) UP
signal

Output

When driver side switch in
power window main switch is
operated in UP position.

17

W

Ground

19

W

Battery power supply

3.
4.

5.

Battery voltage

—

—

0

Input

—

Battery voltage

Work Flow
1.
2.

10

BIS000UO

Check the symptom and customer’s requests.
Understand the outline of system. Refer to GW-32, «System Description (With Front Power Window)» or
GW-35, «System Description (With Front & Rear Power Window)» .
According to the trouble diagnosis chart, repair or replace the cause of the malfunction. Refer to GW-53,
«Trouble Diagnosis Symptom Chart» .
Does power window system operate normally?
YES: GO TO 5.
NO: GO TO 3.
INSPECTION END

GW-52

POWER WINDOW SYSTEM
Trouble Diagnosis Symptom Chart

BIS000UP

A

Make sure other systems using the signal of the following systems operate normally.
Symptom

Repair order
1. Check BCM power supply and ground circuit

None of the power windows can be operated using any switch.

Driver side power window alone does not operated.

Refer to page
GW-54

2. Check power window main switch power supply
and ground circuit

GW-55*1

1. Check front power window motor (driver side)
circuit

GW-58*1

2. Replace power window main switch

GW-56*2

EI-20

Rear RH side power window alone does not operated.

1. Check rear power window motor RH circuit

GW-68

Rear LH side power window alone does not operated.

1. Check rear power window motor LH circuit

GW-71

GW-65*2

1. Door window sliding part malfunction

●

Glass run rubber wear or deformation

●

Sash is tilted too much, or not enough

2. Limit switch adjustment

Anti-pinch system does not operate normally (driver side).

3. Check limit switch circuit (driver side)

4. Check encoder circuit (driver side)
5. Replace power window main switch
Power window lock switch does not function.

1. Check power window lock switch

Auto operation does not operate but manual operates normally
(driver side).

1. Check encoder circuit (driver side)
2. Replace power window main switch

D

GW-61*1

Front passenger side power window alone does not operated.

A foreign material adheres to window glass or
glass run rubber

C

GW-60*2

1. Check front power window motor (passenger
side) circuit

●

B

E

F
—

G
GW-91
GW-75*1

H

GW-78*2
GW-80*1
GW-85*2

GW

EI-20
GW-88

J

GW-80*1
GW-85*2
EI-20

K

*1: With front power window
*2: With front & rear power window

L

M

GW-53

POWER WINDOW SYSTEM
Check BCM Power Supply and Ground Circuit

BIS000UQ

1. CHECK FUSE
10A fuse [No.5, located in fuse block (J/B)]
40A fusible link (letter J , located in the fuse and fusible link box)
NOTE:
Refer to PG-4, «POWER SUPPLY ROUTING CIRCUIT» .
OK or NG
OK
>> GO TO 2.
NG
>> If fuse is blown out, be sure to eliminate cause of malfunction before installing new fuse. Refer to
PG-4, «POWER SUPPLY ROUTING CIRCUIT» .
●
●

2. CHECK POWER SUPPLY CIRCUIT
Check voltage between BCM connector and ground.
Terminal

BCM
connector

(+)

M57

24
74

M59

Voltage [V]
(Approx.)

Condition

(–)

ON
Ground

Ignition switch

Battery voltage
OFF

79

OK or NG
OK
>> GO TO 3.
NG
>> Check BCM power supply circuit for open or short.

MIIB1385E

3. CHECK GROUND CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector.
Check continuity between BCM connector and ground.
BCM connector

Terminal

M57

2

M59

70

Continuity
Ground
Yes

OK or NG
OK
>> BCM power supply and ground circuit are OK.
NG
>> Check BCM ground circuit for open.
MIIB1386E

GW-54

POWER WINDOW SYSTEM
Check Power Window Main Switch Power Supply and Ground Circuit

BIS000UR

A

WITH FRONT POWER WINDOW

1. CHECK POWER SUPPLY CIRCUIT
B

Check voltage between power window main switch connector and
ground.
[LHD models]
Power
window main
switch
connector

(+)

Voltage [V]
(Approx.)

Condition

(–)

D
1

D8

C

Terminal

Ground

Ignition switch

5

ON

Battery voltage

OFF
MIIB1387E

E

[RHD models]
F
Power
window main
switch
connector

Terminal
(–)

1
D8

Voltage [V]
(Approx.)

Condition
(+)

6

G

ON
Ground

Ignition switch

OFF

Battery voltage

H

OK or NG
OK
>> GO TO 2.
NG
>> GO TO 3.

MIIB1389E

GW

2. CHECK GROUND CIRCUIT
1.
2.
3.

J

Turn ignition switch OFF.
Disconnect power window main switch connector.
Check continuity between power window main switch connector
and ground.

Power window main switch
connector

Terminal

D8

12

Ground

K

Continuity

L
Yes

OK or NG
OK
>> Power window main switch power supply and ground
circuit are OK.
NG
>> Repair or replace harness.

M

MIIB1390E

GW-55

POWER WINDOW SYSTEM

3. CHECK HARNESS CONTINUITY
1.
2.

Disconnect BCM connector.
Check continuity between BCM connector and power window
main switch connector.
A

3.

B

BCM connector

Terminal

Power window
main switch
connector

Terminal

M59

78

D8

1

Continuity

Yes

Check continuity between BCM connector and ground.
A

MIIB1388E

BCM connector

Terminal

M59

78

Continuity

Ground

No

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace harness.

4. CHECK BCM OUTPUT SIGNAL
1.
2.
3.

Connect BCM connector.
Turn ignition switch ON.
Check voltage between BCM connector and ground.
Terminal
(+)

(–)

Voltage [V]
(Approx.)

78

Ground

Battery voltage

BCM connector
M59

OK or NG
OK
>> Check condition of harness and connector.
NG
>> Replace BCM.
MIIB1394E

WITH FRONT & REAR POWER WINDOW

1. CHECK POWER SUPPLY CIRCUIT
Check voltage between power window main switch connector D8,
D9 terminal 10, 19 and ground.
Connector

Terminal (Wire color)
(+)

D8

10

D9

19

Ignition switch condition

(-)
Ground

ON

Voltage [V]
(Approx.)
Battery voltage

OFF

OK or NG
OK
>> GO TO 2.
NG
>> GO TO 3.

PIIB1144E

GW-56

POWER WINDOW SYSTEM

2. CHECK GROUND CIRCUIT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect power window main switch connector.
Check continuity between power window main switch connector
D9 terminal 17 and ground.
17 – Ground

B

: Continuity should exist.

C

OK or NG
OK
>> Power window main switch power supply and ground
circuit are OK.
NG
>> Repair or replace harness.

D

PIIA4172E

E

3. CHECK HARNESS CONTINUITY
1.
2.

A

3.

F

Disconnect BCM connector.
Check continuity between BCM connector and power window
main switch connector.

G

B

BCM connector

Terminal

Power window
main switch
connector

Terminal

M59

78

D8

10

Continuity

H

Yes

GW

Check continuity between BCM connector and ground.
A

MIIB1392E

BCM connector

Terminal

M59

78

Continuity

Ground

J

No

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace harness.

K

4. CHECK BCM OUTPUT SIGNAL

L

1.
2.
3.

M

Connect BCM connector.
Turn ignition switch ON.
Check voltage between BCM connector and ground.
Terminal
BCM connector
M59

(+)

(–)

Voltage [V]
(Approx.)

78

Ground

Battery voltage

OK or NG
OK
>> Check condition of harness and connector.
NG
>> Replace BCM.
MIIB1394E

GW-57

POWER WINDOW SYSTEM
Check Front Power Window Motor (Driver Side) Circuit

BIS000US

WITH FRONT POWER WINDOW

1. CHECK POWER WINDOW MAIN SWITCH OUTPUT SIGNAL
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect front power window motor (driver side) connector.
Turn ignition switch ON.
Check voltage between front power window motor (driver side)
connector and ground.

Front power
window motor
(driver side)
connector

Terminal
Voltage [V]
(Approx.)

Condition
(+)

(–)

3
D4

Ground
4

Power window
main switch

UP

Battery voltage

DOWN

0

UP

0

DOWN

Battery voltage

OK or NG
OK
>> Replace front power window motor (driver side).
NG
>> GO TO 2.

GW-58

MIIB1395E

POWER WINDOW SYSTEM

2. CHECK HARNESS CONTINUITY

A

[LHD models]
1. Turn ignition switch OFF.
2. Disconnect power window main switch connector.
3. Check continuity between power window main switch connector
and front power window motor (driver side) connector.

B

C
A
Power window
main switch
connector

B

Terminal

Front power
window motor
(driver side)
connector

6
D8

4.

Continuity

Terminal

D

3
D4

7

E

Yes

4

Check continuity between power window main switch connector
and ground.

MIIB1396E

F

A
Continuity

Power window main
switch connector

Terminal

G

Ground

6

D8

No

7

H

[RHD models]
1. Turn ignition switch OFF.
2. Disconnect power window main switch connector.
3. Check continuity between power window main switch connector
and front power window motor (driver side) connector.
A
Power window
main switch
connector

J

B

Terminal

Front power
window motor
(driver side)
connector

4

D8

K

Continuity
Terminal

L

3

D4

7

4.

GW

Yes

4

Check continuity between power window main switch connector
and ground.

MIIB1391E

A
Power window main
switch connector
D8

Continuity

Terminal
Ground
4

No

7

OK or NG
OK
>> Replace power window motor.
NG
>> Repair or replace harness between power window main switch and front power window motor
(driver side).

GW-59

M

POWER WINDOW SYSTEM
WITH FRONT & REAR POWER WINDOW

1. CHECK POWER WINDOW MAIN SWITCH OUTPUT SIGNAL
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect front power window motor (driver side) connector.
Turn ignition switch ON.
Check voltage between front power window motor (driver side)
connector and ground.

Front power
window motor
(driver side)
connector

Terminal
(+)

(–)

3
D4

Voltage [V]
(Approx.)

Condition

Ground

Power window
main switch

4

UP

Battery voltage

DOWN

0

UP

0

DOWN

Battery voltage

MIIB1395E

OK or NG
OK
>> Replace front power window motor (driver side).
NG
>> GO TO 2.

2. CHECK HARNESS CONTINUITY
1.
2.
3.

Turn ignition switch OFF.
Disconnect power window main switch connector.
Check continuity between power window main switch connector
and front power window motor (driver side) connector.
A
Power window
main switch
connector

B

Terminal

Front power
window motor
(driver side)
connector

12

D8

Continuity
Terminal

4

D4

16

4.

Yes

3

Check continuity between power window main switch connector
and ground.

MIIB1393E

A
Power window main
switch connector

Continuity
Terminal

Ground

12
D8

No

16

OK or NG
OK
>> Replace power window motor.
NG
>> Repair or replace harness between power window main switch and front power window motor
(driver side).

GW-60

POWER WINDOW SYSTEM
Check Front Power Window Motor (Passenger Side) Circuit

BIS000UT

A

WITH FRONT POWER WINDOW

1. CHECK POWER WINDOW SWITCH OUTPUT SIGNAL
1.
2.
3.
4.

B

Turn ignition switch OFF.
Disconnect front power window motor (passenger side) connector.
Turn ignition switch ON.
Check voltage between front power window motor (passenger
side) connector and ground.

Front power
window motor
(passenger side)
connector

C

Terminal

D
Voltage [V]
(Approx.)

Condition
(+)

(–)

1
D23

Ground

Switch*

2

UP

0

DOWN

Battery voltage

UP

Battery voltage

DOWN

0

E

F
MIIB1397E

*: Power window main switch or front power window switch (passenger side)

G

OK or NG
OK
>> Replace front power window motor (passenger side).
NG
>> GO TO 2.

H

2. CHECK FRONT POWER WINDOW SWITCH
1.
2.
3.

Turn ignition switch OFF.
Disconnect front power window switch (passenger side) connector.
Check continuity between front power window switch (passenger side) terminal 1, 2, 3 and 4, 5.
Terminals

Switch condition
5

UP

4

DOWN

2

5

No operation

3

4

No operation

1

GW

J

Continuity

K
Yes

L

OK or NG
OK
>> GO TO 3.
NG
>> Replace front power window switch (passenger side).

GW-61

PIIB0612E

M

POWER WINDOW SYSTEM

3. CHECK HARNESS CONTINUITY 1
1.

Check continuity between front power window switch (passenger side) connector and front power window motor (passenger
side) connector.
A

B

Front power
window switch
(passenger side)
connector

Front power
window motor
(passenger side)
connector

Terminal

4

D27

Continuity
Terminal

1

D23

5

2.

Yes

2

MIIB1398E

Check continuity between front power window switch (passenger side) connector and ground.
A

Front power window switch
(passenger side)
connector

Continuity

Terminal
Ground
4

D27

No

5

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace harness.

4. CHECK FRONT POWER WINDOW SWITCH POWER SUPPLY
1.
2.

Turn ignition switch ON.
Check voltage between front power window switch (passenger
side) connector D27 terminal 1 and ground.
1 – Ground

: Battery voltage

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

PIIB0608E

GW-62

POWER WINDOW SYSTEM

5. CHECK HARNESS CONTINUITY 2
1.
2.
3.

A

B

BCM connector

Front power
window switch
(passenger side)
connector

Terminal

D27

1

Terminal

M59

4.

A

Turn ignition switch OFF.
Disconnect BCM connector.
Check continuity between BCM connector and front power window switch (passenger side) connector.

78

B

C
Continuity

D
Yes

Check continuity between BCM connector and ground.
MIIB1399E

A

E

Continuity

BCM connector

Terminal

M59

78

Ground
No

OK or NG
OK
>> Check condition of harness and connector.
NG
>> Repair or replace harness.

F

G

H

GW

J

K

L

M

GW-63

POWER WINDOW SYSTEM

6. CHECK HARNESS CONTINUITY 3
[LHD models]
1. Disconnect power window main switch connector.
2. Check continuity between power window main switch connector
and front power window switch (passenger side) connector.
A
Power window
main switch
connector

B

Terminal

Front power
window switch
(passenger side)
connector

2
D8

3.

Continuity

Terminal

2
D27

9

Yes

3

Check continuity between power window main switch connector
and ground.

MIIB1400E

A
Power window main
switch connector

Continuity

Terminal
Ground
2

D8

No

9

[RHD models]
1. Disconnect power window main switch connector.
2. Check continuity between power window main switch connector
and front power window switch (passenger side) connector.
A
Power window
main switch
connector

B

Terminal

Front power
window switch
(passenger side)
connector

13

D8

Continuity
Terminal

2

D27

5

3.

Yes

3

Check continuity between power window main switch connector
and ground.
A
Power window main
switch connector

Continuity
Terminal

Ground

13
D8

No

5

OK or NG
OK
>> GO TO 7.
NG
>> Repair or replace harness.

GW-64

MIIB1402E

POWER WINDOW SYSTEM

7. CHECK POWER WINDOW MAIN SWITCH OUTPUT SIGNAL
1.
2.
3.

A

Connect power window main switch connector.
Turn ignition switch ON.
Check voltage between power window main switch connector
and ground when operating passenger side switch in power window main switch.
[LHD models]
Power window
main switch
connector

Terminal
(–)

2
D8

Ground
9

Power
window main
switch

C

Voltage [V]
(Approx.)

Condition
(+)

B

UP

Battery voltage

DOWN

0

UP

0

DOWN

Battery voltage

D

MIIB1401E

F

[RHD models]
Power window
main switch
connector

E

Terminal

Voltage [V]
(Approx.)

Condition
(+)

(–)

13
D8

Ground
5

Power
window main
switch

UP

Battery voltage

DOWN

0

UP

0

DOWN

Battery voltage

OK or NG
OK
>> Check condition of harness and connector.
NG
>> Replace power window main switch.

G

H

MIIB1403E

GW

J

WITH FRONT & REAR POWER WINDOW

1. CHECK POWER WINDOW SWITCH OUTPUT SIGNAL
1.
2.
3.
4.

K

Turn ignition switch OFF.
Disconnect front power window motor (passenger side) connector.
Turn ignition switch ON.
Check voltage between front power window motor (passenger
side) connector and ground.

Front power
window motor
(passenger side)
connector

L

M

Terminal
Voltage [V]
(Approx.)

Condition
(+)

(–)

1
D23

Ground
2

Switch*

UP

0

DOWN

Battery voltage

UP

Battery voltage

DOWN

0

*: Power window main switch or front power window switch (passenger side)

OK or NG
OK
>> Replace front power window motor (passenger side).
NG
>> GO TO 2.

GW-65

MIIB1397E

POWER WINDOW SYSTEM

2. CHECK FRONT POWER WINDOW SWITCH
1.
2.
3.

Turn ignition switch OFF.
Disconnect front power window switch (passenger side) connector.
Check continuity between front power window switch (passenger side) terminal 1, 2, 3 and 4, 5.
Terminals

Switch condition
5

UP

4

DOWN

2

5

No operation

3

4

No operation

1

Continuity

Yes

OK or NG
OK
>> GO TO 3.
NG
>> Replace front power window switch (passenger side).

PIIB0612E

3. CHECK HARNESS CONTINUITY 1
1.

Check continuity between front power window switch (passenger side) connector and front power window motor (passenger
side) connector.
A

B

Front power
window switch
(passenger side)
connector

Front power
window motor
(passenger side)
connector

Terminal

4
D27

2.

Continuity

Terminal

1
D23

5

Yes

2

MIIB1398E

Check continuity between front power window switch (passenger side) connector and ground.
A

Front power window switch
(passenger side)
connector

Continuity
Terminal

Ground

4
D27

No

5

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace harness.

4. CHECK FRONT POWER WINDOW SWITCH POWER SUPPLY
1.
2.

Turn ignition switch ON.
Check voltage between front power window switch (passenger
side) connector D27 terminal 1 and ground.
1 – Ground

: Battery voltage

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

PIIB0608E

GW-66

POWER WINDOW SYSTEM

5. CHECK HARNESS CONTINUITY 2
1.
2.
3.

A

B

BCM connector

Front power
window switch
(passenger side)
connector

Terminal

D27

1

Terminal

M59

4.

A

Turn ignition switch OFF.
Disconnect BCM connector.
Check continuity between BCM connector and front power window switch (passenger side) connector.

78

B

C
Continuity

D
Yes

Check continuity between BCM connector and ground.
MIIB1399E

A

Continuity

BCM connector

Terminal

M59

78

Ground

F

No

OK or NG
OK
>> Check condition of harness and connector.
NG
>> Repair or replace harness.

G

6. CHECK HARNESS CONTINUITY 3
1.
2.

3.

H

Disconnect power window main switch connector.
Check continuity between power window main switch connector
D8 terminal 8, 11 and front power window switch (passenger
side) connector D27 terminal 2, 3.
8–2
11 – 3

GW

: Continuity should exist.
: Continuity should exist.

J

Check continuity between power window main switch connector
D8 terminal 8, 11 and ground.
8 – Ground
11 – Ground

E

: Continuity should not exist.
: Continuity should not exist.

OK or NG
OK
>> GO TO 7.
NG
>> Repair or replace harness.

K

PIIB0609E

L

M

GW-67

POWER WINDOW SYSTEM

7. CHECK POWER WINDOW MAIN SWITCH OUTPUT SIGNAL
1.
2.
3.

Connect power window main switch connector.
Turn ignition switch ON.
Check voltage between power window main switch connector
and ground when operating passenger side switch in power window main switch.
Terminals (Wire color)
Connector

(+)

(-)

8
D8

Ground
11

Switch
condition

Voltage [V]
(Approx.)

UP

Battery voltage

DOWN

0

UP

0

DOWN

Battery voltage

PIIB0610E

OK or NG
OK
>> Check condition of harness and connector.
NG
>> Replace power window main switch.

Check Rear Power Window Motor RH Circuit

BIS000UU

1. CHECK POWER WINDOW SWITCH OUTPUT SIGNAL
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect rear power window motor RH connector.
Turn ignition switch ON.
Check voltage between rear power window motor RH connector
and ground.

Rear power
window motor
RH connector

Terminal

Voltage [V]
(Approx.)

Condition
(+)

(–)

1
D64

Ground
2

Switch*

UP

0

DOWN

Battery voltage

UP

Battery voltage

DOWN

0
MIIB1404E

*: Power window main switch or rear power window switch RH.

OK or NG
OK
>> Replace rear power window motor RH.
NG
>> GO TO 2.

GW-68

POWER WINDOW SYSTEM

2. CHECK REAR POWER WINDOW SWITCH
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect rear power window switch RH connector.
Check continuity between rear power window switch RH terminal 1, 2, 3 and 4, 5.
Terminals

Switch condition
5

UP

4

DOWN

2

5

No operation

3

4

No operation

1

B

Continuity

C

Yes

D

OK or NG
OK
>> GO TO 3.
NG
>> Replace rear power window switch RH.

PIIA4186E

3. CHECK HARNESS CONTINUITY 1
1.

F

Check continuity between rear power window switch RH connector and rear power window motor RH connector.
A
Rear power
window switch
RH connector

G

B
Terminal

Rear power
window motor
RH connector

Continuity

H

Yes

GW

Terminal

4
D63

2.

E

1
D64

5

2

Check continuity between rear power window switch RH connector and ground.

MIIB1405E

J

A
Rear power window switch
RH connector

Continuity
Terminal

K

Ground

4
D63

No

5

L

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace harness.

M

4. CHECK REAR POWER WINDOW SWITCH POWER SUPPLY
1.
2.

Turn ignition switch ON.
Check voltage between rear power window switch RH connector
D63 terminal 1 and ground.
1 – Ground

: Battery voltage

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

PIIB0615E

GW-69

POWER WINDOW SYSTEM

5. CHECK HARNESS CONTINUITY 2
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector.
Check continuity between BCM connector and rear power window switch RH connector.
A

4.

B

BCM connector

Terminal

Rear power
window switch
RH connector

M59

78

D63

Continuity
Terminal
1

Yes

Check continuity between BCM connector and ground.
A

MIIB1399E

BCM connector

Terminal

M59

78

Ground

Continuity
No

OK or NG
OK
>> Check condition of harness and connector.
NG
>> Repair or replace harness.

6. CHECK HARNESS CONTINUITY 3
1.
2.

Disconnect power window main switch connector.
Check continuity between power window main switch connector
D8 terminal 5, 7 and rear power window switch RH connector
D63 terminal 2, 3.
5–3
7–2

3.

: Continuity should exist.
: Continuity should exist.

Check continuity between power window main switch connector
D8 terminal 5, 7 and ground.
5 – Ground
7 – Ground

: Continuity should not exist.
: Continuity should not exist.

OK or NG
OK
>> GO TO 7.
NG
>> Repair or replace harness.

GW-70

PIIB0619E

POWER WINDOW SYSTEM

7. CHECK POWER WINDOW MAIN SWITCH OUTPUT SIGNAL
1.
2.
3.

A

Connect power window main switch connector.
Turn ignition switch ON.
Check voltage between power window main switch connector
and ground when operating rear RH switch in power window
main switch.

C

Terminals (Wire color)
Connector

(+)

(-)

5
D8

B

Ground
7

Switch
condition

Voltage [V]
(Approx.)

UP

0

DOWN

Battery voltage

UP

Battery voltage

DOWN

0

D

PIIA4189E

OK or NG
OK
>> Check condition of harness and connector.
NG
>> Replace power window main switch.

F

Check Rear Power Window Motor LH Circuit

BIS000UV

1. CHECK POWER WINDOW SWITCH OUTPUT SIGNAL
1.
2.
3.
4.

G

Turn ignition switch OFF.
Disconnect rear power window motor LH connector.
Turn ignition switch ON.
Check voltage between rear power window motor LH connector
and ground.

Rear power
window motor
LH connector

Terminal
(–)

1
D44

Ground
2

Switch*

H

GW

Voltage [V]
(Approx.)

Condition
(+)

E

UP

0

DOWN

Battery voltage

UP

Battery voltage

DOWN

0

J

K

MIIB1404E

*: Power window main switch or rear power window switch LH.

OK or NG
OK
>> Replace rear power window motor LH.
NG
>> GO TO 2.

GW-71

L

M

POWER WINDOW SYSTEM

2. CHECK REAR POWER WINDOW SWITCH
1.
2.
3.

Turn ignition switch OFF.
Disconnect rear power window switch LH connector.
Check continuity between rear power window switch LH terminal
1, 2, 3 and 4, 5.
Terminals

Switch condition
5

UP

4

DOWN

2

5

No operation

3

4

No operation

1

Continuity

Yes

OK or NG
OK
>> GO TO 3.
NG
>> Replace rear power window switch LH.

PIIA4186E

3. CHECK HARNESS CONTINUITY 1
1.

Check continuity between rear power window switch LH connector and rear power window motor LH connector.
A
Rear power
window switch
LH connector

B
Terminal

Rear power
window motor
LH connector

Continuity
Terminal

4
D43

2.

1
D44

5

Yes

2

Check continuity between rear power window switch LH connector and ground.

MIIB1405E

A
Rear power window switch
LH connector

Continuity
Terminal

Ground

4
D43

No

5

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace harness.

4. CHECK REAR POWER WINDOW SWITCH POWER SUPPLY
1.
2.

Turn ignition switch ON.
Check voltage between rear power window switch LH connector
D43 terminal 1 and ground.
1 – Ground

: Battery voltage

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

PIIB0615E

GW-72

POWER WINDOW SYSTEM

5. CHECK HARNESS CONTINUITY 2
1.
2.
3.

A

4.

A

Turn ignition switch OFF.
Disconnect BCM connector.
Check continuity between BCM connector and rear power window switch LH connector.

B

B

BCM connector

Terminal

Rear power
window switch
LH connector

M59

78

D43

C
Continuity
Terminal
1

D

Yes

Check continuity between BCM connector and ground.
A

MIIB1399E

BCM connector

Terminal

M59

78

Ground

E

Continuity
No

F

OK or NG
OK
>> Check condition of harness and connector.
NG
>> Repair or replace harness.

G

6. CHECK HARNESS CONTINUITY 3
1.
2.

1–2
3–3
3.

H

Disconnect power window main switch connector.
Check continuity between power window main switch connector
D8 terminal 1, 3 and rear power window switch LH connector
D43 terminal 2, 3.

GW

: Continuity should exist.
: Continuity should exist.

J

Check continuity between power window main switch connector
D8 terminal 1, 3 and ground.
1 – Ground
3 – Ground

: Continuity should not exist.
: Continuity should not exist.

OK or NG
OK
>> GO TO 7.
NG
>> Repair or replace harness.

K
PIIB0616E

L

M

GW-73

POWER WINDOW SYSTEM

7. CHECK POWER WINDOW MAIN SWITCH OUTPUT SIGNAL
1.
2.
3.

Connect power window main switch connector.
Turn ignition switch ON.
Check voltage between power window main switch connector
and ground when operating rear LH switch in power window
main switch.
Terminals (Wire color)
Connector

(+)

(-)

1
D8

Ground
3

Switch
condition

Voltage [V]
(Approx.)

UP

Battery voltage

DOWN

0

UP

0

DOWN

Battery voltage

OK or NG
OK
>> Check condition of harness and connector.
NG
>> Replace power window main switch.

GW-74

PIIA4187E

POWER WINDOW SYSTEM
Check Limit Switch Circuit (Driver Side)

BIS000UW

A

WITH FRONT POWER WINDOW

1. CHECK POWER WINDOW MAIN SWITCH LIMIT SWITCH SIGNAL
1.
2.

B

Turn ignition switch ON.
Check voltage between power window main switch connector and ground.
[LHD models]

C
Power
window
main
switch
connector

D8

Terminal
Voltage [V]
(Approx.)

Condition
(+)

(–)

11

Ground

Driver side door window is
between fully-open position
and just before fully-closed
position (ON)

0

Driver side door window is
between just before fullyclosed position and fullyclosed position (OFF)

5

D

E

MIIB1406E

G

[RHD models]
Power
window
main
switch
connector

D8

F

Terminal

3

(–)

Ground

H

Voltage [V]
(Approx.)

Condition
(+)

GW

Driver side door window is
between fully-open position
and just before fully-closed
position (ON)

0

Driver side door window is
between just before fullyclosed position and fullyclosed position (OFF)

5

J
MIIB1411E

K

OK or NG
OK
>> Limit switch circuit is OK.
NG
>> GO TO 2.

L

2. CHECK POWER WINDOW MAIN SWITCH OUTPUT VOLTAGE 1
1.
2.
3.
4.

M

Turn ignition switch OFF.
Disconnect front power window motor (driver side) connector.
Turn ignition switch ON.
Check voltage between front power window motor (driver side)
connector and ground.

Front power window
motor (driver side)
connector

(+)

(–)

Voltage [V]
(Approx.)

D4

1

Ground

5

Terminal

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
MIIB1407E

GW-75

POWER WINDOW SYSTEM

3. CHECK HARNESS CONTINUITY 1
1.
2.
3.

Turn ignition switch OFF.
Disconnect power window main switch connector.
Check continuity between power window main switch connector
and front power window motor (driver side) connector.
[LHD models]
A
Power window
main switch
connector
D8

B

Terminal

Front power
window motor
(driver side)
connector

Terminal

11

D4

1

Continuity

Yes
MIIB1408E

[RHD models]
A
Power window
main switch
connector
D8

B

Terminal

Front power
window motor
(driver side)
connector

Terminal

3

D4

1

Continuity

Yes

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace harness.

MIIB1412E

4. CHECK POWER WINDOW MAIN SWITCH OUTPUT VOLTAGE 2
1.
2.

Turn ignition switch ON.
Check voltage between power window main switch connector
and ground.
[LHD models]
Terminal

Power window main
switch connector

(+)

(–)

Voltage [V]
(Approx.)

D8

11

Ground

5

MIIB1406E

[RHD models]
Terminal

Power window main
switch connector

(+)

(–)

Voltage [V]
(Approx.)

D8

3

Ground

5

OK or NG
OK
>> Check condition of harness and connector.
NG
>> Replace power window main switch.

MIIB1411E

GW-76

POWER WINDOW SYSTEM

5. CHECK GROUND CIRCUIT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect front power window motor (driver side) connector.
Check continuity between front power window motor (driver
side) connector and ground.

Front power window motor
(driver side) connector

Terminal

D4

2

B

C

Continuity
Ground
Yes

OK or NG
OK
>> Replace front power window motor (driver side).
NG
>> GO TO 6.

D

MIIB1409E

E

6. CHECK HARNESS CONTINUITY 2
1.
2.

F

Disconnect power window main switch connector.
Check continuity between power window main switch connector
and front power window motor (driver side) connector.
[LHD models]
A
Power window
main switch
connector
D8

G

B

H

Terminal

Front power
window motor
(driver side)
connector

Terminal

13

D4

2

Continuity

GW
Yes
MIIB1410E

J

[RHD models]
A

B

Power window
main switch
connector

Terminal

D8

11

K

Front power
window motor
(driver side)
connector

Terminal

D4

2

Continuity

L
Yes

OK or NG
OK
>> Replace power window main switch.
NG
>> Repair or replace harness.

M
MIIB1413E

GW-77

POWER WINDOW SYSTEM
WITH RFONT & REAR POWER WINDOW

1. CHECK POWER WINDOW MAIN SWITCH LIMIT SWITCH SIGNAL
1.
2.

Turn ignition switch ON.
Check voltage between power window main switch connector and ground.
Terminals (Wire color)

Connector

(+)

D8

(-)

9

Ground

Voltage [V]
(Approx.)

Condition
Driver side door window is
between fully-open position
and just before fully-closed
position (ON)

0

Driver side door window is
between just before fullyclosed position and fullyclosed position (OFF)

5
PIIA4194E

OK or NG
OK
>> Limit switch circuit is OK.
NG
>> GO TO 2.

2. CHECK POWER WINDOW MAIN SWITCH OUTPUT VOLTAGE 1
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect front power window motor (driver side) connector.
Turn ignition switch ON.
Check voltage between front power window motor (driver side)
connector and ground.

Front power window
motor (driver side)
connector

Terminal
(+)

(–)

Voltage [V]
(Approx.)

D4

1

Ground

5

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
MIIB1407E

3. CHECK HARNESS CONTINUITY 1
1.
2.
3.

Turn ignition switch OFF.
Disconnect power window main switch connector.
Check continuity between power window main switch connector
and front power window motor (driver side) connector.
A
Power window
main switch
connector
D8

B

Terminal

Front power
window motor
(driver side)
connector

Terminal

9

D4

1

Continuity

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace harness.

Yes

MIIB1414E

GW-78

POWER WINDOW SYSTEM

4. CHECK POWER WINDOW MAIN SWITCH OUTPUT VOLTAGE 2
1.
2.

A

Turn ignition switch ON.
Check voltage between power window main switch connector
D8 terminal 9 and ground.
9 – Ground

B

: Approx. 5V

OK or NG
OK
>> Check condition of harness and connector.
NG
>> Replace power window main switch.

C

D
PIIA4194E

E

5. CHECK GROUND CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect front power window motor (driver side) connector.
Check continuity between front power window motor (driver
side) connector and ground.

Front power window motor
(driver side) connector

Terminal

D4

2

F

G

Continuity

Ground

H

Yes

OK or NG
OK
>> Replace front power window motor (driver side).
NG
>> GO TO 6.

GW
MIIB1409E

J

6. CHECK HARNESS CONTINUITY 2
1.
2.

Disconnect power window main switch connector.
Check continuity between power window main switch connector
and front power window motor (driver side) connector.
A

K

B

Power window
main switch
connector

Terminal

D8

2

L

Front power
window motor
(driver side)
connector

Terminal

D4

2

Continuity

M

OK or NG
OK
>> Replace power window main switch.
NG
>> Repair or replace harness.

Yes

MIIB1415E

GW-79

POWER WINDOW SYSTEM
Check Encoder Circuit (Driver Side)

BIS000UX

WITH FRONT POWER WINDOW

1. CHECK ENCODER SIGNAL
1.
2.

Turn ignition switch ON.
Check signal between power window main switch connector and
ground with oscilloscope.
[LHD models]

Power
window
main
switch
connector

D8

Terminal
Signal
(Reference value)

Condition
(+)

4

(–)

Ground

MIIB1416E

When power
window motor
operates
OCC3383D

[RHD models]
Power
window
main
switch
connector

D8

Terminal
Signal
(Reference value)

Condition
(+)

(–)

9

Ground

When power
window motor
operates
MIIB1421E

OCC3383D

OK or NG
OK
>> Encoder circuit is OK.
NG
>> GO TO 2.

2. CHECK ENCODER POWER SUPPLY
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect front power window motor (driver side) connector.
Turn ignition switch ON.
Check voltage between front power window motor (driver side)
connector and ground.

Front power window
motor (driver side)
connector

Terminal
(+)

(–)

Voltage [V]
(Approx.)

D4

5

Ground

10

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.
MIIB1417E

GW-80

POWER WINDOW SYSTEM

3. CHECK HARNESS CONTINUITY 1

A

[LHD models]
1. Turn ignition switch OFF.
2. Disconnect power window main switch.
3. Check continuity between power window main switch connector
and front power window motor (driver side) connector.

B

C
A

4.

Power window
main switch
connector
D8

B

Terminal

Front power
window motor
(driver side)
connector

Terminal

3

D4

5

Continuity

D

Yes

Check continuity between power window main switch connector
and ground.

E
MIIB1418E

F

A
Continuity

Power window main switch
connector

Terminal

D8

3

Ground

G

No

[RHD models]
1. Turn ignition switch OFF.
2. Disconnect power window main switch.
3. Check continuity between power window main switch connector
and front power window motor (driver side) connector.
A

4.

Power window
main switch
connector
D8

H

GW

B

J

Terminal

Front power
window motor
(driver side)
connector

Terminal

2

D4

5

Continuity

K
Yes

Check continuity between power window main switch connector
and ground.

MIIB1422E

L

A
Power window main switch
connector

Terminal

D8

2

Ground

Continuity
No

OK or NG
OK
>> Replace power window main switch.
NG
>> Repair or replace harness.

GW-81

M

POWER WINDOW SYSTEM

4. CHECK POWER WINDOW MAIN SWITCH OUTPUT VOLTAGE
1.

Check voltage between front power window motor (driver side)
connector and round.

Front power window
motor (driver side)
connector

(+)

(–)

Voltage [V]
(Approx.)

D4

6

Ground

5

Terminal

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.
MIIB1419E

GW-82

POWER WINDOW SYSTEM

5. CHECK HARNESS CONTINUITY 2

A

[LHD models]
1. Turn ignition switch OFF.
2. Disconnect power window main switch connector.
3. Check continuity between power window main switch connector
and front power window motor (driver side) connector.

B

C
A

4.

Power window
main switch
connector
D8

B

Terminal

Front power
window motor
(driver side)
connector

Terminal

4

D4

6

Continuity

D

Yes

Check continuity between power window main switch connector
and ground.

E
MIIB1420E

F

A
Continuity

Power window main switch
connector

Terminal

D8

4

Ground

G

No

[RHD models]
1. Turn ignition switch OFF.
2. Disconnect power window main switch connector.
3. Check continuity between power window main switch connector
and front power window motor (driver side) connector.
A

4.

Power window
main switch
connector
D8

H

GW

B

J

Terminal

Front power
window motor
(driver side)
connector

Terminal

9

D4

6

Continuity

K
Yes

Check continuity between power window main switch connector
and ground.

MIIB1423E

L

A
Power window main switch
connector

Terminal

D8

9

Ground

Continuity
No

OK or NG
OK
>> Replace power window main switch.
NG
>> Repair or replace harness.

GW-83

M

POWER WINDOW SYSTEM

6. CHECK GROUND CIRCUIT
1.
2.

Turn ignition switch OFF.
Check continuity between front power window motor (driver
side) connector and ground.

Front power window motor
(driver side) connector

Terminal

D4

2

Continuity
Ground
Yes

OK or NG
OK
>> Replace front power window motor (driver side).
NG
>> GO TO 7.
MIIB1409E

7. CHECK HARNESS CONTINUITY 3
1.
2.

Disconnect power window main switch connector.
Check continuity between power window main switch connector
and front power window motor (driver side) connector.
[LHD models]
A
Power window
main switch
connector
D8

B

Terminal

Front power
window motor
(driver side)
connector

Terminal

13

D4

2

Continuity

Yes
MIIB1410E

[RHD models]
A
Power window
main switch
connector
D8

B

Terminal

Front power
window motor
(driver side)
connector

Terminal

11

D4

2

Continuity

Yes

OK or NG
OK
>> Replace power window main switch.
NG
>> Repair or replace harness.
MIIB1413E

GW-84

POWER WINDOW SYSTEM
WITH FRONT & REAR POWER WINDOW
A

1. CHECK ENCODER SIGNAL
1.
2.

Turn ignition switch ON.
Check signal between power window main switch connector and ground with oscilloscope.

Connector

Terminals (Wire color)

Signal
(Reference value)

Condition

(+)

(-)

13

Ground

B

C

D
D8

opening

E
OCC3383D
PIIA4205E

OK or NG
OK
>> Encoder circuit is OK.
NG
>> GO TO 2.

F

2. CHECK ENCODER POWER SUPPLY
1.
2.
3.
4.

G

Turn ignition switch OFF.
Disconnect front power window motor (driver side) connector.
Turn ignition switch ON.
Check voltage between front power window motor (driver side)
connector and ground.

Front power window
motor (driver side)
connector

Terminal
(+)

(–)

Voltage [V]
(Approx.)

D4

5

Ground

10

H

GW

J

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

K
MIIB1417E

L

M

GW-85

POWER WINDOW SYSTEM

3. CHECK HARNESS CONTINUITY 1
1.
2.
3.

Turn ignition switch OFF.
Disconnect power window main switch.
Check continuity between power window main switch connector
and front power window motor (driver side) connector.
A

4.

B

Power window
main switch
connector

Terminal

Front power
window motor
(driver side)
connector

D8

15

D4

Terminal

5

Continuity

Yes

Check continuity between power window main switch connector
and ground.

MIIB1424E

A
Power window main switch
connector

Terminal

D8

15

Ground

Continuity
No

OK or NG
OK
>> Replace power window main switch.
NG
>> Repair or replace harness.

4. CHECK POWER WINDOW MAIN SWITCH OUTPUT VOLTAGE
1.

Check voltage between front power window motor (driver side)
connector and round.

Front power window
motor (driver side)
connector

Terminal
(+)

(–)

Voltage [V]
(Approx.)

D4

6

Ground

5

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.
MIIB1419E

GW-86

POWER WINDOW SYSTEM

5. CHECK HARNESS CONTINUITY 2
1.
2.
3.

A

4.

A

Turn ignition switch OFF.
Disconnect power window main switch connector.
Check continuity between power window main switch connector
and front power window motor (driver side) connector.

B

B

Power window
main switch
connector

Terminal

D8

13

C

Front power
window motor
(driver side)
connector

Terminal

D4

6

Continuity

D
Yes

Check continuity between power window main switch connector
and ground.

MIIB1425E

E

A
Power window main switch
connector

Terminal

D8

13

F

Continuity

Ground

No

G

OK or NG
OK
>> Replace power window main switch.
NG
>> Repair or replace harness.

H

6. CHECK GROUND CIRCUIT
1.
2.

Turn ignition switch OFF.
Check continuity between front power window motor (driver
side) connector and ground.

GW

J

Front power window motor
(driver side) connector

Terminal

D4

2

Continuity

Ground

Yes

K

OK or NG
OK
>> Replace front power window motor (driver side).
NG
>> GO TO 7.

L
MIIB1409E

7. CHECK HARNESS CONTINUITY 3
1.
2.

M

Disconnect power window main switch connector.
Check continuity between power window main switch connector
and front power window motor (driver side) connector.
A

B

Power window
main switch
connector

Terminal

Front power
window motor
(driver side)
connector

Terminal

D8

2

D4

2

Continuity

OK or NG
OK
>> Replace power window main switch.
NG
>> Repair or replace harness.

Yes

MIIB1415E

GW-87

POWER WINDOW SYSTEM
Check Power Window Lock Switch

BIS0014S

1. CHECK POWER WINDOW LOCK SIGNAL
Exchanges for a normal power window main switch, and check operation.
Does power window lock operate?
YES >> Replace power window main switch.
NO
>> Check condition of harness and connector.

GW-88

FRONT DOOR GLASS AND REGULATOR
FRONT DOOR GLASS AND REGULATOR
Removal and Installation

PFP:80300

A
BIS000O1

B

C

D

E

F

G

H

GW
PIIB5343J

1. Pull handle bracket

2. Inner pad

3. Door glass

4. Lower sash (rear)

5. Regulator assembly

6. Power window motor

7.

8. Lower sash (front)

Door glass run

J

K

DOOR GLASS
Removal
1.
2.
3.
4.

5.
6.
7.

Remove front door finisher. Refer to EI-20, «DOOR FINISHER» .
Remove pull handle bracket.
Fully close door glass.
Disconnect front speaker harness connector, and then remove sealing screen.
NOTE:
If sealing screen is reused, cut butyl tape in a way that leaves it on sealing screen.
Remove clip, and then remove inner pad.
While supporting door glass, operate power window switch to
raise/lower door glass until glass bolts can be seen.
Remove door glass bolts.

L

M

MIIB1434E

GW-89

FRONT DOOR GLASS AND REGULATOR
8.

While holding door glass, raise glass up from rear edge while
pulling glass out of sash toward the inside of the door.

SIIA1779J

9. Remove lower sash (rear).
10. Remove door glass run.
11. Remove lower sash (front).

Installation
Install in the reverse order of removal.

REGULATOR ASSENBLY
Removal
1.
2.
3.

4.
5.
6.

Remove front door finisher. Refer to EI-20, «DOOR FINISHER» .
Remove pull handle bracket.
Disconnect front speaker harness connector, and then remove sealing screen.
NOTE:
If sealing screen is reused, cut butyl tape in a way that leaves it on sealing screen.
Remove clips, and then remove inner pad.
Operate the power window main switch to raise/lower the door
window until the glass mounting bolts can be seen.
Remove the glass mounting bolts.

MIIB1434E

7.

Raise up the door glass and hold with a suction lifter A.

PIIB3510J

GW-90

FRONT DOOR GLASS AND REGULATOR
8.

Remove power window motor bolts.
A

B

C
MIIB1435E

D

9.

Disconnect the harness connector for the power window motor, and remove regulator assembly.

Installation
E

Install in the reverse order of removal.

Inspection after Removal
Check the regulator assembly for the following. If a failure is
detected, replace or grease it.
●
Wire wear
●
Regulator assembly deformation
●
Grease condition on each sliding part
Apply grease (Nissan MP Special Grease No. 2) to the areas
indicted by the arrows in the figure.

F

G

H

SIIA1781J

Inspection after Installation

GW

BIS0014Y

SYSTEM INITIALIZATION
If any of the following work has been done, initialize the system.
●
Electric power supply to power window switch or motor is interrupted by blown fuse or disconnecting battery cable, etc.
●
Removal and installation of the regulator assembly.
●
Removal and installation of the motor from the regulator assembly.
●
Removal and installation of the harness connector of the power window switch.
●
Operate the regulator assembly as a unit.
●
Removal and installation of the door glass.
●
Removal and installation of the door glass run.

Initialization
After installing each component to the vehicle, follow the steps below.
1. Disconnect the minus terminal of battery or disconnect power window switch’s harness connector temporarily, then reconnect after at least 1 minute.
2. Turn ignition switch ON.
3. Press and hold the Driver Down window switch until the window glass has reached the Lower Mechanical
limit.
4. Release the Driver Down window switch.
5. Pull and hold the Driver Up window switch (to the second ‘detent’) until the window glass gas reached the
Upper Mechanical limit and continue to hold the Driver Up window switch for a further 5 seconds after the
glass has reached the Upper Mechanical limit (it is necessary that this whole operation is done with one
continuous pull of the Driver Up switch).
6. Release the Driver Up window switch.
7. Inspection of the anti-pinch system function.

GW-91

J

K

L

M

FRONT DOOR GLASS AND REGULATOR
INSPECT THE FUNCTION OF THE ANTI-PINCH SYSTEM.
1.
2.
3.

Fully open the door glass.
Place a wooden piece (wooden hammer handle etc.) at near fully closed position.
Carry out fully closing operation with auto up switch.
● Check that the glass reverses without pinching the wooden piece, is lowered approx.150mm (5.91in) or
for 2 seconds and then stops.
● The glass should not be raised with power window main switch operated while it is reversing or lowering.
CAUTION:
● Do not inspect with pinching a part of workers body, a hand etc. Work carefully not to be
pinched.
● Check that auto up function is normal before inspection following the system initialization.

FITTING INSPECTION
●
●

Make sure glass is securely fit into door glass run groove.
Lower glass slightly (approximately 10 to 20 mm), and confirm clearance to the sash is parallel. If clearance between glass and sash is not parallel, loosen bolts for regulator assembly, glass, and carrier plate,
and then correct glass position.

GW-92

REAR DOOR GLASS AND REGULATOR
REAR DOOR GLASS AND REGULATOR
Removal and Installation

PFP:82300

A
BIS000O2

B

C

D

E

F

G

H

GW
PIIB5346J

1. Pull handle bracket

2. Corner inner cover

3. Lower sash (rear)

4. Door glass

5. Regulator assembly

6. Power window motor

7. Door glass run

8. Lower sash (front)

J

K

DOOR GLASS
Removal
1.
2.
3.
4.
5.
6.

Fully open door glass.
Remove rear door finisher. Refer to EI-20, «DOOR FINISHER» .
Remove pull handle bracket.
Remove rear speaker harness connector.
Remove inner corner cover.
Remove sealing screen.
NOTE:
If sealing screen is reused, cut butyl tape in a way that leaves it on sealing screen.
7. Remove lower sash (rear) bolts, and remove lower sash (rear).
8. While supporting door glass, operate power window switch to
raise/lower door glass until glass bolts can be seen.
9. Remove door glass bolts.
10. Pull door glass up to remove it.

L

M

PIIB5348J

GW-93

REAR DOOR GLASS AND REGULATOR
11. Pull out and remove door glass run from door panel.
12. Remove lower sash (front) bolts, and then remove lower sash (front).

Installation
Install in the reverse order of removal.

REGULATOR ASSEMBLY
Removal
1.
2.
3.
4.

5.
6.

Remove rear door finisher. Refer to EI-20, «DOOR FINISHER» .
Remove pull handle bracket.
Remove rear speaker harness connector.
Remove sealing screen.
NOTE:
If sealing screen is reused, cut butyl tape in a way that leaves it on sealing screen.
Operate power window switch to raise/lower door glass until
glass bolts can be seen.
Remove door glass bolts.

PIIB5348J

7.

Raise up the door glass and hold with a suction lifter A.

PIIB3511J

8.

Remove regulator assembly bolts to remove assembly out of
door panel.

PIIB5347J

Installation
Install in the reverse order of removal.

GW-94

REAR DOOR GLASS AND REGULATOR
Installation after Removal
A

Check the regulator assembly for the following. If a failure is
detected, replace or grease it.
●
Gear wear
●
Regulator assembly deformation
●
Grease condition on each sliding part
Apply grease (Nissan MP Special Grease No. 2) to the areas
indicted by the arrows in the figure.

B

C

PIIB5349J

INSPECTION AFTER INSTALLATION
FITTING INSPECTION
●
●

D

E

Make sure the window is seated in the groove of the glass run.
Lower glass slightly (approximately 10 to 20 mm), and confirm clearance to the sash is parallel. If clearance between glass and sash is not parallel, loosen bolts for regulator assembly, glass, and main channel,
and then correct glass position.

F

G

H

GW

J

K

L

M

GW-95

DOOR MIRROR
DOOR MIRROR
Wiring Diagram — MIRROR — LHD Models (With Retract)

PFP:96301
BIS000O3

MIWA0683E

GW-96

DOOR MIRROR
A

B

C

D

E

F

G

H

GW

J

K

L

M

MIWA0684E

GW-97

DOOR MIRROR
Wiring Diagram — MIRROR — RHD Models (With Retract)

BIS000O4

MIWA0685E

GW-98

DOOR MIRROR
A

B

C

D

E

F

G

H

GW

J

K

L

M

MIWA0686E

GW-99

DOOR MIRROR
Wiring Diagram — MIRROR — LHD Models (Without Retract)

BIS000UH

MIWA0687E

GW-100

DOOR MIRROR
Removal and Installation

BIS000O5

A

B

C

D

E

F

G

H

GW
MIIB1429E

1. Corner cover

2. Door mirror assembly

CAUTION:
Be careful not to damage mirror body.

J

REMOVAL
1.
2.
3.
4.

Remove front door finisher. Refer to EI-20, «DOOR FINISHER» .
Remove corner cover.
Disconnect door mirror harness connector. (Electric door mirrors only)
Remove door mirror bolts and door mirror assembly.

K

L

INSTALLATION
Install in the reverse order of removal.

M

GW-101

DOOR MIRROR
Disassembly and Assembly

BIS000O6

MIIB1427E

1.

Mirror body (mirror holder)

2.

Mirror housing assembly

3.

Cover

DISASSEMBLY
1.
2.
3.

4.
5.

6.

Place the mirror body with mirror glass facing upward.
Put a strip of protective tape B on mirror body.
As shown in the figure, insert a small slotted screwdriver A into
the recess between mirror base (mirror holder)(1) and mirror
holder bracket (2) and push up two pawls (3) to remove mirror
holder lower half side.
NOTE:
Insert screwdriver into recesses, and push up while rotating
(twist) to make work easier.
CAUTION:
PIIB8320J
When pushing up the tabs, do not forcibly push up only 1
concave but try to push up using 2 concave positions.
Remove two terminals of mirror heater attachment.
Lightly lift up lower side of mirror surface from mirror surface, and detach two pawls of upper side as if
pulling it out. Remove mirror surface from mirror body.
NOTE:
Be certain not to allow grease on sealing agent in center of mirror body assembly (actuator) or back side
of mirror surface (mirror holder).
Remove cover.

MIIB1428E

GW-102

DOOR MIRROR
ASSEMBLY
A

Install in the reverse order of removal.
CAUTION:
●
Engage upper tabs of mirror glass (mirror holder) with
power unit. Then, press lower part of mirror glass down
until lower part snaps into place and engages lower tabs.
●
After finishing work, visually confirm that lower tabs (2) at
the bottom of mirror face are securely engaged.

B

C

D
MIIB0206E

E

F

G

H

GW

J

K

L

M

GW-103

INSIDE MIRROR
INSIDE MIRROR
Removal and Installation

PFP:96321
BIS000O7

REMOVAL
Pull the inside mirror upward to remove it.

MIIB1057E

INSTALLATION
Install in the reverse order of removal.

Removal and Installation (With Rain Sensor)

BIS000O8

REMOVAL
Slide the inside mirror downward to remove.

MIIB0991E

INSTALLATION
Install in the reverse order of removal.

GW-104

INSTRUMENT PANEL

I BODY

SECTION

IP

INSTRUMENT PANEL

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 2
Precautions …………………………………………………….. 2
CLIP AND FASTENER ……………………………………….. 3
List of Table …………………………………………………….. 3
INSTRUMENT PANEL ASSEMBLY ……………………… 4
Component Parts Location ………………………………… 4
Removal and Installation …………………………………… 5
WORK ITEM TABLE ……………………………………… 5
REMOVAL ……………………………………………………. 6
REMOVAL AND INSTALLATION OF INSTRU-

MENT PAD …………………………………………………. 10
Disassembly and Assembly ……………………………… 11
GLOVE BOX ASSEMBLY ………………………………….. 12
Removal And Installation …………………………………. 12
REMOVAL ………………………………………………….. 12
INSTALLATION …………………………………………… 12
Disassembly And Assembly …………………………….. 12
DISASSEMBLY …………………………………………… 12
ASSEMBLY ………………………………………………… 12
CENTER CONSOLE ASSEMBLY ………………………. 13
Removal And Installation …………………………………. 13
REMOVAL ………………………………………………….. 13
INSTALLATION …………………………………………… 13
Disassembly And Assembly …………………………….. 13

E

F

G

H

IP

J

K

L

M

IP-1

PRECAUTIONS
PFP:00001
PRECAUTIONS
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

BIS000TY

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Precautions

BIS000TZ

Disconnect both battery cables in advance.
Disconnect air bag system line in advance.
●
Never tamper with or force air bag lid open, as this may adversely affect air bag performance.
●
Be careful not to scratch pad and other parts.
●
When removing or disassembling any part, be careful not to damage or deform it. Protect parts, which
may get in the way with cloth.
●
When removing parts with a screwdriver or other tool, protect parts by wrapping them with vinyl or tape.
●
Keep removed parts protected with cloth.
●
If a clip is deformed or damaged, replace it.
●
If an unreusable part is removed, replace it with a new one.
●
Tighten bolts and nuts firmly to the specified torque.
●
After re-assembly has been completed, make sure each part functions correctly.
●
Remove stains in the following way.
Water-soluble stains:
Dip a soft cloth in warm water, and then squeeze it tightly. After wiping the stain, wipe with a soft dry cloth.
Oil stain:
Dissolve a synthetic detergent in warm water (density of 2 to 3% or less), dip the cloth, then clean off the stain
with the cloth. Next, dip the cloth in fresh water and squeeze it tightly. Then clean off the detergent completely.
Then wipe the area with a soft dry cloth.
●
Do not use any organic solvent, such as thinner or benzine.
●
●

IP-2

CLIP AND FASTENER
CLIP AND FASTENER
List of Table
Symbol No.

PFP:76906

A
BIS000U0

Shape

Removal and installation

B

C

D

E
MIIB0017E

F

G

H

IP

J

K

L

M

IP-3

INSTRUMENT PANEL ASSEMBLY
INSTRUMENT PANEL ASSEMBLY
Component Parts Location

PFP:68200
BIS000U1

MIIB9296E

IP-4

INSTRUMENT PANEL ASSEMBLY
1.

Steering member

2.

Upper instrument panel

3.

Passenger air bag module*

4.

Side ventilator grille (LH)

5.

Instrument pad (driver side)

6.

Instrument pad (passenger side)

7.

Side ventilator grille (RH)

8.

Instrument side mask (LH)

9.

Instrument panel

10. Instrument side mask (RH)

11. Instrument panel stay (LHD only)

12. Instrument member bracket (RH)

13. Combination meter

14. Audio unit bracket (LH)

15. Audio unit (CD changer)

16. Audio unit bracket (RH)

17. Audio unit bracket (LH)

18. Deck pocket

19. Audio unit (CD)

20. Audio unit bracket (RH)

21. Switch panel finisher

22. Cluster lid A

23. Cluster lid C upper mask

24. Glove box cover assembly

25. Glove box lid

26. Fuse block lid

27. Cluster lid C (CD changer)

28. Cluster lid C (CD)

29. Steering column cover upper

30. Steering column protector

31. Steering column cover lower

32. Steering lock escutcheon

33. Central ventilator grille (LH)

34. Cluster lid C lower mask

35. Central ventilator grille (RH)

36. Air conditioner finisher

37. Instrument finisher lower

38. Instrument panel stay cover

39. Cup holder

40. Instrument panel stay finisher
(LHD only)

41. Center console

42. Console mask

A

B

C

D

E

*: Refer to SRS section.

F

: Insertion
: Pawl
: Plastic clip

G

: Metal clip

Removal and Installation

BIS000U2

WORK ITEM TABLE
Component Parts Location

Instrument
panel

Instrument
pad
(passenger
side)

Instrument
pad
(driver side)

Upper
instrument
panel

Combination meter

A. Front pillar garnish

IP-6

[1]

[1]

[1]

B. Upper instrument panel

IP-6

[2]

[2]

[2]

C. Steering lock escutcheon

IP-6

[3]

[3]

D. Instrument finisher lower

IP-6

[4]

[4]

E. Switch panel finisher

IP-6

[5]

[5]

F. Steering column cover upper

IP-7

[6]

[6]

[1]

[1]

G. Steering column cover lower

IP-7

[7]

[7]

[2]

[2]

H. Combination switch

IP-7

[8]

[8]

I. Cluster lid A

IP-7

[9]

[9]

[3]

[3]

J. Combination meter

IP-7

[ 10 ]

[ 10 ]

[4]

[4]

K. Cluster lid C

IP-8

[ 11 ]

[ 11 ]

[5]

L. Air conditioner finisher

IP-9

[ 12 ]

[ 12 ]

[6]

M. Instrument pad
(driver side)

IP-9

[ 13 ]

[ 13 ]

[7]

N. Center consol

IP-9

[ 14 ]

[ 14 ]

O. Instrument panel stay cover

IP-9

[ 15 ]

[ 15 ]

P. Glove box lid

IP-9

Q. Glove box cover assembly

IP-10

[ 16 ]

[ 16 ]

R. Instrument side mask

IP-10

[ 17 ]

[ 17 ]

S. Steering wheel

IP-10

[ 18 ]

[ 18 ]

T. Instrument panel

IP-10

[ 19 ]

[ 19 ]

U. Instrument pad
(passenger side)

IP-10

[ 20 ]

IP-5

Audio unit

H

IP

J

K

L

M
[1]

INSTRUMENT PANEL ASSEMBLY
[ ]: The number shows the removal order.

REMOVAL
A. Front Pillar Garnish
Refer to EI-26, «BODY SIDE TRIM» in EI section.

B. Upper Instrument Panel
1.
2.
3.

Disconnect sunload sensor harness connector and remove the sunload sensor (if equipped). Refer to
ATC-116, «Removal and Installation» .
Lift up the upper instrument panel on one side to disengage
metal clips.
Remove the upper instrument panel.

MIIB9300E

C. Steering Lock Escutcheon
Pull to release steering lock escutcheon from the steering column cover.
CAUTION:
To install, align key cylinder end bottom protrusion with escutcheon inside notch and install.

D. Instrument Finisher Lower
Disengage upper plastic clips, and pull carefully rearward to remove
avoiding interference with surrounding surfaces.

MIIB9315E

E. Switch Panel Finisher
1.

Remove fuse block lid.

MIIB9310E

IP-6

INSTRUMENT PANEL ASSEMBLY
2.
3.

Push the switch panel finisher to rear direction as shown.
Disconnect harness connectors and remove the switch panel
finisher.

A

B

C
MIIB9301E

D

F. Steering Column Cover Upper
1. Tilt down the steering column, and remove screw (1) facing front of vehicle.
2. Disengage hooks and remove.
CAUTION:
Pull out being careful of interference with surrounding objects.

E

G. Steering Column Cover Lower

F

Remove screws (3), and pull downward to remove.
CAUTION:
Pull out being careful of interference with surrounding objects.

G

H. Combination Switch
Refer to LT-112, «Removal and Installation» .

H

I. Cluster Lid A
Pull the cluster lid A to rearward direction and remove.
CAUTION:
Pull out being careful of interference with surrounding objects.

IP

J

K
MIIB9302E

L

J. Combination Meter
1.
2.
3.
4.
5.

Remove screw (1).
Pull rearward to disengage plastic clips as shown.
Disconnect harness connectors.
Lift up the lower side of combination meter to rotate the combination meter from the vertical to horizontal position.
Remove the combination meter from the instrument pad.

M

MIIB9303E

IP-7

INSTRUMENT PANEL ASSEMBLY
K. Cluster Lid C
1.
2.

Remove cluster lid C upper mask and remove upper fixing
screws.
Remove cluster lid C lower mask and remove lower fixing
screws.

MIIB9313E

3.
4.

Pull rearward to release the cluster lid from instrument panel
and pad.
Disconnect antenna connector and audio harness connector.

MIIB9314E

After removal:
●
Separate the central ventilator grille LH and RH. Refer to ATC-130, «Removal and Installation» and MTC76, «Removal and Installation» .
●
For (A) audio unit models, remove screws (4) securing audio
unit bracket LH and RH to release deck pocket and audio unit.
●
For (B) audio unit models, remove screws (2) securing audio
unit bracket LH and RH to release audio unit.

MIIB9311E

IP-8

INSTRUMENT PANEL ASSEMBLY
L. Air Conditioner Finisher
Refer to ATC-112, «Removal and Installation of Controller»
MTC-62, «Removal and Installation» .

A

and

B

C

MIIB9308E

D

M. Instrument Pad (Driver Side)
Pull rearward to disengage metal clips from the instrument panel.
CAUTION:
Pull out being careful of interference with surrounding objects.
After removal and if necessary, remove the side ventilator grille. Refer to ATC-130, «Removal and Installation»
and MTC-76, «Removal and Installation» .

E

F

N. Center Console
Refer to IP-13, «Removal And Installation» .

G

O. Instrument Panel Stay Cover
1.

Remove instrument panel stay finisher.

H

IP

J

MIIB9305E

2.
3.
4.

Remove mounting clips LH and RH.
Pull instrument stay cover to rearward to disengage plastic clips.
Disconnect power supply or cigar lighter harness connector if
equipped.
5. Remove instrument stay cover.
After removal, if necessary, remove screws securing the cup holder
to the instrument stay cover, and remove cup holder.

L

M

MIIB9304E

P. Glove Box Lid.
Refer to IP-12, «GLOVE BOX ASSEMBLY» .

IP-9

K

INSTRUMENT PANEL ASSEMBLY
Q. Glove Box Cover Assembly
1.
2.

Remove screws shown in the figure and remove the glove box
assembly.
After removal, separate parts if necessary. Refer to IP-12,
«GLOVE BOX ASSEMBLY» .

MIIB9307E

R. Instrument Side Mask
1.
2.
3.
4.

From inner side of instrument panel, push to disengage pawls
as shown.
Disconnect airbag cut-off switch from harness (passenger side
only).
Disengage airbag cut-off switch from instrument side mask (passenger side only).
Pull out inserted area of instrument side mask and remove from
vehicle.
MIIB9306E

S. Steering Wheel
Refer to SRS-36, «DRIVER AIR BAG MODULE» and SRS-38, «SPIRAL CABLE» .

T. Instrument Panel
1.
2.
3.

4.

Remove the fuel filler lid opener. Refer to BL-212, «Removal and Installation of Fuel Filler Lid Opener» .
Tilt down steering column.
Remove screws, refer to IP-11, «Disassembly and Assembly» , and remove instrument panel and pad from
passenger door opening.
NOTE:
This operation requires two workers.
After removal, separate parts. Refer to IP-11, «Disassembly and Assembly» .

U. Instrument Pad (Passenger Side)
Remove mountings screws (3) securing the instrument pad to the instrument panel, and release metal clips
and remove the instrument pad (passenger side) from the Instrument panel. Refer to IP-11, «Disassembly and
Assembly» .
After removal and if necessary, remove the side ventilator grille. Refer to ATC-130, «Removal and Installation»
and MTC-76, «Removal and Installation» .

REMOVAL AND INSTALLATION OF INSTRUMENT PAD
Driver Side:
1.
2.
3.
4.
5.
6.
7.

Remove the steering column upper cover. Refer to IP-7, «F. Steering Column Cover Upper» .
Remove the steering column lower cover. Refer to IP-7, «G. Steering Column Cover Lower» .
Remove the cluster lid A. Refer to IP-7, «I. Cluster Lid A» .
Remove the combination meter. Refer to IP-7, «J. Combination Meter» .
Remove the cluster lid C. Refer to IP-8, «K. Cluster Lid C» .
Remove the air conditioner finisher. Refer to IP-9, «L. Air Conditioner Finisher» .
Remove the instrument pad (driver side). Refer to IP-9, «M. Instrument Pad (Driver Side)» .

Passenger Side:
1.

Remove the instrument panel assembly. Refer to IP-6, «REMOVAL» .

IP-10

INSTRUMENT PANEL ASSEMBLY
2.

Remove the instrument pad (passenger side). Refer to IP-10, «U. Instrument Pad (Passenger Side)» .
A

Installation
Install in the reverse order of removal.

B

Disassembly and Assembly

BIS000U3

C

D

E

F

G

H

IP

J
MIIB9298E

1.

Instrument pad (driver side)

2.

Instrument pad (passenger side)

3.

Instrument panel

K

: Metal clip

L

M

IP-11

GLOVE BOX ASSEMBLY
GLOVE BOX ASSEMBLY
Removal And Installation

PFP:68510
BIS0014W

REMOVAL
1.

Remove the glove box assembly. Refer to IP-10, «Q. Glove Box Cover Assembly» .

INSTALLATION
Install in the reverse order of removal.

Disassembly And Assembly

BIS0014X

MIIB9297E

1.

Spring assembly

4.

Air conditioner inlet

2.

Glove box cover

3.

Glove box lid

DISASSEMBLY
1.
2.
3.

Remove spring assembly screw.
Push glove box lid hooks to disengage glove box lid from the
glove box cover.
Remove the air conditioner inlet from the glove box cover.

MIIB9312E

ASSEMBLY
Assembly is in the reverse order of disassembly.

IP-12

CENTER CONSOLE ASSEMBLY
CENTER CONSOLE ASSEMBLY
Removal And Installation

PFP:96910

A
BIS0014U

REMOVAL
1.

Remove shift knob from the shift lever (for manual transmission vehicles only). Refer to MT-12, «Removal
and Installation of Control Device and Cable» (JH3), MT-42, «Removal and Installation of Control Device
and Cable» (JR5).
2. Engage the shift knob in neutral position (for automatic transmission only).
3. Remove console mask. Refer to IP-13, «Disassembly And Assembly» .
4. Pull up parking brake lever, and remove finisher from the lever.
5. Remove the armrest (if equipped) from the driver seat (for manual transmission vehicles only). Refer to
SE-7, «Component Parts Location» .
6. Remove power socket or cigar lighter from the center console and disconnect harness connector.
7. Slide front seat to access to the center console rear fixing
screws.
8. Lift up the front side of the center console to disengage fixing
clips.
9. Disconnect all harness connectors.
10. Remove the center console.

B

C

D

E

F

G

MIIB9309E

H

INSTALLATION
Install in the reverse order of removal.
IP

Disassembly And Assembly

BIS0014V

J

K

L

M

MIIB9299E

1.

Control lever finisher

2.

Coin compartment

3.

Console mask

4.

Switch holder

5.

Cup holder

6.

Power socket

7.

Power socket finisher

8.

Center console

IP-13

CENTER CONSOLE ASSEMBLY

IP-14

LAN SYSTEM

K ELECTRICAL

SECTION

LAN

LAN SYSTEM

A

B

C

D

CONTENTS
CAN
PRECAUTIONS …………………………………………………. 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 3
Maintenance Information …………………………………… 3
RHD MODELS ……………………………………………… 3
LHD MODELS ………………………………………………. 3
Precautions When Using CONSULT-II ………………… 3
CHECK POINTS FOR USING CONSULT-II ……… 3
Precautions for Trouble Diagnosis ……………………… 4
CAN SYSTEM ………………………………………………. 4
Precautions for Harness Repair …………………………. 4
CAN SYSTEM ………………………………………………. 4
TROUBLE DIAGNOSES WORK FLOW ……………….. 5
When Displaying CAN Communication System
Errors …………………………………………………………….. 5
WHEN A MALFUNCTION IS DETECTED BY
CAN COMMUNICATION SYSTEM ………………….. 5
WHEN A MALFUNCTION IS DETECTED
EXCEPT CAN COMMUNICATION SYSTEM …….. 5
TROUBLE DIAGNOSIS FLOW CHART …………… 6
Diagnosis Procedure ………………………………………… 7
SELECTING CAN SYSTEM TYPE (HOW TO
USE SPECIFICATION TABLE) ……………………….. 7
ACQUISITION OF DATA BY CONSULT-II ………… 8
HOW TO USE CHECK SHEET TABLE ……………. 9
CAN Diagnostic Support Monitor ……………………… 15
DESCRIPTION OF “CAN DIAG SUPPORT
MNTR” SCREEN FOR ECM …………………………. 15
DESCRIPTION OF “CAN DIAG SUPPORT
MNTR” SCREEN FOR INTELLIGENT KEY UNIT… 17
DESCRIPTION OF “CAN DIAG SUPPORT
MNTR” SCREEN FOR EPS CONTROL UNIT … 17
DESCRIPTION OF “CAN DIAG SUPPORT
MNTR” SCREEN FOR BCM …………………………. 18
DESCRIPTION OF “CAN DIAG SUPPORT
MNTR” SCREEN FOR ABS ACTUATOR AND

ELECTRIC UNIT (CONTROL UNIT) ………………. 18
DESCRIPTION OF “CAN DIAG SUPPORT
MNTR” SCREEN FOR TCM ………………………….. 20
DESCRIPTION OF “CAN DIAG SUPPORT
MNTR” SCREEN FOR IPDM E/R ………………….. 20
CAN COMMUNICATION ……………………………………. 21
System Description …………………………………………. 21
Component Parts and Harness Connector Location… 21
LHD MODEL ………………………………………………. 21
RHD MODEL ………………………………………………. 22
Wiring Diagram — CAN — ………………………………. 23
CR14DE/HR16DE MODEL …………………………… 23
K9K MODEL ……………………………………………….. 25
CAN Communication Unit ………………………………… 27
TYPE 1/TYPE 2 …………………………………………… 28
TYPE 3/TYPE 4 …………………………………………… 30
TYPE 5/TYPE 6 …………………………………………… 32
TYPE 7/TYPE 8 …………………………………………… 34
TYPE 9/TYPE 10 …………………………………………. 36
CAN SYSTEM (TYPE 1) ……………………………………. 38
Component Parts and Harness Connector Location… 38
Wiring Diagram — CAN — ………………………………. 38
Check Sheet ………………………………………………….. 38
Check Sheet ………………………………………………….. 39
CHECK SHEET RESULTS (EXAMPLE) …………. 41
CAN SYSTEM (TYPE 2) ……………………………………. 51
Component Parts and Harness Connector Location… 51
Wiring Diagram — CAN — ………………………………. 51
Check Sheet ………………………………………………….. 51
Check Sheet ………………………………………………….. 52
CHECK SHEET RESULTS (EXAMPLE) …………. 54
CAN SYSTEM (TYPE 3) ……………………………………. 65
Component Parts and Harness Connector Location… 65
Wiring Diagram — CAN — ………………………………. 65
Check Sheet ………………………………………………….. 65
Check Sheet ………………………………………………….. 66
CHECK SHEET RESULTS (EXAMPLE) …………. 68
CAN SYSTEM (TYPE 4) ……………………………………. 79
Component Parts and Harness Connector Location… 79
Wiring Diagram — CAN — ………………………………. 79

LAN-1

E

F

G

H

I

J

LAN

L

M

Check Sheet ………………………………………………….. 79
Check Sheet ………………………………………………….. 80
CHECK SHEET RESULTS (EXAMPLE) …………. 82
CAN SYSTEM (TYPE 5) ……………………………………. 94
ComponentParts and Harness Connector Location… 94
Wiring Diagram — CAN — ………………………………. 94
Check Sheet ………………………………………………….. 94
Check Sheet ………………………………………………….. 95
CHECK SHEET RESULTS (EXAMPLE) …………. 97
CAN SYSTEM (TYPE 6) ………………………………….. 108
ComponentParts and Harness Connector Location. 108
Wiring Diagram — CAN — …………………………….. 108
Check Sheet ………………………………………………… 108
Check Sheet ………………………………………………… 109
CHECK SHEET RESULTS (EXAMPLE) …………111
CAN SYSTEM (TYPE 7) ………………………………….. 123
ComponentParts and Harness Connector Location. 123
Wiring Diagram — CAN — …………………………….. 123
Check Sheet ………………………………………………… 123
Check Sheet ………………………………………………… 124
CHECK SHEET RESULTS (EXAMPLE) ……….. 126
CAN SYSTEM (TYPE ………………………………….. 136
ComponentParts and Harness Connector Location. 136
Wiring Diagram — CAN — …………………………….. 136
Check Sheet ………………………………………………… 136
Check Sheet ………………………………………………… 137
CHECK SHEET RESULTS (EXAMPLE) ……….. 139
CAN SYSTEM (TYPE 9) ………………………………….. 150
ComponentParts and Harness Connector Location. 150

Wiring Diagram — CAN — …………………………….. 150
Check Sheet ………………………………………………… 150
Check Sheet ………………………………………………… 151
CHECK SHEET RESULTS (EXAMPLE) ………… 153
CAN SYSTEM (TYPE 10) …………………………………. 164
ComponentParts and Harness Connector Location.164
Wiring Diagram — CAN — …………………………….. 164
Check Sheet ………………………………………………… 164
Check Sheet ………………………………………………… 165
CHECK SHEET RESULTS (EXAMPLE) ………… 167
TROUBLE DIAGNOSIS FOR SYSTEM ……………… 179
Inspection Between Data Link Connector and ABS
Actuator and Electric Unit (Control Unit) Circuit …. 179
ECM Circuit Inspection ………………………………….. 180
Data Link Connector Circuit Inspection …………….. 182
Data Link Connector and CAN Communication Circuit Inspection ………………………………………………. 182
Combination Meter Circuit Inspection ………………. 184
Intelligent Key Unit Circuit Inspection ………………. 184
Steering Angle Sensor Circuit Inspection ………….. 185
EPS Control Unit Circuit Inspection …………………. 185
BCM Circuit Inspection ………………………………….. 186
ABS Actuator and Electric Unit (Control Unit) Circuit
Inspection …………………………………………………….. 186
TCM Circuit Inspection …………………………………… 187
IPDM E/R Circuit Inspection …………………………… 188
CAN Communication Circuit Inspection ……………. 188
IPDM E/R Ignition Relay Circuit Inspection ……….. 190

LAN-2

PRECAUTIONS
[CAN]

PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
[CAN]

A

BKS001IN

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Maintenance Information

B

C

D

E

F

BKS0028M

If any of following part is replaced, always replace with new* one.
If it’s not (or fail to do so), the electrical system may not be operated properly.
*: New one means a virgin control unit that has never been energized on-board.

G

RHD MODELS

H

●
●
●
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM
IPDM E/R
Combination meter
EPS control unit

I

J

LHD MODELS
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM

Precautions When Using CONSULT-II

LAN

L
BKS001IO

When connecting CONSULT-II to data link connector, connect them through CONSULT-II CONVERTER.
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carry out CAN communication.

CHECK POINTS FOR USING CONSULT-II
1.
–
–

2.
–
–

3.
4.
5.

Has CONSULT-II been used without connecting CONSULT-II CONVERTER on this vehicle?
If YES, GO TO 2.
If NO, GO TO 5.
Is there any indication other than indications relating to CAN communication system in the self-diagnostic
results?
If YES, GO TO 3.
If NO, GO TO 4.
Based on self-diagnostic results unrelated to CAN communication, carry out the inspection.
Malfunctions may be detected in self-diagnosis depending on control units carrying out CAN communication. Therefore, erase the self-diagnosis results.
Diagnose CAN communication system. Refer to LAN-5, «TROUBLE DIAGNOSES WORK FLOW» .

LAN-3

M

PRECAUTIONS
[CAN]

Precautions for Trouble Diagnosis

BKS001IP

CAN SYSTEM
●
●
●

Do not apply voltage of 7.0 V or higher to the measurement terminals.
Use the tester with its open terminal voltage being 7.0 V or less.
Be sure to turn ignition switch OFF and disconnect the battery cable from the negative terminal before
checking the circuit.

Precautions for Harness Repair

BKS001IQ

CAN SYSTEM
●

Solder the repaired parts, and wrap with tape. [Frays of twisted
line must be within 110 mm (4.33 in).]

PKIA0306E

●

Do not perform bypass wire connections for the repair parts.
(The spliced wire will become separated and the characteristics
of twisted line will be lost.)

PKIA0307E

LAN-4

TROUBLE DIAGNOSES WORK FLOW
[CAN]

TROUBLE DIAGNOSES WORK FLOW
When Displaying CAN Communication System Errors

PFP:00004

A
BKS001HW

WHEN A MALFUNCTION IS DETECTED BY CAN COMMUNICATION SYSTEM
●
●
●

CAN communication line is open. (CAN-H, CAN-L, or both)
CAN communication line is shorted. (Ground, between CAN lines, or other harnesses)
The areas related to CAN communication of unit is malfunctioning.

WHEN A MALFUNCTION IS DETECTED EXCEPT CAN COMMUNICATION SYSTEM
●

●
●

Removal and installation of parts: When the units that perform CAN communication or the sensors related
to CAN communication are removed and installed, malfunction may be detected (or DTC other than CAN
communication may be detected).
Fuse blown out (removed): CAN communication of the unit may be stopped at such time.
Low voltage: If the voltage decreases because of battery discharge when ignition switch is ON, malfunction may be detected by self-diagnosis according to the units.

B

C

D

E

F

G

H

I

J

LAN

L

M

LAN-5

TROUBLE DIAGNOSES WORK FLOW
[CAN]
TROUBLE DIAGNOSIS FLOW CHART
Depending on the control unit which performs CAN communication, “U1010” may be indicated as the result of
self-diagnosis. Replace the control unit if “U1010” is indicated.

PKIC9387E

●
●
●
●
●

Step 1: Refer to LAN-7, «SELECTING CAN SYSTEM TYPE (HOW TO USE SPECIFICATION TABLE)» .
Step 2: Refer to LAN-8, «ACQUISITION OF DATA BY CONSULT-II» .
Step 3: Refer to LAN-9, «HOW TO USE CHECK SHEET TABLE» .
Step 4: Refer to LAN-10, «Example of Filling in Check Sheet When Initial Conditions Are Reproduced» .
Step 5: Refer to LAN-179, «TROUBLE DIAGNOSIS FOR SYSTEM» .

LAN-6

TROUBLE DIAGNOSES WORK FLOW
[CAN]

Diagnosis Procedure

BKS001HX

A

SELECTING CAN SYSTEM TYPE (HOW TO USE SPECIFICATION TABLE)
Determine CAN system type from the equipment of the vehicle to select applicable check sheet.

B

C

D

E

F

G
PKIC9395E

H

I

J

LAN

L

M

LAN-7

TROUBLE DIAGNOSES WORK FLOW
[CAN]
ACQUISITION OF DATA BY CONSULT-II
Attach the data acquired by CONSULT-II on the check sheet determined according to CAN system type.

PKIC9388E

LAN-8

TROUBLE DIAGNOSES WORK FLOW
[CAN]
HOW TO USE CHECK SHEET TABLE
A

B

C

D

E

F
PKIC9389E

1.
2.

Unit names displayed on CONSULT-II.
G
“No indication”: Put a check mark to it if the unit name described in step 1 is not displayed on “SELECT
SYSTEM” screen of CONSULT-II. (Unit communicating with CONSULT-II via CAN communication line)
“–”: Column not used (Unit communicating with CONSULT-II excluding CAN communication line)
H
3. “NG”: Display “NG” when malfunction is detected in the initial diagnosis of the diagnosed unit. Replace the
unit if “NG” is displayed.
“–”: Column not used (Initial diagnosis is not performed.)
I
NOTE:
It is unnecessary to replace ABS actuator and electric unit (control unit) when “NG” on “INITIAL DIAG” of
“ABS” is indicated at this stage. “NG” is indicated not only when malfunctioning ABS actuator and electric
J
unit (control unit) but also other parts. See check sheet results for the system diagnosis.
4. “UNKWN”: Display “UNKWN” when the diagnosed unit does not transmit the data normally. Put a check
mark to it if “UNKWN” is displayed on CONSULT-II.
LAN
“–”: Column not used (transmit diagnosis is not performed.)
5. “UNKWN”: Display “UNKWN” when the diagnosed unit does not receive the data normally. Put a check
mark to it if “UNKWN” is displayed on CONSULT-II.
“–”: Column not used (It is not necessary for CAN communication trouble diagnosis.)
L
NOTE:
CAN communication diagnosis checks if CAN communication works normally. (Contents of data are not diagnosed.)
M
●
When the initial conditions are reproduced, refer to LAN-10, «Example of Filling in Check Sheet When Initial Conditions Are Reproduced» .
●
When the initial conditions are not reproduced, refer to LAN-13, «Example of Filling in Check Sheet When
Initial Conditions Are Not Reproduced» .

LAN-9

TROUBLE DIAGNOSES WORK FLOW
[CAN]
Example of Filling in Check Sheet When Initial Conditions Are Reproduced

PKIC9390E

1.

2.

Put a check mark to “No indication” if some of unit names listed on the column of diagnosis system selection screen of a check sheet table are not displayed on “SELECT SYSTEM” screen attached to the check
sheet.
NOTE:
Do not put a check mark on items in the column of “No indication” on the check sheet when displaying all
items on “SELECT SYSTEM” screen.
Confirm the unit name that “UNKWN” is displayed from the copy of “CAN DIAG SUPPORT MNTR” screen
of “ENGINE” attached to the check sheet, and then put a check mark to the check sheet table.
NOTE:
In “CAN DIAG SUPPORT MNTR” screen, “UNKWN” is displayed on “TRNSMIT DIAG”, “VDC/TCS/ABS”,
“BCM/SEC”, “EPS” and “IPDM E/R”. Put a check mark to it.

LAN-10

TROUBLE DIAGNOSES WORK FLOW
[CAN]
A

B

C

D

E

F

G

H

PKIC9391E

3.

I
Confirm the unit name that “UNKWN” is displayed on the copy of “CAN DIAG SUPPORT MNTR” screen
of “INTELLIGENT KEY”, “EPS”, “BCM”, “ABS” and “IPDM E/R” as well as “ENGINE”. And then, put a
check mark to the check sheet table.
J
NOTE:
● For “INTELLIGENT KEY”, “UNKWN” is displayed on “ECM”. Put a check mark to it.
● For “EPS”, “UNKWN” is displayed on “ECM”. Put a check mark to it.
LAN
● For “BCM”, “UNKWN” is displayed on “ECM”. Put a check mark to it.
● For “ABS”, “UNKWN” is displayed on “ECM”. Put a check mark to it.
● For “IPDM E/R”, “UNKWN” is displayed on “ECM”. Put a check mark to it.
L

M

LAN-11

TROUBLE DIAGNOSES WORK FLOW
[CAN]

PKIC9392E

NOTE:
There is a case that some of “CAN DIAG SUPPORT MNTR” and “SELF-DIAG RESULTS” are not needed for
diagnosis. In the case, “UNKWN” and “CAN COMM CIRCUIT [U1000]” in “Check sheet results (example)”
change to “–”. Then, ignore check marks on the check sheet table.
4. Perform system diagnosis for possible causes identified.
5. Perform diagnosis again after inspection and repair. Make sure that repair is completely performed, and
then end the procedure.
Start CAN system trouble diagnosis if this procedure can be confirmed. Refer to LAN-27, «CAN Communication Unit» .

LAN-12

TROUBLE DIAGNOSES WORK FLOW
[CAN]
Example of Filling in Check Sheet When Initial Conditions Are Not Reproduced
A

B

C

D

E

F

G

H

PKIC9393E

1.

I

See “SELF-DIAG RESULTS” of all units attached to the check sheet. If “CAN COMM CIRCUIT”, “CAN
COMM CIRCUIT [U1000]” or “CAN COMM CIRCUIT [U1001]” is displayed, put a check mark to the applicable column of self-diagnostic results of the check sheet table.
J
NOTE:
● For “ENGINE”, “CAN COMM CIRCUIT [U1001]” is displayed. Put a check mark to it.
● For “INTELLIGENT KEY”, “CAN COMM CIRCUIT [U1000]” is displayed. Put a check mark to it.
LAN
● For “EPS”, “CAN COMM CIRCUIT [U1000]” is displayed. Put a check mark to it.
● For “BCM”, “CAN COMM CIRCUIT [U1000]” is displayed. Put a check mark to it.
L
● For “ABS”, “CAN COMM CIRCUIT [U1000]” is displayed. Put a check mark to it.
● For “IPDM E/R”, “CAN COMM CIRCUIT [U1000]” is displayed. Put a check mark to it.
M

LAN-13

TROUBLE DIAGNOSES WORK FLOW
[CAN]

PKIC9394E

NOTE:
There is a case that some of “CAN DIAG SUPPORT MNTR” and “SELF-DIAG RESULTS” are not needed for
diagnosis. In the case, “UNKWN” and “CAN COMM CIRCUIT [U1000]” in “Check sheet results (example)”
change to “–”. Then, ignore check marks on the check sheet table.
2. For the selected possible causes, it is expected that malfunctions have been found in the past.

LAN-14

TROUBLE DIAGNOSES WORK FLOW
[CAN]

CAN Diagnostic Support Monitor

BKS001HY

A

DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR ECM
CR14DE/HR16DE model

B

C

D
PKIC9371E

E
“SELECT SYSTEM”
screen

“CAN DIAG SUPPORT
MNTR” screen

Description

TRANSMIT DIAG

Make sure of normal transmission.

OK/UNKWN/–

VDC/TCS/ABS

Make sure of normal reception from ABS actuator and electric unit (control unit).

OK/UNKWN/–

Make sure of normal reception from combination
meter. (ESP model)

OK/UNKWN/–

METER/M&A

METER/M&A is not diagnosed. (ABS model)
BCM/SEC
ENGINE

Present

Make sure of normal reception from BCM.

F

G

–
OK/UNKWN/–

ICC

ICC is not diagnosed.

–

HVAC

HVAC is not diagnosed.

–

TCM

Make sure of normal reception from TCM. (A/T
model)

EPS

Past

H
OK/0/1 – 39/–

I
OK/UNKWN/–

TCM is not diagnosed. (M/T model)

–

EPS is not diagnosed.

–

IPDM E/R

Make sure of normal reception from IPDM E/R.

e4WD

e4WD is not diagnosed.

–

AWD/4WD

AWD/4WD is not diagnosed.

–

J

OK/UNKWN/–

Display Results (Present)

LAN

L

●

OK: Normal

●

UNKWN: The diagnosed unit does not transmit or receive the applicable data normally.

●

–: There is no received unit or the unit is not in the condition that reception diagnosis is performed.

Display Results (Past)
●

OK: Normal

●

0: There is malfunction now.

●

1 – 39: Displays when it is normal at present and finds malfunction in the past. It increases like 0→1→2…38→39 after returning to the
normal condition whenever IGN OFF→ON. If it is over 39, it is fixed to 39 until the self-diagnostic results are erased. It returns to 0
when malfunction is detected again in the process.

●

–: Undiagnosed

LAN-15

M

TROUBLE DIAGNOSES WORK FLOW
[CAN]
K9K model

PKIC9372E

“SELECT SYSTEM”
screen

ENGINE

“CAN DIAG SUPPORT
MNTR” screen

Description

Present

TRANSMIT DIAG

Make sure of normal transmission.

OK/UNKWN/–

VDC/TCS/ABS

Make sure of normal reception from ABS actuator
and electric unit (control unit).

OK/UNKWN/–

Make sure of normal reception from combination
meter. (ESP model)

OK/UNKWN/–

METER/M&A

METER/M&A is not diagnosed. (ABS model)
BCM/SEC

Make sure of normal reception from BCM.

TCM

TCM is not diagnosed.

IPDM E/R

Make sure of normal reception from IPDM E/R.

Past

OK/0/1 – 39/–
–
OK/UNKWN/–
–
OK/UNKWN/–

Display Results (Present)
●

OK: Normal

●

UNKWN: The diagnosed unit does not transmit or receive the applicable data normally.

●

–: There is no received unit or the unit is not in the condition that reception diagnosis is performed.

Display Results (Past)
●

OK: Normal

●

0: There is malfunction now.

●

1 – 39: Displays when it finds malfunction in the past even if it is normal or there is a malfunction at present. Also, displays when diagnosis is not performed. It increase like 0→1→2…38→39 after returning to the normal condition whenever IGN OFF→ON. If it is over
39, it is fixed to 39 until the self-diagnostic results are erased. Keep this condition until resetting it.

●

–: Undiagnosed

LAN-16

TROUBLE DIAGNOSES WORK FLOW
[CAN]
DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN
FOR INTELLIGENT KEY UNIT

A

B

C
PKIC9373E

“SELECT SYSTEM”
screen

INTELLIGENT KEY

D

“CAN DIAG SUPPORT
MNTR” screen

Description

Present

INITIAL DIAG

Make sure that microcomputer in ECU works normally.

OK/NG

TRANSMIT DIAG

Make sure of normal transmission.

OK/UNKWN

ECM

Make sure of normal reception from ECM.

OK/UNKWN

METER/M&A

Make sure of normal reception from combination meter.

OK/UNKWN

BCM/SEC

Make sure of normal reception from BCM.

OK/UNKWN

Display Results (Present)

E

F

G

●

OK: Normal

●

NG: Malfunction

●

UNKWN: The diagnosed unit does not transmit or receive the applicable data normally.

H

DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN
FOR EPS CONTROL UNIT
I

J

LAN
PKIC9374E

“SELECT SYSTEM”
screen

“CAN DIAG SUPPORT MNTR” screen

Description

Present

TRANSMIT DIAG

Make sure of normal transmission.

OK/UNKWN

ECM

Make sure of normal reception from ECM.

OK/UNKWN

VDC/TCS/ABS

Make sure of normal reception from ABS actuator and electric unit
(control unit).

OK/UNKWN

METER/M&A

Make sure of normal reception from combination meter.

OK/UNKWN

EPS

Display Results (Present)
●

OK: Normal

●

NG: Malfunction

●

UNKWN: The diagnosed unit does not transmit or receive the applicable data normally.

LAN-17

L

M

TROUBLE DIAGNOSES WORK FLOW
[CAN]
DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN
FOR BCM

PKIC9375E

“SELECT SYSTEM”
screen

BCM

“CAN DIAG SUPPORT
MNTR” screen

Description

Present

TRANSMIT DIAG

Make sure of normal transmission.

OK/UNKWN

ECM

Make sure of normal reception from ECM.

OK/UNKWN

IPDM E/R

Make sure of normal reception from IPDM E/R.

OK/UNKWN

METER/M&A

Make sure of normal reception from combination meter.

OK/UNKWN

I-KEY

Make sure of normal reception from Intelligent Key unit.

OK/UNKWN

VDC/TCS/ABS

Make sure of normal reception from ABS actuator and electric unit
(control unit).

OK/UNKWN

Display Results (Present)
●

OK: Normal

●

NG: Malfunction

●

UNKWN: The diagnosed unit does not transmit or receive the applicable data normally.

DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)
ABS model

PKIC9376E

“SELECT SYSTEM” screen
ABS

“CAN DIAG SUPPORT
MNTR” screen

Description

Present

INITIAL DIAG

Make sure that microcomputer in ECU works normally.

OK/NG

ECM

Make sure of normal reception from ECM.

OK/UNKWN

Display Results (Present)
●

OK: Normal

●

NG: Malfunction

●

UNKWN: The diagnosed unit does not transmit or receive the applicable data normally.

LAN-18

TROUBLE DIAGNOSES WORK FLOW
[CAN]
ESP model
A

B

C
PKIC9377E

“SELECT SYSTEM”
screen

ABS

“CAN DIAG SUPPORT
MNTR” screen

D
Description

Present

TRANSMIT DIAG

Make sure of normal transmission.

OK/UNKWN/–

ECM

Make sure of normal reception from ECM.

OK/UNKWN/–

METER/M&A

Make sure of normal reception from combination
meter.

OK/UNKWN/–

TCM

TCM is not diagnosed.

STRG

Make sure of normal reception from steering
angle sensor.

Past

E

OK/0/1 – 39/–

F

–
OK/UNKWN/–

G

Display Results (Present)
●

OK: Normal

●

UNKWN: The diagnosed unit does not transmit or receive the applicable data normally.

●

–: There is no received unit or the unit is not in the condition that reception diagnosis is performed.

Display Results (Past)

H

I

●

OK: Normal

●

0: There is malfunction now.

●

1 – 39: Displays when it finds malfunction in the past even if it is normal or there is a malfunction at present. Also, displays when diagnosis is not performed. It increase like 0→1→2…38→39 after returning to the normal condition whenever IGN OFF→ON. If it is over
39, it is fixed to 39 until the self-diagnostic results are erased. Keep this condition until resetting it.

●

–: Undiagnosed

J

LAN

L

M

LAN-19

TROUBLE DIAGNOSES WORK FLOW
[CAN]
DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN
FOR TCM

PKIC9378E

“SELECT SYSTEM”
screen

A/T

“CAN DIAG SUPPORT
MNTR” screen

Description

Present

INITIAL DIAG

Make sure that microcomputer in ECU works normally.

OK/NG

TRANSMIT DIAG

Make sure of normal transmission.

OK/UNKWN

ECM

Make sure of normal reception from ECM.

OK/UNKWN

VDC/TCS/ABS

VDC/TCS/ABS is not diagnosed.

UNKWN

METER/M&A

Make sure of normal reception from combination meter.

OK/UNKWN

ICC/e4WD

ICC/e4WD is not diagnosed.

UNKWN

Display Results (Present)
●

OK: Normal

●

NG: Malfunction

●

UNKWN: The diagnosed unit does not transmit or receive the applicable data normally.

DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN
FOR IPDM E/R

PKIC9379E

“SELECT SYSTEM”
screen

IPDM E/R

“CAN DIAG SUPPORT
MNTR” screen

Description

Present

TRANSMIT DIAG

Make sure of normal transmission.

OK/UNKWN

BCM/SEC

Make sure of normal reception from BCM.

OK/UNKWN

ECM

Make sure of normal reception from ECM.

OK/UNKWN

Display Results (Present)
●

OK: Normal

●

UNKWN: The diagnosed unit does not transmit or receive the applicable data normally.

LAN-20

CAN COMMUNICATION
[CAN]

CAN COMMUNICATION
System Description

PFP:23710

A
BKS0014C

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

Component Parts and Harness Connector Location

B

C

BKS001IR

LHD MODEL

D

E

F

G

H

I

J

LAN

L
PKIC9435E

1.

TCM E106

2.

BCM M57

3.

ABS actuator and electric unit (control unit) E32 (ABS model)
ABS actuator and electric unit (control unit) E33 (ESP model)

4.

Intelligent Key unit M60

5.

IPDM E/R E12

6.

ECM E40

7.

EPS control unit M25

8.

Combination meter M27

9.

Data link connector M14

10. Steering angle sensor M40

LAN-21

M

CAN COMMUNICATION
[CAN]
RHD MODEL

PKIC9434E

1.

Steering angle sensor M40

2.

Data link connector M14

3.

Combination meter M27

4.

EPS control unit M25

5.

Intelligent Key unit M60

6.

ABS actuator and electric unit (control unit) E32 (ABS model)
ABS actuator and electric unit (control unit) E33 (ESP model)

7.

IPDM E/R E12

8.

ECM E40

9.

TCM E106

10. BCM M57

LAN-22

CAN COMMUNICATION
[CAN]

Wiring Diagram — CAN —

BKS001IS

A

CR14DE/HR16DE MODEL

B

C

D

E

F

G

H

I

J

LAN

L

M

MKWA4293E

LAN-23

CAN COMMUNICATION
[CAN]

MKWA4294E

LAN-24

CAN COMMUNICATION
[CAN]
K9K MODEL
A

B

C

D

E

F

G

H

I

J

LAN

L

M

MKWA4295E

LAN-25

CAN COMMUNICATION
[CAN]

MKWA4296E

LAN-26

CAN COMMUNICATION
[CAN]

CAN Communication Unit

BKS001IT

A

Go to CAN system, when selecting your car model from the following table.
Body type

Hatchback

Axle

2WD

Engine

HR16DE

K9K

M/T

A/T

M/T

Transmission
Brake control

ABS

CAN system type
CAN system trouble diagnosis

ESP
×

Intelligent Key system

B

CR14DE/HR16DE

ABS
×

ABS
×

C

ESP
×

×

1

2

3

4

5

6

7

8

9

10

LAN38

LAN51

LAN65

LAN79

LAN94

LAN108

LAN123

LAN136

LAN150

LAN164

D

×: Applicable

E

NOTE:
Confirming the presence of the following items helps to identify CAN system type.
●
Model with ESP

F

G

H

SKIB8664E

●

I

Model with Intelligent Key system
J

LAN

L
SKIB8665E

M

LAN-27

CAN COMMUNICATION
[CAN]
TYPE 1/TYPE 2
System diagram
●

Type 1

MKIB1738E

●

Type 2

MKIB1737E

Input/output signal chart
T: Transmit R: Receive

Signals

ECM

Combination meter

Intelligent
Key unit*

EPS control unit

BCM

ABS actuator and
electric
unit (control unit)

IPDM E/R

A/C compressor request signal

T

R

Cooling fan speed request signal

T

R

Engine coolant temperature signal

T

R

Engine speed signal

T

R

Engine status signal

T

Fuel consumption monitor signal

T

R

MI signal

T

R

R

R

R

T

Vehicle speed signal

R

R

R
R

LAN-28

R

T
R

CAN COMMUNICATION
[CAN]

Signals

ECM

Combination meter

Intelligent
Key

unit*

R

Buzzer output signal

R

A
IPDM E/R

B

T
T

KEY indicator signal

R

T

LOCK indicator signal

R

T

R

EPS warning indicator signal

BCM

T

Door lock/unlock request signal

EPS operation signal

EPS control unit

ABS actuator and
electric
unit (control unit)

C

R

D

T
R

T

A/C switch signal

R

T

Blower fan motor switch signal

R

T

Day time light request signal

E

T

Door lock/unlock status signal

R

F

R

T

R

T

R

T

R

Front wiper request signal

T

R

Headlamp washer request signal

T

R

R

T

R

T

R

Position lights request signal

R

T

R

Rear fog lamp status signal

R

T

Door switch signal

R

Front fog lamp request signal

R

High beam request signal
Low beam request signal

Rear window defogger switch signal
R

T

R

T

R

Sleep/wake up signal

R

Turn indicator signal

R

ABS warning lamp signal

R

T

Brake warning lamp signal

R

T

Front wiper stop position signal

R

Low beam status signal

R

T

R

LAN-29

L

T
T

*: with Intelligent Key system model only

J

T
T

Rear window defogger control signal

I

LAN

R

R

H

T

High beam status signal

Oil pressure switch signal

G

M

CAN COMMUNICATION
[CAN]
TYPE 3/TYPE 4
System diagram
●

Type 3

PKIC8680E

●

Type 4

PKIC8679E

Input/output signal chart
T: Transmit R: Receive

Signals

ECM

Combination
meter

A/C compressor request signal

T

Accelerator pedal position signal

T

Cooling fan speed request signal

T

Engine coolant temperature signal

T

R

Engine speed signal

T

R

Engine status signal

T

Fuel consumption monitor signal

T

R

MI signal

T

R

Parking brake switch signal

Intelligent Key
unit

*

Steering
angle
sensor

EPS control unit

BCM

ABS
actuator
and electric unit
(control
unit)

IPDM
E/R

R
R
R
R
R
R

T

R

LAN-30

CAN COMMUNICATION
[CAN]

Signals

Vehicle speed signal

ECM

Combination
meter

R

R

R

T

Intelligent Key
unit*

EPS control unit

R
Door lock/unlock request signal

BCM

R
R

R

R

Buzzer output signal

B

T
R

C

T
T

R

T

LOCK indicator signal

R

T

Steering angle signal
R

D

R

T

EPS warning indicator signal

A
IPDM
E/R

T

KEY indicator signal

EPS operation signal

Steering
angle
sensor

ABS
actuator
and electric unit
(control
unit)

E

R
T

R

T

F

A/C switch signal

R

T

Blower fan motor switch signal

R

T

Day time light request signal

T

Door lock/unlock status signal

R

R

T

R

T

R

T

R

Front wiper request signal

T

R

Headlamp washer request signal

T

R

T

R

T

R
R

Door switch signal

R

Front fog lamp request signal

R

High beam request signal

R

Low beam request signal
Position lights request signal

R

T

Rear fog lamp status signal

R

T

Rear window defogger switch signal
R

T

R

T

R

Sleep/wake up signal

R

Turn indicator signal

R

ABS warning lamp signal

R

T

Brake warning lamp signal

R

T

ESP OFF indicator signal

R

T

ESP warning lamp signal

R

T

SLIP indicator lamp signal

R

T

R

T

R

T

Low beam status signal

R

T

Rear window defogger control signal

R

T

R

T

*: with Intelligent Key system model only

LAN-31

I

J

LAN

M

High beam status signal

Oil pressure switch signal

H

L

T

Front wiper stop position signal

G

CAN COMMUNICATION
[CAN]
TYPE 5/TYPE 6
System diagram
●

Type 5

MKIB1736E

●

Type 6

MKIB1735E

Input/output signal chart
T: Transmit R: Receive

Signals

ECM

Combination
meter

Intelligent Key
unit

*

EPS
control
unit

BCM

ABS
actuator
and
electric
unit
(control
unit)

TCM

A/C compressor request signal

T

Accelerator pedal position signal

T

R

Closed throttle position signal

T

R

Cooling fan speed request signal

T

Engine and A/T integrated control signal

IPDM
E/R

R

R

T

R

R

T

Engine coolant temperature signal

T

R

Engine speed signal

T

R

LAN-32

R

CAN COMMUNICATION
[CAN]

Signals

ECM

Combination
meter

Engine status signal

T

Fuel consumption monitor signal

T

R

MI signal

T

R

Wide open throttle position signal

T

Intelligent Key
unit

*

EPS
control
unit

BCM

ABS
actuator
and
electric
unit
(control
unit)

A
TCM

B

R

C

R

Overdrive control switch signal

T

R

Stop lamp switch signal

T

R

Vehicle speed signal

R

R

R

T

R
R

R

R
Buzzer output signal

T

KEY indicator signal

R

T

LOCK indicator signal

R

T

Door lock/unlock request signal

T

R

EPS warning lamp signal

D

E

T
R
T

R

EPS operation signal

IPDM
E/R

F

R

G
T

R

H

T

A/C switch signal

R

T

Blower fan motor switch signal

R

T

Day time light request signal

I

T

Door lock/unlock status signal

R

R

T

R

T

R

T

R

Front wiper request signal

T

R

Headlamp washer request signal

T

R

T

R

T

R
R

Door switch signal

R

Front fog lamp request signal

R

High beam request signal

R

Low beam request signal
Position lights request signal

R

T

Rear fog lamp status signal

R

T

Rear window defogger switch signal

R

T

R

R

Turn indicator signal

R

ABS warning lamp signal

R

T

Brake warning lamp signal

R

T

A/T position indicator signal

R

OD OFF indicator signal
Output shaft revolution signal

T

T

R

T
R

T

R

T

Front wiper stop position signal

R

T

High beam status signal

R

T

Low beam status signal

R

T

LAN-33

LAN

L

M

T

Sleep/wake up signal

A/T self-diagnosis signal

R

J

CAN COMMUNICATION
[CAN]

Signals

ECM

Oil pressure switch signal
Rear window defogger control signal

Combination
meter

Intelligent Key
unit*

R
R

EPS
control
unit

BCM

ABS
actuator
and
electric
unit
(control
unit)

TCM

IPDM
E/R

T
T

*: with Intelligent Key system model only

TYPE 7/TYPE 8
System diagram
●

Type 7

●

Type 8

MKIB1738E

MKIB1737E

LAN-34

CAN COMMUNICATION
[CAN]
Input/output signal chart
T: Transmit R: Receive

Signals

ECM

Combination meter

Intelligent
Key unit*

EPS control unit

BCM

ABS actuator and
electric
unit (control unit)

IPDM E/R

A/C compressor request signal

T

R

Cooling fan speed request signal

T

R

Engine coolant temperature signal

T

R

Engine coolant temperature warning
lamp signal

T

R

Engine speed signal

T

R

Engine status signal

T

Glow indicator signal

T

R

Fuel consumption monitor signal

T

R

MI signal

T

R

R

R

Vehicle speed signal

R

E

F
R
R

R

T

R

G
T

R

T

Door lock/unlock request signal

T

KEY indicator signal

R

T

LOCK indicator signal

R

T

EPS warning indicator signal

R

H

R

I
T

Day time light request signal

T

Door lock/unlock status signal

R

J

R

T

R

T

R

T

R

Front wiper request signal

T

R

Headlamp washer request signal

T

R

T

R

T

R
R

Door switch signal

R

Front fog lamp request signal

R

High beam request signal

R

Low beam request signal
Position lights request signal

R

T

Rear fog lamp status signal

R

T

Rear window defogger switch signal
Sleep/wake up signal
Starter signal

R

R

R

T

R

T

R

T
R

ABS warning lamp signal

R

T

Brake warning lamp signal

R

T

Front wiper stop position signal

T

R
R

*: with Intelligent Key system model only

LAN-35

LAN

L

M

Turn indicator signal

Oil pressure switch signal

C

D

R
Buzzer output signal

B

R

R

T

A

T
T

CAN COMMUNICATION
[CAN]
TYPE 9/TYPE 10
System diagram
●

Type 9

PKIC8680E

●

Type 10

PKIC8679E

Input/output signal chart
T: Transmit R: Receive

Signals

ECM

Combination
meter.

A/C compressor request signal

T

Accelerator pedal position signal

T

Cooling fan speed request signal

T

Engine coolant temperature signal

T

R

Engine coolant temperature warning
lamp signal

T

R

Engine speed signal

T

R

Engine status signal

T

Fuel consumption monitor signal

T

Intelligent Key
unit

*

Steering
angle
sensor

EPS control unit

BCM

ABS
actuator
and electric unit
(control
unit)

IPDM
E/R

R
R
R
R

R
R

R

LAN-36

CAN COMMUNICATION
[CAN]

Signals

ECM

Combination
meter.

Glow indicator signal

T

R

MI signal

T

R

R

R

R

T

Vehicle speed signal

Intelligent Key
unit*

Steering
angle
sensor

EPS control unit

R
Door lock/unlock request signal

R

R

T

R

D

T
T

R

T

LOCK indicator signal

R

T

Steering angle sensor signal

R

T
R

E

R

T
R

Door switch signal

R

Front fog lamp request signal

R

F

T

Day time light request signal
Door lock/unlock status signal

B

T

KEY indicator signal

EPS warning indicator signal

A
IPDM
E/R

C
R

R

Buzzer output signal

BCM

ABS
actuator
and electric unit
(control
unit)

G

T
T

R

T

R

Front wiper request signal

T

R

Headlamp washer request signal

T

R

T

R

T

R
R

High beam request signal

R

R

R

Low beam request signal
Position lights request signal

R

T

Rear fog lamp status signal

R

T

Rear window defogger switch signal
Sleep/wake up signal

R

Turn indicator signal

R

Starter signal

R

T

R

T

R

I

J

LAN

T

R

T

L

ABS warning lamp signal

R

T

Brake warning lamp signal

R

T

ESP OFF indicator signal

R

T

ESP warning lamp signal

R

T

SLIP indicator lamp signal

R

M

T

Front wiper stop position signal
Oil pressure switch signal

H

R
R

T
T

*: with Intelligent Key system model only

LAN-37

CAN SYSTEM (TYPE 1)
[CAN]

CAN SYSTEM (TYPE 1)
Component Parts and Harness Connector Location

PFP:23710
BKS001IU

Refer to LAN-21, «Component Parts and Harness Connector Location» .

Wiring Diagram — CAN —

BKS001IW

Refer to LAN-23, «Wiring Diagram — CAN —» .

Check Sheet

BKS001LE

Refer to LAN-39, «Check Sheet» .

LAN-38

CAN SYSTEM (TYPE 1)
[CAN]

Check Sheet

BKS001IX

A

NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

B

C

D

E

F

G

H

I

J

LAN

L

M

PKIC9195E

LAN-39

CAN SYSTEM (TYPE 1)
[CAN]

PKIC9192E

LAN-40

CAN SYSTEM (TYPE 1)
[CAN]
CHECK SHEET RESULTS (EXAMPLE)
A

NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

Case 1
Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, «Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit» .

B

C

D

E

F

G
PKIC9271E

H

I

J

LAN

L

M
MKIB1813E

LAN-41

CAN SYSTEM (TYPE 1)
[CAN]
Case 2
Check ECM circuit. Refer to LAN-180, «ECM Circuit Inspection» .

PKIC9272E

MKIB1815E

LAN-42

CAN SYSTEM (TYPE 1)
[CAN]
Case 3
A

Check data link connector circuit. Refer to LAN-182, «Data Link Connector Circuit Inspection» .

B

C

D

E

F
PKIC9273E

G

H

I

J

LAN

MKIB1817E

L

M

LAN-43

CAN SYSTEM (TYPE 1)
[CAN]
Case 4
Check combination meter circuit. Refer to LAN-184, «Combination Meter Circuit Inspection» .

PKIC9274E

MKIB1819E

LAN-44

CAN SYSTEM (TYPE 1)
[CAN]
Case 5
A

Check EPS control unit circuit. Refer to LAN-185, «EPS Control Unit Circuit Inspection» .

B

C

D

E

F
PKIC9275E

G

H

I

J

LAN

MKIB1821E

L

M

LAN-45

CAN SYSTEM (TYPE 1)
[CAN]
Case 6
Check BCM circuit. Refer to LAN-186, «BCM Circuit Inspection» .

PKIC9276E

MKIB1823E

LAN-46

CAN SYSTEM (TYPE 1)
[CAN]
Case 7
Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, «ABS Actuator and Electric Unit
(Control Unit) Circuit Inspection» .

A

B

C

D

E

F
PKIC9277E

G

H

I

J

LAN

L
MKIB1825E

M

LAN-47

CAN SYSTEM (TYPE 1)
[CAN]
Case 8
Check IPDM E/R circuit. Refer to LAN-188, «IPDM E/R Circuit Inspection» .

PKIC9278E

MKIB1827E

LAN-48

CAN SYSTEM (TYPE 1)
[CAN]
Case 9
A

Check CAN communication circuit. Refer to LAN-188, «CAN Communication Circuit Inspection» .

B

C

D

E

F
PKIC9279E

Case 10
Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

G

H

I

J

LAN

L
PKIC9280E

M

LAN-49

CAN SYSTEM (TYPE 1)
[CAN]
Case 11
Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

PKIC9281E

LAN-50

CAN SYSTEM (TYPE 2)
[CAN]

CAN SYSTEM (TYPE 2)
Component Parts and Harness Connector Location

PFP:23710

A
BKS001IY

Refer to LAN-21, «Component Parts and Harness Connector Location» .
B

Wiring Diagram — CAN —

BKS001J0

Refer to LAN-23, «Wiring Diagram — CAN —» .

Check Sheet

BKS001LF

C

Refer to LAN-52, «Check Sheet» .
D

E

F

G

H

I

J

LAN

L

M

LAN-51

CAN SYSTEM (TYPE 2)
[CAN]

Check Sheet

BKS001J1

NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

PKIC9196E

LAN-52

CAN SYSTEM (TYPE 2)
[CAN]
A

B

C

D

E

F

G

H

I

J

LAN

L

M

PKIC9146E

LAN-53

CAN SYSTEM (TYPE 2)
[CAN]
CHECK SHEET RESULTS (EXAMPLE)
NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

Case 1
Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, «Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit» .

PKIC9284E

MKIB1790E

LAN-54

CAN SYSTEM (TYPE 2)
[CAN]
Case 2
A

Check ECM circuit. Refer to LAN-180, «ECM Circuit Inspection» .

B

C

D

E

F
PKIC9285E

G

H

I

J

LAN

MKIB1792E

L

M

LAN-55

CAN SYSTEM (TYPE 2)
[CAN]
Case 3
Check data link connector circuit. Refer to LAN-182, «Data Link Connector Circuit Inspection» .

PKIC9286E

MKIB1794E

LAN-56

CAN SYSTEM (TYPE 2)
[CAN]
Case 4
A

Check combination meter circuit. Refer to LAN-184, «Combination Meter Circuit Inspection» .

B

C

D

E

F
PKIC9287E

G

H

I

J

LAN

MKIB1796E

L

M

LAN-57

CAN SYSTEM (TYPE 2)
[CAN]
Case 5
Check Intelligent Key unit circuit. Refer to LAN-184, «Intelligent Key Unit Circuit Inspection» .

PKIC9288E

MKIB1798E

LAN-58

CAN SYSTEM (TYPE 2)
[CAN]
Case 6
A

Check EPS control unit circuit. Refer to LAN-185, «EPS Control Unit Circuit Inspection» .

B

C

D

E

F
PKIC9289E

G

H

I

J

LAN

MKIB1800E

L

M

LAN-59

CAN SYSTEM (TYPE 2)
[CAN]
Case 7
Check BCM circuit. Refer to LAN-186, «BCM Circuit Inspection» .

PKIC9290E

MKIB1802E

LAN-60

CAN SYSTEM (TYPE 2)
[CAN]
Case 8
Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, «ABS Actuator and Electric Unit
(Control Unit) Circuit Inspection» .

A

B

C

D

E

F
PKIC9291E

G

H

I

J

LAN

L
MKIB1804E

M

LAN-61

CAN SYSTEM (TYPE 2)
[CAN]
Case 9
Check IPDM E/R circuit. Refer to LAN-188, «IPDM E/R Circuit Inspection» .

PKIC9292E

MKIB1806E

LAN-62

CAN SYSTEM (TYPE 2)
[CAN]
Case 10
A

Check CAN communication circuit. Refer to LAN-188, «CAN Communication Circuit Inspection» .

B

C

D

E

F
PKIC9293E

Case 11
Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

G

H

I

J

LAN

L
PKIC9294E

M

LAN-63

CAN SYSTEM (TYPE 2)
[CAN]
Case 12
Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

PKIC9295E

LAN-64

CAN SYSTEM (TYPE 3)
[CAN]

CAN SYSTEM (TYPE 3)
Component Parts and Harness Connector Location

PFP:23710

A
BKS001J2

Refer to LAN-21, «Component Parts and Harness Connector Location» .
B

Wiring Diagram — CAN —

BKS001J4

Refer to LAN-23, «Wiring Diagram — CAN —» .

Check Sheet

BKS001LG

C

Refer to LAN-66, «Check Sheet» .
D

E

F

G

H

I

J

LAN

L

M

LAN-65

CAN SYSTEM (TYPE 3)
[CAN]

Check Sheet

BKS001J5

NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

PKIC9197E

LAN-66

CAN SYSTEM (TYPE 3)
[CAN]
A

B

C

D

E

F

G

H

I

J

LAN

L

M

PKIC9192E

LAN-67

CAN SYSTEM (TYPE 3)
[CAN]
CHECK SHEET RESULTS (EXAMPLE)
NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

Case 1
Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, «Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit» .

PKIC9296E

PKIC8690E

LAN-68

CAN SYSTEM (TYPE 3)
[CAN]
Case 2
A

Check ECM circuit. Refer to LAN-180, «ECM Circuit Inspection» .

B

C

D

E

F
PKIC9297E

G

H

I

J

LAN

PKIC8691E

L

M

LAN-69

CAN SYSTEM (TYPE 3)
[CAN]
Case 3
Check data link connector circuit. Refer to LAN-182, «Data Link Connector Circuit Inspection» .

PKIC9298E

PKIC8692E

LAN-70

CAN SYSTEM (TYPE 3)
[CAN]
Case 4
A

Check combination meter circuit. Refer to LAN-184, «Combination Meter Circuit Inspection» .

B

C

D

E

F
PKIC9299E

G

H

I

J

LAN

PKIC8693E

L

M

LAN-71

CAN SYSTEM (TYPE 3)
[CAN]
Case 5
Check steering angle sensor circuit. Refer to LAN-185, «Steering Angle Sensor Circuit Inspection» .

PKIC9300E

PKIC9283E

LAN-72

CAN SYSTEM (TYPE 3)
[CAN]
Case 6
A

Check EPS control unit circuit. Refer to LAN-185, «EPS Control Unit Circuit Inspection» .

B

C

D

E

F
PKIC9301E

G

H

I

J

LAN

PKIC8694E

L

M

LAN-73

CAN SYSTEM (TYPE 3)
[CAN]
Case 7
Check BCM circuit. Refer to LAN-186, «BCM Circuit Inspection» .

PKIC9302E

PKIC8695E

LAN-74

CAN SYSTEM (TYPE 3)
[CAN]
Case 8
Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, «ABS Actuator and Electric Unit
(Control Unit) Circuit Inspection» .

A

B

C

D

E

F
PKIC9303E

G

H

I

J

LAN

L
PKIC8696E

M

LAN-75

CAN SYSTEM (TYPE 3)
[CAN]
Case 9
Check IPDM E/R circuit. Refer to LAN-188, «IPDM E/R Circuit Inspection» .

PKIC9304E

PKIC8697E

LAN-76

CAN SYSTEM (TYPE 3)
[CAN]
Case 10
A

Check CAN communication circuit. Refer to LAN-188, «CAN Communication Circuit Inspection» .

B

C

D

E

F
PKIC9305E

Case 11
Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

G

H

I

J

LAN

L
PKIC9306E

M

LAN-77

CAN SYSTEM (TYPE 3)
[CAN]
Case 12
Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

PKIC9307E

LAN-78

CAN SYSTEM (TYPE 4)
[CAN]

CAN SYSTEM (TYPE 4)
Component Parts and Harness Connector Location

PFP:23710

A
BKS001J6

Refer to LAN-21, «Component Parts and Harness Connector Location» .
B

Wiring Diagram — CAN —

BKS001J8

Refer to LAN-23, «Wiring Diagram — CAN —» .

Check Sheet

BKS001LH

C

Refer to LAN-80, «Check Sheet» .
D

E

F

G

H

I

J

LAN

L

M

LAN-79

CAN SYSTEM (TYPE 4)
[CAN]

Check Sheet

BKS001J9

NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

PKIC9198E

LAN-80

CAN SYSTEM (TYPE 4)
[CAN]
A

B

C

D

E

F

G

H

I

J

LAN

L

M

PKIC9146E

LAN-81

CAN SYSTEM (TYPE 4)
[CAN]
CHECK SHEET RESULTS (EXAMPLE)
NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

Case 1
Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, «Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit» .

PKIC9308E

PKIC8681E

LAN-82

CAN SYSTEM (TYPE 4)
[CAN]
Case 2
A

Check ECM circuit. Refer to LAN-180, «ECM Circuit Inspection» .

B

C

D

E

F
PKIC9309E

G

H

I

J

LAN

PKIC8682E

L

M

LAN-83

CAN SYSTEM (TYPE 4)
[CAN]
Case 3
Check data link connector circuit. Refer to LAN-182, «Data Link Connector Circuit Inspection» .

PKIC9310E

PKIC8683E

LAN-84

CAN SYSTEM (TYPE 4)
[CAN]
Case 4
A

Check combination meter circuit. Refer to LAN-184, «Combination Meter Circuit Inspection» .

B

C

D

E

F
PKIC9311E

G

H

I

J

LAN

PKIC8684E

L

M

LAN-85

CAN SYSTEM (TYPE 4)
[CAN]
Case 5
Check Intelligent Key unit circuit. Refer to LAN-184, «Intelligent Key Unit Circuit Inspection» .

PKIC9312E

PKIC8685E

LAN-86

CAN SYSTEM (TYPE 4)
[CAN]
Case 6
A

Check steering angle sensor circuit. Refer to LAN-185, «Steering Angle Sensor Circuit Inspection» .

B

C

D

E

F
PKIC9313E

G

H

I

J

LAN

PKIC9282E

L

M

LAN-87

CAN SYSTEM (TYPE 4)
[CAN]
Case 7
Check EPS control unit circuit. Refer to LAN-185, «EPS Control Unit Circuit Inspection» .

PKIC9314E

PKIC8686E

LAN-88

CAN SYSTEM (TYPE 4)
[CAN]
Case 8
A

Check BCM circuit. Refer to LAN-186, «BCM Circuit Inspection» .

B

C

D

E

F
PKIC9315E

G

H

I

J

LAN

PKIC8687E

L

M

LAN-89

CAN SYSTEM (TYPE 4)
[CAN]
Case 9
Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, «ABS Actuator and Electric Unit
(Control Unit) Circuit Inspection» .

PKIC9316E

PKIC8688E

LAN-90

CAN SYSTEM (TYPE 4)
[CAN]
Case 10
A

Check IPDM E/R circuit. Refer to LAN-188, «IPDM E/R Circuit Inspection» .

B

C

D

E

F
PKIC9317E

G

H

I

J

LAN

PKIC8689E

L

M

LAN-91

CAN SYSTEM (TYPE 4)
[CAN]
Case 11
Check CAN communication circuit. Refer to LAN-188, «CAN Communication Circuit Inspection» .

PKIC9318E

Case 12
Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

PKIC9319E

LAN-92

CAN SYSTEM (TYPE 4)
[CAN]
Case 13
Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

A

B

C

D

E

F
PKIC9320E

G

H

I

J

LAN

L

M

LAN-93

CAN SYSTEM (TYPE 5)
[CAN]

CAN SYSTEM (TYPE 5)
Component Parts and Harness Connector Location

PFP:23710
BKS001JA

Refer to LAN-21, «Component Parts and Harness Connector Location» .

Wiring Diagram — CAN —

BKS001JC

Refer to LAN-23, «Wiring Diagram — CAN —» .

Check Sheet

BKS001LI

Refer to LAN-95, «Check Sheet» .

LAN-94

CAN SYSTEM (TYPE 5)
[CAN]

Check Sheet

BKS001L4

A

NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

B

C

D

E

F

G

H

I

J

LAN

L

M

PKIC9199E

LAN-95

CAN SYSTEM (TYPE 5)
[CAN]

PKIC9193E

LAN-96

CAN SYSTEM (TYPE 5)
[CAN]
CHECK SHEET RESULTS (EXAMPLE)
A

NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

Case 1
Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, «Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit» .

B

C

D

E

F

G
PKIC9244E

H

I

J

LAN

L

M
MKIB1767E

LAN-97

CAN SYSTEM (TYPE 5)
[CAN]
Case 2
Check ECM circuit. Refer to LAN-180, «ECM Circuit Inspection» .

PKIC9245E

MKIB1769E

LAN-98

CAN SYSTEM (TYPE 5)
[CAN]
Case 3
A

Check data link connector circuit. Refer to LAN-182, «Data Link Connector Circuit Inspection» .

B

C

D

E

F
PKIC9246E

G

H

I

J

LAN

MKIB1771E

L

M

LAN-99

CAN SYSTEM (TYPE 5)
[CAN]
Case 4
Check combination meter circuit. Refer to LAN-184, «Combination Meter Circuit Inspection» .

PKIC9247E

MKIB1773E

LAN-100

CAN SYSTEM (TYPE 5)
[CAN]
Case 5
A

Check EPS control unit circuit. Refer to LAN-185, «EPS Control Unit Circuit Inspection» .

B

C

D

E

F
PKIC9248E

G

H

I

J

LAN

MKIB1775E

L

M

LAN-101

CAN SYSTEM (TYPE 5)
[CAN]
Case 6
Check BCM circuit. Refer to LAN-186, «BCM Circuit Inspection» .

PKIC9249E

MKIB1777E

LAN-102

CAN SYSTEM (TYPE 5)
[CAN]
Case 7
Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, «ABS Actuator and Electric Unit
(Control Unit) Circuit Inspection» .

A

B

C

D

E

F
PKIC9250E

G

H

I

J

LAN

L
MKIB1779E

M

LAN-103

CAN SYSTEM (TYPE 5)
[CAN]
Case 8
Check TCM circuit. Refer to LAN-187, «TCM Circuit Inspection» .

PKIC9251E

MKIB1781E

LAN-104

CAN SYSTEM (TYPE 5)
[CAN]
Case 9
A

Check IPDM E/R circuit. Refer to LAN-188, «IPDM E/R Circuit Inspection» .

B

C

D

E

F
PKIC9252E

G

H

I

J

LAN

MKIB1783E

L

M

LAN-105

CAN SYSTEM (TYPE 5)
[CAN]
Case 10
Check CAN communication circuit. Refer to LAN-188, «CAN Communication Circuit Inspection» .

PKIC9253E

Case 11
Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

PKIC9254E

LAN-106

CAN SYSTEM (TYPE 5)
[CAN]
Case 12
Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

A

B

C

D

E

F
PKIC9255E

G

H

I

J

LAN

L

M

LAN-107

CAN SYSTEM (TYPE 6)
[CAN]

CAN SYSTEM (TYPE 6)
Component Parts and Harness Connector Location

PFP:23710
BKS001JE

Refer to LAN-21, «Component Parts and Harness Connector Location» .

Wiring Diagram — CAN —

BKS001JG

Refer to LAN-23, «Wiring Diagram — CAN —» .

Check Sheet

BKS001LJ

Refer to LAN-109, «Check Sheet» .

LAN-108

CAN SYSTEM (TYPE 6)
[CAN]

Check Sheet

BKS001JH

A

NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

B

C

D

E

F

G

H

I

J

LAN

L

M

PKIC9132E

LAN-109

CAN SYSTEM (TYPE 6)
[CAN]

PKIC9194E

LAN-110

CAN SYSTEM (TYPE 6)
[CAN]
CHECK SHEET RESULTS (EXAMPLE)
A

NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

Case 1
Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, «Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit» .

B

C

D

E

F

G
PKIC9256E

H

I

J

LAN

L

M
MKIB1742E

LAN-111

CAN SYSTEM (TYPE 6)
[CAN]
Case 2
Check ECM circuit. Refer to LAN-180, «ECM Circuit Inspection» .

PKIC9257E

MKIB1744E

LAN-112

CAN SYSTEM (TYPE 6)
[CAN]
Case 3
A

Check data link connector circuit. Refer to LAN-182, «Data Link Connector Circuit Inspection» .

B

C

D

E

F
PKIC9258E

G

H

I

J

LAN

MKIB1746E

L

M

LAN-113

CAN SYSTEM (TYPE 6)
[CAN]
Case 4
Check combination meter circuit. Refer to LAN-184, «Combination Meter Circuit Inspection» .

PKIC9259E

MKIB1748E

LAN-114

CAN SYSTEM (TYPE 6)
[CAN]
Case 5
A

Check Intelligent Key unit circuit. Refer to LAN-184, «Intelligent Key Unit Circuit Inspection» .

B

C

D

E

F
PKIC9260E

G

H

I

J

LAN

MKIB1750E

L

M

LAN-115

CAN SYSTEM (TYPE 6)
[CAN]
Case 6
Check EPS control unit circuit. Refer to LAN-185, «EPS Control Unit Circuit Inspection» .

PKIC9261E

MKIB1752E

LAN-116

CAN SYSTEM (TYPE 6)
[CAN]
Case 7
A

Check BCM circuit. Refer to LAN-186, «BCM Circuit Inspection» .

B

C

D

E

F
PKIC9262E

G

H

I

J

LAN

MKIB1754E

L

M

LAN-117

CAN SYSTEM (TYPE 6)
[CAN]
Case 8
Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, «ABS Actuator and Electric Unit
(Control Unit) Circuit Inspection» .

PKIC9263E

MKIB1756E

LAN-118

CAN SYSTEM (TYPE 6)
[CAN]
Case 9
A

Check TCM circuit. Refer to LAN-187, «TCM Circuit Inspection» .

B

C

D

E

F
PKIC9264E

G

H

I

J

LAN

MKIB1758E

L

M

LAN-119

CAN SYSTEM (TYPE 6)
[CAN]
Case 10
Check IPDM E/R circuit. Refer to LAN-188, «IPDM E/R Circuit Inspection» .

PKIC9265E

MKIB1760E

LAN-120

CAN SYSTEM (TYPE 6)
[CAN]
Case 11
A

Check CAN communication circuit. Refer to LAN-188, «CAN Communication Circuit Inspection» .

B

C

D

E

F
PKIC9266E

Case 12
Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

G

H

I

J

LAN

L
PKIC9267E

M

LAN-121

CAN SYSTEM (TYPE 6)
[CAN]
Case 13
Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

PKIC9268E

LAN-122

CAN SYSTEM (TYPE 7)
[CAN]

CAN SYSTEM (TYPE 7)
Component Parts and Harness Connector Location

PFP:23710

A
BKS001JI

Refer to LAN-21, «Component Parts and Harness Connector Location» .
B

Wiring Diagram — CAN —

BKS001JK

Refer to LAN-23, «Wiring Diagram — CAN —» .

Check Sheet

BKS001LK

C

Refer to LAN-124, «Check Sheet» .
D

E

F

G

H

I

J

LAN

L

M

LAN-123

CAN SYSTEM (TYPE 7)
[CAN]

Check Sheet

BKS001L8

NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

PKIC9200E

LAN-124

CAN SYSTEM (TYPE 7)
[CAN]
A

B

C

D

E

F

G

H

I

J

LAN

L

M

PKIC9192E

LAN-125

CAN SYSTEM (TYPE 7)
[CAN]
CHECK SHEET RESULTS (EXAMPLE)
NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

Case 1
Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, «Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit» .

PKIC9321E

MKIB1813E

LAN-126

CAN SYSTEM (TYPE 7)
[CAN]
Case 2
A

Check ECM circuit. Refer to LAN-180, «ECM Circuit Inspection» .

B

C

D

E

F
PKIC9322E

G

H

I

J

LAN

MKIB1815E

L

M

LAN-127

CAN SYSTEM (TYPE 7)
[CAN]
Case 3
Check data link connector circuit. Refer to LAN-182, «Data Link Connector and CAN Communication Circuit
Inspection» .

PKIC9323E

MKIB1817E

LAN-128

CAN SYSTEM (TYPE 7)
[CAN]
Case 4
A

Check combination meter circuit. Refer to LAN-184, «Combination Meter Circuit Inspection» .

B

C

D

E

F
PKIC9324E

G

H

I

J

LAN

MKIB1819E

L

M

LAN-129

CAN SYSTEM (TYPE 7)
[CAN]
Case 5
Check EPS control unit circuit. Refer to LAN-185, «EPS Control Unit Circuit Inspection» .

PKIC9325E

MKIB1821E

LAN-130

CAN SYSTEM (TYPE 7)
[CAN]
Case 6
A

Check BCM circuit. Refer to LAN-186, «BCM Circuit Inspection» .

B

C

D

E

F
PKIC9326E

G

H

I

J

LAN

MKIB1823E

L

M

LAN-131

CAN SYSTEM (TYPE 7)
[CAN]
Case 7
Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, «ABS Actuator and Electric Unit
(Control Unit) Circuit Inspection» .

PKIC9327E

MKIB1825E

LAN-132

CAN SYSTEM (TYPE 7)
[CAN]
Case 8
A

Check IPDM E/R circuit. Refer to LAN-188, «IPDM E/R Circuit Inspection» .

B

C

D

E

F
PKIC9328E

G

H

I

J

LAN

MKIB1827E

L

M

LAN-133

CAN SYSTEM (TYPE 7)
[CAN]
Case 9
Check CAN communication circuit. Refer to LAN-182, «Data Link Connector and CAN Communication Circuit
Inspection» .

PKIC9329E

Case 10
Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

PKIC9330E

LAN-134

CAN SYSTEM (TYPE 7)
[CAN]
Case 11
Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

A

B

C

D

E

F
PKIC9331E

G

H

I

J

LAN

L

M

LAN-135

CAN SYSTEM (TYPE
[CAN]

CAN SYSTEM (TYPE
Component Parts and Harness Connector Location

PFP:23710
BKS001JM

Refer to LAN-21, «Component Parts and Harness Connector Location» .

Wiring Diagram — CAN —

BKS001JO

Refer to LAN-23, «Wiring Diagram — CAN —» .

Check Sheet

BKS001LL

Refer to LAN-137, «Check Sheet» .

LAN-136

CAN SYSTEM (TYPE
[CAN]

Check Sheet

BKS001L9

A

NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

B

C

D

E

F

G

H

I

J

LAN

L

M

PKIC9201E

LAN-137

CAN SYSTEM (TYPE
[CAN]

PKIC9146E

LAN-138

CAN SYSTEM (TYPE
[CAN]
CHECK SHEET RESULTS (EXAMPLE)
A

NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

Case 1
Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, «Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit» .

B

C

D

E

F

G
PKIC9332E

H

I

J

LAN

L

M
MKIB1790E

LAN-139

CAN SYSTEM (TYPE
[CAN]
Case 2
Check ECM circuit. Refer to LAN-180, «ECM Circuit Inspection» .

PKIC9333E

MKIB1792E

LAN-140

CAN SYSTEM (TYPE
[CAN]
Case 3
Check data link connector circuit. Refer to LAN-182, «Data Link Connector and CAN Communication Circuit
Inspection» .

A

B

C

D

E

F
PKIC9334E

G

H

I

J

LAN

L
MKIB1794E

M

LAN-141

CAN SYSTEM (TYPE
[CAN]
Case 4
Check combination meter circuit. Refer to LAN-184, «Combination Meter Circuit Inspection» .

PKIC9335E

MKIB1796E

LAN-142

CAN SYSTEM (TYPE
[CAN]
Case 5
A

Check Intelligent Key unit circuit. Refer to LAN-184, «Intelligent Key Unit Circuit Inspection» .

B

C

D

E

F
PKIC9336E

G

H

I

J

LAN

MKIB1798E

L

M

LAN-143

CAN SYSTEM (TYPE
[CAN]
Case 6
Check EPS control unit circuit. Refer to LAN-185, «EPS Control Unit Circuit Inspection» .

PKIC9337E

MKIB1800E

LAN-144

CAN SYSTEM (TYPE
[CAN]
Case 7
A

Check BCM circuit. Refer to LAN-186, «BCM Circuit Inspection» .

B

C

D

E

F
PKIC9338E

G

H

I

J

LAN

MKIB1802E

L

M

LAN-145

CAN SYSTEM (TYPE
[CAN]
Case 8
Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, «ABS Actuator and Electric Unit
(Control Unit) Circuit Inspection» .

PKIC9339E

MKIB1804E

LAN-146

CAN SYSTEM (TYPE
[CAN]
Case 9
A

Check IPDM E/R circuit. Refer to LAN-188, «IPDM E/R Circuit Inspection» .

B

C

D

E

F
PKIC9340E

G

H

I

J

LAN

MKIB1806E

L

M

LAN-147

CAN SYSTEM (TYPE
[CAN]
Case 10
Check CAN communication circuit. Refer to LAN-182, «Data Link Connector and CAN Communication Circuit
Inspection» .

PKIC9341E

Case 11
Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

PKIC9342E

LAN-148

CAN SYSTEM (TYPE
[CAN]
Case 12
Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

A

B

C

D

E

F
PKIC9343E

G

H

I

J

LAN

L

M

LAN-149

CAN SYSTEM (TYPE 9)
[CAN]

CAN SYSTEM (TYPE 9)
Component Parts and Harness Connector Location

PFP:23710
BKS001JY

Refer to LAN-21, «Component Parts and Harness Connector Location» .

Wiring Diagram — CAN —

BKS001K0

Refer to LAN-23, «Wiring Diagram — CAN —» .

Check Sheet

BKS001LM

Refer to LAN-151, «Check Sheet» .

LAN-150

CAN SYSTEM (TYPE 9)
[CAN]

Check Sheet

BKS001L5

A

NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

B

C

D

E

F

G

H

I

J

LAN

L

M

PKIC9202E

LAN-151

CAN SYSTEM (TYPE 9)
[CAN]

PKIC9192E

LAN-152

CAN SYSTEM (TYPE 9)
[CAN]
CHECK SHEET RESULTS (EXAMPLE)
A

NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

Case 1
Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, «Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit» .

B

C

D

E

F

G
PKIC9344E

H

I

J

LAN

L

M
PKIC8690E

LAN-153

CAN SYSTEM (TYPE 9)
[CAN]
Case 2
Check ECM circuit. Refer to LAN-180, «ECM Circuit Inspection» .

PKIC9345E

PKIC8691E

LAN-154

CAN SYSTEM (TYPE 9)
[CAN]
Case 3
Check data link connector circuit. Refer to LAN-182, «Data Link Connector and CAN Communication Circuit
Inspection» .

A

B

C

D

E

F
PKIC9346E

G

H

I

J

LAN

L
PKIC8692E

M

LAN-155

CAN SYSTEM (TYPE 9)
[CAN]
Case 4
Check combination meter circuit. Refer to LAN-184, «Combination Meter Circuit Inspection» .

PKIC9347E

PKIC8693E

LAN-156

CAN SYSTEM (TYPE 9)
[CAN]
Case 5
A

Check steering angle sensor circuit. Refer to LAN-185, «Steering Angle Sensor Circuit Inspection» .

B

C

D

E

F
PKIC9348E

G

H

I

J

LAN

PKIC9283E

L

M

LAN-157

CAN SYSTEM (TYPE 9)
[CAN]
Case 6
Check EPS control unit circuit. Refer to LAN-185, «EPS Control Unit Circuit Inspection» .

PKIC9349E

PKIC8694E

LAN-158

CAN SYSTEM (TYPE 9)
[CAN]
Case 7
A

Check BCM circuit. Refer to LAN-186, «BCM Circuit Inspection» .

B

C

D

E

F
PKIC9350E

G

H

I

J

LAN

PKIC8695E

L

M

LAN-159

CAN SYSTEM (TYPE 9)
[CAN]
Case 8
Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, «ABS Actuator and Electric Unit
(Control Unit) Circuit Inspection» .

PKIC9351E

PKIC8696E

LAN-160

CAN SYSTEM (TYPE 9)
[CAN]
Case 9
A

Check IPDM E/R circuit. Refer to LAN-188, «IPDM E/R Circuit Inspection» .

B

C

D

E

F
PKIC9352E

G

H

I

J

LAN

PKIC8697E

L

M

LAN-161

CAN SYSTEM (TYPE 9)
[CAN]
Case 10
Check CAN communication circuit. Refer to LAN-182, «Data Link Connector and CAN Communication Circuit
Inspection» .

PKIC9353E

Case 11
Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

PKIC9354E

LAN-162

CAN SYSTEM (TYPE 9)
[CAN]
Case 12
Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

A

B

C

D

E

F
PKIC9355E

G

H

I

J

LAN

L

M

LAN-163

CAN SYSTEM (TYPE 10)
[CAN]

CAN SYSTEM (TYPE 10)
Component Parts and Harness Connector Location

PFP:23710
BKS001K2

Refer to LAN-21, «Component Parts and Harness Connector Location» .

Wiring Diagram — CAN —

BKS001K4

Refer to LAN-23, «Wiring Diagram — CAN —» .

Check Sheet

BKS001LN

Refer to LAN-165, «Check Sheet» .

LAN-164

CAN SYSTEM (TYPE 10)
[CAN]

Check Sheet

BKS001LA

A

NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

B

C

D

E

F

G

H

I

J

LAN

L

M

PKIC9203E

LAN-165

CAN SYSTEM (TYPE 10)
[CAN]

PKIC9146E

LAN-166

CAN SYSTEM (TYPE 10)
[CAN]
CHECK SHEET RESULTS (EXAMPLE)
A

NOTE:
If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit.

Case 1
Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, «Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit» .

B

C

D

E

F

G
PKIC9356E

H

I

J

LAN

L

M
PKIC8681E

LAN-167

CAN SYSTEM (TYPE 10)
[CAN]
Case 2
Check ECM circuit. Refer to LAN-180, «ECM Circuit Inspection» .

PKIC9357E

PKIC8682E

LAN-168

CAN SYSTEM (TYPE 10)
[CAN]
Case 3
Check data link connector circuit. Refer to LAN-182, «Data Link Connector and CAN Communication Circuit
Inspection» .

A

B

C

D

E

F
PKIC9358E

G

H

I

J

LAN

L
PKIC8683E

M

LAN-169

CAN SYSTEM (TYPE 10)
[CAN]
Case 4
Check combination meter circuit. Refer to LAN-184, «Combination Meter Circuit Inspection» .

PKIC9359E

PKIC8684E

LAN-170

CAN SYSTEM (TYPE 10)
[CAN]
Case 5
A

Check Intelligent Key unit circuit. Refer to LAN-184, «Intelligent Key Unit Circuit Inspection» .

B

C

D

E

F
PKIC9360E

G

H

I

J

LAN

PKIC8685E

L

M

LAN-171

CAN SYSTEM (TYPE 10)
[CAN]
Case 6
Check steering angle sensor circuit. Refer to LAN-185, «Steering Angle Sensor Circuit Inspection» .

PKIC9361E

PKIC9282E

LAN-172

CAN SYSTEM (TYPE 10)
[CAN]
Case 7
A

Check EPS control unit circuit. Refer to LAN-185, «EPS Control Unit Circuit Inspection» .

B

C

D

E

F
PKIC9362E

G

H

I

J

LAN

PKIC8686E

L

M

LAN-173

CAN SYSTEM (TYPE 10)
[CAN]
Case 8
Check BCM circuit. Refer to LAN-186, «BCM Circuit Inspection» .

PKIC9363E

PKIC8687E

LAN-174

CAN SYSTEM (TYPE 10)
[CAN]
Case 9
Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, «ABS Actuator and Electric Unit
(Control Unit) Circuit Inspection» .

A

B

C

D

E

F
PKIC9364E

G

H

I

J

LAN

L
PKIC8688E

M

LAN-175

CAN SYSTEM (TYPE 10)
[CAN]
Case 10
Check IPDM E/R circuit. Refer to LAN-188, «IPDM E/R Circuit Inspection» .

PKIC9365E

PKIC8689E

LAN-176

CAN SYSTEM (TYPE 10)
[CAN]
Case 11
Check CAN communication circuit. Refer to LAN-182, «Data Link Connector and CAN Communication Circuit
Inspection» .

A

B

C

D

E

F
PKIC9366E

Case 12

G

Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .
H

I

J

LAN

L

PKIC9367E

LAN-177

M

CAN SYSTEM (TYPE 10)
[CAN]
Case 13
Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, «IPDM E/R Ignition Relay
Circuit Inspection» .

PKIC9368E

LAN-178

TROUBLE DIAGNOSIS FOR SYSTEM
[CAN]

TROUBLE DIAGNOSIS FOR SYSTEM
PFP:00000
Inspection Between Data Link Connector and ABS Actuator and Electric Unit
(Control Unit) Circuit

A

BKS001I5

1. CHECK CONNECTOR

B

1.
2.
3.

C

Turn ignition switch OFF.
Disconnect the battery cable from the negative terminal.
Check following terminals and connectors for damage, bend and loose connection (connector side and
harness side).
–
Harness connector M1
–
Harness connector E101
OK or NG
OK
>> GO TO 2.
NG
>> Repair terminal or connector.

2. CHECK HARNESS FOR OPEN CIRCUIT
1.
2.

Connector

G

B
Terminal

Connector

6
M14

E

F

Disconnect harness connector M1.
Check continuity between data link connector (A) and harness
connector (B).
A

D

14

M1

Terminal

Continuity

4A

Yes

3A

Yes

H

I

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness.

PKIC9436E

J

LAN

L

M

LAN-179

TROUBLE DIAGNOSIS FOR SYSTEM
[CAN]

3. CHECK HARNESS FOR OPEN CIRCUIT
ABS model
1. Disconnect ABS actuator and electric unit (control unit) connector.
2. Check continuity between harness connector (A) and ABS actuator and electric unit (control unit) harness connector (B).
A
Connector

B
Terminal

Connector

Terminal

4A
E101

E32

3A

Continuity

26

Yes

15

Yes

PKIC9437E

ESP model
1. Disconnect ABS actuator and electric unit (control unit) connector.
2. Check continuity between harness connector (A) and ABS actuator and electric unit (control unit) harness connector (B).
A
Connector

B
Terminal

Connector

4A
E101

3A

E33

Terminal

Continuity

26

Yes

15

Yes

PKIC9437E

OK or NG
OK
>> Connect all the connectors and diagnose again. Refer to LAN-5, «TROUBLE DIAGNOSES
WORK FLOW» .
NG
>> Repair harness.

ECM Circuit Inspection

BKS001I9

1. CHECK CONNECTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect the battery cable from the negative terminal.
Check following terminals and connectors for damage, bend and loose connection (control module side
and harness side).
–
ECM connector
–
Harness connector E101
–
Harness connector M1
OK or NG
OK
>> GO TO 2.
NG
>> Repair terminal or connector.

LAN-180

TROUBLE DIAGNOSIS FOR SYSTEM
[CAN]

2. CHECK HARNESS FOR OPEN CIRCUIT

A

CR14DE model
1. Disconnect ECM connector.
2. Check resistance between ECM harness connector terminals.
ECM connector
E40

Resistance
(Approx.)

Terminal
94

B

86

C

108 – 132 Ω

D

PKIA9860E

HR16DE model
1. Disconnect ECM connector.
2. Check resistance between ECM harness connector terminals.
ECM connector
E40

84

F

Resistance
(Approx.)

Terminal
83

E

G

108 – 132 Ω

H

I
PKIC0706E

J

K9K model
1. Disconnect ECM connector.
2. Check resistance between ECM harness connector terminals.
ECM connector
E40

Terminal
1

LAN

Resistance
(Approx.)
7

108 – 132 Ω

L

M

PKIC9438E

OK or NG
OK
>> Replace ECM.
NG
>> Repair harness between ECM and data link connector.

LAN-181

TROUBLE DIAGNOSIS FOR SYSTEM
[CAN]

Data Link Connector Circuit Inspection

BKS001IE

1. CHECK CONNECTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect the battery cable from the negative terminal.
Check data link connector and terminals for damage, bend and loose connection (connector side and harness side).
OK or NG
OK
>> GO TO 2.
NG
>> Repair terminal or connector.

2. CHECK HARNESS FOR OPEN CIRCUIT
Check resistance between data link connector terminals.
Data link
connector
M14

Resistance
(Approx.)

Terminal
6

14

54 – 66 Ω

OK or NG
OK
>> Diagnose again. Refer to LAN-5, «TROUBLE DIAGNOSES WORK FLOW» .
NG
>> Repair harness between data link connector and combination meter.
SKIA6868E

Data Link Connector and CAN Communication Circuit Inspection

BKS001M6

1. CHECK CONNECTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect the battery cable from the negative terminal.
Check data link connector and terminals for damage, bend and loose connection (connector side and harness side).
OK or NG
OK
>> GO TO 2.
NG
>> Repair terminal or connector.

2. CHECK HARNESS FOR OPEN CIRCUIT
Check resistance between data link connector terminals.
Data link
connector
M14

Terminal
6

Continuity
14

Yes

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness between data link connector and combination meter.
SKIA6868E

3. CHECK CONNECTOR
Disconnect the harness connector for each unit on the CAN network and check terminals for deformation, disconnection, looseness or damage.
OK or NG
OK
>> GO TO 4.
NG
>> Repair terminal or connector as necessary.

LAN-182

TROUBLE DIAGNOSIS FOR SYSTEM
[CAN]

4. CHECK HARNESS FOR SHORT CIRCUIT

A

With all module and control unit connectors disconnected, check
continuity between data link connector terminals.
B

Data link
connector

Terminal

M14

6

Continuity
14

No

OK or NG
OK
>> GO TO 5.
NG
>> ● Repair harness.
● Replace harness if shielded lines are used for the
harness.

C

D
SKIA6868E

5. CHECK HARNESS FOR SHORT CIRCUIT

E

Check continuity between data link connector terminals and ground.
Data link
connector

F
Terminal

Continuity
Ground

6

M14

No

14

G

No

OK or NG
OK
>> GO TO 6.
NG
>> ● Repair harness.
● Replace harness if shielded lines are used for the
harness.

H
PKIA9872E

I

6. ECM AND IPDM E/R INTERNAL CIRCUIT INSPECTION
1.
2.

Terminal
1

3.

J

Remove ECM and IPDM E/R from vehicle.
Check resistance between ECM terminals.
Resistance (Approx.)

LAN

108 – 132 Ω

7

Check resistance between IPDM E/R terminals.
L
Terminal
52

Resistance (Approx.)
58

108 – 132 Ω

OK or NG
OK
>> GO TO 7.
NG
>> Replace ECM and/or IPDM E/R.

LKIA0037E

7. CHECK SYMPTOM
1. Fill in described symptoms on the column “Symptom” in the check sheet.
2. Connect all connectors, and then make sure that the symptom is reproduced.
Check results
Reproduced>>GO TO 8.
Not reproduced>>Refer to LAN-13, «Example of Filling in Check Sheet When Initial Conditions Are Not
Reproduced» .

LAN-183

M

TROUBLE DIAGNOSIS FOR SYSTEM
[CAN]

8. UNIT REPRODUCIBILITY INSPECTION
Perform the following procedure for each unit on the CAN network, and then perform reproducibility test.
1. Turn ignition switch OFF.
2. Disconnect the battery cable from the negative terminal.
3. Disconnect the unit connector.
4. Connect the battery cable to the negative terminal.
5. Make sure that the symptom filled in the “Symptom” of the check sheet is reproduced.
NOTE:
Malfunction (related to a unit that the connector is disconnected) is reproduced. Do not confuse the malfunction with the symptom filled in the column of “Symptom” on the check sheet.
Inspection results
Reproduced>>Connect the disconnected connector. Check other units applying the above procedure.
Not reproduced>>Replace the unit that the connector is disconnected.

Combination Meter Circuit Inspection

BKS001IF

1. CHECK CONNECTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect the battery cable from the negative terminal.
Check terminals and connector of combination meter for damage, bend and loose connection (meter side
and harness side).
OK or NG
OK
>> GO TO 2.
NG
>> Repair terminal or connector.

2. CHECK HARNESS FOR OPEN CIRCUIT
1.
2.

Disconnect combination meter connector.
Check resistance between combination meter harness connector terminals.

combination meter
connector
M27

Resistance
(Approx.)

Terminal
1

54 – 66 Ω

2

OK or NG
OK
>> Replace combination meter
NG
>> Repair harness between combination meter and data
link connector.
PKIC0707E

Intelligent Key Unit Circuit Inspection

BKS001IA

1. CHECK CONNECTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect the battery cable from the negative terminal.
Check terminals and connector of Intelligent Key unit for damage, bend and loose connection (unit side
and harness side).
OK or NG
OK
>> GO TO 2.
NG
>> Repair terminal or connector.

LAN-184

TROUBLE DIAGNOSIS FOR SYSTEM
[CAN]

2. CHECK HARNESS FOR OPEN CIRCUIT
1.
2.

A

Disconnect Intelligent Key unit connector.
Check resistance between Intelligent Key unit harness connector terminals.

Intelligent Key unit
connector
M60

Resistance
(Approx.)

Terminal
2

B

C

54 – 66 Ω

3

OK or NG
OK
>> Replace Intelligent Key unit.
NG
>> Repair harness between Intelligent Key unit and data
link connector.

D
PKIB5312E

E

Steering Angle Sensor Circuit Inspection

BKS001IG

1. CHECK CONNECTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect the battery cable from the negative terminal.
Check terminals and connector of steering angle sensor for damage, bend and loose connection (sensor
side and harness side).
OK or NG
OK
>> GO TO 2.
NG
>> Repair terminal or connector.

2. CHECK HARNESS FOR OPEN CIRCUIT
1.
2.

M40

3

4

H

J

Resistance
(Approx.)

Terminal

G

I

Disconnect steering angle sensor connector.
Check resistance between steering angle sensor harness connector terminals.

Steering angle
sensor connector

F

LAN

54 – 66 Ω

OK or NG
OK
>> Replace steering angle sensor.
NG
>> Repair harness between steering angle sensor and data
link connector.

L

PKIC9439E

M

EPS Control Unit Circuit Inspection

BKS001ID

1. CHECK CONNECTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect the battery cable from the negative terminal.
Check terminals and connector of display control unit for damage, bend and loose connection (control unit
side and harness side).
OK or NG
OK
>> GO TO 2.
NG
>> Repair terminal or connector.

LAN-185

TROUBLE DIAGNOSIS FOR SYSTEM
[CAN]

2. CHECK HARNESS FOR OPEN CIRCUIT
1.
2.

Disconnect EPS control unit connector.
Check resistance between EPS control unit harness connector
terminals.
EPS control unit
connector
M25

Resistance
(Approx.)

Terminal
9

16

54 – 66 Ω

OK or NG
OK
>> Replace EPS control unit.
NG
>> Repair harness between EPS control unit and data link
connector.
PKIC0708E

BCM Circuit Inspection

BKS001IC

1. CHECK CONNECTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect the battery cable from the negative terminal.
Check terminals and connector of BCM for damage, bend and loose connection (control module side and
harness side).
OK or NG
OK
>> GO TO 2.
NG
>> Repair terminal or connector.

2. CHECK HARNESS FOR OPEN CIRCUIT
1.
2.

Disconnect BCM connector.
Check resistance between BCM harness connector terminals.
BCM connector
M57

Resistance
(Approx.)

Terminal
19

39

54 – 66 Ω

OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
NG
>> Repair harness between BCM and data link connector.
PKIC9440E

ABS Actuator and Electric Unit (Control Unit) Circuit Inspection

BKS001IJ

1. CHECK CONNECTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect the battery cable from the negative terminal.
Check terminals and connector of ABS actuator and electric unit (control unit) for damage, bend and loose
connection (control unit side and harness side).
OK or NG
OK
>> GO TO 2.
NG
>> Repair terminal or connector.

LAN-186

TROUBLE DIAGNOSIS FOR SYSTEM
[CAN]

2. CHECK HARNESS FOR OPEN CIRCUIT

A

ABS model
1. Disconnect ABS actuator and electric unit (control unit) connector.
2. Check resistance between ABS actuator and electric unit (control unit) harness connector terminals.
ABS actuator and
electric unit (control unit) connector
E32

C

Resistance
(Approx.)

Terminal
26

B

15

54 – 66 Ω

D

PKIC9441E

ESP model
1. Disconnect ABS actuator and electric unit (control unit) connector.
2. Check resistance between ABS actuator and electric unit (control unit) harness connector terminals.

E

F

G
ABS actuator and
electric unit (control unit) connector
E33

Resistance
(Approx.)

Terminal
26

15

H

54 – 66 Ω

I
PKIC9441E

J

OK or NG
OK
>> Replace ABS actuator and electric unit (control unit).
NG
>> Repair harness between ABS actuator and electric unit (control unit) and IPDM E/R.

LAN

TCM Circuit Inspection

BKS001IB

1. CHECK CONNECTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect the battery cable from the negative terminal.
Check terminals and connector of TCM for damage, bend and loose connection (control module side and
harness side).
OK or NG
OK
>> GO TO 2.
NG
>> Repair terminal or connector.

LAN-187

L

M

TROUBLE DIAGNOSIS FOR SYSTEM
[CAN]

2. CHECK HARNESS FOR OPEN CIRCUIT
1.
2.

Disconnect TCM connector.
Check resistance between TCM harness connector terminals.
TCM connector
E106

Resistance
(Approx.)

Terminal
5

54 – 66 Ω

6

OK or NG
OK
>> Replace TCM.
NG
>> Repair harness between TCM and IPDM E/R.
PKIB5313E

IPDM E/R Circuit Inspection

BKS001IK

1. CHECK CONNECTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect the battery cable from the negative terminal.
Check terminals and connector of IPDM E/R for damage, bend and loose connection (control module side
and harness side).
OK or NG
OK
>> GO TO 2.
NG
>> Repair terminal or connector.

2. CHECK HARNESS FOR OPEN CIRCUIT
1.
2.

Disconnect IPDM E/R connector.
Check resistance between IPDM E/R harness connector terminals.
IPDM E/R
connector
E12

Resistance
(Approx.)

Terminal
52

108 – 132 Ω

58

OK or NG
OK
>> Replace IPDM E/R.
NG
>> Repair harness between IPDM E/R and ABS actuator
and electric unit (control unit).
PKIC9442E

CAN Communication Circuit Inspection

BKS001IL

1. CHECK CONNECTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect the battery cable from the negative terminal.
Disconnect the harness connector for each unit on the CAN network and check terminals for deformation,
disconnection, looseness or damage.
OK or NG
OK
>> GO TO 2.
NG
>> Repair terminal or connector as necessary.

LAN-188

TROUBLE DIAGNOSIS FOR SYSTEM
[CAN]

2. CHECK HARNESS FOR SHORT CIRCUIT

A

With all module and control unit connectors disconnected, check
continuity between data link connector terminals.
B

Data link
connector

Terminal

M14

6

Continuity
14

No

OK or NG
OK
>> GO TO 3.
NG
>> ● Repair harness.
● Replace harness if shielded lines are used for the
harness.

C

D
SKIA6868E

3. CHECK HARNESS FOR SHORT CIRCUIT

E

Check continuity between data link connector terminals and ground.
Data link
connector

F
Terminal

Continuity
Ground

6

M14

No

14

G

No

OK or NG
OK
>> GO TO 4.
NG
>> ● Repair harness.
● Replace harness if shielded lines are used for the
harness.

H
PKIA9872E

I

4. ECM AND IPDM E/R INTERNAL CIRCUIT INSPECTION
1.
2.

ECM

3.

J

Remove ECM and IPDM E/R from vehicle.
Check resistance between ECM terminals.
Resistance
(Approx.)

Terminal

CR14DE

94

86

108 – 132 Ω

HR16DE

84

83

108 – 132 Ω

LAN

L

Check resistance between IPDM E/R terminals.
Terminal
52

Resistance (Approx.)
58

108 – 132 Ω

LKIA0037E

OK or NG
OK
>> GO TO 5.
NG
>> Replace ECM and/or IPDM E/R.

5. CHECK SYMPTOM
1. Fill in described symptoms on the column “Symptom” in the check sheet.
2. Connect all connectors, and then make sure that the symptom is reproduced.
Check results
Reproduced>>GO TO 6.
Not reproduced>>Refer to LAN-13, «Example of Filling in Check Sheet When Initial Conditions Are Not
Reproduced» .

LAN-189

M

TROUBLE DIAGNOSIS FOR SYSTEM
[CAN]

6. UNIT REPRODUCIBILITY INSPECTION
Perform the following procedure for each unit on the CAN network, and then perform reproducibility test.
1. Turn ignition switch OFF.
2. Disconnect the battery cable from the negative terminal.
3. Disconnect the unit connector.
4. Connect the battery cable to the negative terminal.
5. Make sure that the symptom filled in the “Symptom” of the check sheet is reproduced.
NOTE:
Malfunction (related to a unit that the connector is disconnected) is reproduced. Do not confuse the malfunction with the symptom filled in the column of “Symptom” on the check sheet.
Inspection results
Reproduced>>Connect the disconnected connector. Check other units applying the above procedure.
Not reproduced>>Replace the unit that the connector is disconnected.

IPDM E/R Ignition Relay Circuit Inspection

BKS001IM

Check the following. If no malfunction is found, replace the IPDM E/R.
●
IPDM E/R power supply circuit. Refer to PG-34, «Check IPDM E/R Power Supply and Ground Circuit» .
●
Ignition power supply circuit. Refer to PG-12, «IGNITION POWER SUPPLY — IGNITION SW. IN “ON”
AND/OR “START”» .

LAN-190

LIGHTING SYSTEM

K ELECTRICAL

SECTION

LT

LIGHTING SYSTEM

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 5
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 5
Maintenance Information …………………………………… 5
RHD MODELS ……………………………………………… 5
LHD MODELS ………………………………………………. 5
General Precautions for Service Operations ………… 5
HEADLAMP -CONVENTIONAL TYPE- ………………… 7
Component Parts and Harness Connector Location….. 7
System Description ………………………………………….. 7
OUTLINE ……………………………………………………… 7
HEADLAMP OPERATION ……………………………… 8
COMBINATIONSWITCHREADING FUNCTION….. 9
AUTO LIGHT OPERATION …………………………….. 9
FRIENDRY LIGHTING FUNCTION …………………. 9
EXTERIORLAMPBATTERYSAVERCONTROL….. 9
FAIL-SAFE FUNCTION ………………………………….. 9
CAN Communication System Description ……………. 9
CAN Communication Unit …………………………………. 9
Schematic …………………………………………………….. 10
Wiring Diagram — H/LAMP — …………………………..11
Terminals and Reference Values for BCM …………. 15
Terminals and Reference Values for IPDM E/R ….. 17
How to Perform Trouble Diagnoses ………………….. 17
Preliminary Check ………………………………………….. 18
CHECK POWER SUPPLY AND GROUND CIRCUIT ………………………………………………………….. 18
CONSULT-II Functions (BCM) …………………………. 19
CONSULT-II INSPECTION PROCEDURE ……… 19
CONSULT-II Application Items (BCM) ……………….. 19
WORK SUPPORT ……………………………………….. 19
DATA MONITOR …………………………………………. 19
ACTIVE TEST …………………………………………….. 20
CONSULT-II Functions (IPDM E/R) ………………….. 20
CONSULT-II INSPECTION PROCEDURE ……… 20
CONSULT-II Application Items (IPDM E/R) ………… 20
DATA MONITOR …………………………………………. 20
ACTIVE TEST …………………………………………….. 20
Headlamp High Beam Does Not Illuminate (Both

Sides) …………………………………………………………… 21
Headlamp High Beam Does Not Illuminate (One
Side) …………………………………………………………….. 23
Headlamp Low Beam Does Not Illuminate (Both
Sides) …………………………………………………………… 25
Headlamp Low Beam Does Not Illuminate (One
Side) …………………………………………………………….. 27
Headlamps Do Not Turn OFF …………………………… 29
Aiming Adjustment ………………………………………….. 30
PREPARATION BEFORE ADJUSTING ………….. 30
LOW BEAM AND HIGH BEAM ……………………… 30
Bulb Replacement ………………………………………….. 32
HEADLAMP (HIGH/LOW) …………………………….. 32
PARKING (CLEARANCE) LAMP …………………… 32
FRONT TURN SIGNAL LAMP ………………………. 32
Removal and Installation …………………………………. 32
REMOVAL ………………………………………………….. 32
INSTALLATION …………………………………………… 33
Disassembly and Assembly ……………………………… 34
DISASSEMBLY …………………………………………… 34
ASSEMBLY ………………………………………………… 34
HEADLAMP — DAYTIME LIGHT SYSTEM — …………. 35
Component Parts and Harness Connector Location… 35
System Description …………………………………………. 35
OUTLINE ……………………………………………………. 35
HEADLAMP OPERATION …………………………….. 36
DAYTIME LIGHT OPERATION ……………………… 37
COMBINATIONSWITCHREADING FUNCTION… 37
AUTO LIGHT OPERATION …………………………… 37
FRIENDRY LIGHTING FUNCTION ………………… 37
EXTERIORLAMPBATTERYSAVERCONTROL… 37
FAIL-SAFE FUNCTION ………………………………… 37
CAN Communication System Description ………….. 37
CAN Communication Unit ………………………………… 37
Schematic ……………………………………………………… 38
Wiring Diagram — DTRL — …………………………….. 39
Terminals and Reference Values for BCM ………….. 42
Terminals and Reference Values for IPDM E/R …… 43
How to Perform Trouble Diagnosis ……………………. 43
Preliminary Check ………………………………………….. 44

LT-1

E

F

G

H

I

J

LT

L

M

INSPECTION FOR POWER SUPPLY AND
GROUND CIRCUIT ……………………………………… 44
CONSULT-II Functions (BCM) ………………………….. 45
CONSULT-II INSPECTION PROCEDURE ………. 45
CONSULT-II Application Items (BCM) ……………….. 45
WORK SUPPORT ……………………………………….. 45
DATA MONITOR ………………………………………….. 45
ACTIVE TEST …………………………………………….. 46
CONSULT-II Functions (IPDM E/R) …………………… 46
CONSULT-II INSPECTION PROCEDURE ………. 46
CONSULT-II Application Items (IPDM E/R) ………… 46
DATA MONITOR ………………………………………….. 46
ACTIVE TEST …………………………………………….. 46
Daytime Light Control Does Not Operate Properly… 47
RH High beam Does Not Illuminate …………………… 48
RH Low Beam Does Not Illuminate …………………… 50
Headlamp High Beam Does Not Illuminate (Both
Sides) …………………………………………………………… 51
Headlamp Low Beam Does Not Illuminate (Both
Sides) …………………………………………………………… 51
Headlamp LH High Beam Does Not Illuminate ……. 51
Headlamp LH Low Beam Does Not Illuminate ……. 51
Headlamps Do Not Turn OFF …………………………… 51
Aiming Adjustment ………………………………………….. 51
Bulb Replacement ………………………………………….. 51
Removal and Installation …………………………………. 51
Disassembly and Assembly ……………………………… 51
AUTO LIGHT SYSTEM ……………………………………… 52
ComponentParts and Harness Connector Location… 52
System Description …………………………………………. 52
OUTLINE ……………………………………………………. 52
COMBINATIONSWITCHREADING FUNCTION… 53
FRIENDRY LIGHTING FUNCTION ………………… 53
EXTERIORLAMPBATTERYSAVERCONTROL… 53
CAN Communication System Description ………….. 53
CAN Communication Unit ………………………………… 53
Major Components and Functions …………………….. 53
Schematic ……………………………………………………… 54
Wiring Diagram — AUTO/L — ………………………….. 55
Terminals and Reference Values for BCM ………….. 59
Terminals and Reference Values for IPDM E/R …… 61
How to Proceed With Trouble Diagnosis ……………. 61
Preliminary Check ………………………………………….. 62
CHECK POWER SUPPLY AND GROUND CIRCUIT ………………………………………………………….. 62
CONSULT-II Functions (BCM) ………………………….. 63
CONSULT-II INSPECTION PROCEDURE ………. 63
CONSULT-II Application Items …………………………. 63
WORK SUPPORT ……………………………………….. 63
DATA MONITOR ………………………………………….. 64
ACTIVE TEST …………………………………………….. 64
Light and rain sensor System Inspection ……………. 65
Removal and Installation of Light and Rain Sensor… 67
REMOVAL ………………………………………………….. 67
INSTALLATION OF LIGHT AND RAIN SENSOR… 67
INSTALLATION OF LIGHT AND RAIN SENSOR
HOUSING …………………………………………………… 67
HEADLAMP AIMING CONTROL ………………………… 68
Schematic ……………………………………………………… 68

Wiring Diagram—H/AIM— ………………………………..69
Removal and Installation …………………………………..72
REMOVAL ……………………………………………………72
INSTALLATION …………………………………………….72
Switch Circuit Inspection …………………………………..72
FRONT FOG LAMP ……………………………………………73
ComponentParts and Harness Connector Location…73
System Description ………………………………………….73
OUTLINE …………………………………………………….73
FOG LAMP OPERATION ………………………………74
COMBINATIONSWITCHREADINGFUNCTION…74
EXTERIORLAMPBATTERYSAVERCONTROL…74
FAIL-SAFE FUNCTION …………………………………74
CAN Communication System Description …………..74
CAN Communication Unit …………………………………74
Schematic ………………………………………………………75
Wiring Diagram — F/FOG — …………………………….76
Terminals and Reference Values for BCM …………..79
Terminals and Reference Values for IPDM E/R ……80
How to Proceed With Trouble Diagnosis …………….80
Preliminary Check ……………………………………………81
CHECK POWER SUPPLY AND GROUND CIRCUIT ……………………………………………………………81
CONSULT-II Functions (BCM) …………………………..82
CONSULT-II Functions (IPDM E/R) ……………………82
Front Fog lamps Do Not Illuminate (Both Sides) …82
Front Fog Lamp Does Not Illuminate (One Side) …85
Aiming Adjustment …………………………………………..86
Bulb Replacement ……………………………………………86
Removal and Installation …………………………………..87
REMOVAL ……………………………………………………87
INSTALLATION …………………………………………….87
REAR FOG LAMP ……………………………………………..88
ComponentParts and Harness Connector Location…88
System Description ………………………………………….88
OUTLINE …………………………………………………….88
COMBINATIONSWITCHREADINGFUNCTION…89
CAN Communication System Description …………..89
CAN Communication Unit …………………………………89
Wiring Diagram — R/FOG — …………………………….90
Terminals and Reference Values for BCM …………..92
How to Proceed With Trouble Diagnosis …………….93
Preliminary Check ……………………………………………94
CHECK POWER SUPPLY AND GROUND CIRCUIT ……………………………………………………………94
CONSULT-II Functions (BCM) …………………………..94
Rear Fog Lamp Does Not Operate …………………….95
Bulb Replacement ……………………………………………97
Removal and Installation …………………………………..97
REMOVAL ……………………………………………………97
INSTALLATION …………………………………………….97
TURN SIGNAL AND HAZARD WARNING LAMPS…98
ComponentParts and Harness Connector Location…98
System Description ………………………………………….98
TURN SIGNAL OPERATION ………………………….98
HAZARD LAMP OPERATION ………………………..99
COMBINATIONSWITCHREADINGFUNCTION.100
CAN Communication System Description ………… 100
CAN Communication Unit ………………………………. 100

LT-2

Wiring Diagram — TURN — ………………………….. 101
Terminals and Reference Values for BCM ……….. 103
How to Proceed With Trouble Diagnosis ………….. 104
Preliminary Check ………………………………………… 105
CHECK POWER SUPPLY AND GROUND CIRCUIT ………………………………………………………… 105
CONSULT-II Functions (BCM) ……………………….. 106
CONSULT-II INSPECTION PROCEDURE ……. 106
CONSULT-II Application Items ……………………….. 106
WORK SUPPORT ……………………………………… 106
DATA MONITOR ……………………………………….. 106
ACTIVE TEST …………………………………………… 106
Turn Signal Lamp Does Not Operate ………………. 107
Hazard Warning Lamp Does Not Operate But Turn
Signal Lamp Operates ………………………………….. 109
Bulb Replacement (Front Turn Signal Lamp) …….. 111
Bulb Replacement (Rear Turn Signal Lamp) …….. 111
Bulb Replacement (Side Turn Signal Lamp) ……… 111
Removal and Installation of Front Turn Signal Lamp.. 111
Removal and Installation of Rear Turn Signal Lamp.. 111
Removal and Installation of Side Turn Signal Lamp.. 111
REMOVAL …………………………………………………. 111
INSTALLATION ………………………………………….. 111
LIGHTING AND TURN SIGNAL SWITCH ……………112
Removal and Installation …………………………………112
REMOVAL ………………………………………………….112
INSTALLATION …………………………………………..112
HAZARD SWITCH ……………………………………………113
Removal and Installation …………………………………113
REMOVAL ………………………………………………….113
INSTALLATION …………………………………………..113
COMBINATION SWITCH …………………………………..114
System Description ………………………………………..114
COMBINATIONSWITCHREADING FUNCTION..114
Wiring Diagram — COMBSW — ………………………117
Terminals and Reference Values for BCM …………118
Reference Values for BCM (Input) ………………….. 121
CONSULT-II Function (BCM) …………………………. 124
CONSULT-II INSPECTION PROCEDURE ……. 124
CONSULT-II Application Items ……………………….. 124
DATA MONITOR ……………………………………….. 124
Combination Switch Inspection ………………………. 125
Removal and Installation ……………………………….. 128
STOP LAMP ………………………………………………….. 129
Wiring Diagram — STOP/L — ………………………… 129
Bulb Replacement of High-Mounted Stop Lamp . 130
BulbReplacementofRearCombinationLamp(Stop
Lamp) …………………………………………………………. 130
Removal and Installation of High-Mounted Stop
Lamp ………………………………………………………….. 130
REMOVAL ………………………………………………… 130
INSTALLATION …………………………………………. 130
Removal and Installation of Rear Combination
Lamp (Stop Lamp) ………………………………………… 130
BACK-UP LAMP ……………………………………………. 131
Wiring Diagram — BACK/L — ……………………….. 131
Bulb Replacement ………………………………………… 133
Removal and Installation ……………………………….. 133
PARKING, LICENSE PLATE AND TAIL LAMPS … 134

Component Parts and Harness Connector Location. 134
System Description ……………………………………….. 134
OPERATION BY LIGHTING SWITCH …………… 134
COMBINATIONSWITCHREADING FUNCTION. 135
EXTERIORLAMPBATTERYSAVERCONTROL. 135
FAIL-SAFE FUNCTION ………………………………. 135
CAN Communication System Description ………… 135
CAN Communication Unit ………………………………. 135
Schematic ……………………………………………………. 136
Wiring Diagram — TAIL/L — ………………………….. 137
Terminals and Reference Values for BCM ………… 140
Terminals and Reference Values for IPDM E/R …. 141
How to Proceed With Trouble Diagnosis ………….. 141
Preliminary Check ………………………………………… 142
CHECK POWER SUPPLY AND GROUND CIRCUIT ………………………………………………………… 142
CONSULT-II Functions (BCM) ………………………… 143
CONSULT-II Functions (IPDM E/R) …………………. 143
Parking, License Plate and Tail Lamps Do Not Illuminate …………………………………………………………. 143
Parking, License Plate and Tail Lamps Do Not Turn
OFF (After Approx. 10 Minutes) ……………………… 147
Bulb Replacement ………………………………………… 148
PARKING LAMP ………………………………………… 148
LICENSE PLATE LAMP ……………………………… 148
TAIL LAMP ……………………………………………….. 148
Removal and Installation ……………………………….. 148
PARKING LAMP ………………………………………… 148
LICENSE PLATE LAMP ……………………………… 148
TAIL LAMP ……………………………………………….. 148
REAR COMBINATION LAMP …………………………… 149
Bulb Replacement ………………………………………… 149
Removal and Installation ……………………………….. 149
REMOVAL ………………………………………………… 149
INSTALLATION …………………………………………. 149
INTERIOR ROOM LAMP …………………………………. 150
Component Parts and Harness Connector Location. 150
System Description ……………………………………….. 150
POWER SUPPLY AND GROUND ……………….. 150
SWITCH OPERATION ……………………………….. 151
INTERIOR ROOM LAMP TIMER OPERATION. 152
INTERIOR ROOM LAMP BATTERY SAVER
CONTROL ………………………………………………… 152
Schematic ……………………………………………………. 153
—MODELS WITHOUT PERSONAL LAMP— … 153
—MODELS WITH PERSONAL LAMP— ……….. 154
Wiring Diagram — ROOM/L — ………………………. 155
—MODELS WITHOUT PERSONAL LAMP— … 155
—MODELS WITH PERSONAL LAMP— ……….. 159
Terminals and Reference Values for BCM ………… 163
How to Proceed With Trouble Diagnosis ………….. 164
Preliminary Check ………………………………………… 165
CHECK POWER SUPPLY AND GROUND CIRCUIT ………………………………………………………… 165
CONSULT-II Functions (BCM) ………………………… 166
CONSULT-II INSPECTION PROCEDURE …….. 166
CONSULT-II Application Items ……………………….. 166
DATA MONITOR ……………………………………….. 166
ACTIVE TEST …………………………………………… 166

LT-3

A

B

C

D

E

F

G

H

I

J

LT

L

M

Map Lamp Control Does Not Operate ……………… 167
Personal Lamp Control Does Not Operate (Models
With Personal Lamp) …………………………………….. 169
Bulb Replacement ………………………………………… 171
MAP LAMP, PERSONAL LAMP …………………… 171
LUGGAGE LOOM LAMP ……………………………. 171
Removal and Installation ……………………………….. 171
MAP LAMP, PERSONAL LAMP …………………… 171
LUGGAGE ROOM LAMP ……………………………. 172
ILLUMINATION ………………………………………………. 173
System Description ……………………………………….. 173

ILLUMINATION OPERATION BY LIGHTING
SWITCH ……………………………………………………. 173
EXTERIORLAMPBATTERYSAVERCONTROL.174
CAN Communication System Description ………… 174
CAN Communication Unit ………………………………. 174
Schematic ……………………………………………………. 175
Wiring Diagram — ILL — ……………………………….. 176
BULB SPECIFICATIONS …………………………………. 183
Headlamp …………………………………………………….. 183
Exterior Lamp ……………………………………………….. 183
Interior Lamp/Illumination ……………………………….. 183

LT-4

PRECAUTIONS
PRECAUTIONS
PFP:00011
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

A

BKS001CE

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Maintenance Information

B

C

D

E

F

BKS0028K

If any of following part is replaced, always replace with new* one.
If it’s not (or fail to do so), the electrical system may not be operated properly.
*: New one means a virgin control unit that has never been energized on-board.

G

RHD MODELS

H

●
●
●
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM
IPDM E/R
Combination meter
EPS control unit

I

J

LHD MODELS
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM

General Precautions for Service Operations
●
●

●

●

●

●

LT

L
BKS001CF

Never work with wet hands.
Xenon headlamp includes high voltage generating part. Be sure
to disconnect battery negative cable (negative terminal) or
power fuse before removing, installing, or touching the xenon
headlamp (including lamp bulb).
Turn the lighting switch OFF before disconnecting and connecting the connector.
When turning the xenon headlamp on and while it is illuminated,
never touch the harness, bulb, and socket of the headlamp.
When checking the headlamp on/off operation, check it on vehiPKIA0183E
cle and with the power connected to the vehicle-side connector.
Do not touch the headlamp bulb glass surface with bare hands or allow oil or grease to get on it. Do not
touch the headlamp bulb just after the headlamp is turned off, because it is very hot.

LT-5

M

PRECAUTIONS
●

●

●

●

●

Install the xenon headlamp bulb socket correctly. If it is installed
improperly, high-voltage leak or corona discharge may occur
that can melt the bulb, connector, and housing. Do not illuminate
the xenon headlamp bulb out of the headlamp housing. Doing
so can cause fire and harm your eyes.
When the bulb has burned out, wrap it in a thick vinyl bag and
discard. Do not break the bulb.
Leaving the bulb removed from the headlamp housing for a long
period of time can deteriorate the performance of the lens and
reflector (dirt, clouding). Always prepare a new bulb and have it
EL-3422D
on hand when replacing the bulb.
When adjusting the headlamp aiming, turn the aiming adjustment screw only in the tightening direction. (If it is necessary to loosen the screw, first fully loosen the
screw, and then turn it in the tightening direction.)
Do not use organic solvent (paint thinner or gasoline) to clean lamps and to remove old sealant.

LT-6

HEADLAMP -CONVENTIONAL TYPEHEADLAMP -CONVENTIONAL TYPEComponent Parts and Harness Connector Location

PFP:26010

A
BKS001CH

B

C

D

E

F

G
MKIB2268E

1.

IPDM E/R E8,E11,E12

4.

Combination meter M27

2.

BCM M57,M59 (View with instrument
upper panel removed)

3.

Combination switch M38

System Description

H
BKS001CI

The control of the headlamp system operation is dependent upon the position of the combination switch (lighting switch). When the lighting switch is placed in the 2ND position, the BCM (body control module) receives
input signal requesting the headlamps (and tail lamps) illuminate. This input signal is communicated to the
IPDM E/R (intelligent power distribution module engine room) via the CAN communication. The CPU (central
processing unit) located in the IPDM E/R controls the headlamp high and headlamp low relay coils. These
relays, when energized, direct power to the respective headlamps, which then illuminate.

I

J

LT

OUTLINE
Power is supplied at all times
●
to ignition relay (located in IPDM E/R),
●
to headlamp high RH and LH relay (located in IPDM E/R)
●
to headlamp low relay (located in IPDM E/R) from battery directly,
●
through 20A fuse (No. 61, located in IPDM E/R),
●
through 20A fuse (No. 62, located in IPDM E/R),
●
through 40A fusible link (letter J, located in fuse, fusible link and relay box)
●
to BCM terminals 74 and 79,
●
through 10A fuse [No. 7, located in fuse block (J/B)]
●
to combination meter terminal 27.
With the ignition switch in the ON or START position, power is supplied
●
to ignition relay (located in IPDM E/R) from battery directly,
●
through 10A fuse [No. 5, located in fuse block (J/B)]
●
to BCM terminal 24,
●
through 10A fuse [No. 4, located in fuse block (J/B)]
●
to combination meter terminal 28.
Ground is supplied
●
to BCM terminals 2 and 70
●
to combination meter terminals 21, 22 and 23

LT-7

L

M

HEADLAMP -CONVENTIONAL TYPE●
●
●

through grounds M21 and M66,
to IPDM E/R terminals 3 and 54
through grounds E45 (CR and HR engine models),E28 and E44.

HEADLAMP OPERATION
Low Beam Operation
With the lighting switch in 2ND position, the BCM receives input signal requesting the headlamps to illuminate.
This input signal is communicated to the IPDM E/R via the CAN communication. The CPU located in the IPDM
E/R controls the headlamp low relay coil, which when energized, directs power
●
through 15A fuse (No. 50, located in IPDM E/R)
●
through IPDM E/R terminal 48
●
to headlamp RH terminal 1,
●
through 15A fuse (No. 49, located in IPDM E/R)
●
through IPDM E/R terminal 50
●
to headlamp LH terminal 1.
Ground is supplied
●
to headlamp RH and LH terminals 3
●
through grounds E45 (CR and HR engine models),E28 and E44.
With power and ground supplied, low beam headlamps illuminate.

High Beam Operation/Flash-to-Pass Operation
With the lighting switch in 2ND position and placed in HIGH or PASS position, the BCM receives input signal
requesting the headlamp high beams to illuminate. This input signal is communicated to the IPDM E/R via the
CAN communication. The CPU located in the IPDM E/R controls the headlamp high relay coil, which when
energized, directs power
●
through 10A fuse (No. 43, located in IPDM E/R)
●
through IPDM E/R terminal 46
●
to headlamp RH terminal 2,
●
through 10A fuse (No. 44, located in IPDM E/R)
●
through IPDM E/R terminal 47
●
to headlamp LH terminal 2.
Ground is supplied
●
to headlamp RH and LH terminals 3
●
through grounds E45 (CR and HR engine models),E28 and E44.
With power and ground supplied, the high beam headlamps illuminate.
The combination meter that received the high beam request signal by BCM via the CAN communication
makes a high beam indicator lamp turn ON in combination meter.

LT-8

HEADLAMP -CONVENTIONAL TYPECOMBINATION SWITCH READING FUNCTION
A

Refer to LT-114, «COMBINATION SWITCH READING FUNCTION» .

AUTO LIGHT OPERATION
Refer to LT-52, «System Description» .

B

FRIENDRY LIGHTING FUNCTION
Low beam headlamps will illuminate for 30 seconds when,
●
ignition switch is in OFF position,
●
lighting switch is placed in OFF position, and
●
lighting switch is placed in PASS position.
Each activation of the switch adds 30 seconds to a maximum of 2 minutes.

C

D

EXTERIOR LAMP BATTERY SAVER CONTROL
To avoid flat battery caused by user leaving exterior lamps ON. When ignition is OFF and the driver side door
is opened, all exterior lamps will be turned OFF. If the user wants some lamps to remain ON then they must
switch these lamps OFF then ON again with the combination switch once the driver side door has been
opened. A buzzer will sound if any exterior lamps are ON with the driver side door opened and ignition OFF.
*:This setting can be changed by CONSULT-II. Refer to LT-19, «WORK SUPPORT» .

E

F

FAIL-SAFE FUNCTION
When CAN communication with other control units is impossible, IPDM E/R performs fail-safe control. If the
fail-safe system is operating, headlamps illuminate when the ignition switch is turned from OFF to ON and
headlamps are turned off when the ignition switch is turn from ON to OFF. If the fail-safe system is operating,
headlamps does not operate when the combination switch is in any position. After CAN communication recovers normally, it also returns to normal control. (Refer to PG-18, «Fail-safe Control» .)

CAN Communication System Description

H

BKS001CJ

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

CAN Communication Unit

G

BKS001CK

I

J

LT

Refer to LAN-27, «CAN Communication Unit» .
L

M

LT-9

HEADLAMP -CONVENTIONAL TYPESchematic

BKS001CL

MKWA4318E

LT-10

HEADLAMP -CONVENTIONAL TYPEWiring Diagram — H/LAMP —

BKS001CM

A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4319E

LT-11

HEADLAMP -CONVENTIONAL TYPE-

MKWA4320E

LT-12

HEADLAMP -CONVENTIONAL TYPEA

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4321E

LT-13

HEADLAMP -CONVENTIONAL TYPE-

MKWA4322E

LT-14

HEADLAMP -CONVENTIONAL TYPETerminals and Reference Values for BCM

BKS001CN

CAUTION:
●
Check combination switch system terminal waveform under the loaded condition with lighting
switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded.
●
Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position.
Wiper dial position can be confirmed on CONSULT-II. Refer to LT-19, «DATA MONITOR» .
Terminal
No.

Wire
color

2

B

Signal name
Ground

Ignition
switch

Operation or condition

—

ON

—

B

C

Measuring condition

Signal
input/
output

A

Reference value

D

Approx. 0V

E
OFF

8

L

Combination
switch output 3

Output

ON

Lighting,
turn,
wiper
switch
(Wiper
intermittent dial
position
4)

F
PKIB4958J

Approx. 1.2V

G
Any of the conditions below
●

Lighting switch 2ND

●

Lighting switch HI beam
(Operates only HI beam
switch)

H

PKIB4959J

I

Approx. 1.0V

J

OFF

LT
PKIB4956J

L

Approx. 0.9V

15

W

Combination
switch input 5

Input

ON

Lighting,
turn,
wiper
switch
(Wiper
intermittent dial
position
4)

M
Lighting switch 2ND

PKIB8639J

Approx. 2.5 — 3.0V

Lighting switch HIGH beam
(Operates only HIGH beam
switch)
PKIB8644J

Approx. 1.5 — 2.0V
19

L

CAN − H

Input/
Output

ON

—

LT-15

Approx. 2.6V

HEADLAMP -CONVENTIONAL TYPETerminal
No.

Wire
color

Signal name

24

O

Ignition switch
(ON)

Measuring condition

Signal
input/
output

Ignition
switch

Operation or condition

Input

ON

—

Reference value

Battery voltage

OFF

28

G

Combination
switch output 2

Output

ON

Lighting,
turn,
wiper
switch
(Wiper
intermittent dial
position
4)

PKIB4958J

Approx. 1.2V

Any of the conditions below
●

Lighting switch 2ND

●

Lighting switch PASSING
(Operates only PASSING
switch)
PKIB4959J

Approx. 1.0V

OFF

PKIB4958J

Approx. 1.0V

34

Y

Combination
switch input 4

Input

ON

Lighting,
turn,
wiper
switch
(Wiper
intermittent dial
position
4)

Lighting switch 2ND

PKIB8628J

Approx. 1.5 — 2.0V

Lighting switch PASSING
(Operates only PASSING
switch)
PKIB8629J

Approx. 2.0V
39

Y

CAN − L

Input/
Output

ON

—

Approx. 2.4V

70

B

Ground

—

ON

—

Approx. 0V

74
79

Y

Battery power
supply

Input

OFF

—

Battery voltage

LT-16

HEADLAMP -CONVENTIONAL TYPETerminals and Reference Values for IPDM E/R

BKS001CO

A
Measuring condition
Signal
input/
output

Terminal
No.

Wire
color

3

B

Ground

46

Y

Headlamp HIGH
RH

ON

Headlamp HIGH LH

ON

47

G

Signal name

—

Ignition
switch

Operation or condition

ON

—

Output

Reference value

B
Approx. 0V

Lighting switch HIGH
beam or PASSING
position

OFF

Approx. 0V

ON

Battery voltage

Lighting switch HIGH
beam or PASSING
position

OFF

Approx. 0V

ON

Battery voltage
Approx. 0V

P

Headlamp LOW RH

ON

Lighting switch 2ND
position

OFF

48

ON

Battery voltage
Approx. 0V

L

Headlamp LOW LH

ON

Lighting switch 2ND
position

OFF

50

ON

Battery voltage

52

L

CAN − H

Input/
Output

54

B

Ground

—

ON

—

Approx. 0V

58

Y

CAN − L

Input/
Output

—

—

—

—

—

—

D

E

F

G

H

How to Perform Trouble Diagnoses
1.
2.
3.
4.
5.
6.

C

BKS001CP

Confirm the symptom or customer complaint.
Understand operation description and function description. Refer to LT-7, «System Description» .
Perform the Preliminary Check. Refer to LT-18, «Preliminary Check» .
Check symptom and repair or replace the cause of malfunction.
Does the headlamp operate normally? If YES, GO TO 6. If NO, GO TO 4.
INSPECTION END

I

J

LT

L

M

LT-17

HEADLAMP -CONVENTIONAL TYPEPreliminary Check

BKS001CQ

CHECK POWER SUPPLY AND GROUND CIRCUIT

1. CHECK FUSE
Check for blown fuses.
Unit

Power source

Fuse and fusible link No.

Battery

J

Ignition switch ON or START position

5

BCM

43
44
IPDM E/R

49

Battery

50
61
62

Refer to LT-11, «Wiring Diagram — H/LAMP —» .
OK or NG
OK
>> GO TO 2.
NG
>> If fuse or fusible link is blown, be sure to eliminate cause of malfunction before installing new fuse
or fusible link. Refer to PG-4, «POWER SUPPLY ROUTING CIRCUIT» .

2. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector.
Check voltage between BCM harness connector and ground.
Terminal

Ignition switch position

(+)
BCM
Connector

Terminal

M57

24
74

(−)

Ground

M59

OFF

ACC

ON

Approx. 0V

Approx. 0V

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

MKIB0352E

79

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

3. CHECK GROUND CIRCUIT
Check continuity between BCM harness connector and ground.
BCM connector

Terminal

M57

2

M59

70

Continuity
Ground
Yes

OK or NG
OK
>> INSPECTION END
NG
>> Repair harness or connector.
MKIB0353E

LT-18

HEADLAMP -CONVENTIONAL TYPECONSULT-II Functions (BCM)

BKS001CR

A

CONSULT-II can display each diagnostic item using the diagnostic test mode shown following.
BCM diagnosis part

Diagnosis mode

Changes the setting for each function.

DATA MONITOR

Displays BCM input data in real time.

HEADLAMP

ACTIVE TEST
SELF-DIAG RESULTS

BCM

Description

WORK SUPPORT

CAN DIAG SUPPORT MNTR

B

Operation of electrical loads can be checked by sending drive signal to them.

C

BCM performs self-diagnosis of CAN communication.
The result of transmit/receive diagnosis of CAN communication can be read.

D

CONSULT-II INSPECTION PROCEDURE
Refer to GI-36, «CONSULT-II Start Procedure» .

CONSULT-II Application Items (BCM)

BKS001LZ

E

WORK SUPPORT
Operation Procedure
1.
2.
3.
4.
5.
6.
7.

F

Touch “HEAD LAMP” on “SELECT TEST ITEM” screen.
Touch “WORK SUPPORT” on “SELECT DIAG MODE” screen.
Touch “BATTERY SAVER SET” on “SELECT WORK ITEM” screen.
Touch “START”.
Touch “CHANGE SET”.
The setting will be changed and “CUSTOMIZING COMPLETED” will be displayed.
Touch “END”.

G

H

Display Item List
Item
BATTERY SAVER SET

Description

CONSULT-II

Factory setting

Exterior lamp battery saver control mode can be changed in this mode.
Select exterior lamp battery saver control mode between ON and OFF.

ON

×

OFF

—

I

J

DATA MONITOR
Monitor item UNIT.

Display content

IGN ON SW

[ON/OFF]

Displays status (Ignition switch ON: ON/Others OFF, ACC: OFF) as judged from the ignition switch signal.

HI BEAM SW

[ON/OFF]

Displays status (High beam switch: ON/Others: OFF) as judged from lighting switch signal.

H/L SW POS

[ON/OFF]

Displays status (Headlamp switch: ON/Others: OFF) as judged from lighting switch signal.

LIGHT SW 1ST

[ON/OFF]

Displays status (Lighting switch 1st position: ON/Others: OFF) as judged from lighting
switch signal.

PASSING SW

[ON/OFF]

Displays status (Flash-to-pass switch: ON/Others: OFF) as judged from lighting switch
signal.

FR FOG SW

[ON/OFF]

Displays status (Front fog lamp switch: ON/Others: OFF) as judged from lighting switch
signal.

RR FOG SW

[ON/OFF]

Displays status (Rear fog lamp switch: ON/Others: OFF) as judged from lighting switch
signal.

DOOR SW-DR

[ON/OFF]

Displays status (Door open: ON/door closed: OFF) as judged from the door switch DR signal.

H/L WASH SW

[ON/OFF]

Displays status (Headlamp washer switch: ON/Others: OFF) as judged from headlamp
washer switch signal.

ENGINE STATUS

[STOP/
STALL/
RUN/
CRA]

Displays status (Engine stop: STOP/engine stall: STALL/engine running: RUN/engine
cranking: CRA) as judged from the engine status.

LT-19

LT

L

M

HEADLAMP -CONVENTIONAL TYPEACTIVE TEST
Test item

CONSULT-II screen display

Description

Tail lamp relay output

TAIL LAMP

Tail lamp relay can be operated by any ON–OFF operation.

Headlamp relay output

HEAD LAMP

Headlamp relay can be operated by any ON–OFF operation.

Front fog lamp relay output

FR FOG LAMP

Front fog lamp relay can be operated by any ON–OFF operation.

Rear fog lamp relay output

RR FOG LAMP

Rear fog lamp relay can be operated by any ON–OFF operation.

CONSULT-II Functions (IPDM E/R)

BKS001LC

CONSULT-II can display each diagnostic item using the diagnostic test mode shown following.
Diagnosis Mode
SELF-DIAGNOSTIC RESULTS

Description
Refer to PG-20, «SELF-DIAG RESULTS» .

DATA MONITOR

The input/output data of IPDM E/R is displayed in real time.

CAN DIAG SUPPORT MNTR

The result of transmit/receive diagnosis of CAN communication can be read.

ACTIVE TEST

IPDM E/R sends a drive signal to electronic components to check their operation.

CONSULT-II INSPECTION PROCEDURE
Refer to GI-36, «CONSULT-II Start Procedure» .

CONSULT-II Application Items (IPDM E/R)

BKS001M0

DATA MONITOR
All Signals, Main Signals, Selection From Menu
Monitor item selection
Monitor item name

Display and unit

All
signals

Main
signals

selection
from
menu

Display content

TAIL & CLR REQ

ON/OFF

×

×

×

Signal status input from BCM

HL LO REQ

ON/OFF

×

×

×

Signal status input from BCM

HL HI REQ

ON/OFF

×

×

×

Signal status input from BCM

FR FOG REQ

ON/OFF

×

×

×

Signal status input from BCM

IGN RLY

ON/OFF

×

×

×

Status of ignition relay being monitored by
IPDM E/R

ACTIVE TEST
Test item

CONSULT-II screen display

Description

Headlamp relay (HI, LO) output

HEAD LAMP

Headlamp relay (LO, HI) can be operated using random
operation (OFF, HI ON, LO ON).

Front fog lamp relay output

FRONT FOG LAMP

Fog lamp relay can be operated by any ON–OFF operation.

Tail lamp relay output

TAIL LAMP

Tail lamp relay can be operated by any ON–OFF operation.

LT-20

HEADLAMP -CONVENTIONAL TYPEHeadlamp High Beam Does Not Illuminate (Both Sides)

BKS001CT

1. CHECK COMBINATION SWITCH INPUT SIGNAL

A

With CONSULT-II
1. Select “BCM” on CONSULT-II. Select “HEAD LAMP” on
“SELECT TEST ITEM” screen.
2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure that “HI BEAM SW” turns ON-OFF linked with operation of lighting switch.
When lighting switch is high
position

B

C

: HI BEAM SW ON

D

Without CONSULT-II
Refer to LT-125, «Combination Switch Inspection» .
PKIA7585E
OK or NG
OK
>> GO TO 2.
NG
>> Check combination switch (lighting switch). Refer to LT-125, «Combination Switch Inspection» .

E

F

2. HEADLAMP ACTIVE TEST
G

With CONSULT-II
1. Select “IPDM E/R” on CONSULT-II. Select “ACTIVE TEST” on
“SELECT DIAG MODE” screen.
2. Select “HEADLAMP” on “SELECT TEST ITEM” screen.
3. Touch “HI” screen.
4. Make sure headlamp high beam operates.

H

I

Headlamp high beam should operate
Without CONSULT-II
1. Start auto active test. Refer to PG-22, «Auto Active Test» .
2. Make sure headlamp high beam operates.

J
SKIA2339E

LT

Headlamp high beam should operate.
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 4.

L

3. CHECK IPDM E/R
M

1.
2.

Select “IPDM E/R” on CONSULT-II. Select “DATA MONITOR”
on “SELECT DIAG MODE” screen.
Make sure “HL HI REQ” turns ON when lighting switch is in high
position.
When lighting switch is high
position

: HL HI REQ ON

OK or NG
OK
>> Replace IPDM E/R. Refer to PG-37, «Removal and
Installation of IPDM E/R» .
NG
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .

LT-21

PKIB8696E

HEADLAMP -CONVENTIONAL TYPE-

4. CHECK HEADLAMP INPUT SIGNAL
1.
2.
3.
4.
5.
6.

With CONSULT-II
Turn ignition switch OFF.
Disconnect headlamp RH and LH connector.
Select “IPDM E/R” on CONSULT-II. Select “ACTIVE TEST” on “SELECT DIAG MODE” screen.
Select “HEADLAMP” on “SELECT TEST ITEM” screen.
Touch “HI” screen.
When headlamp high beam is operating, check voltage between
headlamp RH and LH harness connector and ground.
Terminal
(+)
Headlamp connector

1.
2.
3.
4.

RH

E26

LH

E46

(−)

Voltage

Terminal
2

Ground

Battery voltage

Without CONSULT-II
MKIB2273E
Turn ignition switch OFF.
Disconnect headlamp RH and LH connector.
Start auto active test. Refer to PG-22, «Auto Active Test» .
When headlamp high beam is operating, check voltage between headlamp RH and LH harness connector
and ground.
Terminal
(+)
Headlamp connector
RH

E26

LH

E46

(−)

Voltage

Terminal
2

Ground

Battery voltage

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 6.

5. CHECK HEADLAMP GROUND CIRCUIT
1.
2.

Turn ignition switch OFF.
Check continuity between headlamp RH and LH harness connector and ground.
Headlamp connector
RH

E26

LH

E46

Terminal
3

Continuity
Ground

Yes

OK or NG
OK
>> Check headlamp bulb.
NG
>> Repair harness or connector.
MKIB2274E

LT-22

HEADLAMP -CONVENTIONAL TYPE-

6. CHECK HEADLAMP CIRCUIT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect IPDM E/R connector.
Check continuity between IPDM E/R harness connector (A) and
headlamp RH and LH harness connector (B).
A
Circuit

B

Connector

RH
LH

4.

B

E8

Terminal

Connector

46

E26

47

E46

Terminal

C

Continuity

2

Yes

D

Check continuity between IPDM E/R harness connector (A) and
ground.
MKIB2275E

A
Circuit

Connector

LH

Continuity

Terminal

RH

Ground

46
E8

E

F
No

47

OK or NG
OK
>> Replace IPDM E/R. Refer to PG-37, «Removal and Installation of IPDM E/R» .
NG
>> Repair harness or connector.

Headlamp High Beam Does Not Illuminate (One Side)

G

BKS001CU

H

1. CHECK BULB
Check headlamp bulb which does not illuminate.
OK or NG
OK
>> GO TO 2.
NG
>> Replace bulb.

I

J

2. CHECK HEADLAMP INPUT SIGNAL
1.
2.
3.
4.
5.

LT

Turn ignition switch OFF.
Disconnect headlamp RH or LH connector.
Turn ignition switch ON.
Lighting switch is turned to HIGH position.
Check voltage between headlamp RH or LH harness connector
and ground.

L

M

Terminal
(+)
Headlamp connector
RH

E26

LH

E46

Voltage
Terminal
2

(−)

Ground

Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 4.

MKIB2273E

LT-23

HEADLAMP -CONVENTIONAL TYPE-

3. CHECK HEADLAMP GROUND CIRCUIT
1.
2.

Turn ignition switch OFF.
Check continuity between headlamp RH or LH harness connector and ground.
Headlamp connector
RH

E26

LH

E46

Terminal

Continuity
Ground

3

Yes

OK or NG
OK
>> Check connecting condition headlamp harness connector.
NG
>> Repair harness or connector.

MKIB2274E

4. CHECK HEADLAMP CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R connector.
Check continuity between IPDM E/R harness connector (A) and
headlamp RH or LH harness connector (B).
A
Circuit

Connector

RH
LH

4.

E8

B
Terminal

Connector

46

E26

47

E46

Terminal

Continuity

2

Yes

Check continuity between IPDM E/R harness connector (A) and
ground.
MKIB2275E

A
Circuit

Connector

RH
LH

46
E8

Continuity

Terminal
Ground

No

47

OK or NG
OK
>> Replace IPDM E/R. Refer to PG-37, «Removal and Installation of IPDM E/R» .
NG
>> Repair harness or connector.

LT-24

HEADLAMP -CONVENTIONAL TYPEHeadlamp Low Beam Does Not Illuminate (Both Sides)

BKS001CV

1. CHECK COMBINATION SWITCH INPUT SIGNAL

A

With CONSULT-II
1. Select “BCM” on CONSULT-II. Select “HEAD LAMP” on
“SELECT TEST ITEM” screen.
2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure that “H/L SW POS” turns ON-OFF linked with operation of lighting switch.
When lighting switch is
2nd position
When lighting switch is
OFF position

B

C

: H/L SW POS ON

D

: H/L SW POS OFF
E
MKIB2276E

Without CONSULT-II
Refer to LT-125, «Combination Switch Inspection» .
OK or NG
OK
>> GO TO 2.
NG
>> Check combination switch (lighting switch). Refer to LT-125, «Combination Switch Inspection» .

F

G

2. CHECK HEADLAMP ACTIVE TEST
With CONSULT-II
1. Select “IPDM E/R” on CONSULT-II. Select “ACTIVE TEST” on
“SELECT DIAG MODE” screen.
2. Select “HEADLAMP” on “SELECT TEST ITEM” screen.
3. Touch “LO” screen.
4. Make sure headlamp low beam operates.

H

I

J

Headlamp low beam should operate.
Without CONSULT-II
1. Start auto active test. Refer to PG-22, «Auto Active Test» .
2. Make sure headlamp low beam operates.

LT
SKIA2339E

Headlamp low beam should operate.
L

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 4.

M

3. CHECK IPDM E/R
1.
2.

Select “IPDM E/R” on CONSULT-II. Select “DATA MONITOR”
on “SELECT DIAG MODE” screen.
Make sure “HL LO REQ” turns ON when lighting switch is in
2ND position.
When lighting switch is 2ND
position

: HL LO REQ ON

OK or NG
OK
>> Replace IPDM E/R. Refer to PG-37, «Removal and
Installation of IPDM E/R» .
NG
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .

LT-25

PKIA7644E

HEADLAMP -CONVENTIONAL TYPE-

4. CHECK HEADLAMP INPUT SIGNAL
1.
2.
3.
4.
5.
6.

With CONSULT-II
Turn ignition switch OFF.
Disconnect headlamp RH and LH connector.
Select “IPDM E/R” on CONSULT-II. Select “ACTIVE TEST” on “SELECT DIAG MODE” screen.
Select “HEADLAMP” on “SELECT TEST ITEM” screen.
Touch “LO” screen.
When headlamp low beam is operating, check voltage between
headlamp RH and LH harness connector and ground.
Terminal
(+)
Headlamp connector

1.
2.
3.
4.

RH

E26

LH

E46

(−)

Voltage

Terminal
1

Ground

Battery voltage

Without CONSULT-II
MKIB2277E
Turn ignition switch OFF.
Disconnect headlamp RH and LH connector.
Start auto active test. Refer to PG-22, «Auto Active Test» .
When headlamp low beam is operating, check voltage between headlamp RH and LH harness connector
and ground.
Terminal
(+)
Headlamp connector
RH

E26

LH

E46

(−)

Voltage

Terminal
1

Ground

Battery voltage

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 6.

5. CHECK HEADLAMP GROUND CIRCUIT
1.
2.

Turn ignition switch OFF.
Check continuity between headlamp RH and LH harness connector and ground.
Headlamp connector
RH

E26

LH

E46

Terminal
3

Continuity
Ground

Yes

OK or NG
OK
>> Check headlamp bulbs.
NG
>> Repair harness or connector.
MKIB2274E

LT-26

HEADLAMP -CONVENTIONAL TYPE-

6. CHECK HEADLAMP CIRCUIT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect IPDM E/R connector.
Check continuity between IPDM E/R harness connector (A) and
headlamp RH or LH harness connector (B).
A
Circuit

Connector

RH
LH

4.

E8

B

B
Terminal

Connector

48

E26

50

E46

Terminal

C

Continuity

1

Yes

D

Check continuity between IPDM E/R harness connector (A) and
ground.
MKIB2278E

A
Circuit

Connector

RH
LH

Continuity

Terminal
Ground

48
E8

E

F
No

50

OK or NG
OK
>> Replace IPDM E/R. Refer to PG-37, «Removal and Installation of IPDM E/R» .
NG
>> Repair harness or connector.

Headlamp Low Beam Does Not Illuminate (One Side)

G

BKS001CW

H

1. CHECK BULB
Check bulb of headlamp which does not illuminate.
OK or NG
OK
>> GO TO 2.
NG
>> Replace bulb.

I

J

2. CHECK HEADLAMP INPUT SIGNAL
1.
2.
3.
4.
5.

LT

Turn ignition switch OFF.
Disconnect headlamp RH or LH connector.
Turn ignition switch ON.
Lighting switch is turned to 2ND position.
Check voltage between headlamp RH or LH harness connector
and ground.

L

M

Terminal
(+)
Headlamp connector
RH

E26

LH

E46

Voltage
Terminal
1

(−)

Ground

Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 4.

MKIB2277E

LT-27

HEADLAMP -CONVENTIONAL TYPE-

3. CHECK HEADLAMP GROUND CIRCUIT
1.
2.

Turn ignition switch OFF.
Check continuity between headlamp RH or LH harness connector and ground.
Headlamp connector
RH

E26

LH

E46

Terminal

Continuity
Ground

3

Yes

OK or NG
OK
>> Check connecting condition headlamp harness connector.
NG
>> Repair harness or connector.

MKIB2274E

4. CHECK HEADLAMP CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R connector.
Check continuity between IPDM E/R harness connector (A) and
headlamp RH or LH harness connector (B).
A

Circuit

Connector

B
Terminal

Connector

48

E26

50

E46

RH
LH

4.

E8

Terminal

Continuity

1

Yes

Check continuity between IPDM E/R harness connector (A) and
ground.
MKIB2278E

A
Circuit

Connector

RH
LH

48
E8

Continuity

Terminal
Ground

No

50

OK or NG
OK
>> Replace IPDM E/R. Refer to PG-37, «Removal and Installation of IPDM E/R» .
NG
>> Repair harness or connector.

LT-28

HEADLAMP -CONVENTIONAL TYPEHeadlamps Do Not Turn OFF

BKS001CX

1. CHECK HEADLAMP TURN OFF

A

Make sure that lighting switch is OFF. And make sure headlamp turns off when ignition switch is turned OFF.
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

C

2. CHECK COMBINATION SWITCH INPUT SIGNAL
1.
2.

Select “BCM” on CONSULT-II. Select “HEAD LAMP” on
“SELECT TEST ITEM” screen.
Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure that “H/L SW POS” and “HEAD LAMP SW 2” turns
ON-OFF linked with operation of lighting switch.
When lighting switch is
OFF position

B

D

E

: H/L SW POS OFF
F

OK or NG
OK
>> Replace IPDM E/R. Refer to PG-37, «Removal and
Installation of IPDM E/R» .
NG
>> Check combination switch (lighting switch). Refer to LT125, «Combination Switch Inspection» .

MKIB2279E

3. CHECKING CAN COMMUNICATIONS BETWEEN BCM AND IPDM E/R

G

H

Select “BCM” on CONSULT-II, and perform self-diagnosis for
“BCM”.
Display of self-diagnosis results
NO DTC>> Replace IPDM E/R. Refer to PG-37, «Removal and
Installation of IPDM E/R» .
CAN COMM CIRCUIT>> Refer to BCS-17, «CAN Communication
Inspection With CONSULT-II (Self-Diagnosis)» .

I

J

LT
PKIA7627E

L

M

LT-29

HEADLAMP -CONVENTIONAL TYPEAiming Adjustment

BKS001M7

MKIB2306E

Turn the aiming adjusting screw to adjust.
●
For positions of the adjustment screws, refer to the figures.
CAUTION:
Adjustment with the aiming adjusting screw must be done in the tightening direction. (When adjusting
in the loosening direction, first loosen the screw, then tighten again.)
●

PREPARATION BEFORE ADJUSTING
For details, refer to the regulations in your own country.
Before performing aiming adjustment, check the following.
1. Keep all tires inflated to correct pressures.
2. Place vehicle on flat surface.
3. Set that there is no-load in vehicle other than the driver (or equivalent weight placed in driver’s position).
Coolant, engine oil filled up to correct level and full fuel tank.

LOW BEAM AND HIGH BEAM
NOTE:
Aim each headlamp individually and ensure other headlamp beam pattern is blocked from screen.
1. Turn headlamp low beam ON.
2. Use adjusting screws to perform aiming adjustment.
● First tighten the adjusting screw all the way and then make adjustment by loosening the screw.
If the vehicle front body has been repaired and/or the headlamp assembly has been replaced, check
aiming. Use the aiming chart shown in the figure.

LT-30

HEADLAMP -CONVENTIONAL TYPE●

●

●

Adjust headlamps so that main axis of light is parallel to center line of body and is aligned with point P shown in illustration.
Figure shows headlamp aiming pattern for driving on right
side of road; for driving on left side of road, aiming pattern is
reversed.
Dotted lines to point P in illustration show center of headlamp.
“H”
“WL ”
“L”
“C”

A

B

C

: Horizontal center line of headlamps
: Distance between each headlamp center
: 25,000 mm (984.25 in)
: 250 mm (9.84 in) – 310 mm (12.20 in)

Elbow point for LHD models must be in 300 mm (11.81 in) to
the right form point P.
Elbow point for RHD models must be in 300 mm (11.81 in) to
the left form point P.
● Basic illuminating area for adjustment should be within the
range shown in the figure. Adjust headlamps accordingly.
CAUTION:
Be sure aiming switch is set to “0” when preforming aiming
adjustment.

D

E

●

F

G
PKIA3537E

H

I

J

LT

L

M

LT-31

HEADLAMP -CONVENTIONAL TYPEBulb Replacement

BKS001CZ

CAUTION:
After installing bulb, be sure to install plastic cap and bulb socket securely to ensure watertightness.

HEADLAMP (HIGH/LOW)
1.
2.
3.
4.

Turn lighting switch OFF.
Remove the socket connected to the bulb.
Remove back cover.
Unlock retaining spring and remove bulb from headlamp.
Headlamp (High/Low)

: 12V — 60/55W (H4)

PARKING (CLEARANCE) LAMP
1.
2.
3.

Turn lighting switch OFF.
Turn bulb socket counterclockwise and unlock it.
Remove bulb from its socket.
Parking (Clearance) lamp

: 12V — 5W

FRONT TURN SIGNAL LAMP
1.
2.
3.

Turn lighting switch OFF.
Turn bulb socket counterclockwise and unlock it.
Remove bulb from its socket.
Front turn signal lamp

: 12V — 21W (amber)

Removal and Installation

BKS001D0

SKIB3797J

1.

Bolt

2.

Headlamp

REMOVAL
1.
2.
3.
4.

Disconnect the battery cable from the negative terminal.
Remove front bumper. Refer to EI-4, «FRONT BUMPER» .
Remove headlamp mounting bolts.
Pull headlamp toward the vehicle front, disconnect connector, and remove headlamp.
CAUTION:
When removing headlamps, put a shop cloth or something similar between headlamps and
bumper to protect bumper.

LT-32

HEADLAMP -CONVENTIONAL TYPEINSTALLATION
A

Installation is the reverse order of removal.
Headlamp mounting bolt

: 5.5 N·m (0.56 kg-m, 49 in-lb)

NOTE:
After installation, perform aiming adjustment. Refer to LT-30, «Aiming Adjustment» .

B

C

D

E

F

G

H

I

J

LT

L

M

LT-33

HEADLAMP -CONVENTIONAL TYPEDisassembly and Assembly

BKS001D1

MKIB2292E

1.

Retaining spring

2.

Parking (clearance) lamp bulb

3.

Parking (clearance) lamp bulb socket

4.

Halogen bulb (High/Low)

5.

Back cover

6.

Front turn signal lamp bulb

7.

Front turn signal lamp bulb socket

8.

Headlamp housing assembly

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

Disconnect the socket connected to the bulb (High/low).
Remove back cover.
Unlock retaining spring and remove bulb (High/Low).
Turn parking (clearance) lamp bulb socket counterclockwise and unlock it.
Remove parking (clearance) lamp bulb from its socket.
Turn front turn signal lamp bulb socket counterclockwise and unlock it.
Remove front turn signal lamp bulb from its socket.

ASSEMBLY
Assembly is the reverse order of disassembly.
CAUTION:
●
After installing bulb, be sure to install plastic cap and bulb socket securely to insure watertightness.

LT-34

HEADLAMP — DAYTIME LIGHT SYSTEM HEADLAMP — DAYTIME LIGHT SYSTEM Component Parts and Harness Connector Location

PFP:26010

A
BKS001D2

B

C

D

E

F

G
MKIB2271E

1.

IPDM E/R E8,E11,E12

2.

BCM M57,M59 (View with instrument upper panel removed)

4.

Combination meter M27

5.

Daytime light relay E54

3.

System Description

Combination switch M38

H
BKS001D3

DAYTIME LIGHT SYSTEM turns on daytime light lamps while engine is running.
Engine run or stop signal are sent to BCM (body control module) by CAN communication line, and control daytime light system.

I

J

OUTLINE
Power is supplied at all times
●
to ignition relay (located in IPDM E/R),
●
to headlamp high RH and LH relay (located in IPDM E/R)
●
to headlamp low relay (located in IPDM E/R) from battery directly,
●
through 20A fuse (No. 61, located in IPDM E/R),
●
through 20A fuse (No. 62, located in IPDM E/R),
●
through 40A fusible link (letter J, located in fuse and fusible link block)
●
to BCM terminals 74 and 79,
●
through 10A fuse [No. 7, located in fuse block (J/B)]
●
to combination meter terminal 27,
●
through 10A fuse (No. 37, located in fuse and fusible link block)
●
to daytime light relay terminals 1 and 5.
When the ignition switch is in ON or START position, power is supplied
●
to ignition relay (located in IPDM E/R),
●
through 10A fuse [No. 5, located in fuse block (J/B)]
●
to BCM terminal 24,
●
through 10A fuse [No. 4, located in fuse block (J/B)]
●
to combination meter terminal 28.
Ground is supplied
●
to BCM terminals 2 and 70
●
to combination meter terminals 21, 22, and 23
●
through grounds E21 and M66,

LT-35

LT

L

M

HEADLAMP — DAYTIME LIGHT SYSTEM ●
●

to IPDM E/R terminals 3 and 54
through grounds E45 (CR and HR engine models), E28 and E44.

HEADLAMP OPERATION
Low Beam Operation
With the lighting switch in 2ND position, the BCM receives input signal requesting the headlamps to illuminate.
This input signal is communicated to IPDM E/R across the CAN communication lines. The CPU located in the
IPDM E/R controls the headlamp low relay coil, which when energized, directs power
●
through 15A fuse (No. 50, located in IPDM E/R)
●
through IPDM E/R terminal 48
●
to headlamp RH terminal 1,
●
through 15A fuse (No. 49, located in IPDM E/R)
●
through IPDM E/R terminal 50
●
to headlamp LH terminal 1.
Ground is supplied
●
to headlamp RH terminals 3
●
through daytime light relay terminal 3 and 4,
●
to headlamp LH terminal 3
●
through grounds E45 (CR and HR engine models), E28 and E44.
With power and ground supplied, low beam headlamps illuminate.

High Beam Operation (When Daytime Light Does Not Operate)/Flash-to-Pass Operation
With the lighting switch in 2ND position and placed in HIGH BEAM or PASSING position, the BCM receives
input signal requesting headlamp high beams to illuminate. High beam request signal is communicated to the
IPDM E/R across the CAN communication lines. The CPU located in the IPDM E/R controls headlamp high
relay coil and low relay coil, which when energized, directs power
●
through 10A fuse (No. 43, located in IPDM E/R)
●
through IPDM E/R terminal 46
●
through headlamp RH terminals 2
●
through 10A fuse (No. 44, located in IPDM E/R)
●
through IPDM E/R terminal 47
●
to headlamp LH terminal 2,
●
through 15A fuse (No. 50, located in IPDM E/R)
●
through IPDM E/R terminal 48
●
to headlamp RH terminal 1,
●
through 15A fuse (No. 49, located in IPDM E/R)
●
through IPDM E/R terminal 50
●
to headlamp LH terminal 1.
Ground is supplied
●
to headlamp RH terminal 3
●
to daytime light relay terminals 3and 4
●
to headlamp LH terminal 3
●
through grounds E45 (CR and HR engine models), E28 and E44.
With the power and ground supplied, the headlamp high beam and low headlamp illuminate.
High beam indicator illuminates when combination meter receives input signal requesting high beam indicator
to illuminate. This is communicated to BCM across the CAN communication lines.

LT-36

HEADLAMP — DAYTIME LIGHT SYSTEM DAYTIME LIGHT OPERATION
With the engine running, the lighting switch in the OFF or AUTO position (headlamp is not illuminate) and
parking brake released, the IPDM E/R receives input request signal from BCM to turn on daytime light. This
input is communicated across the CAN communication lines. The CPU of the IPDM E/R controls the daytime
light relay coil. When energized, this relay directs power
●
through 10A fuse (No. 37, located in fuse and fusible link block)
●
through daytime light relay terminals 5 and 3
●
through headlamp RH terminals 3 and 1
●
through IPDM E/R terminal 48
●
through 15A fuse (No. 50, located in IPDM E/R)
●
through 15A fuse (No. 49, located in IPDM E/R)
●
through IPDM E/R terminal 50
●
to headlamp LH terminal 1.
Ground is supplied
●
to headlamp LH terminal 3
●
through grounds E45 (CR and HR engine models), E28 and E44.
Because the low beam headlamps are now wired in series, they operate at half illumination.
If the lighting switch is in the 1st and 2nd position, daytime light operation is canceled.

A

B

C

D

E

F

G

COMBINATION SWITCH READING FUNCTION
Refer to LT-114, «COMBINATION SWITCH READING FUNCTION» .

AUTO LIGHT OPERATION

H

Refer to LT-52, «System Description» .

FRIENDRY LIGHTING FUNCTION
I

Low beam headlamps will illuminate for 30 seconds when,
●
ignition switch is in OFF position,
●
lighting switch is placed in OFF position, and
●
lighting switch is placed in PASS position.
Each activation of the switch adds 30 seconds to a maximum of 2 minutes.

J

EXTERIOR LAMP BATTERY SAVER CONTROL

LT

To avoid flat battery caused by user leaving exterior lamps ON. When ignition is OFF and the driver side door
is opened, all exterior lamps will be turned OFF. If the user wants some lamps to remain ON then they must
switch these lamps OFF then ON again with the combination switch once the driver side door has been
opened. A buzzer will sound if any exterior lamps are ON with the driver side door opened and ignition OFF.
*:This setting can be changed by CONSULT-II. Refer to LT-45, «WORK SUPPORT» .

L

FAIL-SAFE FUNCTION

M

When CAN communication with other control units is impossible, IPDM E/R performs fail-safe control. If the
fail-safe system is operating, headlamps illuminate when the ignition switch is turned from OFF to ON and
headlamps are turned off when the ignition switch is turn from ON to OFF. If the fail-safe system is operating,
headlamps does not operate when the combination switch is in any position. After CAN communication recovers normally, it also returns to normal control. (Refer to PG-18, «Fail-safe Control» .)

CAN Communication System Description

BKS001M4

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

CAN Communication Unit

BKS001M5

Refer to LAN-27, «CAN Communication Unit» .

LT-37

HEADLAMP — DAYTIME LIGHT SYSTEM Schematic

BKS001D5

MKWA4323E

LT-38

HEADLAMP — DAYTIME LIGHT SYSTEM Wiring Diagram — DTRL —

BKS001D6

A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4324E

LT-39

HEADLAMP — DAYTIME LIGHT SYSTEM —

MKWA4325E

LT-40

HEADLAMP — DAYTIME LIGHT SYSTEM A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4326E

LT-41

HEADLAMP — DAYTIME LIGHT SYSTEM Terminals and Reference Values for BCM

BKS001D7

CAUTION:
●
Check combination switch system terminal waveform under the loaded condition with lighting
switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded.
●
Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position.
Wiper dial position can be confirmed on CONSULT-II. Refer to LT-45, «DATA MONITOR» .
Terminal
No.

Wire
color

2

B

13

SB

Combination switch
input 1

14

P

Combination switch
input 3

15

W

Combination switch
input 5

33

R

Combination switch
input 2

34

Y

Combination switch
input 4

7

BR

Combination switch
output 5

8

L

Combination switch
output 3

9

V

Combination switch
output 1

27

28

GR

G

Signal designation
Ground

Combination switch
output 4

Measuring condition

Signal
input/
output

Ignition
switch

Operation or condition

Voltage [V]
(Approx.)

—

ON

—

0

Input

ON

Headlamps, turn signal,
wipers OFF

SKIA2167J

Headlamps, turn signal,
wipers OFF (wiper volume
is 1 or 7)
SKIA2166J

Output

ON

Headlamps, turn signal,
wipers OFF (wiper volume
is other than 1 or 7)

Combination switch
output 2

SKIA2167J

Input/
Output

ON

—

Approx. 2.6V

Input

ON

—

Battery voltage

19

L

CAN- H

24

O

Ignition power supply

39

Y

CAN- L

Input/
Output

ON

—

Approx. 2.4V

70

B

Ground

—

ON

—

0

74
79

Y

Battery power supply

Input

OFF

—

Battery voltage

LT-42

HEADLAMP — DAYTIME LIGHT SYSTEM Terminals and Reference Values for IPDM E/R

BKS001D8

A
Terminal
No.

Wire
color

3

B

Ground

46

Y

Headlamp HI (RH)

47

G

Headlamp HI (LH)

Signal designation

48

P

Headlamp LO (RH)

50

L

Headlamp LO (LH)

Measuring condition

Signal
input/
output

Ignition
switch

Operation or condition

Voltage [V]
(Approx.)

—

ON

—

0

ON
ON
Output

ON
ON

Lighting switch (high
beam)

ON

Battery voltage

OFF

0

Lighting switch (low
beam)

ON

Battery voltage

OFF

0

52

L

CAN- H

Input/
Output

54

B

Ground

—

ON

—

0

58

Y

CAH- L

Input/
Output

—

—

—

65

L

Daytime light relay

Input

ON

—

—

—

Engine status
(Lighting switch OFF)

RUNNING
STOP

C

D

E

F

0
Battery voltage

How to Perform Trouble Diagnosis
1.
2.
3.
4.
5.
6.

B

BKS001D9

Confirm the symptom or customer complaint.
Understand operation description and function description. Refer to LT-35, «System Description» .
Perform the Preliminary Check. Refer to LT-44, «Preliminary Check» .
Check symptom and repair or replace the cause of malfunction.
Does the headlamp operate normally? If YES: GO TO 6. If NO: GO TO 4.
INSPECTION END

G

H

I

J

LT

L

M

LT-43

HEADLAMP — DAYTIME LIGHT SYSTEM Preliminary Check

BKS001DA

INSPECTION FOR POWER SUPPLY AND GROUND CIRCUIT

1. CHECK FUSES
Check for blown fuses or fusible link.
Unit

Power source

Fuse No.

Battery

J

Ignition switch ON or START position

5

BCM

43
44
IPDM E/R

49

Battery

50
61
62

Refer to LT-39, «Wiring Diagram — DTRL —» .
OK or NG
OK
>> GO TO 2.
NG
>> If fuse is blown, be sure to eliminate cause of malfunction before installing new fuse. Refer to PG4, «POWER SUPPLY ROUTING CIRCUIT» .

2. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector.
Check voltage between BCM harness connector and ground.
Terminal

Ignition switch position

(+)
BCM
Connector

Terminal

M57

24
74

(−)

Ground

M59

OFF

ACC

ON

Approx. 0V

Approx. 0V

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

MKIB0352E

79

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

3. CHECK GROUND CIRCUIT
Check continuity between BCM harness connector and ground.
BCM connector

Terminal

M57

2

M59

70

Continuity
Ground
Yes

OK or NG
OK
>> INSPECTION END
NG
>> Repair harness or connector.
MKIB0353E

LT-44

HEADLAMP — DAYTIME LIGHT SYSTEM CONSULT-II Functions (BCM)

BKS001DB

A

CONSULT-II can display each diagnostic item using the diagnostic test mode shown following.
BCM diagnosis part

Diagnosis mode

Changes the setting for each function.

DATA MONITOR

Displays BCM input data in real time.

HEADLAMP

ACTIVE TEST
SELF-DIAG RESULTS

BCM

Description

WORK SUPPORT

CAN DIAG SUPPORT MNTR

B

Operation of electrical loads can be checked by sending drive signal to them.

C

BCM performs self-diagnosis of CAN communication.
The result of transmit/receive diagnosis of CAN communication can be read.

D

CONSULT-II INSPECTION PROCEDURE
Refer toGI-36, «CONSULT-II Start Procedure» .

CONSULT-II Application Items (BCM)

BKS001M1

E

WORK SUPPORT
Operation Procedure
1.
2.
3.
4.
5.
6.
7.

F

Touch “HEAD LAMP” on “SELECT TEST ITEM” screen.
Touch “WORK SUPPORT” on “SELECT DIAG MODE” screen.
Touch “BATTERY SAVER SET” on “SELECT WORK ITEM” screen.
Touch “START”.
Touch “CHANGE SET”.
The setting will be changed and “CUSTOMIZING COMPLETED” will be displayed.
Touch “END”.

G

H

Display Item List
Item
BATTERY SAVER SET

Description

CONSULT-II

Factory setting

Exterior lamp battery saver control mode can be changed in this mode.
Select exterior lamp battery saver control mode between ON and OFF.

ON

×

OFF

—

I

J

DATA MONITOR
Monitor item UNIT.

Display content

IGN ON SW

[ON/OFF]

Displays status (Ignition switch ON: ON/Others OFF, ACC: OFF) as judged from the ignition switch signal.

HI BEAM SW

[ON/OFF]

Displays status (High beam switch: ON/Others: OFF) as judged from lighting switch signal.

H/L SW POS

[ON/OFF]

Displays status (Headlamp switch: ON/Others: OFF) as judged from lighting switch signal.

LIGHT SW 1ST

[ON/OFF]

Displays status (Lighting switch 1st position: ON/Others: OFF) as judged from lighting
switch signal.

PASSING SW

[ON/OFF]

Displays status (Flash-to-pass switch: ON/Others: OFF) as judged from lighting switch
signal.

FR FOG SW

[ON/OFF]

Displays status (Front fog lamp switch: ON/Others: OFF) as judged from lighting switch
signal.

RR FOG SW

[ON/OFF]

Displays status (Rear fog lamp switch: ON/Others: OFF) as judged from lighting switch
signal.

DOOR SW-DR

[ON/OFF]

Displays status (Door open: ON/door closed: OFF) as judged from the door switch DR signal.

H/L WASH SW

[ON/OFF]

Displays status (Headlamp washer switch: ON/Others: OFF) as judged from headlamp
washer switch signal.

ENGINE STATUS

[STOP/
STALL/
RUN/
CRA]

Displays status (Engine stop: STOP/engine stall: STALL/engine running: RUN/engine
cranking: CRA) as judged from the engine status.

LT-45

LT

L

M

HEADLAMP — DAYTIME LIGHT SYSTEM ACTIVE TEST
Test item

CONSULT-II screen display

Description

Tail lamp relay output

TAIL LAMP

Tail lamp relay can be operated by any ON–OFF operation.

Headlamp relay output

HEADLAMP

Headlamp relay can be operated by any ON–OFF operation.

Front fog lamp relay output

FR FOG LAMP

Front fog lamp relay can be operated by any ON–OFF operation.

Rear fog lamp relay output

RR FOG LAMP

Rear fog lamp relay can be operated by any ON–OFF operation.

CONSULT-II Functions (IPDM E/R)

BKS001DC

CONSULT-II can display each diagnostic item using the diagnostic test mode shown following.
Diagnosis Mode
SELF-DIAGNOSTIC RESULTS

Description
Refer to PG-20, «SELF-DIAG RESULTS» .

DATA MONITOR

The input/output data of IPDM E/R is displayed in real time.

CAN DIAG SUPPORT MNTR

The result of transmit/receive diagnosis of CAN communication can be read.

ACTIVE TEST

IPDM E/R sends a drive signal to electronic components to check their operation.

CONSULT-II INSPECTION PROCEDURE
Refer to GI-36, «CONSULT-II Start Procedure» .

CONSULT-II Application Items (IPDM E/R)

BKS001M2

DATA MONITOR
All Signals, Main Signals, Selection From Menu
Monitor item selection
Monitor item name

Display and unit

All
signals

Main
signals

selection
from
menu

Display content

TAIL & CLR REQ

ON/OFF

×

×

×

Signal status input from BCM

HL LO REQ

ON/OFF

×

×

×

Signal status input from BCM

HL HI REQ

ON/OFF

×

×

×

Signal status input from BCM

FR FOG REQ

ON/OFF

×

×

×

Signal status input from BCM

IGN RLY

ON/OFF

×

×

×

Status of ignition relay being monitored by
IPDM E/R

ACTIVE TEST
Test item

CONSULT-II screen display

Description

Headlamp relay (HI, LO) output

HEAD LAMP

Headlamp relay (LO, HI) can be operated using random
operation (OFF, HI ON, LO ON).

Front fog lamp relay output

FRONT FOG LAMP

Fog lamp relay can be operated by any ON–OFF operation.

Tail lamp relay output

TAIL LAMP

Tail lamp relay can be operated by any ON–OFF operation.

LT-46

HEADLAMP — DAYTIME LIGHT SYSTEM Daytime Light Control Does Not Operate Properly

BKS001LO

1. CHECK HEADLAMP OPERATION

A

Lighting switch is turned to 2nd position.
Does headlamp operate normally?
Yes
>> GO TO 2.
No
>> Check the following.
● Headlamp does not illuminate (both sides). GO TO LT-25, «Headlamp Low Beam Does Not Illuminate (Both Sides)» .
● Headlamp does not illuminate (one side). GO TO LT-27, «Headlamp Low Beam Does Not Illuminate (One Side)» .

B

C

D

2. CHECK DAYTIME LIGHT RELAY
1.
2.
3.

E

Turn ignition switch OFF.
Disconnect daytime light relay connector.
Check voltage between daytime light relay harness connector
and ground.

F

Terminals
(+)
Connector

(–)

Voltage [V]
(Approx.)

Ground

Battery voltage

G

Terminal

E54

1

H

5

OK or NG
OK
>> GO TO 3.
NG
>> Check the following.
● 10A fuse (No. 37, located in fuse and fusible link box).
● Harness for open or short between daytime relay and fuse.

MKIB0408E

I

J

3. CHECK IPDM E/R OUTPUT SIGNAL
1.
2.
3.

LT

Connect daytime light relay.
Disconnect IPDM E/R connector.
Check voltage between IPDM E/R harness connector E5 terminal 65 and ground.
65 — Ground

L

: Battery voltage
M

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 5.
MKIB0745E

LT-47

HEADLAMP — DAYTIME LIGHT SYSTEM —

4. CHECK IPDM E/R OUTPUT SIGNAL
1.
2.

Connect IPDM E/R connector.
Check voltage between IPDM and ground.
Terminals
(+)

Connector

Terminal

E5

65

Ground

Voltage [V]
(Approx.)

Condition

(–)

Engine stop

Battery voltage

Engine running

0

OK or NG
OK
>> Replace daytime relay.
NG
>> Replace IPDM E/R.

MKIB0551E

5. CHECK IPDM E/R OUTPUT SIGNAL CIRCUIT
1.
2.

Disconnect daytime light relay connector.
Check continuity between daytime light relay harness connector
E54 terminal 2 and IPDM E/R harness connector E5 terminal
65.
2 — 65

: Continuity should exist.

OK or NG
OK
>> Replace daytime light relay.
NG
>> Repair or replace harness or connector.

MKIB0409E

RH High beam Does Not Illuminate

BKS001LQ

1. CHECK BULB
Check bulb of headlamp RH.
OK or NG
OK
>> GO TO 2.
NG
>> Replace bulb of headlamp.

2. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect headlamp RH connector.
Check voltage between headlamp RH harness connector E26
terminal 2 and ground.
Terminals
(+)

Condition

Connector

Terminal

E26

2

(–)
Ground

Lighting switch
high beam ON

Voltage [V]
(Approx.)

Battery voltage

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.

MKIB1921E

LT-48

HEADLAMP — DAYTIME LIGHT SYSTEM —

3. CHECK IPDM E/R CIRCUIT
1.
2.

A

Disconnect IPDM E/R connector.
Check continuity between IPDM E/R harness connector (A) and
headlamp RH harness connector (B).
A

3.

B

B

Continuity

Connector

Terminal

Connector

Terminal

E8

46

E26

2

C
Yes

Check continuity between IPDM E/R harness connector (A) and
ground.
A

Continuity

Connector

Terminal

E8

46

Ground

D
MKIB2287E

E
No

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace harness or connector.

F

4. CHECK FUSE

G

Check 10A fuse [No. 43, located in IPDM E/R].
OK or NG
OK
>> Replace IPDM E/R.
NG
>> Replace fuse. If fuse is blown, be sure to eliminate cause of malfunction before installing new
fuse.

5. CHECK HEADLAMP RH GROUND CIRCUIT
Check continuity between daytime light relay harness connector E54
terminal 3 and headlamp RH harness connector E26 terminal 3.
3- 3

H

I

J

: Continuity should exist.
LT

OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace harness or connector.

L

MKIB2015E

6. CHECK DAYTIME LIGHT GROUND CIRCUIT
Check continuity daytime light relay harness connector E54 terminal
4 and ground.
4 — Ground

: Continuity should exist.

OK or NG
OK
>> Replace daytime light relay.
NG
>> Repair or replace harness or connector.

MKIB0420E

LT-49

M

HEADLAMP — DAYTIME LIGHT SYSTEM RH Low Beam Does Not Illuminate

BKS001LT

1. CHECK BULB
Check bulb of headlamp RH.
OK or NG
OK
>> GO TO 2.
NG
>> Replace bulb of lamp.

2. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect headlamp RH connector.
Check voltage between headlamp RH harness connector E26
terminal 1 and ground.
Terminals
(+)

Voltage [V]
(Approx.)

Condition

Connector

Terminal

E26

1

(–)
Ground

Lighting switch
low beam ON

Battery voltage

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.

MKIB2019E

3. CHECK IPDM E/R CIRCUIT
1.
2.

Disconnect IPDM E/R connector.
Check continuity between IPDM E/R harness connector (A) and
headlamp RH harness connector (B).
A

3.

B

Continuity

Connector

Terminal

Connector

Terminal

E8

48

E26

1

Yes

Check continuity between IPDM E/R harness connector (A) and
ground.
A

Continuity

Connector

Terminal

E8

48

Ground

MKIB2288E

No

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace harness or connector.

4. CHECK FUSE
Check 15A fuse (No. 50 located in IPDM E/R). Refer to PG-34, «IPDM E/R Terminal Inspection» .
OK or NG
OK
>> Replace IPDM E/R.
NG
>> Replace fuse. If fuse is blown, be sure to eliminate cause of malfunction before installing new
fuse.

LT-50

HEADLAMP — DAYTIME LIGHT SYSTEM —

5. CHECK HEADLAMP RH GROUND CIRCUIT

A

Check continuity between daytime light relay harness connector E54
terminal 3 and headlamp RH harness connector E26 terminal 3.
3-3

B

: Continuity should exist.

OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace harness or connector.

C

D
MKIB2015E

6. CHECK DAYTIME LIGHT GROUND CIRCUIT

E

Check continuity daytime light relay harness connector E54 terminal
4 and ground.
4 — Ground

F

: Continuity should exist.

OK or NG
OK
>> Replace daytime light relay.
NG
>> Repair or replace harness connector.

G

H
MKIB0420E

Headlamp High Beam Does Not Illuminate (Both Sides)

BKS001LP

I

BKS001LX

J

BKS001LY

LT

Refer to LT-21, «Headlamp High Beam Does Not Illuminate (Both Sides)» .

Headlamp Low Beam Does Not Illuminate (Both Sides)
Refer to LT-25, «Headlamp Low Beam Does Not Illuminate (Both Sides)» .

Headlamp LH High Beam Does Not Illuminate
Refer to LT-23, «Headlamp High Beam Does Not Illuminate (One Side)» .

Headlamp LH Low Beam Does Not Illuminate

BKS001LU

Refer toLT-27, «Headlamp Low Beam Does Not Illuminate (One Side)» .

Headlamps Do Not Turn OFF

L

BKS001LW

M

Refer toLT-29, «Headlamps Do Not Turn OFF» .

Aiming Adjustment

BKS001DN

Refer to LT-30, «Aiming Adjustment» .

Bulb Replacement

BKS001DO

Refer toLT-32, «Bulb Replacement» .

Removal and Installation

BKS001DP

Refer to LT-32, «Removal and Installation» .

Disassembly and Assembly

BKS001DQ

Refer to LT-34, «Disassembly and Assembly» .

LT-51

AUTO LIGHT SYSTEM
AUTO LIGHT SYSTEM
Component Parts and Harness Connector Location

PFP:28491
BKS001DR

MKIB2270E

1.

IPDM E/R E8,E12

2.

BCM M57,M59 (View with instrument upper panel removed)

4.

Combination switch M38

5.

Front door switch driver side
[B14 (LHD models)]
[B29 (RHD models)]

3.

Light and rain sensor R2

System Description

BKS001DS

Automatically turns ON/OFF the parking lamps and the headlamps in accordance with ambient light.

OUTLINE
The auto light control system has an light and rain sensor inside it that detects outside brightness.
When the lighting switch is in AUTO position, it automatically turns ON/OFF the parking lamps and the
headlamps in accordance with ambient light.
Light and rain sensor, power is supplied
●
through BCM terminal 73
●
to light and rain sensor terminal 1.
Light and rain sensor, ground is supplied
●
to light and rain sensor terminal 3
●
through grounds M21 and M66.
When ignition switch is turn to ON position and
When outside brightness is darker than prescribed level, input is supplied
●
to light and rain sensor terminal 2
●
through BCM terminal 63.
The headlamps will then illuminate. For a description of headlamp operation, Refer to LT-52, «System Description» .

LT-52

AUTO LIGHT SYSTEM
COMBINATION SWITCH READING FUNCTION
A

Refer to LT-114, «COMBINATION SWITCH READING FUNCTION» .

FRIENDRY LIGHTING FUNCTION
Low beam headlamps will illuminate for 30 seconds when,
●
ignition switch is in OFF position,
●
lighting switch is placed in OFF position, and
●
lighting switch is placed in PASS position.
Each activation of the switch adds 30 seconds to a maximum of 2 minutes.

B

C

EXTERIOR LAMP BATTERY SAVER CONTROL
To avoid flat battery caused by user leaving exterior lamps ON. When ignition is OFF and the driver side door
is opened, all exterior lamps will be turned OFF. If the user wants some lamps to remain ON then they must
switch these lamps OFF then ON again with the combination switch once the driver side door has been
opened. A buzzer will sound if any exterior lamps are ON with the driver side door opened and ignition OFF.
*:This setting can be changed by CONSULT-II. Refer to LT-63, «WORK SUPPORT» .

CAN Communication System Description

BKS001DT

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

D

E

F

G

H

CAN Communication Unit

BKS001DU

Refer to LAN-27, «CAN Communication Unit» .

Major Components and Functions

BKS001DV

Components
BCM
Light and rain sensor

I

Functions
●

Turns ON/OFF circuits of tail light and headlamp according to signals from light sensor, lighting switch
(AUTO), driver’s door switch, passenger’s door switch and ignition switch (ON, OFF).

●

Converts outside brightness (lux) to voltage, and sends it to BCM. (Detects brightness of 50 to 1,300 lux)

J

LT

L

M

LT-53

AUTO LIGHT SYSTEM
Schematic

BKS001DW

MKWA4333E

LT-54

AUTO LIGHT SYSTEM
Wiring Diagram — AUTO/L —

BKS001DX

A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4334E

LT-55

AUTO LIGHT SYSTEM

MKWA4335E

LT-56

AUTO LIGHT SYSTEM
A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4336E

LT-57

AUTO LIGHT SYSTEM

MKWA4337E

LT-58

AUTO LIGHT SYSTEM
Terminals and Reference Values for BCM

BKS001DY

CAUTION:
●
Check combination switch system terminal waveform under the loaded condition with lighting
switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded.
●
Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position.
Wiper dial position can be confirmed on CONSULT-II. Refer to LT-64, «DATA MONITOR» .
Terminal
No.

Wire
color

2

B

Signal name
Ground

Ignition
switch

Operation or condition

—

ON

—

B

C

Measuring condition

Signal
input/
output

A

Reference value

D

Approx. 0V

E
OFF

F

14

P

Combination
switch input 3

Input

ON

Lighting,
turn, wiper
switch
(Wiper intermittent dial
position 4)

PKIB4958J

Approx. 1.0V

G

H
Lighting switch AUTO

PKIB8631J

I

Approx. 2.0V
19

L

CAN − H

Input/
Output

24

O

Ignition switch
(ON)

Input

ON

—

Approx. 2.6V

ON

—

Battery voltage

J

LT

L

OFF

27

GR

Combination
switch output 4

Output

ON

Lighting,
turn, wiper
switch
(Wiper intermittent dial
position 4)

PKIB4958J

Approx. 1.2V

Lighting switch AUTO

PKIB4959J

Approx. 1.0V

LT-59

M

AUTO LIGHT SYSTEM
Terminal
No.

Wire
color

Signal name

Signal
input/
output

Measuring condition
Ignition
switch

Reference value
Operation or condition
ON (open)

29

LG*1
BR*2

Front door switch
(driver side) signal

Input

OFF

Front door
switch
(driver side)

Approx. 0V

OFF (closed)

PKIB4950J

Approx. 11.0V
CAN − L

Input/
Output

ON

—

Approx. 2.4V

Light and rain
sensor signal

Input

ON

When light and rain sensor is illuminated.

Approx. 8.9VNOTE

—

ON

—

Approx. 0V

Light and rain
sensor power
supply

Output

ON

—

Approx. 5V

Battery power
supply

Input

OFF

—

Battery voltage

39

Y

63

BR

70

B

Ground

73

V

74
79

Y

*1:LHD models
*2:RHD models
NOTE:
Light and rain sensor must be securely subjected to work lamp light. If the light and rain sensor is insufficiently illuminated, the measured
value may not satisfy standard.

LT-60

AUTO LIGHT SYSTEM
Terminals and Reference Values for IPDM E/R

BKS001DZ

A
Terminal No.

Wire
color

3

B

15

GR

16

45

46

V

BR

Y

Signal name
Ground

Measuring condition

Signal
input/
output

Ignition
switch

Operation or condition

—

ON

—

Rear combination lamp LH (Tail)

ON

Rear combination lamp RH (Tail)
and license plate lamp RH and
LH

ON

Parking lamp RH

Headlamp HIGH RH

48

49

50

G

P

O

L

Headlamp HIGH LH

Headlamp LOW RH

Lighting switch 1ST
position

OFF

Approx. 0V

ON

Battery voltage

OFF

Approx. 0V

ON

Battery voltage
Approx. 0V

Lighting switch 1ST
position

ON

Battery voltage

OFF

Approx. 0V

ON

Lighting switch HIGH
beam or PASSING
position

ON

Battery voltage

Lighting switch HIGH
beam or PASSING
position

OFF

Approx. 0V

ON

ON

Battery voltage

Lighting switch 2ND
position

OFF

Approx. 0V

ON

Battery voltage

Lighting switch 1ST
position

OFF

Approx. 0V

ON

Battery voltage

Lighting switch 2ND
position

OFF

Approx. 0V

ON

Battery voltage

ON

Headlamp LOW LH

Lighting switch 1ST
position

ON

ON

Parking lamp LH

B
Approx. 0V

OFF

Output
47

Reference value

ON

52

L

CAN − H

Input/
Output

54

B

Ground

—

ON

—

Approx. 0V

58

Y

CAN − L

Input/
Output

—

—

—

—

—

—

How to Proceed With Trouble Diagnosis
1.
2.
3.
4.
5.
6.

Confirm the symptom or customer complaint.
Understand operation description and function description. Refer to LT-52, «System Description» .
Perform the preliminary check. Refer to LT-62, «Preliminary Check» .
Check symptom and repair or replace the cause of malfunction.
Does the auto light system operate normally? If YES, GO TO 6. If NO, GO TO 4.
INSPECTION END

LT-61

C

D

E

F

G

H

I

J

BKS001E0

LT

L

M

AUTO LIGHT SYSTEM
Preliminary Check

BKS001E1

CHECK POWER SUPPLY AND GROUND CIRCUIT

1. CHECK FUSES
Check for blown fuses.
Unit

Power source

Fuse and fusible link No.

Battery

J

Ignition switch ON or START position

5

BCM

43
44
45
IPDM E/R

46

Battery

49
50
61
62

Refer to LT-55, «Wiring Diagram — AUTO/L —» .
OK or NG
OK
>> GO TO 2.
NG
>> If fuse or fusible link is blown, be sure to eliminate cause of malfunction before installing new fuse
or fusible link. Refer to PG-4, «POWER SUPPLY ROUTING CIRCUIT» .

2. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector.
Check voltage between BCM harness connector and ground.
Terminal

Ignition switch position

(+)
BCM
Connector

Terminal

M57

24
74

M59

(−)

Ground

OFF

ACC

ON

Approx. 0V

Approx. 0V

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

MKIB0352E

79

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

LT-62

AUTO LIGHT SYSTEM

3. CHECK GROUND CIRCUIT

A

Check continuity between BCM harness connector and ground.
BCM connector

Terminal

M57

2

M59

70

Continuity
Ground

B

Yes

C

OK or NG
OK
>> INSPECTION END
NG
>> Repair harness or connector.

D
MKIB0353E

CONSULT-II Functions (BCM)

BKS001E2

E

CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.
BCM diagnosis part

Diagnosis mode

Changes the setting for each function.

DATA MONITOR

Displays BCM input data in real time.

HEADLAMP

ACTIVE TEST
SELF-DIAG RESULTS
BCM

Description

WORK SUPPORT

CAN DIAG SUPPORT MNTR

F

Operation of electrical loads can be checked by sending drive signal to them.

G

BCM performs self-diagnosis of CAN communication.
The result of transmit/receive diagnosis of CAN communication can be read.

H

CONSULT-II INSPECTION PROCEDURE
Refer to GI-36, «CONSULT-II Start Procedure» .
I

CONSULT-II Application Items

BKS001L1

WORK SUPPORT
Operation Procedure
1.
2.
3.
4.
5.
6.
7.

J

Touch “HEAD LAMP” on “SELECT TEST ITEM” screen.
Touch “WORK SUPPORT” on “SELECT DIAG MODE” screen.
Touch “BATTERY SAVER SET” on “SELECT WORK ITEM” screen.
Touch “START”.
Touch “CHANGE SET”.
The setting will be changed and “CUSTOMIZING COMPLETED” will be displayed.
Touch “END”.

LT

L

Display Item List
Item
BATTERY SAVER SET

M
Description

CONSULT-II

Factory setting

Exterior lamp battery saver control mode can be changed in this mode.
Select exterior lamp battery saver control mode between ON and OFF.

ON

×

OFF

—

LT-63

AUTO LIGHT SYSTEM
DATA MONITOR
Monitor item UNIT.

Display content

IGN ON SW

[ON/OFF]

Displays status (Ignition switch ON: ON/Others OFF, ACC: OFF) as judged from the ignition switch signal.

HI BEAM SW

[ON/OFF]

Displays status (High beam switch: ON/Others: OFF) as judged from lighting switch signal.

H/L SW POS

[ON/OFF]

Displays status (Headlamp switch: ON/Others: OFF) as judged from lighting switch signal.

LIGHT SW 1ST

[ON/OFF]

Displays status (Lighting switch 1st position: ON/Others: OFF) as judged from lighting
switch signal.

PASSING SW

[ON/OFF]

Displays status (Flash-to-pass switch: ON/Others: OFF) as judged from lighting switch
signal.

FR FOG SW

[ON/OFF]

Displays status (Front fog lamp switch: ON/Others: OFF) as judged from lighting switch
signal.

RR FOG SW

[ON/OFF]

Displays status (Rear fog lamp switch: ON/Others: OFF) as judged from lighting switch
signal.

DOOR SW-DR

[ON/OFF]

Displays status (Door open: ON/door closed: OFF) as judged from the door switch DR signal.

H/L WASH SW

[ON/OFF]

Displays status (Headlamp washer switch: ON/Others: OFF) as judged from headlamp
washer switch signal.

ENGINE STATUS

[STOP/
STALL/
RUN/
CRA]

Displays status (Engine stop: STOP/engine stall: STALL/engine running: RUN/engine
cranking: CRA) as judged from the engine status.

ACTIVE TEST
Test item

CONSULT-II screen display

Description

Tail lamp relay output

TAIL LAMP

Tail lamp relay can be operated by any ON–OFF operation.

Headlamp relay output

HEAD LAMP

Headlamp relay can be operated by any ON–OFF operation.

Front fog lamp relay output

FR FOG LAMP

Front fog lamp relay can be operated by any ON–OFF operation.

Rear fog lamp relay output

RR FOG LAMP

Rear fog lamp relay can be operated by any ON–OFF operation.

LT-64

AUTO LIGHT SYSTEM
Light and rain sensor System Inspection

BKS001E5

1. CHECK LIGHT AND RAIN SENSOR INPUT SIGNAL
1.
2.

A

Turn ignition switch ON.
Check voltage between BCM harness connector M58 terminal
63 and ground.
Illuminated
LIGHT AND RAIN SENSOR

B

C

: Approx. 8.9V

D

MKIB2282E

CAUTION:
Light and rain sensor must be securely subjected to work lamp light. If light and rain sensor is insufficiently illuminated, the measured value may not satisfy the standard.
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

2. CHECK LIGHT AND RAIN SENSOR VOLTAGE
1.
2.

E

F

G

H

Turn ignition switch ON.
Check voltage between BCM harness connector and ground.

I

Terminals
(+)

Voltage

Connector

Terminal

M59

73

(–)
Ground

J
Approx. 5 V

OK or NG
OK
>> GO TO 3.
NG
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .

LT

MKIB2286E

L

M

LT-65

AUTO LIGHT SYSTEM

3. CHECK LIGHT AND RAIN SENSOR POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector and light and rain sensor connector.
Check continuity between BCM harness connector (A) and light
and rain sensor harness connector (B).
A

4.

B

Continuity

Connector

Terminal

Connector

Terminal

M59

73

R2

1

Yes

Check continuity between BCM harness connector (A) and
ground.
A

Continuity

Connector

Terminal

M59

MKIB2283E

Ground
No

73

OK or NG
OK
>> GO TO 4.
NG
>> Repair harness or connector.

4. CHECK LIGHT AND RAIN SENSOR SIGNAL CIRCUIT
1.

Check continuity between BCM harness connector (A) and light
and rain sensor harness connector (B).
A

2.

B

Continuity

Connector

Terminal

Connector

Terminal

M58

63

R2

2

Yes

Check continuity between BCM harness connector (A) and
ground.
A

Continuity

Connector

Terminal

M58

63

Ground

MKIB2284E

No

OK or NG
OK
>> GO TO 5.
NG
>> Repair harness or connector.

5. CHECK LIGHT AND RAIN SENSOR GROUND CIRCUIT
Check continuity between light and rain sensor harness connector
R2 terminal 3 and ground.
Light and rain sensor
Connector

Terminal

R2

3

Ground

Continuity
Yes

OK or NG
OK
>> Replace light and rain sensor.
NG
>> Repair harness or connector.
MKIB2285E

LT-66

AUTO LIGHT SYSTEM
Removal and Installation of Light and Rain Sensor

BKS001E6

A

REMOVAL
1. Remove inside mirror. Refer to GW-104, «INSIDE MIRROR» .
2. Remove clip and pawl.
3. Pull out the light and rain sensor.
4. Remove light and rain sensor harness connector.
CAUTION:
Do not touch the electronic circuit board on rain sensor.

B

C

D
MKIB2028E

INSTALLATION OF LIGHT AND RAIN SENSOR

E

Install in the reverse order of removal.

INSTALLATION OF LIGHT AND RAIN SENSOR HOUSING
F

CAUTION:
When windshield is replaced, always replace rain sensor housing.
1. Clean the surface of bonded area on the windshield.
2. Fix rain sensor housing against light and rain sensor bracket
from the top, then press it in a downward motion until it is completely attach together.
CAUTION:
Do not touch the adhesive.

G

H

I
MKIB2029E

J

LT

L

M

LT-67

HEADLAMP AIMING CONTROL
HEADLAMP AIMING CONTROL
Schematic

PFP:26010
BKS001E7

MKWA4342E

LT-68

HEADLAMP AIMING CONTROL
Wiring Diagram—H/AIM—

BKS001H8

A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4343E

LT-69

HEADLAMP AIMING CONTROL

MKWA4344E

LT-70

HEADLAMP AIMING CONTROL
A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4345E

LT-71

HEADLAMP AIMING CONTROL
Removal and Installation

BKS001E8

REMOVAL
1.
2.

Remove the switch panel assembly. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Spread pawls (A) of switch panel assembly to remove headlamp
aiming switch(1).

MKIB2310E

INSTALLATION
Installation is the reverse order of removal.

Switch Circuit Inspection

BKS001E9

Using a circuit tester, check resistance between the headlamp aiming switch connector terminals in each operation status of the aiming
switch.

MKIB0746E

LT-72

FRONT FOG LAMP
FRONT FOG LAMP
Component Parts and Harness Connector Location

PFP:26150

A
BKS001EA

B

C

D

E

F

G
MKIB2268E

1.

IPDM E/R E8,E11,E12

4.

Combination meter M27

2.

BCM M57,M59 (View with instrument
upper panel removed)

3.

Combination switch M38

System Description

H
BKS001EB

I
The control of the front fog lamps is dependent upon the position of the lighting switch. The lighting switch
must be in the 1ST/ 2ND position or AUTO position (headlamp is ON) for front fog lamp operation. When the
lighting switch is placed in front fog lamp switch ON position the BCM (body control module) receives input
signal requesting the front fog lamps to illuminate. When the headlamps are illuminated, this input signal is J
communicated to the IPDM E/R (intelligent power distribution module engine room) via the CAN communication. The CPU (central processing unit) located in the IPDM E/R controls the front fog lamp relay coil. When
activated, this relay directs power to the front fog lamps.
LT

OUTLINE
Power is supplied at all times
●
to front fog lamp relay, located in IPDM E/R, and
●
to ignition relay, located in IPDM E/R, from battery directly,
●
through 20A fuse (No. 61, located in IPDM E/R),
●
through 20A fuse (No. 62, located in IPDM E/R),
●
through 40A fusible link (letter J, located in fuse, fusible link and relay box)
●
to BCM terminals 74 and 79,
●
through 10A fuse [No. 7, located in fuse block (J/B)]
●
to combination meter terminal 27.
With the ignition switch in the ON or START position, power is supplied
●
to ignition relay, located in IPDM E/R, from battery directly,
●
through 10A fuse [No. 5, located in fuse block (J/B)]
●
to BCM terminal 24,
●
through 10A fuse [No. 4, located in fuse block (J/B)]
●
to combination meter terminal 28.
Ground is supplied
●
to BCM terminal 2 and 70
●
to combination meter terminals 21, 22 and 23
●
through grounds M21 and M66,

LT-73

L

M

FRONT FOG LAMP
●
●

to IPDM E/R terminals 3 and 54
through grounds E45 (CR and HR engine models),E28 and E44.

FOG LAMP OPERATION
The front fog lamp switch is built in lighting switch. The lighting switch must be in 1ST/2ND position or AUTO
position (headlamp is ON) and front fog lamp switch must be ON position for front fog lamp operation.
With the front fog lamp switch in the ON position, the CPU located in the IPDM E/R grounds coil side of the
front fog lamp relay. Front fog lamp relay then directs power
●
through 20A fuse (No. 65, located in IPDM E/R),
●
through IPDM E/R terminal 44
●
to front fog lamp LH terminal 1,
●
through IPDM E/R terminal 43
●
to front fog lamp RH terminal 1.
Ground is supplied
●
to front fog lamp LH and RH terminals 2
●
through grounds E45 (CR and HR engine models),E28 and E44.
With power and grounds supplied, front fog lamps illuminate.

COMBINATION SWITCH READING FUNCTION
Refer to LT-114, «COMBINATION SWITCH READING FUNCTION» .

EXTERIOR LAMP BATTERY SAVER CONTROL
Refer to LT-9, «EXTERIOR LAMP BATTERY SAVER CONTROL» .

FAIL-SAFE FUNCTION
When CAN communication with other control units is impossible, IPDM E/R performs fail-safe control. If the
fail-safe system is operating, front fog lamps does not operate when the combination switch is in any position.
After CAN communication recovers normally, it also returns to normal control. (Refer to PG-18, «Fail-safe Control» .)

CAN Communication System Description

BKS001EC

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

CAN Communication Unit

BKS001ED

Refer to LAN-27, «CAN Communication Unit» .

LT-74

FRONT FOG LAMP
Schematic

BKS001EE

A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4349E

LT-75

FRONT FOG LAMP
Wiring Diagram — F/FOG —

BKS001EF

MKWA4350E

LT-76

FRONT FOG LAMP
A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4351E

LT-77

FRONT FOG LAMP

MKWA4352E

LT-78

FRONT FOG LAMP
Terminals and Reference Values for BCM

BKS001EG

CAUTION:
●
Check combination switch system terminal waveform under the loaded condition with lighting
switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded.
●
Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position.
Wiper dial position can be confirmed on CONSULT-II. Refer to LT-19, «DATA MONITOR» .
Terminal
No.

Wire
color

2

B

Signal name
Ground

Ignition
switch

Operation or condition

—

ON

—

B

C

Measuring condition

Signal
input/
output

A

Reference value

D

Approx. 0V

E
OFF

7

BR

Combination
switch output 5

Output

ON

F

Lighting,
turn, wiper
switch
(Wiper
intermittent
dial position 4)

PKIB8643J

Approx. 1.2V

G

Front fog lamp switch
ON (Operates only front
fog lamp switch)

H

PKIB4956J

I

Approx. 1.0V
19

L

CAN − H

Input/
Output

24

O

Ignition switch
(ON)

Input

ON

—

Approx. 2.6V

ON

—

Battery voltage

J

LT

L

OFF

34

Y

Combination
switch input 4

Input

ON

Lighting,
turn, wiper
switch
(Wiper
intermittent
dial position 4)

PKIB4958J

Approx. 1.0V

Front fog lamp switch
ON (Operates only front
fog lamp switch)
PKIB8627J

Approx. 1.5 — 2.0V
CAN − L

39

Y

70

B

Ground

Y

Battery power
supply

74
79

Input/
Output

ON

—

Approx. 2.4V

—

ON

—

Approx. 0V

Input

OFF

—

Battery voltage

LT-79

M

FRONT FOG LAMP
Terminals and Reference Values for IPDM E/R

BKS001EH

Measuring condition

Signal
input/
output

Ignition
switch

Operation or condition

—

ON

—

Front fog
lamp RH

Output

ON

Terminal No.

Wire
color

3

B

Ground

43

W

Signal name

Reference value
Approx. 0V

Lighting switch must be in
the 2ND position or AUTO
position (headlamp is ON)

Front fog lamp switch: OFF

Approx. 0V

Front fog lamp switch: ON

Battery voltage

Lighting switch must be in
the 2ND position or AUTO
position (headlamp is ON)

Front fog lamp switch: OFF

Approx. 0V

Front fog lamp switch: ON

Battery voltage

44

V

Front fog
lamp LH

Output

52

L

CAN − H

Input/
Output

—

—

—

54

B

Ground

—

ON

—

Approx. 0V

58

Y

CAN − L

Input/
Output

—

—

—

ON

How to Proceed With Trouble Diagnosis
1.
2.
3.
4.
5.
6.

Confirm the symptom or customer complaint.
Understand operation description and function description. Refer to LT-73, «System Description» .
Perform the Preliminary Check. Refer to LT-81, «Preliminary Check» .
Check symptom and repair or replace the malfunctioning parts.
Does the front fog lamp operate normally? If YES, GO TO 6. If NO, GO TO 4.
INSPECTION END

LT-80

BKS001EI

FRONT FOG LAMP
Preliminary Check

BKS001EJ

A

CHECK POWER SUPPLY AND GROUND CIRCUIT

1. CHECK FUSES
B

Check for blown fuses.
Unit

Power source

Fuse and fusible link No.

Battery

J

Ignition switch ON or START position

5

BCM

C

61
IPDM E/R

Battery

D

62
65

Refer to LT-76, «Wiring Diagram — F/FOG —» .
OK or NG
OK
>> GO TO 2.
NG
>> If fuse or fusible link is blown, be sure to eliminate cause of malfunction before installing new fuse
or fusible link. Refer to PG-4, «POWER SUPPLY ROUTING CIRCUIT» .

2. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

F

G

Turn ignition switch OFF.
Disconnect BCM connector.
Check voltage between BCM harness connector and ground.
Terminal

E

H

Ignition switch position

I

(+)
BCM
Connector

Terminal

M57

24

(−)

74

Ground

M59

OFF

ACC

ON

Approx. 0V

Approx. 0V

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

J

LT
MKIB0352E

Battery
voltage

79

Battery
voltage

Battery
voltage

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

L

3. CHECK GROUND CIRCUIT

M

Check continuity between BCM harness connector and ground.
BCM
Connector

Terminal

M57

2

M59

70

Continuity
Ground
Yes

OK or NG
OK
>> INSPECTION END
NG
>> Repair harness or connector.
MKIB0353E

LT-81

FRONT FOG LAMP
CONSULT-II Functions (BCM)

BKS001EK

Refer to LT-19, «CONSULT-II Functions (BCM)» in “HEADLAMP — CONVENTIONAL TYPE -”.

CONSULT-II Functions (IPDM E/R)

BKS001EL

Refer to LT-20, «CONSULT-II Functions (IPDM E/R)» in “HEADLAMP — CONVENTIONAL TYPE -”.

Front Fog lamps Do Not Illuminate (Both Sides)

BKS001EM

1. CHECK COMBINATION SWITCH INPUT SIGNAL
With CONSULT-II
1. Select “BCM” on CONSULT-II. Select “HEAD LAMP” on
“SELECT TEST ITEM” screen.
2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure that “FR FOG SW” turns ON-OFF linked with operation of fog lamp switch.
When fog lamp switch is ON

: FR FOG SW ON

Without CONSULT-II
Refer to LT-125, «Combination Switch Inspection» .
OK or NG
PKIA7598E
OK
>> GO TO 2.
NG
>> Check combination switch (lighting switch). Refer to LT-125, «Combination Switch Inspection» .

2. FOG LAMP ACTIVE TEST
With CONSULT-II
1. Select “IPDM E/R” on CONSULT-II. Select “ACTIVE TEST” on
“SELECT DIAG MODE” screen.
2. Select “FR FOG LAMP” on “SELECT TEST ITEM” screen.
3. Touch “ON” screen.
4. Make sure front fog lamp operates.
Front fog lamp should operate.
Without CONSULT-II
1. Start auto active test. Refer to PG-22, «Auto Active Test» .
2. Make sure front fog lamp operates.

MKIB0552E

Front fog lamp should operate.
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 4.

3. CHECK IPDM E/R
1.
2.

Select “IPDM E/R” on CONSULT-II. Select “DATA MONITOR”
on “SELECT DIAG MODE” screen.
Make sure “FR FOG REQ” turns ON when front fog lamp switch
is in ON position.
When front fog lamp switch
is ON position

: FR FOG REQ ON

OK or NG
OK
>> Replace IPDM E/R. Refer to PG-37, «Removal and
Installation of IPDM E/R» .
NG
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .

LT-82

SKIA5898E

FRONT FOG LAMP

4. CHECK FOG LAMP INPUT SIGNAL
1.
2.
3.
4.
5.
6.

With CONSULT-II
Turn ignition switch OFF.
Disconnect front fog lamp RH and LH connector.
Select “IPDM E/R” on CONSULT-II, and select “ACTIVE TEST” on “SELECT DIAG MODE” screen.
Select “FR FOG LAMP” on “SELECT TEST ITEM” screen.
Touch “ON” screen.
When front fog lamp relay is operating, check voltage between
front fog lamp RH and LH harness connector and ground.
(+)

(−)

Front fog lamp connector

1.
2.
3.
4.

A

RH

E23

LH

E14

Ground

(+)

E23

LH

E14

Battery voltage

(−)

Voltage

Ground

Battery voltage

LT

A
Connector
E8

LH

4.

M

B
Terminal

Connector

43

E23

44

E14

L

Continuity
Terminal
1

Yes

Check continuity between IPDM E/R harness connector (A) and
ground.

Connector
RH
LH

MKIB2266E

A

Circuit

E8

H

J

Turn ignition switch OFF.
Disconnect IPDM E/R connector.
Check continuity between IPDM E/R harness connector (A) and
front fog lamp RH and LH harness connector (B).

RH

G

I
1

5. CHECK FOG LAMP CIRCUIT

Circuit

F

Terminal

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

1.
2.
3.

D

E

Without CONSULT-II
Turn ignition switch OFF.
SKIB6284E
Disconnect front fog lamp RH and LH connector.
Start auto active test. Refer to PG-22, «Auto Active Test» .
When front fog lamp relay is operating, check voltage between front fog lamp (RH and LH) harness connector and ground.

RH

C

Voltage

Terminal
1

Front fog lamp connector

B

Continuity
Terminal

Ground

43

No

44

OK or NG
OK
>> Replace IPDM E/R. Refer to PG-37, «Removal and Installation of IPDM E/R» .
NG
>> Repair harness or connector.

LT-83

FRONT FOG LAMP

6. CHECK FOG LAMP GROUND
1.

Check continuity between front fog lamp RH and LH harness
connector and ground.
Front fog lamp connector
RH

E23

LH

E14

Terminal
2

Continuity
Ground

Yes

OK or NG
OK
>> Check front fog lamp bulbs.
NG
>> Repair harness or connector.
SKIB6285E

LT-84

FRONT FOG LAMP
Front Fog Lamp Does Not Illuminate (One Side)

1.

BKS001EN

A

CHECK BULB

Check bulb of lamp with does not illuminate which does not illuminate.
OK or NG
OK
>> GO TO 2.
NG
>> Replace front fog lamp bulb.

B

C

2. CHECK FOG LAMP CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R connector and front fog lamp RH or LH connector.
Check continuity between IPDM E/R harness connector (A) and
front fog lamp RH or LH harness connector (B).
A

Circuit

Connector

4.

E

B
Terminal

Connector

43

E23

RH
E8

LH

D

44

Terminal

Continuity

F
1

E14

Yes

Check continuity between IPDM E/R harness connector (A) and
ground.
MKIB2266E

A
Circuit

Connector

Continuity

Terminal

RH
LH

G

Ground

43
E8

H

No

44

I

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

J

3. CHECK FOG LAMP GROUND
1.

LT

Check continuity between front fog lamp RH or LH harness connector and ground.
Front fog lamp connector
RH

E23

LH

E14

Terminal
2

Continuity
Ground

L

Yes

OK or NG
OK
>> Replace IPDM E/R. Refer to PG-37, «Removal and
Installation of IPDM E/R» .
NG
>> Repair harness or connector.

LT-85

M

SKIB6285E

FRONT FOG LAMP
Aiming Adjustment

BKS001EO

The front fog lamp is a semi-sealed beam type which uses a replaceable halogen bulb. Before performing
aiming adjustment, make sure of the following.
●
Keep all tires inflated to correct pressure.
●
Place vehicle on level surface.
●
Set that there is no-load in vehicle other than the driver (or equivalent weight placed in driver’s position).
Coolant, engine oil filled up to correct level and full fuel tank.
Adjust aiming in the vertical direction by turning the adjusting screw
(A).

MKIB2313E

1.
2.
3.

Set the distance between the screen and the center of front fog
lamp lens as shown.
Turn front fog lamps ON.
Adjust front fog lamps using adjusting screws so that the top
edge of the high intensity zone is in the figure.
When performing adjustment, if necessary, cover the headlamps
and opposite front fog lamp.

MKIB2314E

Bulb Replacement
1.
2.
3.
4.
5.

BKS001EP

Turn lighting switch OFF.
Turn off the fender protector (front) to obtain work space
between the fender protector and fender.
Disconnect front fog lamp connector (1).
Turn bulb socket (2) counterclockwise unlock and remove it.
Remove bulb from its socket.
Front fog lamp

: 12V-35W (H8)
SKIB3270J

LT-86

FRONT FOG LAMP
Removal and Installation

BKS001EQ

A

REMOVAL
1.
2.
3.
4.
5.

Turn front fog lamp switch OFF.
Turn over the fender protector and undercover to obtain work space between the fender protector and
fender.
Remove pawl (A), and front bumper finisher (1) from front
bumper.
Disconnect front fog lamp connector.
Remove screw (3) and remove front fog lamp (2) from bracket.

B

C

D

E
SKIB3804J

INSTALLATION
●

F

Installation is the reverse order of removal.
Tightening torque

: 5.5 N·m (0.56 kg-m, 49 in-lb)
G

H

I

J

LT

L

M

LT-87

REAR FOG LAMP
REAR FOG LAMP
Component Parts and Harness Connector Location

PFP:26550
BKS001ER

MKIB2267E

1.

BCM M57,M59 (View with instrument upper panel removed)

2.

Combination switch M38

3.

Combination meter M27

System Description

BKS001ES

The control of the rear fog lamps is dependent upon the position of the lighting switch. The lighting switch must
be in the 1ST/2ND position for rear fog lamp operation. When the lighting switch is placed in the rear fog lamp
position* the BCM (body control module) receives input signal requesting the rear fog lamps to illuminate.
*:Rear fog lamp switch is an auto return switch. BCM reads a change when rear fog lamp switch is operated. It
switches between ON and OFF every time when rear fog lamp switch is operated.

OUTLINE
Power is also supplied at all times
●
through 40A fusible link (letter J, located in the fuse and fusible link block),
●
to BCM terminals 74 and79,
●
through 10A fuse [No. 7, located in the fuse block (J/B)]
●
to combination meter terminal 27.
With the ignition switch in the ON or START position, power is supplied
●
through 10A fuse [No. 5 located in the fuse block (J/B)]
●
to BCM terminal 24,
●
through 10A fuse [No. 4, located in the fuse block (J/B)]
●
to combination meter terminal 28.
Ground is supplied
●
to BCM terminals 2 and 70
●
to combination meter terminals 21, 22 and 23
●
through grounds M21 and M66.

REAR FOG LAMP OPERATION
The lighting switch must be in the 1ST or 2ND position for rear fog lamp operation.
With the rear fog lamp switch in the ON position, the BCM directs power
●
through BCM terminal 69
●
to rear combination lamp RH (rear fog lamp) terminal 2.
Ground is supplied
●
to rear combination lamp RH (rear fog lamp) terminal 1
●
through grounds B13,B28,B38 and B48.
With power and grounds supplied, the rear fog lamp illuminate.
The unified meter control unit that received the rear fog lamp request signal by BCM via the CAN communication makes a rear fog lamp indicator lamp turn on in combination meter.

LT-88

REAR FOG LAMP
COMBINATION SWITCH READING FUNCTION
A

Refer to LT-114, «COMBINATION SWITCH READING FUNCTION» .

CAN Communication System Description

BKS001ET

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

CAN Communication Unit

BKS001EU

B

C

D

Refer to LAN-27, «CAN Communication Unit» .
E

F

G

H

I

J

LT

L

M

LT-89

REAR FOG LAMP
Wiring Diagram — R/FOG —

BKS001EW

MKWA4353E

LT-90

REAR FOG LAMP
A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4354E

LT-91

REAR FOG LAMP
Terminals and Reference Values for BCM

BKS001EX

CAUTION:
●
Check combination switch system terminal waveform under the loaded condition with lighting
switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded.
●
Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position.
Wiper dial position can be confirmed on CONSULT-II. Refer to LT-19, «DATA MONITOR» .
Terminal
No.

Wire
color

2

B

Signal name
Ground

Measuring condition

Signal
input/
output

Ignition
switch

Operation or condition

—

ON

—

Reference value
Approx. 0V

OFF

7

BR

Combination
switch output 5

Output

ON

Lighting,
turn, wiper
switch
(Wiper
intermittent
dial position 4)

PKIB8643J

Approx. 1.2V

Rear fog lamp switch ON
(Operates only rear fog
lamp switch)
PKIB4956J

Approx. 1.0V

OFF

14

P

Combination
switch input 3

Input

ON

Lighting,
turn, wiper
switch
(Wiper
intermittent
dial position 4)

PKIB4958J

Approx. 1.0V

Rear fog lamp switch ON
(Operates only rear fog
lamp switch)
PKIC1030E

Approx. 1.5V
19

L

CAN − H

Input/
Output

ON

—

Approx. 2.6V

24

O

Ignition switch
(ON)

Input

ON

—

Battery voltage

39

Y

CAN − L

Input/
Output

ON

—

Approx.2.4V

69

R

Rear fog lamp

Output

ON

Rear fog
lamp switch

LT-92

ON

Battery voltage

OFF

Approx. 0V

REAR FOG LAMP
Terminal
No.

Wire
color

70

B

Ground

74
79

Y

Battery power
supply

Signal name

Measuring condition

Signal
input/
output

Ignition
switch

Operation or condition

—

ON

—

Approx. 0V

Input

OFF

—

Battery voltage

How to Proceed With Trouble Diagnosis
1.
2.
3.
4.
5.
6.

A

Reference value

Confirm the symptom or customer complaint.
Understand operation description and function description. Refer to LT-88, «System Description» .
Perform the Preliminary Check. Refer to LT-94, «Preliminary Check» .
Check symptom and repair or replace the cause of malfunction.
Does the rear fog lamp operate normally? If YES, GO TO 6. If NO, GO TO 4.
INSPECTION END

B

BKS001EY

C

D

E

F

G

H

I

J

LT

L

M

LT-93

REAR FOG LAMP
Preliminary Check

BKS001EZ

CHECK POWER SUPPLY AND GROUND CIRCUIT

1. CHECK FUSES
Check for blown fuses.
Unit

Power source

Fuse and fusible link No.

Battery

J

Ignition switch ON or START position

5

BCM

Refer to LT-90, «Wiring Diagram — R/FOG —» .
OK or NG
OK
>> GO TO 2.
NO
>> If fuse or fusible link is blown, be sure to eliminate cause of malfunction before installing new fuse
or fusible link. Refer to PG-4, «POWER SUPPLY ROUTING CIRCUIT» .

2. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector.
Check voltage between BCM harness connector and ground.
Terminal

Ignition switch position

(+)
BCM
Connector

Terminal

M57

24

(−)

74

Ground

M59

OFF

ACC

ON

Approx. 0V

Approx. 0V

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

MKIB0352E

79

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

3. CHECK GROUND CIRCUIT
Check continuity between BCM harness connector and ground.
BCM
Connector

Terminal

M57

2

M59

70

Continuity
Ground
Yes

OK or NG
OK
>> INSPECTION END
NG
>> Repair harness or connector.
MKIB0353E

CONSULT-II Functions (BCM)

BKS001F0

Refer to LT-19, «CONSULT-II Functions (BCM)» in “HEADLAMP — CONVENTIONAL TYPE -.”

LT-94

REAR FOG LAMP
Rear Fog Lamp Does Not Operate

BKS001F1

1. CHECK BULB

A

Check bulb of lamp which does not illuminate.
OK or NG
OK
>> GO TO 2.
NG
>> Replace rear fog lamp bulb.

B

C

2. CHECK COMBINATION SWITCH INPUT SIGNAL
1.
2.

Select “BCM” on CONSULT-II. Select “HEAD LAMP” on
“SELECT TEST ITEM” screen.
Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure “RR FOG SW” turns ON-OFF linked with operation of
rear fog lamp switch.
When lighting switch 1ST or 2ND
position and rear fog lamp switch
ON position

D

E

: RR FOG SW ON
F

OK or NG
OK
>> GO TO 3.
NG
>> Replace combination switch (lighting switch).

PKIB7212E

3. ACTIVE TEST
1.
2.
3.
4.

G

H

Select “BCM” on CONSULT-II. Select “HEAD LAMP” on
“SELECT TEST ITEM” screen.
Select “ACTIVE TEST” on “SELECT DIAG MODE” screen.
Touch “RR FOG LAMP” screen.
Make sure rear fog lamp operates.

I

J

Rear fog lamp should operate.
OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
NG
>> GO TO 4.

LT
PKIB7213E

L

4. CHECK REAR FOG LAMP CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector and rear combination lamp RH (rear fog lamp) connector.
Check continuity between BCM harness connector (A) and rear
combination lamp RH (rear fog lamp) harness connector (B).
A

B

M

Continuity

Connector

Terminal

Connector

Terminal

M59

69

B44

2

Yes

OK or NG
OK
>> GO TO 5.
NG
>> Repair harness or connector.
MKIB2258E

LT-95

REAR FOG LAMP

5. CHECK REAR FOG LAMP GROUND
Check continuity between rear combination lamp RH (rear fog lamp)
harness connector and ground.
connector

Terminal

B44

1

Ground

Continuity
Yes

OK or NG
OK
>> GO TO 6.
NG
>> Repair harness or connector.
MKIB2259E

6. CHECK SHORT CIRCUIT
Check continuity between BCM harness connector and ground.
BCM connector

Terminal

M59

69

Ground

Continuity
No

OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
NG
>> After repairing harness be sure to disconnect battery
negative cable, and then reconnect it.
MKIB2260E

LT-96

REAR FOG LAMP
Bulb Replacement
1.
2.
3.
4.

BKS001F2

A

Remove rear bumper fascia. Refer to EI-8, «REAR BUMPER» .
Disconnect rear fog lamp connector.
Turn bulb socket (2) counterclockwise and unlock it.
Remove bulb (1) from its socket.
Rear fog lamp

B

: 12V — 21W
C

D
MKIB2311E

Removal and Installation

BKS001F3

REMOVAL

E

1.
2.
3.

F

Remove rear bumper fascia. Refer to EI-8, «REAR BUMPER» .
Disconnect rear fog lamp connector.
While pressing metal clip (A) on the revers side of the bumper
fascia.

G

H
MKIB2312E

INSTALLATION
I

Installation is the reverse order of removal.

J

LT

L

M

LT-97

TURN SIGNAL AND HAZARD WARNING LAMPS
TURN SIGNAL AND HAZARD WARNING LAMPS
Component Parts and Harness Connector Location

PFP:26120
BKS001F4

MKIB2253E

1.

BCM M57,M59 (View with instrument upper panel removed)

4.

Combination meter M27

2.

Combination switch M38

System Description

3.

Hazard switch M63

BKS001F5

TURN SIGNAL OPERATION
With the ignition switch in the ON or START position, power is supplied
●
through 10A fuse [No. 5, located in fuse block (J/B)]
●
to BCM terminal 24,
●
through 10A fuse [No. 4, located in fuse block (J/B)]
●
to combination meter terminal 28.
Ground is supplied
●
to BCM terminals 2 and 70
●
to combination meter terminals 21, 22 and 23
●
through grounds M21 and M66.

LH Turn Signal Lamp
When turn signal switch is moved to left position, BCM receives input signal requesting left turn signals to
flash. BCM then supplies power
●
through BCM terminal 65
●
to front combination lamp LH (turn signal) terminal 1
●
to side turn signal lamp LH terminal 1
●
to rear combination lamp LH (turn signal) terminal 3.
Ground is supplied
●
to front combination lamp LH (turn signal) terminal 2
●
to side turn signal lamp LH terminal 2
●
through grounds E45 (CR and HR engine models),E28 and E44,
●
to rear combination lamp LH (turn signal) terminal 2
●
through grounds B13,B28,B38 and B48.
The BCM also supplies input to combination meter terminals 1 and 2 via the CAN communication. This input is
processed by unified meter control unit in combination meter, which in turn supplies ground to the left turn signal indicator lamp.

LT-98

TURN SIGNAL AND HAZARD WARNING LAMPS
With power and input supplied, BCM controls flashing of LH turn signal lamps.
A

RH Turn Signal Lamp
When turn signal switch is moved to right position, BCM receives input signal requesting right turn signals to
flash. BCM then supplies power
●
through BCM terminal 66
●
to front combination lamp RH (turn signal) terminal 1
●
to side turn signal lamp RH terminal 1
●
to rear combination lamp RH (turn signal) terminal 3.
Ground is supplied
●
to front combination lamp RH (turn signal) terminal 2
●
to side turn signal lamp RH terminal 2
●
through grounds E45 (CR and HR engine models),E28 and E44,
●
to rear combination lamp RH (turn signal) terminal 2
●
through grounds B13,B28,B38 and B48.
The BCM also supplies input to combination meter terminals 1 and 2 via the CAN communication. This input is
processed by unified meter control unit in combination meter, which in turn supplies ground to the right turn
signal indicator lamp.
With power and input supplied, BCM controls flashing of RH turn signal lamps.

B

C

D

E

F

G

HAZARD LAMP OPERATION
Power is supplied at all times
●
through 40A fusible link (letter J, located in fuse, fusible link and relay box)
●
to BCM terminals 74 and 79,
●
through 10A fuse [No. 7, located in fuse block (J/B)]
●
to BCM terminal 27.
Ground is supplied
●
to hazard switch terminal 1
●
to BCM terminals 2 and 70
●
to combination meter terminals 21, 22 and 23
●
through grounds M21 and M66.
When hazard switch is depressed, ground is supplied
●
to BCM terminal 26
●
through hazard switch terminal 2.
BCM then supplies power
●
through BCM terminal 65
●
to front combination lamp LH (turn signal) terminal 1
●
to side turn signal lamp LH terminal 1
●
to rear combination lamp LH (turn signal) terminal 3,
●
through BCM terminal 66
●
to front combination lamp RH (turn signal) terminal 1
●
to side turn signal lamp RH terminal 1
●
to rear combination lamp RH (turn signal) terminal 3.
Ground is supplied
●
to front combination lamp LH and RH (turn signal) terminal 2
●
to side turn signal lamp LH and RH terminals 2
●
through grounds E45 (CR and HR engine models),E28 and E44,
●
to rear combination lamp LH and RH (turn signal) terminal 2
●
through grounds B13,B28,B38 and B48.

LT-99

H

I

J

LT

L

M

TURN SIGNAL AND HAZARD WARNING LAMPS
The BCM also supplies input to combination meter terminals 1 and 2 across CAN communication lines. This
input is processed by unified meter control unit in combination meter, which in turn supplies ground to the left
and right turn signal indicator lamps.
With power and input supplied, BCM controls flashing of hazard warning lamps.

COMBINATION SWITCH READING FUNCTION
Refer to LT-114, «COMBINATION SWITCH READING FUNCTION» .

CAN Communication System Description

BKS001F6

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

CAN Communication Unit

BKS001F7

Refer to LAN-27, «CAN Communication Unit» .

LT-100

TURN SIGNAL AND HAZARD WARNING LAMPS
Wiring Diagram — TURN —

BKS001F9

A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4355E

LT-101

TURN SIGNAL AND HAZARD WARNING LAMPS

MKWA4356E

LT-102

TURN SIGNAL AND HAZARD WARNING LAMPS
Terminals and Reference Values for BCM

BKS001FA

CAUTION:
●
Check combination switch system terminal waveform under the loaded condition with lighting
switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded.
●
Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position.
Wiper dial position can be confirmed on CONSULT-II. Refer to LT-106, «DATA MONITOR» .
Terminal
No.

Wire
color

2

B

Signal name
Ground

Ignition
switch

Operation or condition

—

ON

—

B

C

Measuring condition

Signal
input/
output

A

Reference value

D

Approx. 0V

E
OFF

F

9

V

Combination
switch output
1

Output

ON

Lighting,
turn, wiper
switch
(Wiper intermittent dial
position 4)

PKIB4958J

Approx. 1.2V

G
Any of the conditions
below
●

Turn signal switch to
right

●

Turn signal switch to
left

H

PKIB4959J

I

Approx. 1.0V

J

OFF

15

W

Combination
switch input 5

Input

ON

Lighting,
turn, wiper
switch
(Wiper intermittent dial
position 4)

LT
PKIB4956J

L

Approx. 0.9V

M
Turn signal switch to right

PKIB8625J

Approx. 1.5 — 2.0V
19

L

CAN − H

Input/
Output

ON

—

Approx. 2.6V

24

O

Ignition
switch (ON)

Input

ON

—

Battery voltage

26

L

Hazard
switch signal

Input

OFF

Hazard
switch

LT-103

ON

Approx. 0V

OFF

Battery voltage

TURN SIGNAL AND HAZARD WARNING LAMPS
Terminal
No.

Wire
color

Signal name

Signal
input/
output

Measuring condition
Ignition
switch

Reference value
Operation or condition

OFF

34

Y

Combination
switch input 4

Input

ON

Lighting,
turn, wiper
switch
(Wiper intermittent dial
position 4)

PKIB4958J

Approx. 1.0V

Turn signal switch to left

PKIB8630J

Approx. 2.0V
39

Y

CAN − L

Input/
Output

ON

—
OFF

65

LG

Flasher output (Left)

Output

ON

Turn signal
switch

Approx. 2.4V
Approx. 0V

To left

SKIA3009J

OFF

66

W

Flasher output (Right)

Output

ON

Turn signal
switch

Approx. 0V

To right

SKIA3009J

70

B

Ground

74
79

Y

Battery
power supply

—

ON

—

Approx. 0V

Input

OFF

—

Battery voltage

How to Proceed With Trouble Diagnosis
1.
2.
3.
4.
5.
6.

Confirm the symptom or customer complaint.
Understand operation description and function description. Refer to LT-98, «System Description» .
Perform the preliminary check. Refer to LT-105, «Preliminary Check» .
Check symptom and repair or replace the malfunctioning parts.
Do turn signal and hazard warning lamps operate normally? If YES, GO TO 6. If NO, GO TO 4.
INSPECTION END

LT-104

BKS001FB

TURN SIGNAL AND HAZARD WARNING LAMPS
Preliminary Check

BKS001FC

A

CHECK POWER SUPPLY AND GROUND CIRCUIT

1. CHECK FUSES
B

Check for blown fuses.
Unit

Power source

Fuse and fusible link No.

Battery

J

Ignition switch ON or START position

5

BCM

C

Refer to LT-101, «Wiring Diagram — TURN —» .
OK or NG
OK
>> GO TO 2.
NG
>> If fuse or fusible link is blown, be sure to eliminate cause of malfunction before installing new fuse
or fusible link. Refer to PG-4, «POWER SUPPLY ROUTING CIRCUIT» .

D

E

2. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

F

Turn ignition switch OFF.
Disconnect BCM connector.
Check voltage between BCM harness connector and ground.
Terminal

G

Ignition switch position

(+)
BCM
Connector

Terminal

M57

24
74

(−)

Ground

M59

OFF

ACC

ON

Approx. 0V

Approx. 0V

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

H

I

MKIB0352E

79

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

J

LT

3. CHECK GROUND CIRCUIT

L

Check continuity between BCM harness connector and ground.
M

BCM
Connector

Terminal

M57

2

M59

70

Continuity
Ground
Yes

OK or NG
OK
>> INSPECTION END
NG
>> Repair harness or connector.
MKIB0353E

LT-105

TURN SIGNAL AND HAZARD WARNING LAMPS
CONSULT-II Functions (BCM)

BKS001FD

CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.
BCM diagnosis part

Diagnosis mode

FLASHER

Description

Work Support

Changes the setting for each function.

DATA MONITOR

Displays BCM input data in real time.

ACTIVE TEST

Operation of electrical loads can be checked by sending driving signal to them.

CONSULT-II INSPECTION PROCEDURE
Refer to GI-36, «CONSULT-II Start Procedure» .

CONSULT-II Application Items

BKS001KZ

WORK SUPPORT
Supported Item

All items will be monitored.

HAZARD LAMP SET

hazard reminder function mode can be changed in this mode.

Hazard Lamp Set
MODE1

MODE2

MODE3

MODE4

Remote controller operation

Lock

Unlock

Lock

Unlock

Lock

Unlock

Lock

Unlock

Hazard warning lamp flash

—

—

—

Twice

Once

—

Once

Twice

DATA MONITOR
Monitor item

Contents

IGN ON SW

“ON/OFF”

Displays status (ignition switch IGN position: ON/other: OFF) of ignition switch judged from the
ignition switch signal.

HAZARD SW

“ON/OFF”

Displays status (hazard switch ON position: ON/other: OFF) of hazard switch judged from the
hazard switch signal.

TURN SIGNAL R

“ON/OFF”

Displays status (turn signal switch right position: ON/other: OFF) of turn RH switch judged from
the turn signal switch signal.

TURN SIGNAL L

“ON/OFF”

Displays status (turn signal switch left position: ON/other: OFF) of turn LH switch judged from
the turn signal switch signal.

TURN/L MNTR

“ON/OFF”

Displays status (One bulb blown: ON/Others: OFF) as judged from bulb signal.

ACTIVE TEST
Test Item
FLASHER

Description
This test is able to check left or right turn signal lamp operation. The turn signal lamp turned ON
when “LH” or “RH” on CONSULT-II screen is touched.

LT-106

TURN SIGNAL AND HAZARD WARNING LAMPS
Turn Signal Lamp Does Not Operate

BKS001FE

1. CHECK BULB

A

Check bulb standard of each turn signal lamp is correct.
OK or NG
OK
>> GO TO 2.
NG
>> Replace turn signal lamp bulb.

B

C

2. CHECK COMBINATION SWITCH INPUT SIGNAL
With CONSULT-II
1. Select “BCM” on CONSULT-II. Select “FLASHER” on “SELECT
TEST ITEM” screen.
2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure that “TURN SIGNAL R” and “TURN SIGNAL L” turns
ON-OFF linked with operation of lighting switch.
When turn signal switch is
right position
When turn signal switch is
left position

D

E

: TURN SIGNAL R ON

F

: TURN SIGNAL L ON
G

Without CONSULT-II
Refer to LT-125, «Combination Switch Inspection» .
OK or NG
OK
>> GO TO 3.
NG
>> Check combination switch. Refer to LT-125, «Combination Switch Inspection» .

PKIA7600E

H

I

3. ACTIVE TEST
With CONSULT-II
1. Select “BCM” on CONSULT-II. Select “FLASHER” on “SELECT
TEST ITEM” screen.
2. Select “ACTIVE TEST” on “SELECT DIAG MODE” screen.
Select “FLASHER” on “SELECT TEST ITEM” screen.
3. Make sure turn signal lamp operates.

J

LT

L

Turn signal lamp should operate.
Without CONSULT-II
GO TO 4.
OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
NG
>> GO TO 4.

LT-107

M
PKIA7749E

TURN SIGNAL AND HAZARD WARNING LAMPS

4. CHECK TURN SIGNAL LAMP CIRCUIT
1.
2.

Turn ignition switch OFF.
Disconnect BCM connector and all turn signal lamp connectors.

3.

Check continuity between BCM harness connector (A) and front
combination lamp LH and RH (turn signal) harness connector
(B).
A

Circuit
connector
LH

M59

RH

B
Terminal

connector

65

E13

66

E22

Continuity
Terminal
1

Yes

MKIB2254E

4.

Check continuity between BCM harness connector (A) and side
turn signal lamp LH and RH harness connector (B).
A
Circuit

connector

LH
M59

RH

B
Terminal

connector

65

E41

66

E31

Terminal

Continuity

1

Yes

MKIB2255E

5.

Check continuity between BCM harness connector (A) and rear
combination lamp LH and RH (turn signal) harness connector
(B).
A
Circuit

connector

LH
M59

RH

OK
NG

B
Terminal

connector

65

B17

66

B39

Terminal

Continuity

3

Yes

>> GO TO 5.
>> Repair harness or connector.

MKIB2256E

5. CHECK SIGNAL LAMP CIRCUIT (SHORT CIRCUIT)
Check continuity between BCM harness connector and ground.
BCM connector
LH
RH

M59

Terminal
65

Continuity
Ground

No

66

OK or NG
OK
>> Replace BCM if turn signal lamps does not work after
setting the connector again. Refer to BCS-17, «Removal
and Installation of BCM» .
NG
>> Repair harness or connector.

LT-108

MKIB2257E

TURN SIGNAL AND HAZARD WARNING LAMPS
Hazard Warning Lamp Does Not Operate But Turn Signal Lamp Operates

BKS001FF

1. CHECK BULB

A

Make sure bulb standard of each turn signal lamp is correct.
OK or NG
OK
>> GO TO 2.
NG
>> Replace bulb.

B

C

2. CHECK HAZARD SWITCH INPUT SIGNAL
With CONSULT-II
1. Select “BCM” on CONSULT-II. Select “FLASHER” on “SELECT
TEST ITEM” screen.
2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure that “HAZARD SW” turns ON-OFF linked with operation of malfunction switch (hazard switch).
When hazard switch is ON position

D

E

: HAZARD SW ON

F

G
PKIA7601E

Without CONSULT-II
Check voltage between BCM harness connector and ground.

H

Terminal

I

(+)
(−)

BCM
connector

Terminal

M57

26

Ground

Condition

Voltage

Hazard switch is ON

Approx. 0V

Hazard switch is OFF

Battery voltage

OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
NG
>> GO TO 3.

J

LT
MKIB1922E

L

3. CHECK HAZARD SWITCH CIRCUIT
1.
2.
3.

M

Turn ignition switch OFF.
Disconnect BCM connector and hazard switch connector.
Check continuity between BCM harness connector M57 terminal
26 and hazard switch harness connector M63 terminal 2.
26 — 2

: Continuity should exist.

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace harness or connector.

MKIB0359E

LT-109

TURN SIGNAL AND HAZARD WARNING LAMPS

4. CHECK GROUND
Check continuity hazard switch harness connector M63 terminal 1
and ground.
1 – Ground

: Continuity should exist.

OK or NG
OK
>> GO TO 5.
NG
>> Repair harness or connector.

PKIC1016E

5. CHECK HAZARD SWITCH
1.
2.

Disconnect hazard switch connector.
Check continuity hazard switch terminal.
Terminal

Condition

Continuity

Hazard switch is ON

Yes

Hazard switch is OFF

No

Hazard switch
1

2

OK or NG
OK
>> Replace BCM if turn signal lamps does not work after
setting the connector again. Refer to BCS-17, «Removal
and Installation of BCM» .
NG
>> Replace hazard switch.

LT-110

PKIC1017E

TURN SIGNAL AND HAZARD WARNING LAMPS
Bulb Replacement (Front Turn Signal Lamp)

BKS001FG

A

Refer to LT-32, «Bulb Replacement» in “HEADLAMP — CONVENTIONAL TYPE -”.

Bulb Replacement (Rear Turn Signal Lamp)

BKS001FH

B

Refer to LT-149, «Bulb Replacement» .

Bulb Replacement (Side Turn Signal Lamp)
1.
2.
3.

BKS001FI

Remove side turn signal lamp (2). Refer to LT-111, «Removal
and Installation of Side Turn Signal Lamp» .
Turn bulb socket (1) counterclockwise and unlock it.
Remove the bulb (3) from the socket.
Side turn signal lamp

C

D

: 12V — 5W
E

SKIB3806J

Removal and Installation of Front Turn Signal Lamp

BKS001FJ

Refer to LT-32, «Removal and Installation» in “HEADLAMP — CONVENTIONAL TYPE -”.

Removal and Installation of Rear Turn Signal Lamp

F

G
BKS001FK

Refer to LT-149, «Removal and Installation» .

H

Removal and Installation of Side Turn Signal Lamp

BKS001FL

REMOVAL
1.

2.

Insert a spatula or the similar tool under the side turn signal
lamp (1). While pushing the pawl (A) of the lamp, pull off the
lamp from the vehicle.
Disconnect side turn signal lamp.
NOTE:
Support side turn signal lamp harness with tape so that it won’t
fall into the front fender.
CAUTION:
Install the lamp housing with the bead facing up.

I

J

LT

SKIB3805J

L

INSTALLATION
Installation is the reverse order of removal.

M

LT-111

LIGHTING AND TURN SIGNAL SWITCH
LIGHTING AND TURN SIGNAL SWITCH
Removal and Installation

PFP:25540
BKS001FM

REMOVAL
1.
2.

Remove steering column cover. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
While pressing pawls (A) in direction as shown in the figure, pull
lighting and turn signal switch (1) toward driver door and disconnect from the base.

MKIB2297E

INSTALLATION
Installation is the reverse order of removal.

LT-112

HAZARD SWITCH
HAZARD SWITCH
Removal and Installation

PFP:25290

A
BKS001FN

REMOVAL
1.
2.
3.

Remove controller (1). Refer to ATC-112, «CONTROLLER» .
Disconnect hazard switch connector.
Press pawl (A) on reverse side and remove the hazard switch
(2).

B

C

D

E
SKIB3816J

F

INSTALLATION
Installation is the reverse order of removal.

G

H

I

J

LT

L

M

LT-113

COMBINATION SWITCH
COMBINATION SWITCH
System Description

PFP:25567
BKS0027I

COMBINATION SWITCH READING FUNCTION
Description
●

●

BCM reads combination switch (wiper) status, and controls related systems such as headlamps and wipers, according to the results.
BCM reads information for a maximum of 20 switches by combining 5 output terminals (OUTPUT 1-5) and
5 input terminals (INPUT 1-5).

Operation Description
●

●

●

BCM activates transistors of output terminals (OUTPUT 1-5) periodically, and allows current to flow in
turn.
If any (1 or more) switches are turned ON, the circuit of output terminals (OUTPUT 1-5) and input terminals (INPUT 1-5) becomes active.
At this time, transistors of output terminals (OUTPUT 1-5) are activated to allow current to flow. When voltage of the input terminal (INPUT 1-5) corresponding to that switch changes, the interface in the BCM
detects a voltage change, and the BCM determines that the switch is ON.

MKIB2223E

LT-114

COMBINATION SWITCH
BCM — Operation Table of Combination Switches
●

BCM reads operation status of the combination switch using combinations shown in the table below.

A

B

C

D

E

F

PKIC0420E

G

Sample Operation: (When Lighting Switch 1st Position Turned ON)
●

●

●

When lighting switch 1st position is turned ON, contact in combination switch turns ON. At this time if
OUTPUT 4 transistor is activated, BCM detects that voltage changes in INPUT 5.
When OUTPUT 4 transistor is ON, BCM detects that voltage changes in INPUT 5, and judges lighting
switch 1st position is ON. Then BCM sends tail lamp ON signal to IPDM E/R using CAN communication.
When OUTPUT 4 transistor is activated again, BCM detects that voltage changes in INPUT 5 and recognizes that lighting switch 1st position is continuously ON.

H

I

J

LT

L

M

MKIB2289E

NOTE:
Each output terminal transistor operates at 20 ms intervals. Therefore, after a switch is turned ON, the electrical loads are activate with a time delay, However, this delay is too small to be detected.

LT-115

COMBINATION SWITCH
Operation Mode
Combination switch reading function has operation modes shown below.
1. Normal status
● When BCM is not in sleep status, output terminals (OUTPUT 1-5) send out ON signal every 10 ms.
2. Sleep status
● When BCM is in sleep status, BCM enters low power mode. Mean while out put terminals (OUTPUT 15) send out ON signal every 60ms, and accept only input from light switch system.

PKIC0832E

LT-116

COMBINATION SWITCH
Wiring Diagram — COMBSW —

BKS001FO

A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4364E

LT-117

COMBINATION SWITCH
Terminals and Reference Values for BCM

BKS001FQ

CAUTION:
●
Check combination switch system terminal waveform under the loaded condition with lighting
switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded.
●
Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position.
Wiper dial position can be confirmed on CONSULT-II. Refer to LT-124, «DATA MONITOR» .
Measuring condition

Terminal
No.

Wire
color

Signal
name

Signal
input/
output

Ignition
switch

Operation or condition

2

B

Ground

—

ON

—

Reference value
Approx. 0V

OFF
(Wiper intermittent dial position 4)

PKIB8643J

Approx. 1.2V

7

BR

Combination
switch
output 5

Output

ON

Lighting,
turn,
wiper
switch

Any of several conditions below
●

Front fog lamp switch (Operates
only front fog lamp switch)
(Wiper intermittent dial position 4)

●

Rear fog lamp switch
(Wiper intermittent dial position 4)

●

Rear wiper ON
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 2

●

Wiper intermittent dial position 6

●

Wiper intermittent dial position 7

PKIB4956J

Approx. 1.0V

OFF
(Wiper dial position 4)

PKIB4958J

8

L

Combination
switch
output 3

Output

ON

Lighting,
turn,
wiper
switch

Approx. 1.2V
Any of several conditions below
●

Lighting switch 2ND
(Wiper intermittent dial position 4)

●

Lighting switch HI beam
(Operates only HI beam switch)
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 2

●

Wiper intermittent dial position 3

LT-118

PKIB4959J

Approx. 1.0V

COMBINATION SWITCH
Terminal
No.

Wire
color

Signal
name

Signal
input/
output

Measuring condition
Reference value

Ignition
switch

A

Operation or condition

B

OFF

9

V

Combination
switch
output 1

Output

ON

Lighting,
turn,
wiper
switch
(Wiper
intermittent dial
position
4)

C

PKIB4958J

Approx. 1.2V

D

Any of several conditions below
●

Turn signal switch to right

●

Turn signal switch to left

●

Front wiper switch MIST

●

Front wiper switch LO

●

Front washer switch

E

F
PKIB4959J

Approx. 1.0V

13

14

15

SB

P

W

Combination
switch
input 1

Combination
switch
input 3

Combination
switch
input 5

Input

Input

Input

ON

ON

ON

Lighting,
turn,
wiper
switch

Lighting,
turn,
wiper
switch
(Wiper
intermittent dial
position
4)
Lighting,
turn,
wiper
switch
(Wiper
intermittent dial
position
4)

G

●

OFF

●

Front wiper switch HI
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 2

●

Wiper intermittent dial position 3

●

Wiper intermittent dial position 6

●

Wiper intermittent dial position 7

●

OFF

●

Lighting switch AUTO

●

Rear fog lamp switch

●

Front wiper switch MIST

●

Front wiper switch INT

●

Front wiper switch LO

●

OFF

●

Lighting switch 1ST

●

Lighting switch 2ND

●

Lighting switch HIGH beam
(Operates only HIGH beam
switch)

●

Turn signal switch to right

Refer to LT-121, «Reference Values for BCM (Input)» .

H

I

J
Refer to LT-121, «Reference Values for BCM (Input)» .

L

M
Refer to LT-121, «Reference Values for BCM (Input)» .

19

L

CAN − H

Input/
Output

ON

—

Approx. 2.6V

22

Y

Battery
safety
line

Input

OFF

—

—

24

O

Ignition
switch
(ON)

Input

ON

—

Battery voltage

LT-119

LT

COMBINATION SWITCH
Terminal
No.

Wire
color

Signal
name

Signal
input/
output

Measuring condition
Reference value

Ignition
switch

Operation or condition

OFF
(Wiper intermittent dial position 4)

PKIB4958J

27

GR

Combination
switch
output 4

Output

ON

Lighting,
turn,
wiper
switch

Approx. 1.2V
Any of several conditions below
●

Lighting switch AUTO
(Wiper intermittent dial position 4)

●

Lighting switch 1ST
(The same result with
lighting switch 2ND)
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 5

●

Wiper intermittent dial position 6

PKIB4959J

Approx. 1.0V

OFF

28

G

Combination
switch
output 2

Output

ON

Lighting,
turn,
wiper
switch
(Wiper
intermittent dial
position
4)

PKIB4958J

Approx. 1.2V
Any of several conditions below
●

Lighting switch 2ND

●

Lighting switch PASSING
(Operates only PASSING switch)

●

Front wiper switch INT

●

Front wiper switch HI

PKIB4959J

Approx. 1.0V

33

34

39

R

Y

Y

Combination
switch
input 2

Combination
switch
input 4

CAN − L

Input

Input

Input/
Output

ON

ON

ON

Lighting,
turn,
wiper
switch

Lighting,
turn,
wiper
switch
(Wiper
intermittent dial
position
4)

●

OFF

●

Front washer switch
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 5

●

Wiper intermittent dial position 6

●

OFF

●

Front fog lamp switch ON

●

Lighting switch 2ND

●

Lighting switch PASSING
(Operates only PASSING switch)

●

Turn signal switch to left

—

LT-120

Refer to LT-121, «Reference Values for BCM (Input)» .

Refer to LT-121, «Reference Values for BCM (Input)» .

Approx. 2.4V

COMBINATION SWITCH
Measuring condition

Terminal
No.

Wire
color

Signal
name

Signal
input/
output

Ignition
switch

Operation or condition

70

B

Ground

—

ON

—

Approx. 0V

Input

OFF

—

Battery voltage

74
79

Y

Battery
power
supply

A

Reference value

B

C

Reference Values for BCM (Input)

BKS001FR

CAUTION:
●
Check combination switch system terminal waveform under the loaded condition with lighting
switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded.
●
Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position.
Wiper dial position can be confirmed on CONSULT-II. Refer to LT-124, «DATA MONITOR» .
INPUT

D

E

Condition and reference value
OFF

Lighting switch 1ST

Lighting switch 2ND

F

G
PKIB4956J

INPUT 5
(Wiper intermittent
dial position 4)

PKIB8624J

Approx. 0.9V

Approx. 1.5 — 2.0V

Lighting switch HI beam
(Operates only HI beam switch)

Turn signal switch to right

PKIB8639J

Approx. 2.5 — 3.0V

H

I
—

J
PKIB8625J
PKIB8644J

Approx. 1.5 — 2.0V
OFF

Approx. 1.5 — 2.0V
Lighting switch 2ND

LT
Turn signal switch to left

L

M
PKIB4958J

INPUT 4
(Wiper intermittent
dial position 4)

PKIB8628J

Approx. 1.0V

Approx. 1.5 — 2.0V

Front fog lamp switch
(Operates only front fog lamp
switch)

Lighting switch PASSING
(Operates only PASSING switch)

PKIB8630J

Approx. 2.0V

—

PKIB8629J
PKIB8627J

Approx. 1.5 — 2.0V

Approx. 2.0V

LT-121

COMBINATION SWITCH
INPUT

Condition and reference value
OFF

Lighting switch AUTO

PKIB4958J

PKIB8631J

Approx. 1.0V
INPUT 3
(Wiper intermittent
dial position 4)

Front wiper switch INT

Approx. 2.0V

PKIB8632J

Approx. 2.0V

Any of several conditions below
● Front
● Front

wiper switch LO

Rear fog lamp switch

wiper switch MIST

—

PKIC1030E

Approx. 1.5V

PKIB8629J

Approx. 2.0V
OFF
(Wiper intermittent dial position 4)

Front washer switch
(Wiper intermittent dial position 4)

PKIB4958J

Rear washer switch
(Wiper intermittent dial position 4)

PKIB8632J

Approx. 1.0V

Approx. 2.0V

PKIB8631J

Approx. 2.0V

Any of the conditions below
INPUT 2

Rear wiper switch ON
(Wiper intermittent dial position 4)

● Wiper

intermittent dial position
1

● Wiper

intermittent dial position
5

● Wiper

intermittent dial position
6
—

PKIB8634J

Approx. 1.5 — 2.0V
PKIB8633J

Approx. 2.0V

LT-122

COMBINATION SWITCH
INPUT

Condition and reference value
Any of the conditions below
OFF
(Wiper intermittent dial position 4)

Front wiper switch HI
(Wiper intermittent dial position 4)

A

● Rear wiper switch INT
(Wiper intermittent dial position 4)
● Wiper

intermittent dial position 3

B

C
PKIB4958J

PKIB8635J

Approx. 1.0V

Approx. 2.0V

PKIB8636J

D

Approx. 2.0V
INPUT 1

Any of the conditions below
Any of the conditions below
● Wiper

intermittent dial position 1

● Wiper

intermittent dial position 2

● Wiper

intermittent dial position
6

● Wiper

intermittent dial position
7

E

F
—

G
PKIB8637J

Approx. 2.5 — 3.0V

PKIB8638J

H

Approx. 2.0V

I

J

LT

L

M

LT-123

COMBINATION SWITCH
CONSULT-II Function (BCM)

BKS001FS

CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.
BCM diagnosis part

Diagnosis mode

Description

COMB SW

DATA MONITOR

Displays BCM input data in real time.

CONSULT-II INSPECTION PROCEDURE
Refer to GI-36, «CONSULT-II Start Procedure» .

CONSULT-II Application Items

BKS001KX

DATA MONITOR
Monitor item “UNIT”

Display content

TURN SIGNAL R

[ON/OFF]

Displays status (Turn right: ON/Others: OFF) as judged from lighting switch signal.

TURN SIGNAL L

[ON/OFF]

Displays status (Turn left: ON/Others: OFF) as judged from lighting switch signal.

HI BEAM SW

[ON/OFF]

Displays status (High beam switch: ON/Others: OFF) as judged from lighting switch signal.

H/L SW POS

[ON/OFF]

Displays status (Headlamp switch 1: ON/Others: OFF) as judged from lighting switch
signal.

LIGHT SW 1ST

[ON/OFF]

Displays status (Lighting switch 1st position: ON/Others: OFF) as judged from lighting
switch signal.

PASSING SW

[ON/OFF]

Displays status (Flash-to-pass switch: ON/Others: OFF) as judged from lighting switch
signal.

FR FOG SW

[ON/OFF]

Displays status (Front fog lamp switch: ON/Others: OFF) as judged from lighting switch
signal. (ON is also displayed when rear fog lamp switch is on.)

RR FOG SW

[ON/OFF]

Displays status (Rear fog lamp switch: ON/Others: OFF) as judged from lighting switch
signal.

FR WIPER HI

[ON/OFF]

Displays status (Front Wiper HI: ON/Others: OFF) as judged from wiper switch signal.

FR WIPER LOW

[ON/OFF]

Displays status (Front Wiper LOW: ON/Others: OFF) as judged from wiper switch signal.

FR WIPER INT

[ON/OFF]

Displays status (Front Wiper INT: ON/Others: OFF) as judged from wiper switch signal.

FR WASHER SW

[ON/OFF]

Displays status (Front Washer Switch: ON/Others: OFF) as judged from wiper switch
signal.

[1 — 7]

Displays intermittent operation dial position setting (1 — 7) as judged from wiper switch
signal.

RR WIPER ON

[ON/OFF]

Displays status (Rear Wiper ON: ON/Others: OFF) as judged from wiper switch signal.

RR WIPER INT

[ON/OFF]

Displays status (Rear Wiper INT: ON/Others: OFF) as judged from wiper switch signal.

RR WASHER SW

[ON/OFF]

Displays status (Rear Washer Switch: ON/Others: OFF) as judged from wiper switch
signal.

INT VOLUME

LT-124

COMBINATION SWITCH
Combination Switch Inspection

BKS001FT

1. SYSTEM CHECK 1

A

Check which systems (INPUT and OUTPUT) the malfunctioning switch belongs to. Refer to the table below.
OUTPUT1

INPUT1

INPUT2

INPUT3

INPUT4

INPUT5

—

FRONT WASHER

FRONT WIPER LO

TURN LH

TURN RH

1

PASSING

HEAD LAMP 1

OUTPUT2

FRONT WIPER HI

—

*

OUTPUT3

INT VOLUME 1

RR WASHER

—

HEAD LAMP 2

HI BEAM

OUTPUT4

REAR WIPER INT

INT VOLUME 3

AUTO LIGHT

—

LIGHT SW 1ST

OUTPUT5

INT VOLUME 2

RR WIPER

REAR FOG

FRONT FOG

—

B

C

D

*1: FRONT WIPER INT (without light and rain sensor), AUTO WIPER (with light and rain sensor)

E

>> GO TO 2.

2. SYSTEM CHECK 2
1.
2.
3.

F

Connect CONSULT-II and select “COMB SW” on “SELECT
TEST ITEM” screen.
Select “DATA MONITOR”.
Select “START”.

G

H

I
PKIA7602E

4.

Confirm that other switches in malfunctioning system operate normally.

J

Example: When “TURN RH” is malfunctioning, confirm other switches in malfunctioning system operate
properly as described below.
LT
–
INPUT5
Confirm that “HEAD LAMP1”, “HI BEAM” and “LIGHT SW 1ST” can be turned ON and OFF properly.
–
OUTPUT1
L
Confirm that “TURN LH”, “FRONT WIPER LO” and “FRONT WASHER” can be turned ON and OFF properly.
OK or NG
M
OK
>> Replace malfunctioning lighting switch or wiper switch. Refer to LT-112, «LIGHTING AND TURN
SIGNAL SWITCH» or WW-46, «Removal and Installation of Front Wiper and Washer Switch» .
NG
>> GO TO 3.

LT-125

COMBINATION SWITCH

3. HARNESS INSPECTION
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector and combination switch connector.
Check for continuity between BCM harness connector of the
suspected system and the corresponding combination switch
harness connector.
BCM

Connector

M57

4.

Combination switch
Terminal

Connector

Terminal

INPUT1

13

6

INPUT2

33

7

INPUT3

14

10

INPUT4

34

9

INPUT5

15

Continuity

8
M38

OUTPUT1

9

OUTPUT2

28

2

OUTPUT3

8

3

OUTPUT4

27

4

OUTPUT5

7

5

Yes

1

Check for continuity between BCM harness connector of the
suspected system and ground.
BCM

Connector

M57

MKIB0753E

Continuity

Terminal
INPUT1

13

INPUT2

33

INPUT3

14

INPUT4

34

INPUT5

15

OUTPUT1

9

OUTPUT2

28

OUTPUT3

8

OUTPUT4

27

OUTPUT5

7

Ground
No

OK or NG
OK
>> GO TO4.
NG
>> Repair or replace harness connector.

4. SELECTION MALFUNCTION SYSTEM
Which system does malfunction system belong to?
INPUT or OUTPUT
INPUT >> GO TO 5.
OUTPUT >>GO TO 6.

LT-126

COMBINATION SWITCH

5. CHECK BCM INPUT TERMINAL
1.
2.
3.
4.
5.

A

Connect BCM and combination switch connectors.
Turn ignition switch ON.
Turn “lighting”, “wiper” and “turn” switch OFF.
Set wiper intermittent dial to position 4.
Check BCM input terminal voltage waveform of the suspected malfunctioning system.
BCM
INPUT

Connector

B

C

Voltage
Terminal

1

13

2

33

3

14

4

34

D

E
PKIB4958J

Ground

Approx. 1.2V

F

M57

G
5

15

H
PKIB8643J

Approx. 1.2V

OK or NG
OK
>> Replace BCM.Refer to BCS-17, «Removal and Installation of BCM» .
NG (0V) >>GO TO 7.
NG (Other than 0V) >>Replace BCM.Refer to BCS-17, «Removal and Installation of BCM» .

I

J

LT

L

M

LT-127

COMBINATION SWITCH

6. CHECK BCM OUTPUT TERMINAL
1.
2.
3.
4.
5.

Connect BCM and combination switch connectors.
Turn ignition switch ON.
Turn “lighting”, “wiper” and “turn” switch OFF.
Set wiper intermittent dial to position 4.
Check BCM input terminal voltage waveform of the suspected malfunctioning system.
BCM

OUTPUT

Connector

Voltage
Terminal

1

9

2

28

3

8

4

27

PKIB4958J

Ground

Approx. 1.0V

M57

5

7

PKIB4956J

Approx. 0.9V

OK or NG
OK
>> GO TO 7.
NG
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .

7. COMBINATION SWITCH INSPECTION
Perform combination switch inspection. Refer to the table below.
Procedure
1
Replace
lighting
switch

2
Confirm
check
results

3
OK

INSPECTION END

NG

Replace wiper switch

4
Confirm
check
results

5
OK

INSPECTION END

NG

Replace switch base

6
Confirm
check
results

7
OK

INSPECTION END

NG

Confirm symptom again

>> INSPECTION END

Removal and Installation

BKS001FU

Refer to LT-112, «LIGHTING AND TURN SIGNAL SWITCH» .

LT-128

STOP LAMP
STOP LAMP
Wiring Diagram — STOP/L —

PFP:26550

A
BKS001FV

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4361E

LT-129

STOP LAMP
Bulb Replacement of High-Mounted Stop Lamp
1.
2.
3.

BKS001FW

Remove high-mounted stop lamp (1). Refer to LT-130, «Removal
and Installation of High-Mounted Stop Lamp» .
Turn bulb socket (2) counter clock and unlock it.
Remove the bulb (3) from the socket.
High-mounted stop lamp

: 12V — 16W

SKIB3809J

Bulb Replacement of Rear Combination Lamp (Stop Lamp)

BKS001FX

Refer to LT-149, «Bulb Replacement» .

Removal and Installation of High-Mounted Stop Lamp

BKS001FY

REMOVAL
1.
2.

Open the back door and remove seal cover (1).
Remove nuts (A).

SKIB3808J

3.
4.

Pull the high-mounted stop lamp toward rear of the vehicle and remove from the back door.
Disconnect high-mounted stop lamp connector.

INSTALLATION
Installation is the reverse order of removal.

Removal and Installation of Rear Combination Lamp (Stop Lamp)
Refer to LT-149, «Removal and Installation» .

LT-130

BKS001FZ

BACK-UP LAMP
BACK-UP LAMP
Wiring Diagram — BACK/L —

PFP:26550

A
BKS001G0

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4362E

LT-131

BACK-UP LAMP

MKWA4363E

LT-132

BACK-UP LAMP
Bulb Replacement

BKS001G1

A

Refer to LT-149, «Bulb Replacement» .

Removal and Installation

BKS001G2

B

Refer to LT-149, «Removal and Installation» .

C

D

E

F

G

H

I

J

LT

L

M

LT-133

PARKING, LICENSE PLATE AND TAIL LAMPS
PARKING, LICENSE PLATE AND TAIL LAMPS
Component Parts and Harness Connector Location

PFP:26550
BKS001G3

MKIB2252E

1.

IPDM E/R E8,E10,E11,E12

2.

BCM M57,M59 (View with instrument
upper panel removed)

System Description

3.

Combination switch M38

BKS001G4

The control of the parking, license plate and tail lamp operation is dependent upon the position of lighting
switch. When the lighting switch is placed in the 1ST position, the BCM (body control module) receives input
signal requesting the parking, license plate and tail lamps to illuminate. This input signal is communicated to
the IPDM E/R (intelligent power distribution module engine room) via the CAN communication. The CPU (central processing unit) located in the IPDM E/R controls the tail lamp relay coil. This relay, when energized,
directs power to parking, license plate and tail lamps, which then illuminate.
Power is supplied at all times
●
to ignition relay located in IPDM E/R and
●
to tail lamp relay located in IPDM E/R from battery directly,
●
through 20A fuse (No. 61, located in IPDM E/R),
●
through 20A fuse (No. 62, located in IPDM E/R),
●
through 40A fusible link (letter J, located in fuse, fusible link and relay box)
●
to BCM terminals 74 and 79.
With the ignition switch in the ON or START position, power is supplied
●
to ignition relay located in IPDM E/R, from battery directly and
●
through 10A fuse [No. 5, located in fuse block (J/B)]
●
to BCM terminal 24.
Ground is supplied
●
to BCM terminals 2 and 70,
●
through grounds M21 and M66,
●
to IPDM E/R terminals 3 and 54
●
through grounds E45 (CR and HR engine models), E28 and E44.

OPERATION BY LIGHTING SWITCH
With the lighting switch in the 1ST or 2ND position (or if auto light system is activated), the BCM receives input
signal requesting parking, license plate and tail lamps to illuminate. This input signal is communicated to the
IPDM E/R via CAN communication. The CPU located in the IPDM E/R controls tail lamp relay coil, which when
energized, directs power
●
through 10A fuse (No. 45, located in IPDM E/R),
●
through IPDM E/R terminal 45
●
to parking lamp RH terminal 1,
●
through IPDM E/R terminal 16
●
to rear combination lamp RH (tail) terminal 5 and
●
to license plate lamp LH and RH terminals 1,
●
through 10A fuse (No. 46, located in IPDM E/R),
●
through IPDM E/R terminal 49

LT-134

PARKING, LICENSE PLATE AND TAIL LAMPS
to parking lamp LH terminal 1 and
through IPDM E/R terminal 15
●
to rear combination lamp LH (tail) terminal 5.
Ground is supplied
●
to parking lamp LH and RH terminals 2
●
through grounds E45 (CR and HR engine models), E28 and E44,
●
to rear combination lamp LH (tail) and RH (tail) terminal 2,
●
to license plate lamp LH and RH terminals 2
●
through grounds B13,B28,B38 and B48.
With power and ground supplied, parking, license plate and tail lamps illuminate.
●

A

●

B

C

D

COMBINATION SWITCH READING FUNCTION
Refer to LT-114, «COMBINATION SWITCH READING FUNCTION» .

E

EXTERIOR LAMP BATTERY SAVER CONTROL
Refer to LT-135, «EXTERIOR LAMP BATTERY SAVER CONTROL» .
F

FAIL-SAFE FUNCTION
When CAN communication with other control units is impossible, IPDM E/R performs fail-safe control. If the
fail-safe system is operating, parking, license plate and tail lamps illuminate when the ignition switch is turned
from OFF to ON and parking, license plate and tail lamps are turned off when the ignition switch is turn from
ON to OFF. If the fail-safe system is operating, parking, license plate and tail lamps does not operate when the
combination switch is in any position. After CAN communication recovers normally, it also returns to normal
control. (Refer to PG-18, «Fail-safe Control» .)

CAN Communication System Description

H

BKS001G5

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

CAN Communication Unit

G

I

J

BKS001G6

LT

Refer to LAN-27, «CAN Communication Unit» .

L

M

LT-135

PARKING, LICENSE PLATE AND TAIL LAMPS
Schematic

BKS001G7

MKWA4357E

LT-136

PARKING, LICENSE PLATE AND TAIL LAMPS
Wiring Diagram — TAIL/L —

BKS001G8

A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4358E

LT-137

PARKING, LICENSE PLATE AND TAIL LAMPS

MKWA4359E

LT-138

PARKING, LICENSE PLATE AND TAIL LAMPS
A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4360E

LT-139

PARKING, LICENSE PLATE AND TAIL LAMPS
Terminals and Reference Values for BCM

BKS001G9

CAUTION:
●
Check combination switch system terminal waveform under the loaded condition with lighting
switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded.
●
Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position.
Wiper dial position can be confirmed on CONSULT-II. Refer to LT-19, «DATA MONITOR» .
Measuring condition
Terminal
No.

Wire
color

Signal name

2

B

Ground

Signal
input/
output

Ignition
switch

Operation or condition

—

ON

—

Reference value

Approx. 0V

OFF

15

W

Combination
switch input 5

Input

ON

Lighting,
turn, wiper
switch
(Wiper
intermittent
dial position 4)

PKIB4956J

Approx. 0.9V

Lighting switch 1ST

PKIB8624J

Approx. 1.5 — 2.0V
19

L

CAN − H

24

O

Ignition switch
(ON)

Input/
Output

—

—

—

Input

ON

—

Battery voltage

OFF

27

GR

Combination
switch output 4

Output

ON

Lighting,
turn, wiper
switch
(Wiper
intermittent
dial position 4)

PKIB4958J

Approx. 1.2V

Lighting switch 1ST
(The same result with
lighting switch 2ND)
PKIB4959J

Approx. 1.0V
39

Y

CAN − L

Input/
Output

—

—

—

70

B

Ground

—

ON

—

Approx. 0V

74
79

Y

Battery power
supply

Input

OFF

—

Battery voltage

LT-140

PARKING, LICENSE PLATE AND TAIL LAMPS
Terminals and Reference Values for IPDM E/R

BKS001GA

A
Measuring condition
Terminal
No.

Wire
color

3

B

15

GR

16

V

45

BR

Signal name

Ground

Signal
input/
output

Reference value
Operation or condition
—

—

Rear combination lamp LH

Output

Rear combination lamp RH,
license plate lamp RH and LH

Output

Parking lamp RH

Ignition
switch

ON

Output

Lighting
switch 1ST
position

B
Approx. 0V

OFF

Approx. 0V

ON

Battery voltage

OFF

Approx. 0V

ON

Battery voltage

OFF

Approx. 0V

ON

Battery voltage

OFF

Approx. 0V

ON

Battery voltage

49

O

Parking lamp LH

Output

52

L

CAN − H

Input/
Output

—

—

—

54

B

Ground

—

ON

—

Approx. 0V

58

Y

CAN − L

Input/
Output

—

—

—

How to Proceed With Trouble Diagnosis
1.
2.
3.
4.
5.
6.

Confirm the symptom or customer complaint.
Understand operation description and function description. Refer to LT-134, «System Description» .
Perform the preliminary check. Refer to LT-142, «Preliminary Check» .
Check symptom and repair or replace the malfunctioning parts.
Do the parking, license plate and tail lamps operate normally? If YES, GO TO 6. If NO, GO TO 4.
INSPECTION END

C

D

E

F

G
BKS001GB

H

I

J

LT

L

M

LT-141

PARKING, LICENSE PLATE AND TAIL LAMPS
Preliminary Check

BKS001GC

CHECK POWER SUPPLY AND GROUND CIRCUIT

1. CHECK FUSES
Check for blown fuses.
Unit

Power source

Fuse and fusible link No.

Battery

J

Ignition switch ON or START position

5

BCM

45
IPDM E/R

46

Battery

61
62

Refer to LT-137, «Wiring Diagram — TAIL/L —» .
OK or NG
OK
>> GO TO 2.
NG
>> If fuse or fusible link is blown, be sure to eliminate cause of malfunction before installing new fuse
or fusible link. Refer to PG-4, «POWER SUPPLY ROUTING CIRCUIT» .

2. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector.
Check voltage between BCM harness connector and ground.
Terminal

Ignition switch position

(+)
OFF

ACC

ON

24

Approx. 0V

Approx. 0V

Battery
voltage

74

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

BCM
Connector

Terminal

M57

(−)

Ground

M59
79

MKIB0352E

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

3. CHECK GROUND CIRCUIT
Check continuity between BCM harness connector and ground.
BCM
Connector

Terminal

M57

2

M59

70

Continuity
Ground
Yes

OK or NG
OK
>> INSPECTION END
NG
>> Repair harness or connector.
MKIB0353E

LT-142

PARKING, LICENSE PLATE AND TAIL LAMPS
CONSULT-II Functions (BCM)

BKS001GD

A

Refer to LT-19, «CONSULT-II Functions (BCM)» in “HEADLAMP — CONVENTIONAL TYPE -”.

CONSULT-II Functions (IPDM E/R)

BKS001GE

B

Refer to LT-20, «CONSULT-II Functions (IPDM E/R)» in “HEADLAMP — CONVENTIONAL TYPE -”.

Parking, License Plate and Tail Lamps Do Not Illuminate

BKS001GF

1. CHECK COMBINATION SWITCH INPUT SIGNAL

C

With CONSULT-II
1. Select “BCM” on CONSULT-II. Select “HEAD LAMP” on
“SELECT TEST ITEM” screen.
2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure “LIGHT SW 1ST” turns ON-OFF linked with operation of lighting switch.
When lighting switch is 1ST
position

D

E

: LIGHT SW 1ST ON
F

Without CONSULT-II
Refer to LT-125, «Combination Switch Inspection» .
PKIA7607E
OK or NG
OK
>> GO TO 2.
NG
>> Check combination switch (lighting switch). Refer to LT-125, «Combination Switch Inspection» .

2. ACTIVE TEST
With CONSULT-II
Select “IPDM E/R” on CONSULT-II, and select “ACTIVE TEST”
on “SELECT DIAG MODE” screen.
2. Select “TAIL LAMP” on “SELECT TEST ITEM” screen.
3. Touch “ON” screen.
4. Make sure parking, license plate and tail lamp operates.

G

H

I

1.

J

LT

Parking, license plate and tail lamp should operate.
1.
2.

Without CONSULT-II
Start auto active test. Refer to PG-22, «Auto Active Test» .
Make sure parking, license plate and tail lamp operates.
Parking, license plate and tail lamp should operate.

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 4.

LT-143

L
SKIA2348E

M

PARKING, LICENSE PLATE AND TAIL LAMPS

3. CHECK IPDM E/R
1.
2.

Select “IPDM E/R” on CONSULT-II, and select “DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure “TAIL&CLR REQ” turns ON when lighting switch is in
1ST position.
When lighting switch is 1ST
position

: TAIL&CLR REQ ON

OK or NG
OK
>> Replace IPDM E/R. Refer to PG-37, «Removal and
Installation of IPDM E/R» .
NG
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .

LT-144

SKIA5958E

PARKING, LICENSE PLATE AND TAIL LAMPS

4. CHECK INPUT SIGNAL

A

With CONSULT-II
Turn ignition switch OFF.
Disconnect parking lamp RH and LH, license plate lamp RH and LH, and rear combination lamp RH and
LH connectors.
3. Select “IPDM E/R” on CONSULT-II, and select “ACTIVE TEST” on “SELECT DIAG MODE” screen.
4. Select “TAIL LAMP” on “SELECT TEST ITEM” screen.
5. Touch “ON” screen.
6. When tail lamp relay is operating, check voltage between parking lamp, license plate lamp and rear combination lamp harness connector and ground.
1.
2.

Without CONSULT-II
1. Turn ignition switch OFF.
2. Disconnect parking lamp RH and LH, license plate lamp RH and LH, and rear combination lamp RH and
LH connectors.
3. Start auto active test. Refer to PG-22, «Auto Active Test» .
4. When tail lamp relay is operating, check voltage between parking lamp, license plate lamp and rear combination lamp harness connector and ground.

(−)

Parking lamp connector
RH

E30

LH

E43

D

E

F

Voltage

Terminal
1

C

G

Terminal
(+)

B

H
Ground

Battery voltage

I

MKIB2241E

J

Terminal

LT

(+)
(−)

License plate lamp
connector
RH

D103

LH

D105

Voltage

Terminal

L
1

Ground

Battery voltage

M
MKIB2242E

Terminal
(+)
Rear combination lamp
connector
(tail)
RH

B39

LH

B17

(−)

Voltage

Terminal

5

Ground

Battery voltage

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

MKIB2243E

LT-145

PARKING, LICENSE PLATE AND TAIL LAMPS

5. CHECK PARKING, LICENSE PLATE AND TAIL LAMP CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R connector.
Check continuity between IPDM E/R harness connector (A) and
parking lamp harness connector (B).
A
Circuit

Connector

RH
LH

E8

B
Terminal

Connector

45

E30

49

E43

Terminal

Continuity

1

Yes

MKIB2244E

4.

Check continuity between IPDM E/R harness connector (A) and
license plate lamp harness connector (B).
A

Circuit
RH

B

Connector

Terminal

E10

16

LH

Connector

Continuity
Terminal

D103

1

Yes

D105

MKIB2245E

5.

Check continuity between IPDM E/R harness connector (A) and
rear combination lamp harness connector (B).
A
Circuit

Connector

RH
LH

E10

B
Terminal

Connector

16

B39

15

B17

Terminal

Continuity

5

Yes

OK or NG
OK
>> Replace IPDM E/R. Refer to PG-37, «Removal and
Installation of IPDM E/R» .
NG
>> Repair harness or connector.

LT-146

MKIB2246E

PARKING, LICENSE PLATE AND TAIL LAMPS

6. CHECK PARKING, LICENSE PLATE AND TAIL LAMPS GROUND CIRCUIT
1.

A

Check continuity between parking harness connector and
ground.
Parking lamp connector
RH

E30

LH

E43

Terminal
2

B

Continuity
Ground

Yes

C

D
MKIB2247E

2.

Check continuity between license plate lamp harness connector
and ground.
License plate lamp
connector
RH

D103

LH

D105

Terminal

E

Continuity

F

Ground
2

Yes

G

MKIB2248E

3.

Check continuity between rear combination lamp harness connector and ground.
Rear combination lamp
connector
RH

B39

LH

B17

Terminal

H

I

Continuity
Ground

2

J
Yes

OK or NG
OK
>> Check bulbs.
NG
>> Repair harness or connector.

LT
MKIB2249E

Parking, License Plate and Tail Lamps Do Not Turn OFF (After Approx. 10 Minutes)

L

BKS001GG

●

●

This symptom indicates the malfunction of ignition relay in IPDM E/R. Refer to PG-19, «Function of
Detecting Ignition Relay Malfunction» .
Select “BCM” on CONSULT-II. Select “HEADLAMP” on “SELECT TEST ITEM” screen and select “DATA
MONITOR” on “SELECT DIAG MODE” screen. If “LIGHT SW 1ST” is OFF when lighting switch is OFF,
replace IPDM E/R.

LT-147

M

PARKING, LICENSE PLATE AND TAIL LAMPS
Bulb Replacement

BKS001GH

PARKING LAMP
Refer to LT-149, «Bulb Replacement» .

LICENSE PLATE LAMP
1.

Insert a screwdriver A or the like wrapped in a cloth into the lens
(1) notch.

MKIB2308E

2.

Remove bulb (1) from license plate lamp bulb socket.
License plate lamp

: 12V — 5W

MKIB2309E

TAIL LAMP
Refer to LT-149, «Bulb Replacement» .

Removal and Installation

BKS001GI

PARKING LAMP
Refer to LT-149, «Removal and Installation» .

LICENSE PLATE LAMP
Removal
1.
2.
3.

Remove license plate finisher. Refer to EI-24, «Removal and Installation» .
Disconnect the license plate lamp connector.
While pressing pawl on the reverse side of the back door finisher.

MKIB2307E

Installation
Installation is the reverse order of removal.

TAIL LAMP
Removal
Refer to LT-149, «Removal and Installation» .

LT-148

REAR COMBINATION LAMP
REAR COMBINATION LAMP
Bulb Replacement
1.
2.
3.

PFP:26554

A
BKS001GJ

Remove rear combination lamp. Refer to LT-149, «Removal and
Installation» .
Turn bulb socket (1), (2), (3) counterclockwise and unlock it.
Remove bulb (4), (5), (6).
Stop/tail lamp (5)
Rear turn signal lamp (4)
Back-up lamp (6)

B

C

: 12V — 21/5W
: 12V — 16W (amber)
: 12V — 16W

D
SKIB3812J

Removal and Installation

BKS001GK

E

REMOVAL
1.
2.
3.
4.

Remove rear pillar garnish. Refer to EI-26, «BODY SIDE TRIM» .
Disconnect rear combination lamp connector.
Remove rear combination lamp mounting bolts (A).
Pull the rear combination lamp (1) toward rear of the vehicle and
remove from the vehicle.

F

G

H

I
SKIB3813J

5.

While pressing pawls (A) in direction as shown in the figure,
remove the rear combination lamp finisher (2) from the rear
combination lamp body (1).

J

LT

L

SKIB3975J

INSTALLATION
Installation is the reverse order of removal.
Rear combination lamp mounting nut

: 5.5 N·m (0.56 kg-m, 49 in-lb)

LT-149

M

INTERIOR ROOM LAMP
INTERIOR ROOM LAMP
Component Parts and Harness Connector Location

PFP:26410
BKS001GO

MKIB2269E

1.

BCM M57,M59 (View with instrument upper panel removed)

2.

Key switch M33
3.
(without Intelligent Key system)

Key switch and ignition knob switch M34
(with Intelligent Key system)

4.

Front door switch driver side
[B14 (LHD models)]
[B29 (RHD models)]
Front door switch passenger side
[B29 (LHD models)]
[B14 (RHD models)]

5.

Rear door switch LH B19
Rear door switch RH B42

Door lock/unlock switch M54

6.

System Description

BKS001GP

When interior room lamp switch is in DOOR position, interior room lamp ON/OFF is controlled by timer according to signals from switches including key switch, front door switch driver side, unlock signal from key fob, door
lock and unlock switch, key cylinder lock and unlock switch, ignition switch.
When interior room lamp turns ON, there is a gradual brightening over 1 second.
When interior room lamp turns OFF, there is a gradual dimming over 1 second.
Interior room lamp timer is controlled by BCM.

POWER SUPPLY AND GROUND
Power is supplied at all times:
●
through 40A fusible link (letter J, located in the fuse and fusible link box)
●
to BCM terminals 74 and 79,
●
through 10A fuse [No. 9, located in the fuse block (J/B)]
●
to luggage room lamp terminal 1,
●
to BCM terminal 72,
●
to key switch terminal 2 (without Intelligent Key system) or
●
through 10A fuse [No. 13, located in the fuse block (J/B)]
●
to key switch and ignition knob switch terminal 2 and 4 (with Intelligent Key system).
When the key is removed from ignition key cylinder, power is interrupted
●
through key switch terminal 1 (without Intelligent Key system) or
●
through key switch and ignition knob switch terminal 1 (with Intelligent Key system)
●
to BCM terminal 3.
With the ignition key switch in the ON or START position, power is supplied:
●
through 10A fuse [No. 5, located in the fuse block (J/B)]
●
to BCM terminal 24.

LT-150

INTERIOR ROOM LAMP
Ground is supplied:
●
to BCM terminals 2 and 70.
●
through grounds M21 and M66.
When any door is opened, ground is supplied:
●
to BCM terminal 29
●
to front door switch (driver side) terminal 1
●
through case ground of front door switch (driver side),
●
to BCM terminal 30
●
to front door switch (passenger side) terminal 1
●
through case ground of front door switch (passenger side),
●
to BCM terminal 59
●
to rear door switch LH terminal 1
●
through case ground of rear door switch LH,
●
to BCM terminal 60
●
to rear door switch RH terminal 1
●
through case ground of rear door switch RH,
●
to BCM terminal 10
●
to back door switch terminal 2
●
to back door switch terminal 1
●
through grounds B13,B28,B38 and B48.

A

B

C

D

E

F

G

H

SWITCH OPERATION
When map lamp switch is ON, power is supplied:
●
through BCM terminal 73
●
to map lamp terminal 4.
Ground is supplied:
●
to map lamp terminal 3
●
through grounds M21 and M66.
With power and ground are supplied, the map lamp illuminates.
When map lamp switch is DOOR, power is supplied:
●
through BCM terminal 73
●
to map lamp terminal 4.
Ground is supplied:
●
through map lamp terminal 2
●
to BCM terminal 21.
With power and ground are supplied, the map lamp illuminates.
When back door is opened, ground supplied:
●
to luggage room lamp terminal 2
●
through back door switch terminals 2 and 1
●
through grounds B13,B28,B38 and B48.
With power and ground are supplied, the luggage room lamp illuminates.

LT-151

I

J

LT

L

M

INTERIOR ROOM LAMP
Models With Personal Lamp
When personal lamp switch is ON, power is supplied:
●
through BCM terminal 73
●
to personal lamp terminal 4.
Ground is supplied:
●
to personal lamp terminal 3
●
through grounds M21 and M66.
With power and ground are supplied, the personal lamp illuminates.
When personal lamp switch is DOOR, power is supplied:
●
through BCM terminal 73
●
to personal lamp terminal 4.
Ground is supplied:
●
through personal lamp terminal 2
●
to BCM terminal 21.
With power and ground are supplied, the personal lamp illuminates.

INTERIOR ROOM LAMP TIMER OPERATION
When interior room lamp switch is in the “DOOR” position, the BCM keeps the interior room lamp illuminated
for Approx. 28 seconds when:
●
unlock signal is received from Intelligent Key, while all doors are closed and key is out of the ignition key
cylinder (with Intelligent Key system).
●
unlock signal is received from key fob while all doors are closed and key is out of the ignition key cylinder
(without Intelligent Key system).
●
key is removed from ignition key cylinder while all doors are closed (without Intelligent Key system)
●
any door is opened and then closed while key is out of the ignition key cylinder.
The timer is canceled when:
●
ignition switch is turned ON.
●
lock signal is received from Intelligent Key, while all doors are closed and key is out of the ignition key cylinder (with Intelligent Key system).
●
lock signal is received from remote controller while all doors are closed and key is out of the ignition key
cylinder (without Intelligent Key system).

INTERIOR ROOM LAMP BATTERY SAVER CONTROL
If interior room lamp is left ON, it will not be turned off even when door is closed.
BCM turns off interior room lamp automatically to save battery 15 minutes after ignition switch is turned off.
BCM controls interior room lamps listed below:
●
Interior room lamp
After lamps turn OFF by the battery saver system, the lamps illuminate again when
●
door lock switch is operated,
●
Intelligent Key lock or unlock,
●
door is opened,
●
key is removed from ignition key cylinder.

LT-152

INTERIOR ROOM LAMP
Schematic

BKS001GQ

A

—MODELS WITHOUT PERSONAL LAMP—

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4365E

LT-153

INTERIOR ROOM LAMP
—MODELS WITH PERSONAL LAMP—

MKWA4448E

LT-154

INTERIOR ROOM LAMP
Wiring Diagram — ROOM/L —

BKS001GR

A

—MODELS WITHOUT PERSONAL LAMP—

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4366E

LT-155

INTERIOR ROOM LAMP

MKWA4367E

LT-156

INTERIOR ROOM LAMP
A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4368E

LT-157

INTERIOR ROOM LAMP

MKWA4369E

LT-158

INTERIOR ROOM LAMP
—MODELS WITH PERSONAL LAMP—
A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4449E

LT-159

INTERIOR ROOM LAMP

MKWA4450E

LT-160

INTERIOR ROOM LAMP
A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4451E

LT-161

INTERIOR ROOM LAMP

MKWA4452E

LT-162

INTERIOR ROOM LAMP
Terminals and Reference Values for BCM

BKS001GS

A
Terminal
No.

Wire
color

2

B

3

Signal designation
Ground

GR*1

Measuring condition

Signal
input/
output

Ignition
switch

Operation or condition

Voltage [V]
(Approx.)

—

ON

—

0

Input

OFF

Remove key.
Key switch signal

O*2
6

LG

B
0

Key is inserted.
Door lock / unlock
switch (Lock signal)

10

P

Back door switch
signal

19

L

CAN- H

Input

OFF

Battery voltage

Lock operation (ON)

0

Other than above (OFF)

5
ON (open)

Input

OFF

Input/
Output

—

Back door switch signal

21

Y

Input

Battery voltage

E
—

OFF

Interior room
lamp switch:
DOOR position

—

Any door
switch

ON
(Open)

0

OFF
(Close)

Battery voltage

Key is removed from
key cylinder

Close all
doors

Turn ignition switch ON
Key is removed
Interior room lamp timer

24

O

Ignition power supply

25

BR

Door lock/unlock
switch (Unlock signal)

Input

Driver door switch
signal

Input

Passenger door
switch signal

Input

29

LG*3
4

BR*

BR*3
30
LG*4
39
59

60

Input

ON

OFF

Input/
Output
Input

Rear door switch
RH signal

Input

Ground

72

Y

Power source
(Fuse)

ON

0

Unlock operation (ON)

0

Other than above (OFF)

5
0

Driver door switch signal

—

H

I

—

J

LT

Battery voltage
0

Passenger door switch signal
OFF (close)

G

B

OFF

G

Battery voltage

ON (open)

Rear door switch
LH signal

70

Battery voltage

—

F

Battery voltage

OFF

OFF (closed)

CAN- L

L

OFF

0

0

ON (open)

Y

D

0

OFF (close)

Key is
inserted

Logical lighting control

C

L

Battery voltage
—

M
OFF

ON (open)

Rear door switch LH signal

OFF (close)
OFF

Rear door switch RH signal

ON (open)
OFF (close)

0
Battery voltage
0
Battery voltage

—

ON

—

0

Input

OFF

—

Battery voltage

LT-163

INTERIOR ROOM LAMP
Terminal
No.

Wire
color

Signal designation

Signal
input/
output

Measuring condition
Ignition
switch

Operation or condition

Key is
inserted.

OFF
73

V

Interior room lamp
signal

Y

Power supply
(Fusible link)

Input

OFF

ON
(open)
OFF
(closed)

Key is removed after
being fully inserted.

Close all
doors.

—

74
79

Any door
switch

Interior room
lamp switch:
DOOR position

Output

Voltage [V]
(Approx.)

Turn ignition switch
ON.
—

0
Battery voltage
0
Battery voltage
Battery voltage

*1: With Intelligent Key system
*2: Without Intelligent Key system
*3: LHD models
*4: RHD models

How to Proceed With Trouble Diagnosis
1.
2.
3.
4.
5.
6.

Confirm the symptom or customer complaint.
Understand operation description and function description. Refer to LT-150, «System Description» .
Perform the preliminary check. Refer to LT-165, «Preliminary Check» .
Check symptom and repair or replace the malfunctioning parts.
Does the interior room lamp operate normally? If YES, GO TO 6. If NO, GO TO 4.
INSPECTION END

LT-164

BKS001GT

INTERIOR ROOM LAMP
Preliminary Check

BKS001GU

A

CHECK POWER SUPPLY AND GROUND CIRCUIT

1. CHECK FUSES
B

Check for blown fuses.
Unit

Power source

Fuse and fusible link No.

Battery

J

Ignition switch ON or START position

5

BCM

C

Refer to LT-155, «Wiring Diagram — ROOM/L —» .
OK or NG
OK
>> GO TO 2.
NG
>> If fuse or fusible link is blown, be sure to eliminate cause of malfunction before installing new fuse
or fusible link. Refer to PG-4, «POWER SUPPLY ROUTING CIRCUIT» .

D

E

2. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

F

Turn ignition switch OFF.
Disconnect BCM connector.
Check voltage between BCM harness connector and ground.
Terminal

G

Ignition switch position

(+)

H

BCM
Connector

Terminal

M57

24
74

(−)

Ground

M59
79

OFF

ACC

ON

Approx. 0V

Approx. 0V

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

I
MKIB0352E

J

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

LT

L

3. CHECK GROUND CIRCUIT
Check continuity between BCM harness connector and ground.

M
BCM
Connector

Terminal

M57

2

M59

70

Continuity
Ground
Yes

OK or NG
OK
>> INSPECTION END
NG
>> Repair harness or connector.
MKIB0353E

LT-165

INTERIOR ROOM LAMP
CONSULT-II Functions (BCM)
●

BKS001GV

CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.

BCM diagnosis part
INT LAMP

Diagnosis mode

Description

DATA MONITOR

Displays BCM input data in real time.

ACTIVE TEST
BCM

Operation of electrical loads can be checked by sending driving signal to them.

SELFDIAG RESULTS

BCM performs self-diagnosis of CAN communication.

CAN DIAG SUPPORT
MNTR

The result of transmit/receive diagnosis of CAN communication can be read.

CONSULT-II INSPECTION PROCEDURE
Refer to GI-36, «CONSULT-II Start Procedure» .

CONSULT-II Application Items

BKS001KV

DATA MONITOR
Monitor item “UNIT”

Display content

IGN ON SW

[ON/OFF]

Displays status (Ignition switch ON: ON/Others OFF, ACC: OFF) as judged from the
ignition switch signal.

PUSH SW (*1)

[ON/OFF]

Displays status (Ignition knob is pushed: ON/ released: OFF) as judged from the ignition knob switch signal.

KEY IN SW (*2)

[ON/OFF]

Displays status (Key inserted: ON/Key removed: OFF) as judged from the key switch
signal.

DOOR SW-DR

[ON/OFF]

Displays status (Door open: ON/door closed: OFF) as judged from the front door switch
RH signal.

DOOR SW-AS

[ON/OFF]

Displays status (Door open: ON/Door closed: OFF) as judged from the front door switch
LH signal.

DOOR SW-RR

[ON/OFF]

Displays status (Door open: ON/door closed: OFF) as judged from the rear door switch
RH signal.

DOOR SW-RL

[ON/OFF]

Displays status (Door open: ON/Door closed: OFF) as judged from the rear door switch
LH signal.

BACK DOOR SW

[ON/OFF]

Displays status (Door open: ON/Door closed: OFF) as judged from the back door
switch signal.

CDL LOCK SW

[ON/OFF]

Displays status (Locked: ON/Others: OFF) as judged from lock signal.

CDL UNLOCK SW

[ON/OFF]

Displays status (Unlocked: ON/Others: OFF) as judged from unlock signal.

KEYLESS LOCK (*2)

[ON/OFF]

Displays status (Locked: ON/Others: OFF) as judged from lock signal.
(Locked by Multi-Remote control system)

KEYLESS UNLOCK(*2)

[ON/OFF]

Displays status (Unlocked: ON/Others: OFF) as judged from unlock signal.
(Unlocked by Multi-Remote control system)

I-KEY LOCK (*1)

[ON/OFF]

Displays status (Locked: ON/Others: OFF) as judged from lock signal.
(Locked by Intelligent Key system)

I-KEY UNLOCK (*1)

[ON/OFF]

Displays status (Unlocked: ON/Others: OFF) as judged from unlock signal.
(Unlocked by Intelligent Key system)

I-KEY ALL UNL (*1)

[ON/OFF]

Displays status (Unlocked: ON/Others: OFF) as judged from unlock signal.
(Unlocked by Intelligent Key system)

*1: Displayed for models with Intelligent Key system.
*2: Displayed for models without Intelligent Key system.

ACTIVE TEST
Test item
INT LAMP

Description
Interior room lamp can be operated by any ON-OFF operations.

LT-166

INTERIOR ROOM LAMP
Map Lamp Control Does Not Operate

BKS001GW

1. CHECK EACH SWITCH

A

1.

Select “BCM” on CONSULT-II. Select “INT LAMP” on “SELECT
TEST ITEM” screen.
2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure switches listed in display item list turn ON-OFF linked
with switch operation.
OK or NG
OK
>> GO TO 2.
NG
>> Inspect malfunctioning switch system.

B

C

D
PKIB0263E

E

2. ACTIVE TEST
1.
2.
3.

Select “BCM” on CONSULT-II. Select “INT LAMP” on “SELECT
TEST ITEM” screen.
Select “ACTIVE TEST” on “SELECT DIAG MODE” screen.
Select “INT LAMP” on “SELECT TEST ITEM” screen.
When map lamp switch is in DOOR position, make sure map
lamp operates.

F

G

Map lamp should operate.

H

OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
NG
>> GO TO 3.

PKIA6881E

3. CHECK MAP LAMP INPUT VOLTAGE
1.
2.
3.

J

Turn ignition switch OFF.
Disconnect map lamp connector.
Check voltage between map lamp harness connector R3 terminal 4 and ground.
4 — Ground

I

LT

: Battery voltage.

L

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

M
MKIB2250E

LT-167

INTERIOR ROOM LAMP

4. CHECK MAP LAMP INPUT CIRCUIT
1.
2.

Disconnect BCM connector.
Check continuity between BCM harness connector (A) terminal
and map lamp harness connector (B).
A

3.

B

Continuity

Connector

Terminal

Connector

Terminal

M59

73

R3

4

Yes

Check continuity between BCM harness connector (A) and
ground.
A

Continuity

Connector

Terminal

M59

73

Ground

MKIB2280E

No

OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
NG
>> Repair harness or connector.

5. CHECK MAP LAMP
1.

Check continuity between map lamp terminals.
Terminal
Condition

Map lamp
2

4

Continuity

Map lamp switch is DOOR

Yes

Other than above

No

OK or NG
OK
>> GO TO 6.
NG
>> Replace map lamp or check bulb.
MKIB2251E

6. CHECK CIRCUIT BETWEEN MAP LAMP AND BCM
1.
2.

Disconnect BCM connector.
Check continuity between BCM harness connector (A) and map
lamp harness connector (B).
A

3.

B

Continuity

Connector

Terminal

Connector

Terminal

M57

21

R3

2

Yes

Check continuity between BCM harness connector (A) and
ground.
A

Continuity

Connector

Terminal

M57

21

Ground

MKIB2281E

No

OK or NG
OK
>> Replace BCM if map lamp does not work after setting the connector again. Refer to BCS-17,
«Removal and Installation of BCM» .
NG
>> Repair harness or connector.

LT-168

INTERIOR ROOM LAMP
Personal Lamp Control Does Not Operate (Models With Personal Lamp)

BKS0026H

1. CHECK EACH SWITCH

A

1.

Select “BCM” on CONSULT-II. Select “INT LAMP” on “SELECT
TEST ITEM” screen.
2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure switches listed in display item list turn ON-OFF linked
with switch operation.
OK or NG
OK
>> GO TO 2.
NG
>> Inspect malfunctioning switch system.

B

C

D
PKIB0263E

E

2. ACTIVE TEST
1.
2.
3.

Select “BCM” on CONSULT-II. Select “INT LAMP” on “SELECT
TEST ITEM” screen.
Select “ACTIVE TEST” on “SELECT DIAG MODE” screen.
Select “INT LAMP” on “SELECT TEST ITEM” screen.
When personal lamp switch is in DOOR position, make sure personal lamp operates.

F

G

Personal lamp should operate.

H

OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
NG
>> GO TO 3.

PKIA6881E

3. CHECK PERSONAL LAMP INPUT VOLTAGE
1.
2.
3.

J

Turn ignition switch OFF.
Disconnect personal lamp connector.
Check voltage between personal lamp harness connector R4
terminal 4 and ground.
4 — Ground

I

LT

: Battery voltage.

L

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

M
MKIB2250E

LT-169

INTERIOR ROOM LAMP

4. CHECK PERSONAL LAMP INPUT CIRCUIT
1.
2.

Disconnect BCM connector.
Check continuity between BCM harness connector (A) terminal
and personal lamp harness connector (B).
A

3.

B

Continuity

Connector

Terminal

Connector

Terminal

M59

73

R4

4

Yes

Check continuity between BCM harness connector (A) and
ground.
A

Continuity

Connector

Terminal

M59

73

Ground

MKIB2280E

No

OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
NG
>> Repair harness or connector.

5. CHECK PERSONAL LAMP
1.

Check continuity between personal lamp terminals.
Terminal
Condition

Personal lamp
2

4

Continuity

Personal lamp switch is DOOR

Yes

Other than above

No

OK or NG
OK
>> GO TO 6.
NG
>> Replace personal lamp or check bulb.
MKIB2251E

6. CHECK CIRCUIT BETWEEN PERSONAL LAMP AND BCM
1.
2.

Disconnect BCM connector.
Check continuity between BCM harness connector (A) and personal lamp harness connector (B).
A

3.

B

Continuity

Connector

Terminal

Connector

Terminal

M57

21

R4

2

Yes

Check continuity between BCM harness connector (A) and
ground.
A

Continuity

Connector

Terminal

M57

21

Ground

MKIB2281E

No

OK or NG
OK
>> Replace BCM if personal lamp does not work after setting the connector again. Refer to BCS-17,
«Removal and Installation of BCM» .
NG
>> Repair harness or connector.

LT-170

INTERIOR ROOM LAMP
Bulb Replacement

BKS001GX

A

MAP LAMP, PERSONAL LAMP
1.
2.

Remove lamp lens. Refer to LT-171, «MAP LAMP, PERSONAL LAMP» .
Remove bulb.
Map lamp

: 12V — 5W

Personal lamp

: 12V — 5W

B

C

D

MKIB2296E

E

LUGGAGE LOOM LAMP
1.
2.

Remove luggage room lamp lens. Refer to LT-172, «LUGGAGE ROOM LAMP» .
Remove bulb.
Luggage room lamp

F

: 12V — 10W
G

H

MKIB2299E

Removal and Installation

BKS001GY

MAP LAMP, PERSONAL LAMP
Removal
1.

I

J

Insert a screwdriver A or the like wrapped in a cloth into the lens
notch and remove lamp lens (1).
LT

L

M
MKIB2202E

2.
3.

Pull the lamp (1) out forward while shifting the tabs with a screwdriver A or similar tool.
Disconnect lamp connector.

MKIB2295E

Installation
Installation is the reverse order of removal.

LT-171

INTERIOR ROOM LAMP
LUGGAGE ROOM LAMP
Removal
1.
2.

Pull the luggage room lamp.
Disconnect luggage room lamp connector.

MKIB2298E

Installation
Installation is the reverse order of removal.

LT-172

ILLUMINATION
ILLUMINATION
System Description

PFP:27545

A
BKS001GZ

The control of the illumination lamps operation is dependent upon the position of the lighting switch. When the
lighting switch is placed in the 1ST or 2ND position (or if the auto light system is activated) BCM (body control B
module) receives input signal requesting the illumination lamps to illuminate. This input signal is communicated to IPDM E/R (intelligent power distribution module engine room) across CAN communication lines. CPU
(central processing unit) located in the IPDM E/R controls the tail lamp relay coil. This relay, when energized,
C
directs power to the illumination lamps, which then illuminate.
Power is supplied at all times
●
to ignition relay, located in IPDM E/R and
D
●
to tail lamp relay, located in IPDM E/R, from battery directly,
●
through 20A fuse (No. 61, located in IPDM E/R),
●
through 20A fuse (No. 62, located in IPDM E/R),
E
●
through 40A fusible link (letter J, located in fuse, fusible link and relay box)
●
to BCM terminals 74 and 79
●
to power window main switch (illumination) terminal
F
5 [with front power window (LHD models)],
6 [with front power window (RHD models)] or
19 (with front & rear power window),
G
●
through 10A fuse [No. 9, located in fuse block (J/B)]
●
to BCM terminal 72,
●
through 10A fuse [No. 7, located in fuse block (J/B)]
H
●
to combination meter terminal 27.
With the ignition switch in the ON or START position, power is supplied
I
●
to ignition relay, located in IPDM E/R,
●
through 10A fuse [No. 5, located in fuse block (J/B)]
●
to BCM terminal 24 and
J
●
through 10A fuse [No. 4, located in fuse block (J/B)]
●
to combination meter terminal 28.
Ground is supplied
LT
●
to BCM terminals 2 and 70
●
to combination meter terminals 21, 22 and 23
●
to power window main switch (illumination) terminal
L
12 (with front power window) or
17 (with front & rear power window)
●
through grounds M21 and M66,
M
●
to IPDM E/R terminals 3 and 54
●
through grounds E45 (CR and HR engine models), E28 and E44.

ILLUMINATION OPERATION BY LIGHTING SWITCH
With the lighting switch in the 1ST or 2ND position (or if the auto light system is activated), BCM receives input
signal requesting the illumination lamps to illuminate. This input signal is communicated to IPDM E/R across
CAN communication lines. CPU located in the IPDM E/R controls the tail lamp relay coil, which, when energized, directs power
●
through 10A fuse (No. 46, located in IPDM E/R),
●
through IPDM E/R terminal 15
●
to door lock/unlock switch (illumination) terminal 4
●
to heated seat switch RH and LH (illumination) terminal 5 (with heated seat)
●
through 10A fuse (No. 45, located in IPDM E/R),
●
through IPDM E/R terminal 16
●
to audio unit (illumination) terminal 36 (with audio)
●
to heater control panel (illumination) terminal 5 (without auto A/C)

LT-173

ILLUMINATION
to A/C auto amplifier (illumination) terminal 16 (with auto A/C)
to mirror control switch (illumination) terminal 10 (with retract)
●
to hazard switch (illumination) terminal 3
●
to power socket for cigarette lighter (illumination) terminal 3
●
to headlamp aiming switch (illumination) terminal 3
●
to A/T device (illumination) terminal 3 (with A/T)
●
to ESP OFF switch (illumination) terminal 3 (with ESP)
●
to headlamp washer switch (illumination) terminal 3 (with headlamp washer).
Ground is supplied
●
to door lock/unlock switch (illumination) terminal 3
●
to audio unit (illumination) terminal 4 (with audio)
●
to heater control panel (illumination) terminal 6 (without auto A/C)
●
to A/C auto amplifier (illumination) terminal 5 (with auto A/C)
●
to mirror control switch (illumination) terminal 3 (with retract)
●
to hazard switch (illumination) terminal 4
●
to power socket for cigarette lighter (illumination) terminal 2
●
to headlamp aiming switch (illumination) terminal 4
●
to A/T device (illumination) terminal 4 (with AT)
●
to ESP OFF switch (illumination) terminal 4 (with ESP)
●
to headlamp washer switch (illumination) terminal 4 (with headlamp washer)
●
through grounds M21and M66,
●
to heated seat switch RH and LH (illumination) terminal 6 (with heated seat)
●
through grounds B13,B28,B38 and B48
With power and ground supplied, illumination lamps illuminate.
●
●

EXTERIOR LAMP BATTERY SAVER CONTROL
Refer to LT-9, «EXTERIOR LAMP BATTERY SAVER CONTROL» .

CAN Communication System Description

BKS001H0

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

CAN Communication Unit

BKS001H1

Refer to LAN-27, «CAN Communication Unit» .

LT-174

ILLUMINATION
Schematic

BKS001H2

A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4370E

LT-175

ILLUMINATION
Wiring Diagram — ILL —

BKS001H3

MKWA4371E

LT-176

ILLUMINATION
A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4372E

LT-177

ILLUMINATION

MKWA4373E

LT-178

ILLUMINATION
A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4374E

LT-179

ILLUMINATION

MKWA4375E

LT-180

ILLUMINATION
A

B

C

D

E

F

G

H

I

J

LT

L

M

MKWA4376E

LT-181

ILLUMINATION

MKWA4377E

LT-182

BULB SPECIFICATIONS
BULB SPECIFICATIONS
Headlamp

PFP:26297

A
BKS001H5

Item

Wattage (W)

High/Low (Halogen type)

Exterior Lamp

BKS001H6

Item

Rear combination lamp

C

Wattage (W)

Turn signal lamp
Front combination lamp

B

60/55 (H4)

21 (amber)

Parking lamp

5

Stop/Tail lamp

21/5

Turn signal lamp

D

16 (amber)

Back-up lamp

E

16

Front fog lamp

35 (H8)

Side turn signal lamp

5

Rear fog lamp

21

License plate lamp

5

High-mounted stop lamp

16

Interior Lamp/Illumination

F

G
BKS001H7

Item

Wattage (W)

Map lamp

5

Personal lamp

5

Luggage room lamp

10

H

I

J

LT

L

M

LT-183

BULB SPECIFICATIONS

LT-184

MAINTENANCE

L MAINTENANCE

SECTION

MA

MAINTENANCE

A

B

C

D

CONTENTS
PREPARATION ………………………………………………….. 3
Special Service Tools ……………………………………….. 3
Commercial Service Tool ………………………………….. 4
DESCRIPTION …………………………………………………… 5
Pre-delivery Inspection Items …………………………….. 5
GENERAL MAINTENANCE ………………………………… 7
General Maintenance ……………………………………….. 7
PERIODIC MAINTENANCE ………………………………… 8
Periodic Maintenance ……………………………………….. 8
ENGINE AND EMISSION CONTROL MAINTENANCE (CR ENGINE) …………………………………… 8
CHASSIS AND BODY MAINTENANCE (CR
ENGINE) ……………………………………………………… 9
ENGINE AND EMISSION CONTROL MAINTENANCE (HR ENGINE) …………………………………. 10
CHASSIS AND BODY MAINTENANCE (HR
ENGINE) ……………………………………………………..11
ENGINE AND EMISSION CONTROL MAINTENANCE (K9K ENGINE) ………………………………… 12
CHASSIS AND BODY MAINTENANCE (K9K
ENGINE) ……………………………………………………. 13
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS ……………………………………………… 14
ENGINE AND EMISSION CONTROL MAINTENANCE (CR ENGINE) …………………………………. 16
CHASSIS AND BODY MAINTENANCE (CR
ENGINE) ……………………………………………………. 17
ENGINE AND EMISSION CONTROL MAINTENANCE (HR ENGINE) …………………………………. 18
CHASSIS AND BODY MAINTENANCE (HR
ENGINE) ……………………………………………………. 19
ENGINE AND EMISSION CONTROL MAINTENANCE (K9K ENGINE) ………………………………… 20
CHASSIS AND BODY MAINTENANCE (K9K
ENGINE) ……………………………………………………. 21
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS ……………………………………………… 22
RECOMMENDED FLUIDS AND LUBRICANTS …… 24
Fluids and Lubricants ……………………………………… 24
SAE Viscosity Number ……………………………………. 25

GASOLINE ENGINE ……………………………………. 25
DIESEL ENGINE …………………………………………. 25
Engine Coolant Mixture Ratio …………………………… 26
ENGINE MAINTENANCE (CR) …………………………… 27
Checking Drive Belts ………………………………………. 27
Tension Adjustment ………………………………………… 27
ALTERNATOR AND A/C COMPRESSOR BELT
(WITH A/C MODELS) …………………………………… 28
ALTERNATOR BELT (WITHOUT A/C MODELS)… 28
WATER PUMP BELT ……………………………………. 29
Changing Engine coolant ………………………………… 29
DRAINING ENGINE COOLANT …………………….. 29
REFILLING ENGINE COOLANT ……………………. 29
FLUSHING COOLING SYSTEM ……………………. 31
Checking Cooling System ……………………………….. 31
CHECKING COOLING SYSTEM HOSES ……….. 31
CHECKING RADIATOR ……………………………….. 31
CHECKING COOLING SYSTEM FOR LEAKS … 32
Checking Radiator Cap (Models without A/C) …….. 32
Checking Reservoir Tank Cap (Models with A/C)… 33
Checking Fuel Lines ……………………………………….. 33
Changing Air Cleaner Filter ……………………………… 34
REMOVAL ………………………………………………….. 34
INSTALLATION …………………………………………… 34
Changing Engine Oil ……………………………………….. 34
Changing Oil Filter ………………………………………….. 35
Changing Spark Plugs …………………………………….. 36
REMOVAL ………………………………………………….. 36
INSPECTION AFTER REMOVAL ………………….. 36
INSTALLATION …………………………………………… 37
Checking EVAP Vapor Lines ……………………………. 37
ENGINE MAINTENANCE (HR16DE) …………………… 38
Checking Drive Belts ………………………………………. 38
Tension Adjustment ………………………………………… 38
Changing Engine Coolant ………………………………… 39
DRAINING ENGINE COOLANT …………………….. 39
REFILLING ENGINE COOLANT ……………………. 40
FLUSHING COOLING SYSTEM ……………………. 41
Checking Cooling System ……………………………….. 41
CHECKING COOLING SYSTEM HOSES ……….. 42

MA-1

E

F

G

H

I

J

K

MA

M

CHECKING RADIATOR ……………………………….. 42
CHECKING COOLING SYSTEM FOR LEAKS … 42
Checking Radiator Cap (M/T Models without A/C
and A/T Models) …………………………………………….. 43
Checking Reservoir Tank Cap (M/T Models with A/
C) …………………………………………………………………. 44
Checking Fuel Lines ……………………………………….. 44
Changing Air Cleaner Filter ……………………………… 44
REMOVAL ………………………………………………….. 44
INSPECTION AFTER REMOVAL …………………… 44
INSTALLATION ……………………………………………. 45
Changing Engine Oil ……………………………………….. 45
Changing Oil Filter ………………………………………….. 46
REMOVAL ………………………………………………….. 46
INSTALLATION ……………………………………………. 46
INSPECTION AFTER INSTALLATION ……………. 46
Changing Spark Plug (Platinum-Tipped Type) ……. 47
REMOVAL ………………………………………………….. 47
INSPECTION AFTER REMOVAL …………………… 47
INSTALLATION ……………………………………………. 48
Checking EVAP Vapor Lines ……………………………. 48
ENGINE MAINTENANCE (K9K) …………………………. 49
Checking Drive Belts ………………………………………. 49
TENTION ADJUSTMENT ……………………………… 49
Changing Engine coolant ………………………………… 49
DRAINING ENGINE COOLANT …………………….. 49
REFILLING ENGINE COOLANT ……………………. 50
FLUSHING COOLING SYSTEM ……………………. 50
Checking Cooling System ……………………………….. 51
CHECKING COOLING SYSTEM HOSES ……….. 51
CHECKING RADIATOR ……………………………….. 51
Checking Reservoir Tank Cap ………………………….. 51
Checking Radiator ………………………………………….. 52
Checking Fuel Lines ……………………………………….. 52
Changing Air Cleaner Filter ……………………………… 52
REMOVAL ………………………………………………….. 52
INSTALLATION ……………………………………………. 53
Changing Engine Oil ……………………………………….. 53
Changing Oil Filter ………………………………………….. 54
REMOVAL ………………………………………………….. 54
INSTALLATION ……………………………………………. 54
CHASSIS AND BODY MAINTENANCE ………………. 55

Checking Exhaust System ………………………………..55
Checking Clutch Fluid Level and Leaks ………………55
Checking Clutch System …………………………………..55
Checking M/T Oil …………………………………………….55
Changing M/T Oil …………………………………………….56
Checking A/T Fluid …………………………………………..56
Changing A/T Fluid ………………………………………….57
Rotation ………………………………………………………….57
Checking Brake Fluid Level and Leaks ……………….58
Checking Brake Lines and Cables ……………………..58
Changing Brake Fluid ………………………………………58
Checking Disc Brake ………………………………………..58
ROTOR ……………………………………………………….58
CALIPER ……………………………………………………..59
PAD …………………………………………………………….59
Checking Drum Brake ………………………………………59
WHEEL CYLINDER ………………………………………59
DRUM …………………………………………………………59
LINING ………………………………………………………..59
Checking Steering Gear and Linkage …………………60
STEERING GEAR ………………………………………..60
STEERING LINKAGE ……………………………………60
Axle and Suspension Parts ……………………………….60
Drive Shaft ……………………………………………………..60
Lubricating Locks, Hinges and Hood Latches ………61
Checking Seat Belts, Buckles, Retractors, Anchors
and Adjusters ………………………………………………….61
Checking Body Corrosion …………………………………61
HEMMED PANELS ……………………………………….62
PANEL JOINT ………………………………………………62
PANEL EDGE ………………………………………………62
PARTS CONTACT ………………………………………..62
PROTECTORS …………………………………………….62
ANTI-CORROSION MATERIALS ……………………62
DRAIN HOLES ……………………………………………..62
SERVICE DATA AND SPECIFICATIONS (SDS) ……63
Standard and Limit …………………………………………..63
BELT DEFLECTION AND TENSION ……………….63
ENGINE COOLANT CAPACITY ……………………..64
ENGINE OIL CAPACITY ………………………………..64
SPARK PLUG ………………………………………………65
SPARK PLUG (PLATINUM-TIPPED TYPE) ……..65

MA-2

PREPARATION
PREPARATION
Special Service Tools

PFP:00002

A
BLS0003G

NISSAN tool number
(RENAULT tool number)
Tool name

Description

KV10115801
Oil filter wrench
(For CR and HR engine)

B

Removing and installing oil filter

C

D
S-NT772

KV113C0010
(Mot. 1329)
Oil filter wrench
(For K9K engine)

Removing and installing oil filter

E

F
MBIB0369E

EG17650301
Radiator cap tester adapter

Adapter radiator cap tester to radiator filler
neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)

H

I

S-NT564

—
(M.S. 554_07)
Tester

G

Leak checking
Checking reservoir tank and reservoir tank
cap

J

K
MLIA0012E

—
(M.S. 554_01)
Reservoir tank tester adapter

Adapting tester to reservoir tank

MA

M
MLIA0013E

—
(M.S. 554_06)
Reservoir tank cap tester adapter

Adapting tester to reservoir tank cap

MLIA0014E

MA-3

PREPARATION
Commercial Service Tool

BLS0003H

Tool name

Description

Radiator cap tester

Checking radiator and radiator cap

PBIC1982E

Spark plug wrench

Removing and installing spark plug

NT047

MA-4

DESCRIPTION
DESCRIPTION
Pre-delivery Inspection Items

PFP:00000

A
BLS0003I

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

B

C

D

E

F

G

H

I

J

K

MA

M

MA-5

DESCRIPTION

MLIB0002E

MA-6

GENERAL MAINTENANCE
GENERAL MAINTENANCE
General Maintenance

PFP:00000

A
BLS0003K

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

B

OUTSIDE THE VEHICLE
The maintenance items listed here should be performed from time to time, unless otherwise specified.
Item
Tyres

Windshield wiper
blades
Doors and engine
hood

Tyre rotation

C
Reference page

Check the pressure with a gauge periodically when at a service station, including the spare, and adjust to the specified pressure if necessary. Check carefully
for damage, cuts or excessive wear.

—

Check for cracks or wear if not functioning correctly.

—

D

E
Check that all doors and the engine hood operate smoothly as well as the back
door and glass hatch. Also ensure that all latches lock securely. Lubricate if necessary. Make sure that the secondary latch keeps the hood from opening when
the primary latch is released.
When driving in areas using road salt or other corrosive materials, check for
lubrication frequently.
Tyres should be rotated every 10,000 km (6,000 miles).

BL-7, BL-195

F

MA-57

G

INSIDE THE VEHICLE
The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the
vehicle, etc.
Item
Reference page
Lamps

Warning lamps and
chimes
Steering wheel

Seat belts

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

—

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

—

H

I

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

—

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

SB-3

K

MA

UNDER THE HOOD AND VEHICLE
The maintenance items listed here should be checked periodically. e.g. each time you check the engine oil or refuel.
Item
Reference page
Windshield washer
fluid

Check that there is adequate fluid in the tank.

Engine coolant level

Check the coolant level when the engine is cold.

Engine oil level

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

LU-6, LU-16 , LU-23

Brake and clutch fluid
levels

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

MA-58, MA-55

Battery

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

—

MA-7

—
CO-8, CO-27 , CO-48

M

PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
Periodic Maintenance

PFP:00026
BLS0003L

The following tables show the normal maintenance schedule. Depending upon weather and atmospheric conditions, varying road surfaces, individual driving habits and vehicle usage, additional or more frequent maintenance may be required.
Periodic maintenance beyond the last period shown on the tables requires similar maintenance.

ENGINE AND EMISSION CONTROL MAINTENANCE (CR ENGINE)
(Annual Mileage <30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary,
MAINTENANCE OPERATION

R = Replace.

MAINTENANCE INTERVAL

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

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

20
(12)
12

40
(24)
24

60
(36)
36

80
(48)
48

100
(60)
60

120
(72)
72

Reference
page

Engine compartment and under vehicle
Intake and exhaust valve clearance

See NOTE (1)

Drive belts

See NOTE (2)

Engine oil (Use recommended oil.)
Engine oil filter (Use NISSAN genuine part or equivalent)
Engine anti-freeze coolant (Use Nissan Genuine
Coolant L250 or equivalent in its quality.)

EM-47
I

I

I

I

I

I

EM-14

R

R

R

R

R

R

LU-6

R

R

R

R

R

R

LU-9

See NOTE (3)

Cooling system

I
I

Fuel lines

I

R
I

I

I

I

Fuel filter (In-tank type)

I

CO-8

I

FL-3

R

EM-18

I
R

Air cleaner filter

CO-8

See NOTE (4)

FL-4

Spark plugs [Platinum-Tipped Type] (except for Russia and Ukraine)

R

Spark plugs [Platinum-Tipped Type] (for Russia and
Ukraine)

Replace every 30,000 km (18,000 miles)

EVAP vapor lines (With carbon canister)
Heated oxygen sensor 1

R

I

I

See NOTE (5)

MA-36
MA-36

I

EC-40 or
EC-469
EC-183 or
EC-582

NOTE:
●

Maintenance items with “
Conditions”.

” should be performed more frequently according to “Maintenance Under Severe Driving

●

(1) Periodic maintenance is not required. However, if valve noise increases, check valve clearance.

●

(2) Replace the drive belts if found damaged.

●

(3) First replace at 100,000 Km (60,000 miles)/60 months, then every 60,000 km (36,000 miles)/36 months. Perform “I”
(Checking the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement interval.

●

(4) Fuel filter is maintenance-free item. For service procedures, refer to FL-4 .

●

(5) Perform only according to “Maintenance Under Severe Driving conditions” for models without Euro-OBD system. For
models with Euro-OBD system, periodic maintenance is not required.

MA-8

PERIODIC MAINTENANCE
CHASSIS AND BODY MAINTENANCE (CR ENGINE)
A

(Annual Mileage <30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary,
MAINTENANCE OPERATION

R = Replace.

MAINTENANCE INTERVAL

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

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

20
(12)
12

40
(24)
24

60
(36)
36

80
(48)
48

100
(60)
60

120
(72)
72

Reference
page

B

C

Underhood and under vehicle
Headlamp aiming

I

I

I

I

I

I

LT-30

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

I

I

I

I

I

I

MA-58, MA-55

D

Brake fluid

R

R

R

MA-58

Brake booster vacuum hoses, connections
& check valve

I

I

I

BR-17

I

MA-55
MA-60, MA-60
, MA-60 , MA55

F

I

G

Manual transaxle gear oil (For leaks)

I

Steering gear & linkage, axle & suspension

I

I

parts, front drive shafts & exhaust system
Wheel alignment (If necessary, balance &
rotate wheels)
Brake pads, rotors, linings, drums & other
brake components
Foot brake, parking brake & clutch (For free
play, stroke & operation)

I

I

I

I

I

I

I

I

I

FSU-15

I

I

I

I

I

I

MA-59, MA-59
, MA-58

I

BR-6, PB-3 ,
CL-6

R

ATC-129,
MTC-75

I

I
R

Air conditioner filter
Body corrosion

I

See NOTE (1)

I

I
R

I

Maintenance items with “
Conditions”.

●

(1) Inspect once per year.

H

I

MA-61

J

NOTE:
●

E

” should be performed more frequently according to “Maintenance Under Severe Driving

K

MA

M

MA-9

PERIODIC MAINTENANCE
ENGINE AND EMISSION CONTROL MAINTENANCE (HR ENGINE)
(Annual Mileage <30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary,
MAINTENANCE OPERATION

R = Replace, [ ] = At the specified mileage only.

MAINTENANCE INTERVAL

Perform on a kilometer basis, but on an annual
basis when driving less than 30,000 km (18,000
miles) per 2 years.

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

30
(18)
24

60
(36)
48

90
(54)
72

120
(72)
96

Reference
page

Engine compartment and under vehicle
Intake and exhaust valve clearance

See NOTE (1)

Drive belts

See NOTE (2)

EM-166
I

I

I

I

EM-114

R

R

R

R

LU-16

R

R

R

R

LU-19

I

I

R

I

CO-27

Cooling system

I

I

I

I

CO-27

Fuel lines

I

I

I

I

FL-14

R

EM-118

Engine oil (Use recommended oil.)
Engine oil filter (Use NISSAN genuine part or
equivalent in its quality)
Engine anti-freeze coolant (Use Nissan Genuine
Coolant L250 or equivalent in its quality.)

See NOTE (3)

R

Air cleaner filter
Fuel filter (In-tank type)

See NOTE (4)

FL-15

Spark plugs [Platinum-Tipped Type] (except for
Russia and Ukraine)

[R]

Spark plugs [Platinum-Tipped Type] (for Russia
and Ukraine)
EVAP vapor lines (With carbon canister)

Heated oxygen sensor 1

EM-133

[R]

[R]

[R]

[R]

EM-133

I

I

I

I

EC-823
or EC1257

See NOTE (5)

EC-959
or EC1373

NOTE:
●

Maintenance items with “
Conditions”.

” should be performed more frequently according to “Maintenance Under Severe Driving

●

(1) Periodic maintenance is not required. However, if valve noise increases, check valve clearance.

●

(2) Replace the drive belts if found damaged.

●

(3) First replace at 90,000 Km (54,000 miles)/60 months, then every 60,000 km (36,000 miles)/48 months. Perform “I”
(Checking the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement interval.

●

(4) Fuel filter is maintenance-free item. For service procedures, refer to FL-15 .

●

(5) Perform only according to “Maintenance Under Severe Driving conditions” for models without Euro-OBD system. For
models with Euro-OBD system, periodic maintenance is not required.

MA-10

PERIODIC MAINTENANCE
CHASSIS AND BODY MAINTENANCE (HR ENGINE)
A

(Annual Mileage <30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary,
MAINTENANCE OPERATION

R = Replace.

MAINTENANCE INTERVAL

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

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

15
(9)
12

30
(18)
24

45
(27)
36

60
(36)
48

75
(45)
60

90
(54)
72

105
(63)
84

120
(72)
96

Reference
page

Underhood and under vehicle

C

Headlamp aiming

I

I

I

I

LT-30

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

I

I

I

I

MA-58, MA55

Brake fluid

R

R

R

R

MA-58

Brake booster vacuum hoses, connections & check valve

I

I

I

I

BR-17

I

MA-56

Automatic transaxle fluid (For level &

I

leaks)

I

I

I

I

I

I

D

E

F

Manual transaxle gear oil (For leaks)

I

I

I

I

MA-55

Steering gear & linkage, axle & suspension parts, front drive shafts &

I

I

I

I

MA-60, MA60 , MA-60 ,
MA-55

I

I

I

I

FSU-15

exhaust system
Wheel alignment (If necessary, balance & rotate wheels)

G

H

Brake pads, rotors, linings, drums &

I

I

I

I

MA-59, MA59 , MA-58

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

I

I

I

I

BR-6, PB-3 ,
CL-6

Air conditioner filter

R

R

R

R

ATC-129,
MTC-75

other brake components

Body corrosion

B

See NOTE (1)

I

J

MA-61

NOTE:
●

Maintenance items with “
Conditions”.

●

(1) Inspect once per year.

” should be performed more frequently according to “Maintenance Under Severe Driving

K

MA

M

MA-11

PERIODIC MAINTENANCE
ENGINE AND EMISSION CONTROL MAINTENANCE (K9K ENGINE)
(Annual Mileage <30,000 Km/year)
Abbreviations: R = Replace, I = Inspect: Correct or replace if necessary, D = Check filter and drain water, [ ]= At the specified mileage
only.
MAINTENANCE OPERATION

MAINTENANCE INTERVAL

Perform on a kilometer basis, but on an annual
basis when driving less than 20,000 km (12,000
miles) per year.

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

20
(12)
12

40
(24)
24

60
(36)
36

80
(48)
48

100
(60)
60

120
(72)
72

Reference
page

Engine compartment and under vehicle
See NOTE (1)

Engine oil (Use recommended oil.)
Engine oil filter (Use recommended oil filter)
Timing belt

See NOTE (2)

Drive belt

See NOTE (3)

R

R

R

R

R

R

LU-23

R

R

R

R

R

R

LU-25

Replace every 120,000 km (72,000 miles)/60
months

Cooling system
Engine anti-freeze coolant (Use Nissan Genuine
Coolant L250 or equivalent in its quality)

I

I

I

I

I

I

EM-242

I

I

I

I

I

I

CO-48

See NOTE (4)

I

R
R

Air cleaner filter
Intake & exhaust valve clearance

See NOTE (5)

CO-48
R

Inspect every 100,000 km (60,000 miles)

Fuel lines

I
D

Fuel filter

EM-272

[R]

I
D

[R]

D

EM-245
EM-292

I

FL-25

[R]

FL-26

NOTE:
●

Maintenance items with “
Conditions”.

” should be performed more frequently according to “Maintenance Under Severe Driving

●

(1) Maximum 20,000 km (12,000 miles) with one refilling allowed between 2 oil changes or 1 year.

●

(2) The replacement interval for the timing belt is the maximum lifespan which should not be exceeded. Replace the timing belt if it comes into contact with fuel. The frequency of replacement should be adapted depending on vehicle usage.
See “Maintenance Under Severe Driving Conditions”.

●

(3) Replace every 120,000 km (72,000 miles)/maximum 60 months. Replace drive belt if it comes into contact with fuel or
damage is found during inspection.

●

(4) First replace at 100,000 km (60,000 miles)/60 months, then every 60,000 km (36,000 miles)/36 months. After first
replacement, perform “I” (Checking the mixture ratio and correcting the mixture ratio if necessary) at the middle of
replacement interval.

●

(5) If valve noise increases, check valve clearance.

MA-12

PERIODIC MAINTENANCE
CHASSIS AND BODY MAINTENANCE (K9K ENGINE)
A

(Annual Mileage <30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary,
MAINTENANCE OPERATION

R = Replace.

MAINTENANCE INTERVAL

Perform on a kilometer basis, but on an
annual basis when driving less than 20,000
km (12,000 miles) per year.

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

20
(12)
12

40
(24)
24

60
(36)
36

80
(48)
48

100
(60)
60

120
(72)
72

Reference
page

B

C

Underhood and under vehicle
Headlamp aiming

I

I

I

I

I

I

LT-30

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

I

I

I

I

I

I

MA-58, MA-55

D

Brake fluid

R

R

R

MA-58

Brake booster vacuum hoses, connections
& check valve

I

I

I

BR-17

I

MA-55
MA-60, MA-60
, MA-60 , MA55

F

I

G

Manual transaxle gear oil (For leaks)

I

Steering gear & linkage, axle & suspension

I

I

parts, front drive shafts & exhaust system
Wheel alignment (If necessary, rotate & balance wheels)
Brake pads, rotors, linings, drums & other
brake components
Foot brake, parking brake & clutch (For free
play, stroke & operation)

I

I

I

I

I

I

I

I

I

FSU-15

I

I

I

I

I

I

MA-59, MA-59
, MA-58

I

BR-6, PB-3 ,
CL-6

R

ATC-129,
MTC-75

I

I
R

Air conditioner filter
Body corrosion

I

See NOTE (1)

I

I
R

I

Maintenance items with “
Conditions”.

H

I

MA-61

J

NOTE:
● (1) Inspect once per year.
●

E

” should be performed more frequently according to “Maintenance Under Severe Driving

K

MA

M

MA-13

PERIODIC MAINTENANCE
MAINTENANCE UNDER SEVERE DRIVING CONDITIONS
(Annual Mileage <30,000 Km/year)
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is
mainly operated under severe driving conditions as shown below, more frequent maintenance must be performed on the following items as shown in the table.
Severe driving conditions
A — Driving in dusty conditions
B — Repeatedly driving short distances
C — Towing a trailer or caravan
D — Extensive idling
E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F — Driving in high humidity or mountainous areas
G — Driving in areas using salt or other corrosive materials
H — Driving on rough and/or muddy roads or in the desert
I — Driving with frequent use of braking or in mountainous areas
J — Frequent off road use or driving in water
K —Sustained high speed driving
L — For models without Euro-OBD system (For CR and HR petrol engine models)
L — Repeated short journeys, cold engine at low temperature (For K9K diesel engine models)
Maintenance operation: Check = Check and correct or replace as necessary.

Driving condition

Maintenance item

Maintenance
operation

A

.

A

.

B

.

B

.

.

.

C D .

.

.

.

.

D .

.

.

.

.

.

.

.

.

.

.

.

.

.

.

H .

.

.

.

.

.

.

.

.

.

.

L

L

Air cleaner filter

Engine oil &
engine oil filter

Heated oxygen
sensor 1

Timing belt

MA-34

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

MA-44

K9K engine
models

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

MA-52

CR engine
models

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

MA-34, MA-35

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

MA-45, MA-46

K9K engine
models

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

MA-53, MA-54

CR engine
models

Every 40,000 km
(24,000 miles) or 24
months

EC-178, EC577 , EC-756

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

EC-959, EC1373 , EC-1549

HR engine
models

HR engine
models

Replace

Replace

Inspect
HR engine
models
K9K engine
models

Replace

.

.

.

.

F

.

.

.

.

.

.

Brake fluid

Replace
HR and K9K
engine models

MA-14

More frequently

EM-272

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

CR engine
models
.

Reference page

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

CR engine
models
A

Maintenance interval

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

MA-58

PERIODIC MAINTENANCE

Driving condition

.

.

.

A

A

.

.

.

.

.

C

C

.

.

.

.

C .

.

.

.

.

.

.

.

.

.

.

.

.

.

.

H

H

Maintenance item

.

.

G H .

G H I

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

Automatic
transaxle fluid

Fuel filter

Steering gear
& linkage, axle
& suspension
parts, front
drive shafts &
exhaust system
Brake pads,
rotors, linings,
drums & other
brake components

Air conditioner
filter

Maintenance
operation

Maintenance interval

Replace

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

Check
filter &
drain
water

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

Replace

Every 20,000 km
(12,000 miles)

Inspect

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

HR and K9K
engine models

Inspect

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

CR engine
models

Inspect

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

Inspect

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

HR engine
models

K9K engine
models

CR engine
models

HR and K9K
engine models

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

CR engine
models
Replace
HR and K9K
engine models

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

Reference page

MA-57

A

B

C
FL-26

D

E
MA-60, MA-60 ,
MA-60 , MA-55

F

G
MA-58, MA-59

H

ATC-129, MTC75

I

J

K

MA

M

MA-15

PERIODIC MAINTENANCE
ENGINE AND EMISSION CONTROL MAINTENANCE (CR ENGINE)
(Annual Mileage >30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary,
MAINTENANCE OPERATION

MAINTENANCE INTERVAL

Perform at number of kilometers (miles) basis
only.

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

20
(12)

40
(24)

60
(36)

80
(48)

100
(60)

120
(72)

R = Replace,.
Reference
page

Engine compartment and under vehicle
Intake and exhaust valve clearance

See NOTE (1)

Drive belts

See NOTE (2)

Engine oil (Use recommended oil.)
Engine oil filter (Use NISSAN genuine part or
equivalent)
Engine anti-freeze coolant (Use Nissan Genuine
Coolant L250 or equivalent in its quality.)

See NOTE (3)

Cooling system

EM-47
I

I

I

I

I

I

EM-14

R

R

R

R

R

R

MA-34

R

R

R

R

R

R

LU-9

I

R

I

I

CO-8
I

CO-8

Fuel lines

I

I

FL-3

Air cleaner filter

R

R

EM-18

Fuel filter (In-tank type)

See NOTE (4)

FL-4

Spark plugs [Platinum-Tipped Type] (except for
Russia and Ukraine)

R

Spark plugs [Platinum-Tipped Type] (for Russia
and Ukraine)

R

MA-36

Replace every 30,000 km (18,000 miles)

MA-36

EVAP vapor lines (With carbon canister)
Heated oxygen sensor 1

I
See NOTE (5)

I

EC-40 or EC469
EC-178, or
EC-756

NOTE:
●

Maintenance items with “
Conditions”.

” should be performed more frequently according to “Maintenance Under Severe Driving

●

(1) Periodic maintenance is not required. However, if valve noise increases, check valve clearance.

●

(2) Replace the drive belts if found damaged.

●

(3) First replace at 100,000 km (60,000 miles), then every 60,000 km (36,000 miles). Perform “I” (Checking the mixture ratio
and correcting the mixture ratio if necessary) at the middle of replacement interval.

●

(4) Fuel filter is maintenance-free item. For service procedures, refer to FL-4 .

●

(5) Perform only according to “Maintenance Under Severe Driving conditions” for models without Euro-OBD system. For
models with Euro-OBD system, periodic maintenance is not required.

MA-16

PERIODIC MAINTENANCE
CHASSIS AND BODY MAINTENANCE (CR ENGINE)
A

(Annual Mileage >30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace,
MAINTENANCE OPERATION

MAINTENANCE INTERVAL

Perform at number of kilometers (miles)
basis only.

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

20
(12)

40
(24)

60
(36)

80
(48)

100
(60)

120
(72)

L = Lubricate.
Reference
page

B

Underhood and under vehicle
Headlamp aiming

I

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

I

I

I
I

I

I

I

LT-30

I

MA-58, MA-55

D

Brake fluid

R

R

MA-58

Brake booster vacuum hoses, connections
& check valve

I

I

BR-17

I

MA-55

I

MA-60, MA-60
, MA-60 , MA55

I

FSU-6

Manual transaxle gear oil (For leaks)

I

I

Steering gear & linkage, axle & suspension

I

I

I

I

parts, front drive shafts & exhaust system
Wheel alignment (If necessary, rotate & balance wheels)

I

I

I

I

I

E

F

G

Brake pads, rotors, linings, drums & other
brake components
Foot brake, parking brake & clutch (For free
play, stroke & operation)

I

I

I

I

I

I

MA-59, MA-59
, MA-58

I

I

I

I

I

I

BR-6, PB-3 ,
CL-6

R

ATC-129,
MTC-75

R

Air conditioner filter
Body corrosion

C

See NOTE (1)

R

H

I

MA-61

NOTE:
●

Maintenance items with “
Conditions”.

●

(1) Inspect once per year.

” should be performed more frequently according to “Maintenance Under Severe Driving

J

K

MA

M

MA-17

PERIODIC MAINTENANCE
ENGINE AND EMISSION CONTROL MAINTENANCE (HR ENGINE)
(Annual Mileage >30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary,
MAINTENANCE OPERATION

MAINTENANCE INTERVAL

Perform at number of kilometers (miles) basis only.

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

30
(18)

60
(36)

90
(54)

120
(72)

R = Replace,.
Reference
page

Engine compartment and under vehicle
Intake and exhaust valve clearance

See NOTE (1)

Drive belts

See NOTE (2)

Engine oil (Use recommended oil.)
Engine oil filter (Use NISSAN genuine part or equivalent)
Engine anti-freeze coolant (Use Nissan Genuine Coolant L250 or equivalent in its quality.)

See NOTE (3)

Cooling system

EM-166
I

I

I

I

EM-114

R

R

R

R

LU-16

R

R

R

R

LU-19

I

I

R

I

CO-27

I

I

I

I

CO-27

Fuel lines

I

I

FL-14

Air cleaner filter

R

R

EM-118

Fuel filter (In-tank type)

See NOTE (4)

FL-15

Spark plugs [Platinum-Tipped Type] (except for Russia
and Ukraine)

R

Spark plugs [Platinum-Tipped Type] (Russia and
Ukraine)

R

EVAP vapor lines (With carbon canister)
Heated oxygen sensor 1

R

R

I
See NOTE (5)

EM-133
R

EM-133

I

EC-823 or
EC-1257
EC-959 or
EC-1373

NOTE:
●

Maintenance items with “
Conditions”.

” should be performed more frequently according to “Maintenance Under Severe Driving

●

(1) Periodic maintenance is not required. However, if valve noise increases, check valve clearance.

●

(2) Replace the drive belts if found damaged.

●

(3) First replace at 90,000 Km (54,000 miles), then every 60,000 km (36,000 miles). Perform “I” (Checking the mixture ratio
and correcting the mixture ratio if necessary) at the middle of replacement interval.

●

(4) Fuel filter is maintenance-free item. For service procedures, refer to FL-15 .

●

(5) Perform only according to “Maintenance Under Severe Driving conditions” for models without Euro-OBD system. For
models with Euro-OBD system, periodic maintenance is not required.

MA-18

PERIODIC MAINTENANCE
CHASSIS AND BODY MAINTENANCE (HR ENGINE)
A

(Annual Mileage >30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary,
MAINTENANCE OPERATION

MAINTENANCE INTERVAL

Perform at number of kilometers (miles) basis only.

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

15
(9)

30
(18)

45
(27)

60
(36)

75
(45)

90
(54)

105
(63)

120
(72)

R = Replace.
Reference
page

B

Underhood and under vehicle
Headlamp aiming

I

I

I

I

LT-30

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

I

I

I

I

MA-58, MA55

Brake fluid

R

R

MA-58

Brake booster vacuum hoses, connections & check
valve

I

I

BR-17

Automatic transaxle fluid (For level & leaks)

I

I

I

I

MA-56

Manual transaxle gear oil (For leaks)

I

I

I

I

MA-55

I

MA-60, MA60 , MA-60 ,
MA-55

Steering gear & linkage, axle & suspension parts,

I

front drive shafts & exhaust system
I

I

I

I

FSU-6

I

I

I

I

MA-59, MA59 , MA-58

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

I

I

I

I

BR-6, PB-3 ,
CL-6

Air conditioner filter

R

R

R

R

ATC-129,
MTC-75

Brake pads, rotors, linings, drums & other brake
components

See NOTE (1)

MA-61

NOTE:
●

Maintenance items with “
Conditions”.

●

(1) Inspect once per year.

D

E

F

G

Wheel alignment (If necessary, rotate & balance
wheels)

Body corrosion

C

H

I

J

” should be performed more frequently according to “Maintenance Under Severe Driving

K

MA

M

MA-19

PERIODIC MAINTENANCE
ENGINE AND EMISSION CONTROL MAINTENANCE (K9K ENGINE)
(Annual Mileage >30,000 Km/year)
Abbreviations: R = Replace I = Inspect and correct or replace as necessary
MAINTENANCE OPERATION

D= Check filter and drain water.

MAINTENANCE INTERVAL

Perform at number of kilometers (miles)
basis only.

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

20
(12)

40
(24)

60
(36)

80
(48)

100
(60)

120
(72)

Reference
page

Engine compartment and under vehicle
See NOTE (1)

Engine oil (Use recommended oil.)
Engine oil filter (Use recommended oil filter)
Timing belt

See NOTE (2)

Drive belt

See NOTE (3)

Cooling system
Engine anti-freeze coolant (Use Nissan
Genuine Coolant L250 or equivalent in its
quality.)

R

R

R

R

R

R

LU-23

R

R

R

R

R

R

LU-25

Replace every 120,000 km (72,000 miles)
I

I

I

I

I

I

I

I

I

I

See NOTE (4)

I

Intake & exhaust valve clearance

See NOTE (5)

R

I
D

R

D

R

D

CO-48
CO-48

Inspect every 100,000 km (60,000 miles)

Fuel lines
Fuel filter

EM-242
I

R
R

Air cleaner filter

EM-272

EM-245
EM-292

I

FL-25

R

FL-26

NOTE:
●

Maintenance items with “
Conditions”.

” should be performed more frequently according to “Maintenance Under Severe Driving

●

(1) Maximum 20,000 km (12,000 miles) with one refilling allowed between 2 oil changes or 1 year.

●

(2) The replacement interval for the timing belt is the maximum lifespan which should not be exceeded. Replace the timing belt if it comes into contact with fuel. The frequency of replacement should be adapted depending on vehicle usage.
See “Maintenance Under Severe Driving Conditions”.

●

(3) Replace every 120,000 km (72,000 miles). Replace drive belt if it comes into contact with fuel or damage is found during inspection.

●

(4) First replace at 100,000 km (60,000 miles), then every 60,000 km (36,000 miles). After first replacement, Perform “I”
(Checking the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement interval.

●

(5) If valve noise increases, check valve clearance.

MA-20

PERIODIC MAINTENANCE
CHASSIS AND BODY MAINTENANCE (K9K ENGINE)
A

(Annual Mileage >30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace,
MAINTENANCE OPERATION

MAINTENANCE INTERVAL

Perform at number of kilometers (miles)
basis only.

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

20
(12)

40
(24)

60
(36)

80
(48)

100
(60)

120
(72)

L = Lubricate.
Reference
page

B

Underhood and under vehicle
Headlamp aiming

I

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

I

I

I
I

I

I

I

LT-30

I

MA-58, MA-55

D

Brake fluid

R

R

MA-58

Brake booster vacuum hoses, connections
& check valve

I

I

BR-17

I

MA-55

I

MA-60, MA-60
, MA-60 , MA55

I

FSU-6

Manual transaxle gear oil (For leaks)

I

I

Steering gear & linkage, axle & suspension

I

I

I

I

parts, front drive shafts & exhaust system
Wheel alignment (If necessary, rotate & balance wheels)

I

I

I

I

I

E

F

G

Brake pads, rotors, linings, drums & other
brake components
Foot brake, parking brake & clutch (For free
play, stroke & operation)

I

I

I

I

I

I

MA-59, MA-59
, MA-58

I

I

I

I

I

I

BR-6, PB-3 ,
CL-6

R

ATC-129,
MTC-75

R

Air conditioner filter
Body corrosion

C

See NOTE (1)

R

H

I

MA-61

NOTE:
●

Maintenance items with “
Conditions”.

●

(1) Inspect once per year.

” should be performed more frequently according to “Maintenance Under Severe Driving

J

K

MA

M

MA-21

PERIODIC MAINTENANCE
MAINTENANCE UNDER SEVERE DRIVING CONDITIONS
(Annual Mileage >30,000 Km/year)
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is
mainly operated under severe driving conditions as shown below, more frequent maintenance must be performed on the following items as shown in the table.
Severe driving conditions
A — Driving in dusty conditions
B — Repeatedly driving short distances
C — Towing a trailer or caravan
D — Extensive idling
E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F — Driving in high humidity or mountainous areas
G — Driving in areas using salt or other corrosive materials
H — Driving on rough and/or muddy roads or in the desert
I — Driving with frequent use of braking or in mountainous areas
J — Frequent off road use or driving in water
K —Sustained high speed driving
L — For models without Euro-OBD system (For CR and HR petrol engine models)
L — Repeated short journeys, cold engine at low temperature (For K9K diesel engine models)
Maintenance operation: Check = Check and correct or replace as necessary.

Driving condition

Maintenance item

Maintenance
operation

Maintenance interval

CR engine
models
A

.

.

.

.

.

.

.

.

.

.

.

Air cleaner filter

HR engine
models

MA-34
Replace

Every 30,000 km
(18,000 miles)

K9K engine
models

B

C D .

.

.

.

.

.

.

.

Engine oil &
engine oil filter

HR engine
models

Every 10,000 km (6,000
miles)
Replace

K9K engine
models

Every 15,000 km (9,000
miles)

.

.

.

.

.

.

.

.

.

.

L

Heated oxygen
sensor 1

MA-34, MA35
MA-45, MA46
MA-53, MA54
EC-178, EC577 , EC-756

CR engine
models
.

MA-44
MA-52

CR engine
models
A

Reference
page

Inspect

Every 60,000 km
(36,000 miles)

HR engine
models

EC-959, EC1373 , EC1549

A

B

.

D .

.

.

H .

.

.

L

Timing belt

K9K engine
models

Replace

More frequently

EM-272

.

.

.

.

.

F

.

.

.

.

.

.

Brake fluid

All models

Replace

Every 30,000 km
(18,000 miles)

MA-58

.

.

C

.

.

.

.

H

.

.

.

.

Automatic
transaxle fluid

HR engine
models

Replace

Every 60,000 km
(36,000 miles)

MA-57

Check
filter &
drain
water

Every 15,000 km (9,000
miles)

Replace

Every 30,000 km
(18,000 miles)

.

.

C

.

.

.

.

H

.

.

.

.

Fuel filter

K9K engine
models

MA-22

FL-26

PERIODIC MAINTENANCE

Driving condition

.

A

A

.

.

.

.

.

C .

.

.

.

.

.

.

.

.

Maintenance item

G H .

G H I

.

.

.

.

.

.

.

.

.

.

.

.

Steering gear &
linkage, axle &
suspension
parts, drive
shafts &
exhaust system
Brake pads,
rotors, linings,
drums & other
brake components
Air conditioner
filter

Maintenance
operation

Maintenance interval

Reference
page

A

B
All models

Inspect

CR engine
models
HR and K9K
engine models
CR engine
models
HR and K9K
engine models

Every 30,000 km
(18,000 miles)

Every 10,000 km (6,000
miles)
Inspect

Replace

Every 15,000 km (9,000
miles)
Every 20,000 km
(12,000 miles)
Every 15,000 km (9,000
miles)

MA-60, MA60 , MA-60 ,
MA-55

MA-59, MA58 , MA-59

C

D

E
ATC-129,
MTC-75

F

G

H

I

J

K

MA

M

MA-23

RECOMMENDED FLUIDS AND LUBRICANTS
RECOMMENDED FLUIDS AND LUBRICANTS
Fluids and Lubricants

PFP:00000
BLS0003M

Capacity (Approximate)

Engine oil
Drain and
refill

With oil filter
change

Without oil filter change

Dry engine (engine overhaul)

CR engine

Cooling system (with reservoir)

HR engine

Liter

Imp measure

CR engine

3.4

3 qt

HR engine

4.6

4 qt

K9K engine

4.40

3-7/8 qt

CR engine

3.2

2-7/8 qt

HR engine

4.4

3-7/8 qt

K9K engine

4.24

3-3/4 qt

CR engine

3.9

3-3/8 qt

HR engine

4.8

4-1/4 qt

K9K engine

4.56

4 qt

Models with A/C

5.3

4-5/8 qt

Models without
A/C

4.9

4-3/8 qt

M/T models
without A/C

5.6

4-7/8 qt

M/T models
with A/C

6.0

5-1/4 qt

A/T models

5.4

4-3/4 qt

—

6.0

5-1/4 qt

Models with A/C

1.2

1-1/8 qt

Models without
A/C

0.7

5/8 qt

M/T models
without A/C

0.7

5/8 qt

M/T models
with A/C

1.2

1-1/8 qt

K9K engine
CR engine

Reservoir
tank

HR engine

A/T models

0.7

5/8 qt

1.2

1-1/8 qt

JH3

2.6

4-5/8 pt

JR5

2.5

4-3/8 pt

Automatic transaxle fluid

7.7

6-3/4 qt

Brake and clutch fluid

—

—

Multi-purpose grease

—

—

K9K engine
Manual transaxle gear oil

—

Recommended Fluids/Lubricants
●

CR engine
Nissan Genuine Oil
or API SG, SH or SJ*1
ILSAC grade GF-I or GF-II*1
ACEA A2

●

HR engine
Nissan Genuine Oil
or API SL*1
ILSAC Grade GF-III*1

●

K9K engine
Nissan Genuine Oil
or ACEA B3, B4

●

Nissan Genuine Coolant L250
or equivalent in its quality*3

●

Nissan Genuine gear oil Passenger Car
or API GL-4, Viscosity SAE 75W-80

●

Nissan Genuine ATF Matic D
or equivalent*4

●

Nissan Genuine Brake Fluid
or DOT 3 or DOT 4 (US FMVSS No. 116)*5

●

NLGI No. 2 (Lithium soap base)

*1: For further details, see “SAE Viscosity Number”.
*2: Never use API CG-4.
*3: Use Nissan Genuine Coolant L250 or equivalent in its quality, in order to avoid possible aluminum corrosion within the engine cooling
system caused by the use of non-genuine engine coolant.
Note that any repairs for the incidents within the engine cooling system while using non-genuine engine coolant may not be
covered by the warranty even if such incidents occurred during the warranty period.
*4: Contact a Nissan dealership for more information regarding suitable fluids, including recommended brand(s) of DEXRONTM III/MERCONTM Automatic Transaxle Fluid.
*5: Never mix different types of fluids (DOT 3 and DOT 4).

MA-24

RECOMMENDED FLUIDS AND LUBRICANTS
SAE Viscosity Number

BLS0003N

A

GASOLINE ENGINE
●

5W-30 is preferable.
If 5W-30 is not available, select the viscosity, from the chart, that
is suitable for outside temperature range.

B

C

D

E

F

G

H
SMA203D

DIESEL ENGINE
●

I

5W-30 is preferable.
If 5W-30 is not available, select the viscosity, from the chart, that
is suitable for outside temperature range.

J

K

MA

M

SMA204D

MA-25

RECOMMENDED FLUIDS AND LUBRICANTS
Engine Coolant Mixture Ratio

BLS0003O

The engine cooling system is filled at the factory with a high-quality,
year-round and extended life engine coolant. The high quality engine
coolant contains the specific solutions effective for the anti-corrosion
and the anti-freeze function. Therefore, additional cooling system
additives are not necessary.
CAUTION:
●
When adding or replacing coolant, be sure to use only
Nissan Genuine Coolant L250 or equivalent. Because L250
is premixed type coolant.
The use of other types of engine coolant may damage your
SMA089D
cooling system.
●
When checking the engine coolant mixture ratio by the coolant
hydrometer, use the chart below to correct your hydrometer reading (specific gravity) according to coolant
temperature.
Mixed coolant specific gravity
Unit: specific gravity
Coolant temperature °C (°F)

Engine coolant mixture
ratio

15 (59)

25 (77)

35 (95)

45 (113)

30%

1.046 — 1.050

1.042 — 1.046

1.038 — 1.042

1.033 — 1.038

50%

1.076 — 1.080

1.070 — 1.076

1.065 — 1.071

1.059 — 1.065

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could be caused by high pressure fluid escaping from the radiator. Wait until the engine and radiator cool down.

MA-26

ENGINE MAINTENANCE (CR)
ENGINE MAINTENANCE (CR)
Checking Drive Belts
●

●

●

●

PFP:00000

A
BLS0003P

Inspection should be done only when engine is cold or over 30
minutes after the engine is stopped.
Turn the clamp pulleys two times clockwise, and make sure tension on all pulleys is equal before doing the test.
Visually check the belts for wear, damage, and cracks on inside
and edges.

B

C

When measuring deflection, apply 98,1 N (10 kg, 22lb) at the
marked point.

D
PBIC1414E

E

F

G

H
PBIC1415E

CAUTION:
When measuring belt tension immediately after the belt is installed, first set the tension to the standard, rotate the crankshaft for more than two turns in order to eliminate variance in the tension
between pulleys, then measure and adjust tension to the standard again.
Deflection [mm (in)]
[When pressed by force of 98.1N (10 kg,
22lb)]

Tension [N (kg, lb)]
Location
New

Alternator and
A/C compressor belt

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

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

Alternator belt

Water pump belt

446 — 534 (45.5 — 54.5,
100.3 — 120.0)

At adjustment

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

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

348 — 436 (35.5 — 44.5,
78.2 — 98.0)

Tension Adjustment
Location

Limit

Measuring
point

New belt

At adjustment

Limit

A

6.6 — 7.8
(0.260 0.307)

7.3 — 8.5
(0.287 0.335)

13.8
(0.543)

B

5.6 — 6.6
(0.220 0.260)

7.1 — 8.3
(0.280 0.327)

11.9
(0.469)

A

3.1 — 4.1
(0.122 0.161)

9.8 — 10.6
(0.386 0.417)

13.8
(0.543)

C

6.7 — 7.3
(0.264 0.287)

7.6 — 8.6
(0.299 0.339)

12.4
(0.448)

D

4.7 — 5.6
(0.185 0.220)

7.0 — 7.7
(0.276 0.303)

8.6
(0.339)

196 (20,
44.1)

196 (20,
44.1)

137 (14,
30.9)

Alternator and A/C compressor
drive belt

Adjusting bolt on idler pulley

Water pump belt

Adjusting bolt on idler pulley

MA-27

J

K

MA

M

BLS0003Q

Location of adjuster and tightening
method

I

ENGINE MAINTENANCE (CR)
CAUTION:
●
When the belt is replaced with new one, adjust the belt tension to the value for “New belt”,
because new belt will not fully seat in the pulley groove.
●
When tension of the belt being used exceeds “Limit”, adjust it to the value for “At adjustment”.
●
When installing a belt, make sure that it is correctly engaged with the pulley groove.
●
Do not allow oil or engine coolant to get on the belt.
●
Do not twist or bend the belt strongly.

ALTERNATOR AND A/C COMPRESSOR BELT (WITH A/C MODELS)
1.
2.
3.
4.
5.

6.

Remove RH front fender protector.
Loosen lock nut (1).
Tighten lock nut (1) with fingers.
Loosen lock nut (1) half a turn counter-clockwise.
Adjust the belt tension by turning the adjuster bolt (2).
For the specified belt tension, refer to MA-27, «Checking Drive
Belts» .
Tighten lock nut (1).
Nut (1):
: 24.5 — 31.4 N·m (2.5 — 3.2 kg-m, 18 — 23 ft-lb)

7.
8.

Turn the crankshaft pulley two times clockwise.
Check that the belt tension is within the standard. Refer to MA27, «Checking Drive Belts» .

PBIC1290E

ALTERNATOR BELT (WITHOUT A/C MODELS)
1.
2.
3.
4.
5.

6.

Remove RH front fender protector.
Loosen lock nut (1).
Tighten lock nut (1) with fingers.
Loosen lock nut (1) half a turn counter-clockwise.
Adjust the belt tension by turning the adjuster bolt (2).
For the specified belt tension, refer to MA-27, «Checking Drive
Belts» .
Tighten lock nut (1).
Nut (1):
: 24.5 — 31.4 N·m (2.5 — 3.2 kg-m, 18 — 23 ft-lb)

7.
8.

Turn the crankshaft pulley two times clockwise.
Check that the belt tension is within the standard. Refer to MA27, «Checking Drive Belts» .

PBIC1416E

MA-28

ENGINE MAINTENANCE (CR)
WATER PUMP BELT
1.
2.
3.
4.
5.

A

Remove RH front fender protector.
Loosen lock nut (3).
Tighten lock nut (3) with fingers.
Adjust the belt tension by turning the adjuster bolt (4).
For the specified belt tension, refer to MA-27, «Checking Drive Belts» .
Tighten lock nut (3).

B

C

Nut (3) :
: 24.5 — 31.4 N·m (2.5 — 3.2 kg-m, 18 — 23 ft-lb)
6.
7.

D

Turn the crankshaft pulley two times clockwise.
Check that the belt tension is within the standard. Refer to MA-27, «Checking Drive Belts» .

Changing Engine coolant

BLS0003R

E

WARNING:
●
To avoid being scalded, never change the coolant when the engine is hot.
●
Wrap a thick cloth around radiator cap and carefully remove the cap. First, turn the cap a quarter
of a turn to release built-up pressure. Then turn the cap all the way.

F

DRAINING ENGINE COOLANT
Models without A/C

G

1.

2.
a.
b.

3.

Disconnect radiator lower hose and radiator cap.
CAUTION:
Make sure to drain when the engine coolant temperature is cold.

H

Remove reservoir tank and drain the engine coolant in the following procedures.
Move relay case in front of the battery.
Disconnect the reservoir tank from fan shroud to remove. With
force applied in the left direction of vehicle, pull up reservoir
tank.
Check drain coolant for contaminants such as rust, corrosion or
discoloration.
If contaminated, flush engine cooling system.
Refer to MA-31, «FLUSHING COOLING SYSTEM» .

I

J

K

PBIC1476E

MA

Models with A/C
1.

2.

Disconnect radiator lower hose and reservoir tank cap.
CAUTION:
Make sure to drain when the engine coolant temperature is cold.

M

Remove reservoir tank and drain the engine coolant.
: Vehicle front

3.

Check drain coolant for contaminants such as rust, corrosion or
discoloration.
If contaminated, flush engine cooling system.
Refer to MA-31, «FLUSHING COOLING SYSTEM» .

MBIB1360E

REFILLING ENGINE COOLANT
1.
2.

Install reservoir tank.
Connect radiator lower hose.

MA-29

ENGINE MAINTENANCE (CR)
3.

Disconnect heater hose (at heater hose outlet side: upper side)
as shown in figure. Keep hose end at the same height as that of
before removal.

PBIC1477E

4.

Fill radiator and reservoir tank to specified level.
● Pour coolant slowly of less than 2
(1-3/4 lmp qt) a
minute to allow air in system to escape.
● When coolant from heater hose starts to drain, connect
heater hose and continue to fill.
● Use Nissan Genuine Coolant L250 or equivalent mixed
with water (distilled or demineralized).
Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS».
SMA182B

Engine coolant capacity
Models without A/C
With reservoir tank

: Approx. 4.9

Reservoir tank

: 0.7

(4-3/8 Imp qt)

(5/8 lmp qt)

SMA412B

Models with A/C
With reservoir tank

: Approx. 5.3

Reservoir tank

: 1.2

(4-5/8 Imp qt)

(1-1/8 lmp qt)

: Vehicle front

MBIB1360E

MA-30

ENGINE MAINTENANCE (CR)
A

B

C
MBIA0092E

5.
6.

7.
8.
9.
10.
11.
12.
13.
14.

Warm up engine to normal operating temperature with radiator cap installed.
Warm up until thermostat opens. Keep warming at 3,000 rpm for approximately 10 minutes as guide.
● For thermostat opening, touch radiator upper hose by hand to insure that water flow is hot.
CAUTION:
Be careful not to overheat.
Stop the engine.
After cooling engine [approximately 50°C (122 °F) or lower], remove radiator cap and check coolant level.
If the level is low, fill up to the radiator neck again and repeat from step 5.
When the coolant level stabilizes, fill reservoir tank up to the “MAX” line.
Check cooling system for leaks with engine running.
Allow the engine to cool [approximately 50°C (122°F) or lower].
Start the engine. Perform the following cycle three times. Keep an engine speed of 1,000 rpm for approximately 30 seconds. Then increase it gradually to 3,000 rpm.
During the above step 12, make sure water flow sound is not heard from heater core.
● Sound may be noticeable at heater unit.
If water flow sound is heard, repeat from step 4 to 13.
● Clean excess coolant from engine.

E

F

G

H

I

J

FLUSHING COOLING SYSTEM
1.
2.
3.
4.
5.
6.

D

Fill radiator and reservoir tank with water and reinstall radiator cap.
Run engine and warm it up to normal operating temperature.
Rev engine two or three times under no-load.
Stop engine and wait until it cools down.
Drain water.
Repeat steps 1 through 5 until clear water begins to drain from radiator.

Checking Cooling System

K

MA
BLS0003S

WARNING:
Never remove the radiator cap when the engine is hot; serious burns could be caused by high pressure fluid escaping from the radiator.
Wrap a thick cloth around the cap and carefully remove it by turning it a quarter turn to allow built-up
pressure to escape and then turn the cap all the way off.

CHECKING COOLING SYSTEM HOSES
Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.

CHECKING RADIATOR
Check radiator for mud or clogging. If necessary, clean radiator as follows.
●
Be careful not to bend or damage the radiator fins.
●
When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator
shroud and horns. Then tape the harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downward.
2. Apply water again to all radiator core surfaces once per minute.
3. Stop washing if any stains no longer flow out from the radiator.

MA-31

M

ENGINE MAINTENANCE (CR)
4.

Blow air into the back side of radiator core vertically downward.

5.

Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2 , 71 psi) and keep distance more than 30 cm
(11.8 in).
Blow air again into all the radiator core surfaces once per minute until no water sprays out.
●

CHECKING COOLING SYSTEM FOR LEAKS
Models without A/C
●

To check for leakage, apply pressure to the cooling system with
a radiator cap tester (commercial service tool) and radiator cap
tester adapter (SST).
Testing pressure : 157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi)

●

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
If anything is found, repair or replace damaged parts.

SLC134B

Models with A/C
●

To check for leakage, fit the adapter to the reservoir tank (1),
and then connect it to the tester.

MBIB1362E

●
●

Warm up the engine and turn it off.
Apply pressure to the cooling system and stop pumping.
Testing pressure

●
●

: 90 kpa
(0.9 bar, 0.92 kg/cm2 , 13.1 psi)

If the pressure drops, look for leakage.
Unscrew slowly the adapter from the reservoir tank to reduce
the pressure in cooling system, and install the reservoir tank
cap.
WARNING:
Never remove the reservoir tank cap when the engine is
hot. Serious burns could occur from high pressure engine
coolant escaping from the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.

Checking Radiator Cap (Models without A/C)
1.

MBIA0094E

BLS0003T

Pull the negative-pressure valve to open it and check that it closes completely when released.
● Check that there is no dirt or damage on the valve seat of the radiator cap negative-pressure valve.

MA-32

ENGINE MAINTENANCE (CR)
●

Check that there are no unusual conditions in the opening
and closing conditions of the negative-pressure valve.

A

B

C
SMA967B

D

2.

Check radiator cap relief pressure.
Standard:
78 — 98 kPa
(0.78 — 0.98 bar, 0.8 — 1.0 kg/cm2 , 11 — 14 psi)
Limit:

E

F

59 kPa (0.59 bar, 0.6 kg/cm2 , 9 psi)
When connecting the radiator cap to the tester, apply water or
engine coolant to the cap seal part.
SLC135B
● Replace the radiator cap if there is an unusual conditions in
the negative-pressure valve, or if the open-valve pressure is
outside of the standard values.
CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue or foreign material.
●

Checking Reservoir Tank Cap (Models with A/C)
●
●

●

G

H

I

BLS0003U

Fit the adapter to the tester as shown.
When connecting the reservoir tank cap to the tester, apply
water or LLC to the cap seal part.
Check reservoir tank cap relief pressure.

J

K

2

88 kPa (0.88 bar, 0.90 kg/cm , 12.8 psi)
●

Replace the reservoir tank cap if the engine coolant passes
through it, or if any fur signs is detected.

MA

MBIB1079E

Checking Fuel Lines

BLS0003V

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

SMA803A

CAUTION:
Tighten high-pressure rubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end.

MA-33

M

ENGINE MAINTENANCE (CR)
Tightening torque specifications are the same for all rubber hose clamps.
Ensure that screw does not contact adjacent parts.

Changing Air Cleaner Filter

BLS0003W

REMOVAL
1.
2.
3.

4.

Remove air duct. Refer to EM-18, «REMOVAL» .
Remove clips (2) of air cleaner body (1).
After moving the air cleaner body downward, remove it by pulling it forward.
● While pressing down the radiator upper hose, remove air
cleaner body.
Remove air cleaner filter from the air cleaner body.
NOTE:
In some cases the air cleaner filter might remain in the air
cleaner case (upper).

PBIC1296E

INSTALLATION
1.
2.

3.

Set the air cleaner filter on the air cleaner case (upper) (1).
Insert the two projections (3) on the air cleaner body (2) into the
two notch holes (4) on the rear of the air cleaner case (upper)
(1), then lift up and fasten with the clip.
Attach air duct.

PBIC1297E

Changing Engine Oil

BLS0003X

WARNING:
●
Be careful not to burn yourself, as the engine oil is hot.
●
Prolonged and repeated contact with used engine oil may cause skin cancer: try to avoid direct
skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as
soon as possible.
1. Warm up engine put vehicle horizontally, and check for oil leakage from engine components.
2. Stop engine and wait for 10 minutes.
3. Remove oil filler cap, and remove drain plug.
4. Drain engine oil.
5. Install drain plug. Refill with new engine oil.
● Install drain plug washer in the direction shown in figure.
Oil specification and viscosity:
Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS».

PBIC1468E

MA-34

ENGINE MAINTENANCE (CR)
Oil capacity (Approximate):
Unit:
Drain and refill

With oil filter change

A

(Imp qt)

3.4 (3)

Without oil filter change

3.2 (2-7/8)

Dry engine (engine overhaul)

B

3.9 (3-3/8)

CAUTION:
●
Be sure to clean drain plug and install with new washer.

C

Oil pan drain plug:
: 29.4 — 39.2 N·m (3.0 — 3.9 kg-m, 22 — 28 ft-lb)
●

6.
7.
8.

The refill capacity depends on the oil temperature and drain time. Use these specifications for reference only.
Always use the dipstick to determine when the proper amount of oil is in the engine.
Warm up engine and check area around drain plug and oil filter for oil leakage.
Check oil level. Refer to LU-6, «Inspection» .
Stop engine and wait for 10 minutes.

Changing Oil Filter
1.

2.
3.

D

E

F

BLS0003Y

Using an oil filter wrench (special service tool), remove oil filter.
CAUTION:
● Be careful not to get burned when the engine and engine
oil are hot.
● When removing, prepare a shop cloth to absorb any oil
leakage or spillage.
● Do not allow engine oil to adhere to the drive belts.
● Completely wipe off any oil that adheres to the engine
and the vehicle.
Remove foreign materials adhering to the oil filter installation
surface.
Apply engine oil to the oil seal circumference of the new oil filter.
CAUTION:
● Use genuine NISSAN oil filter or the equivalent.

G

H

I

PBIC1469E

J

K

MA

M
SMA010

4.

Screw the oil filter manually until it touches the installation surface, then tighten it by 2/3 turn.
Oil filter:
:14.7 — 20.5 N·m (1.5 — 2.1 kg-m, 11 — 15 ft-lb)

5.
6.

After warming up the engine, check for engine oil leakage.
Check oil level and add engine oil. Refer to LU-6, «ENGINE OIL»
.
SMA229B

MA-35

ENGINE MAINTENANCE (CR)
Changing Spark Plugs

BLS0003Z

REMOVAL
1.
2.

Remove ignition coil. Refer to EM-29, «IGNITION COIL» .
Remove spark plugs with a spark plug wrench.
CAUTION:
Handle spark plug with care. Avoid impacts.

SMA581C

INSPECTION AFTER REMOVAL
●
●

–
–
●

–
–

Use standard type spark plug for normal condition.
The hot type spark plug is suitable when fouling occurs with the standard type spark plug under conditions
such as:
Frequent engine starts
Low ambient temperatures
The cold type spark plug is suitable when spark plug knock occurs with the standard type spark plug
under conditions such as:
Extended highway driving
Frequent high engine revolution
Make

NGK

Champion

Standard type

LFR5AP-11

REC10PYC4

Hot type

LFR4AP-11

—

Cold type

LFR6AP-11

—

Gap (Nominal)

: 1.1 mm (0.043 in)

CAUTION:
●
Do not use a wire brush for cleaning.
●
If plug tip is covered with carbon, spark plug cleaner may
be used.
Cleaner air pressure:
Less than 588 kPa (6 kg/cm2 , 85 psi)
Cleaning time:
Less than 20 seconds
SMA773C

●

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

SMA806CA

MA-36

ENGINE MAINTENANCE (CR)
INSTALLATION
A

Install in the reverse order of removal.
Spark plug
: 19.6 — 29.4 N·m (2.0 — 3.0 kg-m, 15 — 21 ft-lb)

Checking EVAP Vapor Lines

B
BLS00040

1.

Visually inspect EVAP vapor lines for improper attachment and for cracks, damage, loose connections,
chafing and deterioration.
2. Inspect fuel tank filler cap vacuum relief valve for clogging, sticking, etc.
Refer to EC-40, «EVAPORATIVE EMISSION SYSTEM» (CR engine models with E-OBD), EC-469, «EVAPORATIVE EMISSION SYSTEM» (CR engine models without E-OBD).

C

D

E

F

G

H

I

J

K

MA

M

MA-37

ENGINE MAINTENANCE (HR16DE)
ENGINE MAINTENANCE (HR16DE)
Checking Drive Belts
●

●

●

●

PFP:00100
BLS00041

Inspection should be done only when engine is cold or over 30
minutes after the engine is stopped.
1.

Alternator

2.

Water pump

3.

Crankshaft pulley

4.

A/C compressor

5.

Idler pulley

6.

Drive belt

Visually check belts for wear, damage, and cracks on inside and
PBIC3642E
edges.
Turn crankshaft pulley two time clockwise, and make sure tension on all pulleys is equal before doing the
test.
When measuring deflection, apply 98 N (10 kg, 22 lb) at the ( ) marked point.

Measure the belt tension and frequency with acoustic tension gauge (commercial service tool) at the ( )
marked point.
CAUTION:
●
When the tension and frequency are measured, the acoustic tension gauge should be used.
●
When checking immediately after installation, first adjust it to the specified value. Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection
between pulleys.
●

Belt Deflection:
Deflection adjustment *
Location

Drive belt

Unit: mm (in)

Used belt

New belt

Limit

After adjusted

With A/C models

7.9 (0.31)

4.8 — 5.3 (0.19 — 0.21)

4.2 — 4.5 (0.17 — 0.18)

Without A/C models

7.1 (0.28)

4.3 — 4.7 (0.17 — 0.19)

3.6 — 3.9 (0.14 — 0.15)

Applied pushing force

98 N (10 kg, 22lb)

*: When engine is cold.

Tension Adjustment

BLS00042

Location

Location of adjuster and tightening method

Drive belt

Adjusting bolt on idler pulley

CAUTION:
●
When belt is replaced with new one, adjust belt tension to the value for “New belt”, because new
belt will not fully seat in the pulley groove.
●
When tension of the belt being used exceeds “Limit”, adjust it to the value for “After adjusted”.
●
When installing a belt, make sure it is correctly engaged with the pulley groove.
●
Do not allow oil or engine coolant to get on the belt.
●
Do not twist or bend the belt strongly.
1. Remove front fender protector (RH). Refer to EI-14, «FENDER PROTECTOR» .

MA-38

ENGINE MAINTENANCE (HR16DE)
2.

3.

4.

Loosen the idler pulley lock nut (A) from the tightening position
with the specified torque by 45 degrees.
1

: Alternator

2

: Water pump

3

: Crankshaft pulley

4

: A/C compressor (Models with A/C)
Idler pulley (Models without A/C)

5

: Idler pulley

6

: Drive belt

A

B

C

PBIC3643E
CAUTION:
● When the lock nut is loosened excessively, the idler pulley tilts and the correct tension adjustment cannot be performed. Do not loosen it excessively
(more than 45 degrees).
● Put a matching mark on the lock nut (A), and check turning angle with a protractor. Do not visually check the tightening angle.
Adjust the belt tension by turning the adjusting bolt (B). Refer to MA-38, «Checking Drive Belts» .
CAUTION:
● When checking immediately after installation, first adjust it to the specified value. Then, after
turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in
deflection between pulleys.
● When the tension adjustment is performed, the lock nut should be in the condition at step“ 2”. If
the tension adjustment is performed when the lock nut is loosened more than the standard, the
idler pulley tilts and the correct tension adjustment cannot be performed.
Tighten the lock nut (A).

D

E

F

G

H

: 34.8 N·m (3.5 kg-m, 26 ft-lb)
I

Changing Engine Coolant

BLS00043

WARNING:
●
To avoid being scalded, never change the coolant when the engine is hot.
●
Wrap a thick cloth around radiator cap and carefully remove the cap. First, turn the cap a quarter
of a turn to release built-up pressure. Then turn the cap all the way.

K

DRAINING ENGINE COOLANT
M/T Models without A/C and A/T models
1.

2.
a.
b.

3.

Disconnect radiator lower hose and radiator cap.
CAUTION:
Make sure to drain when the engine coolant temperature is cold.
Remove reservoir tank and drain the engine coolant in the following procedures.
Move relay case in front of the battery.
Disconnect the reservoir tank from fan shroud to remove. With
force applied in the left direction of vehicle, pull up reservoir
tank.
Check drain coolant for contaminants such as rust, corrosion or
discoloration.
If contaminated, flush engine cooling system.
Refer to MA-41, «FLUSHING COOLING SYSTEM» .

MA

M

PBIC1476E

M/T Models with A/C
1.

2.

J

Disconnect radiator lower hose and reservoir tank cap.
CAUTION:
Make sure to drain when the engine coolant temperature is cold.
Remove reservoir tank and drain the engine coolant.

MA-39

ENGINE MAINTENANCE (HR16DE)
: Vehicle front

3.

Check drain coolant for contaminants such as rust, corrosion or
discoloration.
If contaminated, flush engine cooling system.
Refer to MA-41, «FLUSHING COOLING SYSTEM» .

MBIB1360E

REFILLING ENGINE COOLANT
1.
2.
3.

Install reservoir tank.
Connect radiator lower hose.
Disconnect heater hose (1) (at heater hose outlet side: upper side) as shown in figure. Keep hose end at
the same height as that of before removal.
: Vehicle front
: Disconnect

MBIB1361E

4.

Fill radiator and reservoir tank to specified level.
● Pour coolant slowly of less than 2
(1-3/4 lmp qt) a
minute to allow air in system to escape.
● When coolant from heater hose starts to drain, connect
heater hose and continue to fill.
● Use Nissan Genuine Coolant L250 or equivalent mixed
with water (distilled or demineralized).
Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS».
SMA182B

Engine coolant capacity
M/T models without A/C
With reservoir tank
: Approx. 5.6
Reservoir tank

: 0.7

A/T models
With reservoir tank

: Approx. 5.4

Reservoir tank

: 0.7

(4-7/8 Imp qt)

(5/8 lmp qt)

(4-3/4 Imp qt)

(5/8 lmp qt)
SMA412B

MA-40

ENGINE MAINTENANCE (HR16DE)
: Vehicle front

A

M/T models with A/C
With reservoir tank : Approx. 6.0 (5-1/4 Imp qt)
Reservoir tank
: 1.2 (1-1/8 lmp qt)

B

C
MBIB1360E

D

E

F

G
MBIA0092E

5.
6.

7.
8.
9.
10.
11.
12.
13.
●

14.
●

Warm up engine to normal operating temperature with radiator cap installed.
Warm up until thermostat opens. Keep warming at 3,000 rpm for approximately 10 minutes as guide.
H
● For thermostat opening, touch radiator upper hose by hand to insure that water flow is hot.
CAUTION:
Be careful not to overheat.
I
Stop the engine.
After cooling engine [approximately 50°C (122 °F) or lower], remove radiator cap and check coolant level.
If the level is low, fill up to the radiator neck again and repeat from step 5.
J
When the coolant level stabilizes, fill reservoir tank up to the “MAX” line.
Check cooling system for leaks with engine running.
K
Allow the engine to cool [approximately 50°C (122°F) or lower].
Start the engine. Perform the following cycle three times. Keep an engine speed of 1,000 rpm for approximately 30 seconds. Then increase it gradually to 3,000 rpm.
MA
During the above step 12, make sure water flow sound is not heard from heater core.
Sound may be noticeable at heater unit.
If water flow sound is heard, repeat from step 4 to 13.
M
Clean excess coolant from engine.

FLUSHING COOLING SYSTEM
1.
2.
3.
4.
5.
6.

Fill radiator and reservoir tank with water and reinstall radiator cap.
Run engine and warm it up to normal operating temperature.
Rev engine two or three times under no-load.
Stop engine and wait until it cools down.
Drain water.
Repeat steps 1 through 5 until clear water begins to drain from radiator.

Checking Cooling System

BLS00044

WARNING:
Never remove the radiator cap when the engine is hot; serious burns could be caused by high pressure fluid escaping from the radiator.
Wrap a thick cloth around the cap and carefully remove it by turning it a quarter turn to allow built-up
pressure to escape and then turn the cap all the way off.

MA-41

ENGINE MAINTENANCE (HR16DE)
CHECKING COOLING SYSTEM HOSES
Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.

CHECKING RADIATOR
Check radiator for mud or clogging. If necessary, clean radiator as follows.
●
Be careful not to bend or damage the radiator fins.
●
When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator
shroud and horns. Then tape harness and electrical connectors to prevent water from entering.
1. Apply water by hose to the back side of radiator core vertically downward.
2. Apply water again to all radiator core surface once per minute.
3. Stop washing if any stains no longer flow out from radiator.
4. Blow air into the back side of radiator core vertically downward.
Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2 , 71 psi) and keep distance more than 30 cm
(11.8 in).
Blow air again into all the radiator core surfaces once per minute until no water sprays out.

●

5.

CHECKING COOLING SYSTEM FOR LEAKS
M/T Models without A/C and A/T Models
●

To check for leakage, apply pressure to the cooling system with
a radiator cap tester (commercial service tool) and radiator cap
tester adapter (SST).
Testing pressure : 157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi)

●

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
If anything is found, repair or replace damaged parts.

SLC134B

M/T Models with A/C
●

To check for leakage, fit the adapter to the reservoir tank (1),
and then connect it to the tester as shown.

MBIB1362E

●

Warm up the engine and turn it off.

MA-42

ENGINE MAINTENANCE (HR16DE)
●

Apply pressure to the cooling system and stop pumping.
Testing pressure

●
●

If the pressure drops, look for leakage.
Unscrew slowly the adapter from the reservoir tank to reduce
the pressure in cooling system, and install the reservoir tank
cap.
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure engine coolant
escaping from the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.

Checking Radiator Cap (M/T Models without A/C and A/T Models)
1.

A

: 90 kpa
(0.9 bar, 0.92 kg/cm2 , 13.1 psi)

B

C
MBIA0094E

D

E
BLS00045

Pull the negative-pressure valve to open it and check that it closes completely when released.
● Check that there is no dirt or damage on the valve seat of the radiator cap negative-pressure valve.
● Check that there are no unusual conditions in the opening
and closing conditions of the negative-pressure valve.

F

G

H

I
SMA967B

2.

J

Check radiator cap relief pressure.
Standard:
78 — 98 kPa
(0.78 — 0.98 bar, 0.8 — 1.0 kg/cm2 , 11 — 14
psi)
Limit:
59 kPa (0.59 bar, 0.6 kg/cm

2

K

MA

, 9 psi)

When connecting the radiator cap to the tester, apply water or
SLC135B
engine coolant to the cap seal part.
● Replace the radiator cap if there is an unusual conditions in the negative-pressure valve, or if the openvalve pressure is outside of the standard values.
CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue or foreign material.
●

MA-43

M

ENGINE MAINTENANCE (HR16DE)
Checking Reservoir Tank Cap (M/T Models with A/C)
●
●

●

BLS00046

Fit the adapter to the tester as shown.
When connecting the reservoir tank cap to the tester, apply
water or LLC to the cap seal part.
Check reservoir tank cap relief pressure.
140 kPa (1.4 bar, 1.43 kg/cm2 , 20.3
psi)

●

Replace the reservoir tank cap if the engine coolant passes
through it, or if any fur signs is detected.
MBIB1079E

Checking Fuel Lines

BLS00047

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

SMA803A

Changing Air Cleaner Filter

BLS00048

REMOVAL
1.
2.

Push the tabs (A) of both ends of the air cleaner cover (1) into
the inside (B).
Pull up the air cleaner cover forward (C) and remove it.

PBIC3557J

3.
4.

Remove the air cleaner filter (1) and holder (2) assembly from
the air cleaner case.
Remove the air cleaner filter from the holder.

PBIC3558J

INSPECTION AFTER REMOVAL
It is necessary to clean air cleaner filter or replace it at the recommended intervals, more often under dusty
driving conditions. Refer to MA-8, «PERIODIC MAINTENANCE» .

MA-44

ENGINE MAINTENANCE (HR16DE)
●

Blow air into the back side of air cleaner filter until no any object
sprays out.

A

B

C
SMA384C

D

INSTALLATION
Note the following, and install in the reverse order of removal.
●
Install the air cleaner cover (1) in the direction shown in the figure.
2

: Air cleaner filter

3

: Holder

E

F

G
PBIC3559J

Changing Engine Oil

BLS00049

H

WARNING:
●
Be careful not to burn yourself, as engine oil may be hot.
I
●
Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct
skin contact with used engine oil. If skin contact is made, wash thoroughly with soap or hand
cleaner as soon as possible.
1. Warm up engine, put vehicle horizontally and check for engine oil leakage from engine components. Refer J
to LU-16, «ENGINE OIL LEAKAGE» .
2. Stop engine and wait for 10 minutes.
K
3. Loosen oil filler cap and then remove drain plug.
4. Drain engine oil.
5. Install drain plug with new washer. Refer to EM-127, «OIL PAN AND OIL STRAINER» .
MA
CAUTION:
Be sure to clean drain plug and install with new washer.
Oil pan drain plug:

M

: 34.3 N·m (3.5 kg-m, 25 ft-lb)
6.

Refill with new engine oil.
Engine oil specification and viscosity:
Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS» .
Engine oil capacity (Approximate):
Unit:

Drain and refill

With oil filter change

(lmp qt)

4.6 (4)

Without oil filter change
Dry engine (Overhaul)

4.4 (3-7/8)
4.8 (4-1/4)

CAUTION:
● The refill capacity depends on the engine oil temperature and drain time. Use these specifications for reference only.
● Always use oil level gauge to the determine when the proper amount of engine oil is in the
engine.

MA-45

ENGINE MAINTENANCE (HR16DE)
7.
8.
9.

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

PBIC0249E

Changing Oil Filter

BLS0004A

REMOVAL
1.

Using oil filter wrench (SST: KV10115801) (A), remove oil filter.
: Vehicle font

CAUTION:
Oil filter is provided with relief valve. Use Genuine NISSAN Oil Filter or equivalent.
● Be careful not to get burned when engine and engine oil
may be hot.
● When removing, prepare a shop cloth to absorb any
engine oil leakage or spillage.
● Do not allow engine oil to adhere to drive belt.
● Completely wipe off any engine oil that adheres to engine and vehicle.
●

MBIB1357E

INSTALLATION
1.
2.

Remove foreign materials adhering to the oil filter installation surface.
Apply new engine oil to the oil seal contact surface of new oil filter.

SMA010

3.

Screw oil filter manually until it touches the installation surface,
then tighten it by 2/3 turn. Or tighten to specification.
Oil filter:
: 17.7 N·m (1.8 kg-m, 13 ft-lb)

SMA229B

INSPECTION AFTER INSTALLATION
1.
2.

Check the engine oil level. Refer to MA-45, «Changing Engine Oil» .
Start engine, and check there is no leaks of engine oil.

MA-46

ENGINE MAINTENANCE (HR16DE)
3.
4.

Stop engine and wait for 10 minutes.
Check the engine oil level and add engine oil. Refer to MA-45, «Changing Engine Oil» .

Changing Spark Plug (Platinum-Tipped Type)

A
BLS0004B

REMOVAL
1.
2.
3.

B

Remove intake manifold. Refer to EM-120, «INTAKE MANIFOLD» .
Remove ignition coil. Refer to EM-132, «IGNITION COIL» .
Remove spark plug using spark plug wrench (commercial service tool).
CAUTION:
Do not drop or shock it.

C

D

E

PBIC3871E

F

INSPECTION AFTER REMOVAL
Use standard type spark plug for normal condition.
Hot type spark plug is suitable when fouling occurs with standard type spark plug under conditions such as:
●
Frequent engine starts
●
Low ambient temperatures
Cold type spark plug is suitable when spark plug knock occurs with standard type spark plug under conditions
such as:
●
Extended highway driving
●
Frequent high engine revolution
Make

NGK

Standard type

PLZKAR6A-11

Hot type

PLZKAR5A-11

Cold type

PLZKAR7A-11

Gap (Nominal)

G

H

I

J

K

: 1.1 mm (0.043 in)

CAUTION:
Do not drop or shock spark plug.
●
Do not use wire brush for cleaning.
●
If plug tip is covered with carbon, spark plug cleaner may
be used.

MA

●

M

Cleaner air pressure:
Less than 588 kPa (5.88 bar, 6 kg/cm2 , 85 psi)
Cleaning time:
Less than 20 seconds
SMA773C

MA-47

ENGINE MAINTENANCE (HR16DE)
●

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

SMA806CA

INSTALLATION
Install in the reverse order of removal.
: 19.6 N·m (2.0 kg-m, 14 ft-lb)

Checking EVAP Vapor Lines
1.
2.

BLS0004C

Visually inspect EVAP vapor lines for improper attachment and for cracks, damage, loose connections,
chafing and deterioration.
Inspect fuel tank filler cap vacuum relief valve for clogging, sticking, etc.
Refer to EC-823, «EVAPORATIVE EMISSION SYSTEM» (with EURO-OBD) or EC-1257, «EVAPORATIVE EMISSION SYSTEM» (without EURO-OBD).

MA-48

ENGINE MAINTENANCE (K9K)
ENGINE MAINTENANCE (K9K)
Checking Drive Belts

PFP:00000

A
BLS0004D

WARNING:
Be sure to perform when the engine is stopped.
1. Inspect belts for cracks, fraying, wear and oil. If necessary,
replace.
2. Tighten auto-tensioner lock nut (models with A/C compressor) or
idler pulley lock nut (models without A/C compressor) by hand
and measure deflection or tension without looseness.

B

C

D

E
MBIB0664E

3.

When measuring deflection, apply 98 N (10 kg, 22 lb) at the
marked point as shown (models without A/C compressor).

F

G

H

MBIB0556E

I

TENTION ADJUSTMENT
Models With A/C Compressor
J

Belt tensioning is not necessary, as it is automatically adjusted by auto-tensioner.

Models Without A/C Compressor
Belt tightening method for adjustment

K

Adjusting bolt on idler pulley

The tension value is 234±10 Hz.
NOTE:
MA
The engine must be turned through two revolutions in order to position the belt correctly.
CAUTION:
●
When checking belt tension immediately after installation, first adjust it to the specified value.
M
Then, after turning the crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection between pulleys.
●
When installing belt, make sure that it is correctly engaged with pulley groove.
●
Keep oil and water away from belt.
●
Do not twist or bend belt excessively.
●

Changing Engine coolant

BLS0004E

WARNING:
●
To avoid being scalded, never change the coolant when the engine is hot.
●
Wrap a thick cloth around cap and carefully remove the cap. First, turn the cap a quarter of a turn
to release built-up pressure. Then turn the cap all the way.

DRAINING ENGINE COOLANT
1.

Remove engine undercover.

MA-49

ENGINE MAINTENANCE (K9K)
2.
3.
4.

Disconnect lower radiator hose, and remove radiator cap.
Remove reservoir tank, drain coolant, then clean reservoir tank.
Check drained coolant for contaminants such as rust, corrosion
or discoloration.
If contaminated, flush engine cooling system. Refer to CO-50,
«FLUSHING COOLING SYSTEM» .

MBIB1056E

REFILLING ENGINE COOLANT
1.
2.

Install reservoir tank, radiator lower hose and air relief plug.
Fill reservoir tank slowly with coolant until coolant spills from radiator cap holes.
CAUTION:
If the filling rate is too fast, this could lead to air being mixed in the coolant. Be sure to fill the coolant slowly according to the rate indicated above.
● Use Nissan Genuine Coolant L250 or equivalent mixed with water (distilled or demineralized).
Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS».
Engine coolant capacity
With reservoir tank
: Approx. 6.0
Reservoir tank

: 1.0

(5-1/4 Imp qt)

(7/8 Imp qt)

Pour coolant through coolant filler neck slowly of less
than 2 (1-3/4 lmp qt) a minute to allow air in system to
escape.
3. Fill reservoir tank to specified level.
4. Warm up engine to normal operating temperature without radiator cap installed.
SMA412B
● If coolant overflows radiator filler hole, install filler cap.
5. Run engine at 3,000 rpm for 10 seconds and return to idle speed with radiator cap installed.
● Repeat two or three times.
Watch coolant temperature gauge so as not to overheat the engine.
6. Stop engine and cool down to less than approximately 50°C (122°F).
● Cool down using a fan to reduce the time.
● If necessary, refill radiator up to filler neck with coolant.
7. Refill reservoir tank to MAX level line with coolant.
8. Repeat steps 5 through 7 two or more times with radiator cap installed until coolant level no longer drops.
9. Check cooling system for leaks with engine running.
10. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with
heater temperature controller set at several position between COOL and WARM.
● Sound may be noticeable at heater unit.
11. If sound is heard, bleed air from cooling system by repeating steps 5 through 7 until coolant level no
longer drops.
● Clean excess coolant from engine.
●

FLUSHING COOLING SYSTEM
1.
2.
3.
4.
5.

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

MA-50

ENGINE MAINTENANCE (K9K)
6.
7.

Repeat steps 1 through 5 until clear water begins to drain from radiator.
Blow compressed air into cooling circuit through the reservoir tank valve hole to drain all the water.

Checking Cooling System

A
BLS0004F

WARNING:
Never remove the radiator cap when the engine is hot; serious burns could be caused by high pressure fluid escaping from the radiator.
Wrap a thick cloth around the cap and carefully remove it by turning it a quarter turn to allow built-up
pressure to escape and then turn the cap all the way off.

B

C

CHECKING COOLING SYSTEM HOSES
Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.

D

CHECKING RADIATOR
Check radiator for mud or clogging. If necessary, clean radiator as follows.
●
Be careful not to bend or damage the radiator fins.
●
When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator
shroud and horns. Then tape the harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downward.
2. Apply water again to all radiator core surfaces once per minute.
3. Stop washing if any stains no longer flow out from the radiator.
4. Blow air into the back side of radiator core vertically downward.
Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2 , 71 psi) and keep distance more than 30 cm
(11.8 in).
Blow air again into all the radiator core surfaces once per minute until no water sprays out.

E

F

G

●

5.

Checking Reservoir Tank Cap
●
●

●
●

BLS0004G

Fit the adapter to the tester as shown.
When connecting the reservoir tank cap to the tester, apply
water or LLC to the cap seal part.
Check reservoir tank cap relief operation.
Replace the reservoir tank cap if the engine coolant passes
through it, or if any fur signs is detected.

H

I

J

K

MA
MBIB1079E

M

MA-51

ENGINE MAINTENANCE (K9K)
Checking Radiator

BLS0004H

Check radiator for mud or clogging. If necessary, clean radiator as follows.
●
Be careful not to bend or damage the radiator fins.
●
When radiator is cleaned without removal, remove all surrounding parts such as radiator fan, radiator
shroud and horns. Then tape the harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downwards.
2. Apply water again to all radiator core surface once per minute.
3. Stop washing if any stains no longer flow out from the radiator.
4. Blow air into the back side of radiator core vertically downwards.
●

5.

Use compressed air lower than 490 kPa (4.9 bar 5 kg/cm2 , 71psi) and keep distance more than 30 cm
(11.8 in).
Blow air again into all the radiator core surface once per minute until no water sprays out.

Checking Fuel Lines

BLS0004I

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

SMA803A

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

Changing Air Cleaner Filter

BLS0004J

REMOVAL
1.

Open air cleaner case.

MBIB1036E

MA-52

ENGINE MAINTENANCE (K9K)
2.

Remove air cleaner filter.
A

B

C
MBIB1036E

D

INSTALLATION
Install in the reverse order of removal.

Changing Engine Oil

BLS0004K

WARNING:
●
Be careful not to burn yourself, as the engine oil is hot.
●
Prolonged and repeated contact with used engine oil may cause skin cancer: try to avoid direct
skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as
soon as possible.
1. Put vehicle horizontally.
2. Warm up engine, and check for oil leakage from engine components.
3. Stop engine and wait for 10 minutes.
4. Remove drain plug and oil filler cap.
5. Drain oil and refill with new engine oil.
●
Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS» .
Oil capacity (Approximate):
With oil filter change

4.40

(3-7/8 Imp qt)

Without oil filter change

4.24

(3-3/4 Imp qt)

Drain and refill
Dry engine (overhaul)

4.56

(4 Imp qt)

E

F

G

H

I

J

K

The refill capacity depends on the oil temperature and drain
MBIB0548E
time. Use these specifications for reference only.
MA
Always use the dipstick to the determine when the proper amount of oil is in the engine.
CAUTION:
●
Be sure to clean drain plug and install with new washer.
●
The refill capacity depends on the oil temperature and drain time. Use these specifications for ref- M
erence only.
Always use the dipstick to the determine when the proper amount of oil is in the engine.
6. Warm up engine and check area around drain plug and oil filter for oil leakage.
7. Stop engine and wait for 10 minutes.
8. Check oil level.
●

MA-53

ENGINE MAINTENANCE (K9K)
Changing Oil Filter

BLS0004L

REMOVAL
1. Using an oil filter wrench (special service too), remove oil filter.
CAUTION:
●
Be careful not to get burned when the engine and engine oil
are hot.
●
When removing, prepare a shop cloth to absorb any oil
leakage or spillage.
●
Do not allow engine oil to adhere to the drive belts.
●
Completely wipe off any oil that adhere to the engine and
the vehicle.
MBIB0551E

INSTALLATION
1.
2.

3.

Remove foreign materials adhering to the oil filter installation surface.
Install oil filter bracket to oil cooler.
CAUTION:
Install oil filter bracket, positioning lug in the hole of oil cooler.
Apply engine oil to the oil seal contact surface of the new oil filter.

SMA010

4.
5.
6.

Install the oil filter to oil filter bracket.
After warming up the engine, check for engine oil leakage.
Check oil level and add engine oil. Refer to LU-23, «ENGINE OIL» .

MA-54

CHASSIS AND BODY MAINTENANCE
CHASSIS AND BODY MAINTENANCE
Checking Exhaust System

PFP:00100

A
BLS0004M

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

B

C

D
SMA211A

Checking Clutch Fluid Level and Leaks

E
BLS0004N

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

G

H
SFIA0066J

Checking Clutch System

BLS0004O

Check fluid lines and operating cylinder for improper attachment,
cracks, damage, loose connections, chafing and deterioration.

I

J

K

MA
SMA859

Checking M/T Oil
●
●

●

BLS0004P

Check that oil is not leaking from transaxle or around it.
Check oil level from filler plug mounting hole as shown in the figure.
CAUTION:
Never start engine while checking oil level.
Set a new gasket on the filler plug and install it on the transaxle.
Filler plug:
: 2 N·m (0.2 kg-m, 1.8 in-lb)
CAUTION:
Do not reuse gasket.

SMA066C

MA-55

M

CHASSIS AND BODY MAINTENANCE
Changing M/T Oil
1.
2.

BLS0004Q

Drain oil from drain plug and refill with new gear oil.
Check oil level.
Oil grade and viscosity:
Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS»
Oil capacity (Reference):
JH3: Approx. 2.6

(4-5/8 lmp pt)

JR5: Approx. 2.5
Drain plug:

(4-3/8 lmp pt)

: 22 N·m (2.2 kg-m, 1.5 — 1.7 ft-lb)
CAUTION:
Do not reuse gasket.

Checking A/T Fluid
1.
2.

BLS00059

Warm up engine.
Check for A/T fluid leakage.

SMA146B

3.

a.
b.
c.

Before driving, A/T fluid level can be checked at A/T fluid temperatures of 30 to 50°C (86 to 122°F) using “COLD” range on A/
T fluid level gauge.
Park vehicle on level surface and set parking brake.
Start engine and move selector lever through each gear position. Leave selector lever in “P” position.
Check A/T fluid level with engine idling.

SCIA3451E

d.

e.

f.

4.

Remove A/T fluid level gauge and wipe clean with lint-free cloth.
CAUTION:
When wiping away the A/T fluid level gauge, always use
lint-free cloth, not a cloth one.
Re-insert A/T fluid level gauge into A/T fluid charging pipe as far
as it will go.
CAUTION:
Firmly fix the A/T fluid level gauge to the A/T fluid charging
pipe using a stopper attached.
Remove A/T fluid level gauge and note reading. If reading is at
low side of range, add ATF to the A/T fluid charging pipe.
CAUTION:
Do not overfill.
Drive vehicle for approximately 5 minutes in urban areas.

MA-56

SMA051D

CHASSIS AND BODY MAINTENANCE
5.

6.

7.

Re-check A/T fluid level at A/T fluid temperatures of 50 to 80°C (122 to 176°F) using “HOT” range on A/T
fluid level gauge.
CAUTION:
● When wiping away the A/T fluid level gauge, always use lint-free cloth, not cloth one.
● Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using a stopper attached.
Check A/T fluid condition:
● If ATF is very dark or smells burned, check operation of A/T
and repair if necessary. Flush cooling system after repair of A/
T.
● If ATF contains frictional material (clutches, bands, etc.),
replace radiator and flush cooler line using cleaning solvent
and compressed air after repair of A/T. Refer to CO-31,
«RADIATOR» .
Install the removed A/T fluid level gauge into the A/T fluid charging pipe.
SAT638A
CAUTION:
Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using a stopper attached.

Changing A/T Fluid
1.
2.
3.

B

C

D

E

F

BLS0005A

Warm up ATF.
Stop engine.
Drain ATF from drain hole and refill with new ATF. Always refill same volume with drained fluid.
CAUTION:
Do not reuse drain plug gasket.

G

H

Fluid grade:
Nissan Genuine ATF Matic D or equivalent. Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS» .
Fluid capacity:
Approx. 7.7

A

I

J

(6-3/4 lmp qt)

Drain plug:

K

: 34.5 N·m (3.5 kg-m, 25 ft-lb)
4.
5.

Run engine at idle speed for 5 minutes.
MA
Check A/T fluid level and condition. Refer to MA-56, «Checking A/T Fluid» . If ATF is still dirty, repeat steps
2 through 5.

Rotation
●
●

BLS0004T

After rotating the tyres, adjust the tyre pressure.
Retighten the wheel nuts when the vehicle has been driven for
1,000 km (600 miles) (also in cases of a flat tyre, etc.).
CAUTION:
When installing wheels, tighten them diagonally by dividing
the work two to three times in order to prevent the wheels
from developing any distortion.
Tightening torque of wheel nut:
98 — 118N·m (10 — 12 kg·m, 72 — 87 ft·lb)
SMA829C

MA-57

M

CHASSIS AND BODY MAINTENANCE
Checking Brake Fluid Level and Leaks

BLS0004U

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

●

SFIA0066J

Checking Brake Lines and Cables

BLS0004V

Check brake fluid lines and parking brake cables for improper
attachment, leaks, chafing, abrasions, deterioration, etc.

●

SBR389C

Changing Brake Fluid
1.
2.

BLS0004W

Drain brake fluid from each air bleeder valve.
Refill until new brake fluid comes out from each air bleeder
valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid.
Refer to BR-9, «BRAKE FLUID» .
● Refill with “Nissan Genuine Brake Fluid or DOT 3 or DOT 4
(US FMVSS No.116)”.
Refer toMA-24, «RECOMMENDED FLUIDS AND LUBRICANTS» .
● Never reuse drained brake fluid.
● Be careful not to splash brake fluid on painted areas.

Checking Disc Brake

BLS0004X

ROTOR
Check condition, wear, and damage.
Applied

Front

Brake model

CL22

Standard thickness
Maximum runout
Minimum thickness (Wear limit)

SBR419C

22.0 mm (0.87 in)
0.058 mm (0.0023 in)
20 mm (0.79 in)

MA-58

CHASSIS AND BODY MAINTENANCE
CALIPER
●

A

Check for leakage.

B

C

SMA922A

D

PAD
Check for wear or damage.
Applied
Brake model

E
Front
CL22

Standard thickness

12.4 mm (0.488 in)

Minimum thickness (Wear Limit)

2.0 mm (0.079 in)

F

G

BRA0010D

Checking Drum Brake

H

BLS0004Y

WHEEL CYLINDER
I

Check for leakage.

DRUM
Check condition and inner surface.

J

Standard inner diameter

202 mm (7.95 in)

Drum repair limit (Maximum inner diameter)

203.2 mm (8.0 in)

K

MA

SMA848B

LINING
Check wear or damage.
Standard thickness

4.5 mm (0.177 in)

Lining Wear Limit (Minimum thickness)

1.5 mm (0.059 in)

SMA849B

MA-59

M

CHASSIS AND BODY MAINTENANCE
Checking Steering Gear and Linkage

BLS0004Z

STEERING GEAR
●

●

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

SLIA0014E

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

Axle and Suspension Parts

BLS00050

Check front and rear axle and suspension parts for excessive play,
cracks, wear or other damage.
●
Shake each wheel to check for excessive play.
●
Check wheel bearings for smooth operation.
●
Check axle and suspension nuts and bolts for looseness.
●
Check strut (shock absorber) for oil leakage or other damage.
●
Check suspension ball joint for grease leakage and ball joint
dust cover for cracks or other damage.
SMA525A

SFA392B

Drive Shaft
●

BLS00051

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

SFA108A

MA-60

CHASSIS AND BODY MAINTENANCE
Lubricating Locks, Hinges and Hood Latches

BLS00052

A
Front door

Refer to BL-195, «DOOR» .

Back door

Refer to BL-207, «BACK DOOR» .

Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters

B
BLS00053

C

D

E

F

G

H

I

J
PIIB3436E

CAUTION:
K
●
After any collision, inspect all seat belt assemblies, including retractors and other attached hardwares (I.e. anchor bolt, guide rail set). Nissan recommends to replace all seat belt assemblies in
use during a collision, unless not damaged and properly operating after minor collision.
Also inspect seat belt assemblies not in use during a collision, and replace if damaged or improp- MA
erly operating.
Seat belt pre-tensioner should be replaced even if the seat belts are not in use during a frontal collision where the driver and passenger air bags are deployed.
M
●
If any component of seat belt assembly is questionable, do not repair.
Replace as seat belt assembly.
●
If webbing is cut, frayed, or damaged, replace belt assembly.
●
Never oil tongue and buckle.
●
Use a genuine NISSAN seat belt assembly.
For details, refer to SB-5, «Inspection» in SB section.
●
Check anchors for loose mounting
●
Check belts for damage
●
Check retractor for smooth operation
●
Check function of buckles and tongues when buckled and released

Checking Body Corrosion

BLS00054

Visually check body panels for collision damage (scratches, chipping, rubbing, etc.) or damage to the anti-corrosion materials. In particular, check the following locations.

MA-61

CHASSIS AND BODY MAINTENANCE
HEMMED PANELS
Hood front end, door lower end, trunk lid rear end, etc.

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

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

PARTS CONTACT
Waist moulding, windshield moulding, bumper, etc.

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

ANTI-CORROSION MATERIALS
Damage or separation of anti-corrosion materials under the body.

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

MA-62

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit

PFP:00030

A
BLS00055

BELT DEFLECTION AND TENSION
CR Engine

B
Deflection [mm (in)]
[When pressed by force of 98.1N (10 kg,
22lb)]

Tension [N (kg, lb)]
Location
New

Alternator and
A/C compressor belt

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

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

Alternator belt

446 — 534 (45.5 — 54.5,
100.3 — 120.0)

Water pump belt

At adjustment

Limit

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

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

348 — 436 (35.5 — 44.5,
78.2 — 98.0)

New belt

At adjustment

Limit

A

6.6 — 7.8
(0.260 0.307)

7.3 — 8.5
(0.287 0.335)

13.8
(0.543)

D

B

5.6 — 6.6
(0.220 0.260)

7.1 — 8.3
(0.280 0.327)

11.9
(0.469)

E

A

3.1 — 4.1
(0.122 0.161)

9.8 — 10.6
(0.386 0.417)

13.8
(0.543)

F

C

6.7 — 7.3
(0.264 0.287)

7.6 — 8.6
(0.299 0.339)

12.4
(0.448)

G

D

4.7 — 5.6
(0.185 0.220)

7.0 — 7.7
(0.276 0.303)

8.6
(0.339)

H

196 (20,
44.1)

196 (20,
44.1)

C

Measuring
point

137 (14,
30.9)

I

J

K
PBIC1414E

PBIC1415E

MA

HR Engine
Deflection adjustment *
Location

Drive belt

Unit: mm (in)

Used belt
New belt

Limit

After adjusted

With A/C models

7.9 (0.31)

4.8 — 5.3 (0.19 — 0.21)

4.2 — 4.5 (0.17 — 0.18)

Without A/C models

7.1 (0.28)

4.3 — 4.7 (0.17 — 0.19)

3.6 — 3.9 (0.14 — 0.15)

Applied pushing force

98 N (10 kg, 22lb)

*: When engine is cold.

K9K Engine
Refer to EM-242, «DRIVE BELTS» .

MA-63

M

SERVICE DATA AND SPECIFICATIONS (SDS)
ENGINE COOLANT CAPACITY
CR Engine
Coolant capacity
[With reservoir tank (MAX level)]

Models with A/C

Approximately 5.3 (4-5/8)

Models without A/C

Approximately 4.9 (4-3/8)

Models with A/C
Reservoir tank

Unit:

(Imp qt)

Unit:

(Imp qt)

Unit:

(Imp qt)

Unit:

(Imp qt)

Unit:

·(Imp qt)

Unit:

(Imp qt)

1.2 (1-1/8)

Models without A/C

0.7 (5/8)

HR Engine
M/T models without A/C
Coolant capacity
[With reservoir tank (MAX level)]

M/T models with A/C

Approximately 6.0 (5-1/4)

A/T models

Approximately 5.4 (4-3/4)

M/T models without A/C
Reservoir tank

Approximately 5.6 (4-7/8)

M/T models with A/C

0.7 (5/8)
1.2 (1-1/8)

A/T models

0.7 (5/8)

K9K Engine
Coolant capacity
[With reservoir tank (MAX level)]

Approximately 6.0 (5-1/4)

Reservoir tank

1.2 (1-1/8)

ENGINE OIL CAPACITY
CR Engine
With oil filter change

3.4 (3)

Without oil filter change

3.2 (2-7/8)

Dry engine (engine overhaul)

3.9 (3-3/8)

HR Engine
With oil filter change

4.6 (4)

Without oil filter change

4.4 (3-7/8)

Dry engine (overhaul)

4.8 (4-1/4)

K9K Engine
With oil filter change

4.40 (3-7/8)

Without oil filter change

4.24 (3-3/4)

Dry engine (engine overhaul)

4.56 (4)

MA-64

SERVICE DATA AND SPECIFICATIONS (SDS)
SPARK PLUG
CR Engine

A
Make

NGK

Champion

Standard type

LFR5AP-11

REC10PYC4

Hot type

LFR4AP-11

—

Cold type

LFR6AP-11

—

Gap (nominal)

1.1 mm (0.043 in)

SPARK PLUG (PLATINUM-TIPPED TYPE)
HR Engine

B

C

D

Make

NGK

Standard type

PLZKAR6A-11

Hot type

PLZKAR5A-11

Cold type

PLZKAR7A-11

Gap (nominal)

1.1 mm (0.043 in)

E

F

G

H

I

J

K

MA

M

MA-65

SERVICE DATA AND SPECIFICATIONS (SDS)

MA-66

MANUAL AIR CONDITIONER

J AIR CONDITIONER

SECTION

MTC

MANUAL AIR CONDITIONER

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 4
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 4
PrecautionsforProcedureswithoutCowlTopCover….. 4
Precautions for Working with HFC-134a (R-134a)….. 4
General Refrigerant Precautions ………………………… 4
Lubricant Precautions ………………………………………. 5
Precautions for Refrigerant Connection ………………. 5
FEATURES OF NEW TYPE REFRIGERANT
CONNECTION ……………………………………………… 5
O-RING AND REFRIGERANT CONNECTION….. 6
Precautions for Servicing Compressor ………………… 8
Precautions for Service Equipment …………………….. 8
RECOVERY/RECYCLING EQUIPMENT ………….. 8
ELECTRONIC LEAK DETECTOR …………………… 8
VACUUM PUMP …………………………………………… 9
MANIFOLD GAUGE SET ……………………………….. 9
SERVICE HOSES …………………………………………. 9
SERVICE COUPLERS …………………………………. 10
REFRIGERANT WEIGHT SCALE …………………. 10
CALIBRATING ACR4 WEIGHT SCALE ………….. 10
CHARGING CYLINDER ……………………………….. 10
Precautions for Leak Detection Dye ……………………11
IDENTIFICATION ………………………………………….11
IDENTIFICATION LABEL FOR VEHICLE …………11
PREPARATION ………………………………………………… 12
HFC-134a (R-134a) Service Tools and Equipment… 12
Commercial Service Tools ……………………………….. 14
REFRIGERATION SYSTEM ………………………………. 15
Refrigerant Cycle …………………………………………… 15
REFRIGERANT FLOW ………………………………… 15
FREEZE PROTECTION ………………………………. 15
Refrigerant System Protection …………………………. 15
REFRIGERANT PRESSURE SENSOR …………. 15
PRESSURE RELIEF VALVE …………………………. 15
Component Layout …………………………………………. 16

LUBRICANT …………………………………………………….. 17
Maintenance of Lubricant Quantity in Compressor… 17
LUBRICANT ……………………………………………….. 17
LUBRICANT RETURN OPERATION ……………… 17
LUBRICANT ADJUSTING PROCEDURE FOR
COMPONENTS REPLACEMENT EXCEPT
COMPRESSOR ………………………………………….. 18
LUBRICANT ADJUSTING PROCEDURE FOR
COMPRESSOR REPLACEMENT ………………….. 18
AIR CONDITIONER CONTROL …………………………. 20
Control Operation …………………………………………… 20
FAN CONTROL DIAL …………………………………… 20
TEMPERATURE CONTROL DIAL …………………. 20
MODE CONTROL DIAL ……………………………….. 20
INTAKE DOOR LEVER ………………………………… 20
REAR WINDOW DEFOGGER SWITCH …………. 20
A/C SWITCH ………………………………………………. 20
Discharge Air Flow …………………………………………. 21
System Description …………………………………………. 22
SWITCHES AND THEIR CONTROL FUNCTION… 22
CAN Communication System Description ………….. 22
TROUBLE DIAGNOSIS …………………………………….. 23
CONSULT-II Function (BCM) …………………………… 23
CONSULT-II BASIC OPERATION ………………….. 23
DATA MONITOR …………………………………………. 23
How to Perform Trouble Diagnosis for Quick and
Accurate Repair ……………………………………………… 24
WORK FLOW ……………………………………………… 24
SYMPTOM TABLE ………………………………………. 24
Component Parts and Harness Connector Location… 25
Wiring Diagram — HEATER — ………………………… 26
Wiring Diagram — A/C — CR Engine Models …….. 27
Wiring Diagram — A/C — HR Engine Models …….. 29
Wiring Diagram — A/C — K9K Engine Models …… 31
Wiring Diagram — PTC/H — ……………………………. 33
Operational Check ………………………………………….. 34
CHECKING BLOWER ………………………………….. 34
CHECKING DISCHARGE AIR ………………………. 34
CHECKING RECIRCULATION ……………………… 34
CHECKING TEMPERATURE DECREASE ……… 35

MTC-1

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CHECKING TEMPERATURE INCREASE ………. 35
CHECKING A/C SWITCH …………………………….. 35
Mode Door …………………………………………………….. 36
INSPECTION FLOW ……………………………………. 36
Air Mix Door …………………………………………………… 37
INSPECTION FLOW ……………………………………. 37
Intake Door ……………………………………………………. 38
INSPECTION FLOW ……………………………………. 38
Blower Motor Circuit ……………………………………….. 39
INSPECTION FLOW ……………………………………. 39
DIAGNOSTIC PROCEDURE FOR BLOWER
MOTOR ……………………………………………………… 39
COMPONENT INSPECTION ………………………… 42
Magnet Clutch Circuit ……………………………………… 43
INSPECTION FLOW ……………………………………. 43
SYSTEM DESCRIPTION ……………………………… 44
DIAGNOSTIC PROCEDURE FOR MAGNET
CLUTCH …………………………………………………….. 44
COMPONENT INSPECTION ………………………… 51
Insufficient Cooling …………………………………………. 52
INSPECTION FLOW ……………………………………. 52
PERFORMANCE TEST DIAGNOSIS …………….. 53
PERFORMANCE CHART …………………………….. 55
TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE …………………………………………………………. 56
Insufficient Heating …………………………………………. 59
INSPECTION FLOW ……………………………………. 59
Noise ……………………………………………………………. 60
INSPECTION FLOW ……………………………………. 60
CONTROLLER …………………………………………………. 62
Removal and Installation …………………………………. 62
REMOVAL ………………………………………………….. 62
INSTALLATION ……………………………………………. 62
Disassembly and Assembly ……………………………… 63
THERMO CONTROL AMPLIFIER ………………………. 64
Removal and Installation …………………………………. 64
REMOVAL ………………………………………………….. 64
INSTALLATION ……………………………………………. 64
A/C UNIT ASSEMBLY ………………………………………. 65
Removal and Installation …………………………………. 65
REMOVAL ………………………………………………….. 65
INSTALLATION ……………………………………………. 66
Disassembly and Assembly ……………………………… 67
BLOWER MOTOR ……………………………………………. 69
Removal and Installation …………………………………. 69
REMOVAL ………………………………………………….. 69
INSTALLATION ……………………………………………. 69
INTAKE DOOR …………………………………………………. 70
Intake Door Cable Adjustment ………………………….. 70
AIR MIX DOOR ………………………………………………… 71
Air Mix Door Cable Adjustment ………………………… 71
MODE DOOR …………………………………………………… 72
Mode Door Cable Adjustment ………………………….. 72
BLOWER FAN RESISTOR ………………………………… 73
Removal and Installation …………………………………. 73
REMOVAL ………………………………………………….. 73
INSTALLATION ……………………………………………. 73

HEATER CORE …………………………………………………74
Removal and Installation …………………………………..74
REMOVAL ……………………………………………………74
INSTALLATION …………………………………………….74
AIR CONDITIONER FILTER ……………………………….75
Removal and Installation …………………………………..75
FUNCTION ………………………………………………….75
REPLACEMENT TIMING ………………………………75
REPLACEMENT PROCEDURES ……………………75
DUCTS AND GRILLES ………………………………………76
Removal and Installation …………………………………..76
REMOVAL ……………………………………………………76
INSTALLATION …………………………………………….80
REFRIGERANT LINES ………………………………………81
HFC-134a (R-134a) Service Procedure ………………81
SETTING OF SERVICE TOOLS AND EQUIPMENT ………………………………………………………….81
Components ……………………………………………………83
CR ENGINE MODELS …………………………………..83
HR ENGINE MODELS …………………………………..84
K9K ENGINE MODELS …………………………………85
Removal and Installation of Compressor …………….86
REMOVAL ……………………………………………………86
INSTALLATION …………………………………………….86
CHECK DISC TO PULLEY CLEARANCE ………..87
Removal and Installation for Pipe and Hose ………..87
REMOVAL ……………………………………………………87
INSTALLATION …………………………………………….87
Removal and Installation for Refrigerant Pressure
Sensor ……………………………………………………………88
REMOVAL AND INSTALLATION …………………….88
Removal and Installation for Condenser (Models
without Integrated Condenser) …………………………..88
REMOVAL ……………………………………………………88
INSTALLATION …………………………………………….89
Removal and Installation for Condenser (Models
with Integrated Condenser) ……………………………….89
REMOVAL ……………………………………………………89
INSTALLATION …………………………………………….89
RemovalandInstallationforLiquidTank(HREngine
with A/T Models) ……………………………………………..90
REMOVAL ……………………………………………………90
INSTALLATION …………………………………………….90
RemovalandInstallationforLiquidTank(ExceptHR
Engine with A/T Models) …………………………………..90
REMOVAL ……………………………………………………90
INSTALLATION …………………………………………….91
Removal and Installation for Evaporator ……………..91
REMOVAL ……………………………………………………91
INSTALLATION …………………………………………….91
Removal and Installation for Expansion Valve ……..91
REMOVAL ……………………………………………………91
INSTALLATION …………………………………………….92
Checking for Refrigerant Leaks …………………………93
Checking System for Leaks Using the Fluorescent
Leak Detector ………………………………………………….93
Dye Injection …………………………………………………..93
Electronic Refrigerant Leak Detector ………………….94
PRECAUTIONS FOR HANDLING LEAK

MTC-2

DETECTOR ……………………………………………….. 94
CHECKING PROCEDURE …………………………… 95
SERVICE DATA AND SPECIFICATIONS (SDS) …… 97
COMPRESSOR …………………………………………….. 97

LUBRICANT ………………………………………………….. 97
REFRIGERANT ……………………………………………… 97
ENGINE IDLING SPEED …………………………………. 97
BELT TENSION ……………………………………………… 97

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MTC-3

PRECAUTIONS
PFP:00001
PRECAUTIONS
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

BJS000CW

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Precautions for Procedures without Cowl Top Cover

BJS000CX

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

PIIB3706J

Precautions for Working with HFC-134a (R-134a)

BJS000CY

WARNING:
●
Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor malfunction is likely to occur.
●
The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed:
–
When removing refrigerant components from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
–
When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just
before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system.
–
Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. Without proper sealing, lubricant will become moisture saturated and should not be used.
–
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant
manufacturers.
–
Do not allow lubricant (Nissan A/C System Oil Type R) to come in contact with styrofoam parts.
Damage may result.

General Refrigerant Precautions

BJS000CZ

WARNING:
●
Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.

MTC-4

PRECAUTIONS
●

●
●

●
●
●

●

Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
Do not store or heat refrigerant containers above 52°C.
Do not heat a refrigerant container with an open flame; if container warming is required, place the
bottom of the container in a warm pail of water.
Do not intentionally drop, puncture, or incinerate refrigerant containers.
Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air conditioning systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a)
have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause
injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers.

Lubricant Precautions
●

●

–

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BJS000D0

Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components.
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If lubricant other than that specified is used, compressor malfunction is likely to occur.
The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following
handling precautions must be observed:
When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize G
the entry of moisture from the atmosphere.
When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the H
entry of moisture into system.
Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. WithI
out proper sealing, lubricant will become moisture saturated and should not be used.
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat.
Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety MTC
information may be obtained from refrigerant and lubricant manufacturers.
Do not allow lubricant (Nissan A/C System Oil Type R) to come in contact with styrofoam parts. Damage
may result.
K

Precautions for Refrigerant Connection

BJS000D1

A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
●
Expansion valve to evaporator
●
Refrigerant pressure sensor to condenser

FEATURES OF NEW TYPE REFRIGERANT CONNECTION
●

A

The O-ring has been relocated. It has also been provided with a groove for proper installation. This eliminates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of
the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing
characteristics.

MTC-5

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PRECAUTIONS
●

The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections.

SHA815E

O-RING AND REFRIGERANT CONNECTION
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse Orings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or
around, the connection.

O-Ring Part Numbers and Specifications (CR Engine Models)
Connection type

New

Piping connection point

Part number

Qty.

Low-pressure flexible hose to heater & cooling unit

92473 BC700

1

High-pressure pipe to heater & cooling unit

92471 BC700

1

Condenser to high-pressure flexible hose

92472 BC700

1

Condenser to high-pressure pipe

92471 BC700

1

Compressor to low-pressure flexible hose

92474 BC700

1

Compressor to high-pressure flexible hose

92472 BC700

1

Liquid tank to condenser pipe

92471 N8210

1

—

–

Inlet

92477 AX000

1

Outlet

92477 AX005

1

Refrigerant pressure sensor
Former
Expansion valve to evaporator

Remarks

O-Ring Part Numbers and Specifications (HR Engine Models)
Connection type

New

Part number

Qty.

Low-pressure flexible hose to heater & cooling unit

Piping connection point

92473 N8210

1

High-pressure pipe to heater & cooling unit

92471 N8210

1

Condenser to high-pressure flexible hose

92472 N8210

1

Condenser to high-pressure pipe

92471 N8210

1

Compressor to low-pressure flexible hose

92474 N8210

1

Compressor to high-pressure flexible hose

92472 N8210

1

Liquid tank to condenser pipe

92471 N8210

1

—

–

Inlet

92477 AX000

1

Outlet

92477 AX005

1

Refrigerant pressure sensor
Former
Expansion valve to evaporator

MTC-6

Remarks

PRECAUTIONS
O-Ring Part Numbers and Specifications (K9K Engine Models)
Connection type

New

Piping connection point

Part number

Qty.

Low-pressure flexible hose to heater & cooling unit

92473 N8210

1

Low-pressure flexible hose to Low-pressure pipe

92473 N8210

1

High-pressure pipe to heater & cooling unit

92471 N8210

1

Condenser to high-pressure flexible hose

92472 N8210

1

Condenser to high-pressure pipe

92471 N8210

1

Compressor to low-pressure flexible hose

92474 N8210

1

Compressor to high-pressure flexible hose

92472 N8210

1

Liquid tank to condenser pipe

92471 N8210

1

—

–

Inlet

92477 AX000

1

Outlet

92477 AX005

1

Refrigerant pressure sensor
Former
Expansion valve to evaporator

Remarks

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WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is F
less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.
CAUTION:
G
When replacing or cleaning refrigerant cycle components, observe the following.
●
When the compressor is removed, store it in the same position as it is when mounted on the car.
Malfunction to do so will cause lubricant to enter the low-pressure chamber.
H
●
When connecting tubes, always use a torque wrench and a back-up wrench.
●
After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
●
When installing an air conditioner in the vehicle, connect the pipes as the final stage of the operaI
tion. Do not remove the seal caps of pipes and other components until just before required for
connection.
●
Allow components stored in cool areas to warm to working area temperature before removing seal
MTC
caps. This prevents condensation from forming inside A/C components.
●
Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
●
Always replace used O-rings.
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When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not
to apply lubricant to threaded portion.

Name
Parts number
●
●
●

Gasoline engine

K9K engine

Nissan A/C System Oil Type R

Nissan A/C System Oil Type S

KLH00 — PAGR0

KLH00 — PAGS0

O-ring must be closely attached to dented portion of tube.
When replacing the O-ring, be careful not to damage O-ring and tube.
Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that
the O-ring is installed to tube correctly.

MTC-7

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After connecting line, perform leak test and make sure that there is no leakage from connections.
When the refrigerant leaking point is found, disconnect that line and replace the O-ring. Then
tighten connections of seal seat to the specified torque.

RHA861F

Precautions for Servicing Compressor
●
●
●

●

●

●

BJS000D2

Plug all openings to prevent moisture and foreign matter from entering.
When the compressor is removed, store it in the same position as it is when mounted on the car.
When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compressor” exactly. Refer to MTC-17, «Maintenance of Lubricant Quantity in Compressor» .
Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubricant, wipe it off by using a clean waste cloth moistened with thinner.
After compressor service operation, turn the compressor shaft by hand more than five turns in
both directions. This will equally distribute lubricant inside the compressor. After the compressor
is installed, let the engine idle and operate the compressor for one hour.
After replacing the compressor magnet clutch, apply voltage to the new one and check for usual
operation.

Precautions for Service Equipment

BJS000D3

RECOVERY/RECYCLING EQUIPMENT
Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never
introduce any refrigerant other than that specified into the machine.

ELECTRONIC LEAK DETECTOR
Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance.

MTC-8

PRECAUTIONS
VACUUM PUMP
A

The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric pressure. So the vacuum pump lubricant may migrate out of the pump
into the service hose. This is possible when the pump is switched off
after evacuation (vacuuming) and hose is connected to it.
To prevent this migration, use a manual valve placed near the hoseto-pump connection, as follows.
●
Usually vacuum pumps have a manual isolator valve as part of
the pump. Close this valve to isolate the service hose from the
pump.
●
For pumps without an isolator, use a hose equipped with a manual shut-off valve near the pump end. Close the valve to isolate
the hose from the pump.
●
If the hose has an automatic shut-off valve, disconnect the hose
from the pump. As long as the hose is connected, the valve is
open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.

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RHA270DA

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MANIFOLD GAUGE SET
Be certain that the gauge face indicates HFC-134a or R-134a. Be
sure the gauge set has 1/2″-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) and specified lubricants.

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SHA533D

SERVICE HOSES

L

Be certain that the service hoses display the markings described
(colored hose with black stripe). All hoses must include positive shutoff devices (either manual or automatic) near the end of the hoses
opposite the manifold gauge.

M

RHA272D

MTC-9

PRECAUTIONS
SERVICE COUPLERS
Never attempt to connect HFC-134a (R-134a) service couplers to a
CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will
not properly connect to the CFC-12 (R-12) system. However, if an
improper connection is attempted, discharging and contamination
may occur.
Shut-off valve rotation

A/C service valve

Clockwise

Open

Counterclockwise

Close
RHA273D

REFRIGERANT WEIGHT SCALE
Verify that no refrigerant other than HFC-134a (R-134a) and specified lubricants have been used with the scale. If the scale controls
refrigerant flow electronically, the hose fitting must be 1/2″-16
ACME.

RHA274D

CALIBRATING ACR4 WEIGHT SCALE
Calibrate the scale every three months.
To calibrate the weight scale on the ACR4:
1. Press “Shift/Reset” and “Enter” at the same time.
2. Press “8787” . “A1” will be displayed.
3. Remove all weight from the scale.
4. Press “0” , then press “Enter” . “0.00” will be displayed and change to “A2” .
5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb) on the center of
the weight scale.
6. Enter the known weight using four digits. (Example 10 lb = 10.00, 10.5 lb = 10.50)
7. Press “Enter” — the display returns to the vacuum mode.
8. Press “Shift/Reset” and “Enter” at the same time.
9. Press “6” — the known weight on the scale is displayed.
10. Remove the known weight from the scale. “0.00” will be displayed.
11. Press “Shift/Reset” to return the ACR4 to the program mode.

CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder’s top valve
when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an
electronic scale or of quality recycle/recharge equipment.

MTC-10

PRECAUTIONS
Precautions for Leak Detection Dye
●

●

●

●

●

●

●

●
●
●

●

BJS000D4

The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet
(UV) lamp is required to illuminate the dye when inspecting for leaks.
Always wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of
the fluorescent dye.
The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluorescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector to pinpoint refrigerant leaks.
For your safety and your customer’s satisfaction, read and follow all manufacture’s operating instructions
and precautions prior to performing the work.
A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal
should only be repaired after confirming the leak with an electronic refrigerant leak detector.
Always remove any remaining dye from the leak area after repairs are complete to avoid a misdiagnosis
during a future service.
Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled,
clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period
of time cannot be removed.
Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).
Do not use more than one refrigerant dye bottle (1/4 ounce /7.4 cc) per A/C system.
Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use
HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system or CFC-12 (R-12) leak detector dye
in HFC-134a (R-134a) A/C system or A/C system damage may result.
The fluorescent properties of the dye will remain for over three (3) years unless a compressor malfunction
occurs.

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IDENTIFICATION
I

NOTE:
Vehicles with factory installed fluorescent dye have a green label.
Vehicles without factory installed fluorescent dye have a blue label.

MTC

IDENTIFICATION LABEL FOR VEHICLE
Vehicles with factory installed fluorescent dye have this identification
label on the front side of hood.

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MJIB0432E

MTC-11

PREPARATION
PREPARATION
HFC-134a (R-134a) Service Tools and Equipment

PFP:00002
BJS000D6

Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or
its lubricant.
Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubricant.
Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles
refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid
mixed use of the refrigerants/lubricant.
Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will
occur and compressor malfunction will result.
Tool number
Tool name

Description

Container color: Light blue
Container marking: HFC-134a (R134a)
Fitting size: Thread size

HFC-134a (R-134a) refrigerant

●

Large container 1/2″ -16 ACME

S-NT196

Type: Polyalkylene glycol oil (PAG),
type R (DH-PR)
Application: HFC-134a (R-134a) vane
rotary compressors (Nissan only)
Lubricity: 40 m
(1.4 Imp fl oz.)

KLH00-PAGR0
Nissan A/C System Oil Type R
(DH-PR)
S-NT197

Recovery/Recycling/
Recharging equipment (ACR4)

Function: Refrigerant recovery and
recycling and recharging

RJIA0195E

Power supply:
DC 12V (Cigarette lighter)

Electrical leak detector

SHA705EB

MTC-12

PREPARATION
Tool number
Tool name

Description

(J-43926)
Refrigerant dye leak detection kit
Kit includes:
(J-42220)
UV lamp and UV safety goggles
(J-41459)
HFC-134a (R-134a) dye injector
Use with J-41447, 1/4 ounce
bottle
(J-41447)
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
(J-43872)
Refrigerant dye cleaner

A

B

C
Power supply:
DC 12V (Battery terminal)

D

ZHA200H

E
Power supply:
DC 12V (Battery terminal)
For checking refrigerant leak when
fluorescent dye is installed in A/C
system
Includes:
UV lamp and UV safety goggles

(J-42220)
UV lamp and UV safety goggles

SHA438F

Application:
For HFC-134a (R-134a) PAG oil
Container:
1/4 ounce (7.4 cc) bottle
(Includes self-adhesive dye
identification labels for affixing to
vehicle after charging system with
dye.)

(J-41447)
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
SHA439F

F

G

H

I

MTC

(J-41459)
HFC-134a (R-134a) dye injector
Use with J-41447, 1/4 ounce
bottle

For injecting 1/4 ounce of fluorescent
leak detection dye into A/C system

K

L

SHA440F

M
(J-43872)
Refrigerant dye cleaner

For cleaning dye spills

SHA441F

Identification:
●

Manifold gauge set (with hoses
and couplers)

The gauge face indicates HFC-134a
(R-134a).

Fitting size: Thread size
●

RJIA0196E

MTC-13

1/2″ -16 ACME

PREPARATION
Tool number
Tool name

Description
Hose color:

Service hoses
●

High-pressure side hose

●

Low-pressure side hose

●

Utility hose

Service couplers
High-pressure side coupler

●

Low-pressure side coupler

Low hose: Blue with black stripe

●

High hose: Red with black stripe

●

Utility hose: Yellow with black stripe
or green with black stripe

Hose fitting to gauge:
S-NT201

●

●

●

1/2″ -16 ACME

Hose fitting to service hose:
●

M14 x 1.5 fitting is optional or
permanently attached.

S-NT202

For measuring of refrigerant
Fitting size: Thread size

Refrigerant weight scale

●

1/2″ -16 ACME

S-NT200

Capacity:

Vacuum pump
(Including the isolator valve)

●

Air displacement: 4 CFM

●

Micron rating: 20 microns

●

Oil capacity: 482 g (17 oz.)

Fitting size: Thread size
S-NT203

●

1/2″ -16 ACME

Commercial Service Tools

BJS000D7

Tool name

Description

Power tool

For loosening bolts and nuts

PBIC0190E

MTC-14

REFRIGERATION SYSTEM
REFRIGERATION SYSTEM
Refrigerant Cycle

PFP:KA990

A
BJS000D8

REFRIGERANT FLOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank,
through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator is
controlled by an externally equalized expansion valve, located inside the evaporator case.

FREEZE PROTECTION

B

C

Under usual operating conditions, when the A/C is switched ON, the compressor runs continuously, and the
evaporator pressure, and therefore, temperature is controlled by the compressor to prevent freeze up.

Refrigerant System Protection

BJS000D9

D

REFRIGERANT PRESSURE SENSOR
The refrigerant system is protected against excessively high- or low-pressures by the refrigerant pressure sensor, located on the condenser. If the system pressure rises above, or falls below the specifications, the refrigerant pressure sensor detects the pressure inside the refrigerant line and sends the voltage signal to the ECM.
ECM makes the A/C relay go OFF and stops the compressor when pressure on the high-pressure side
detected by refrigerant pressure sensor is over about 2,746 kPa (27.46 bar, 28.0 kg/cm2 , 398 psi), or below
about 134 kPa (1.34 bar, 1.4 kg/cm2 , 20 psi).

PRESSURE RELIEF VALVE
The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor.
When the pressure of refrigerant in the system increases to an unusual level [more than 3.8 MPa (38 bar,
38.76 kg/cm2 , 551 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere.

E

F

G

H

I

MTC

K

L

M

MJIB0355E

MTC-15

REFRIGERATION SYSTEM
Component Layout

BJS000DA

MJIB0368E

1.

Defroster nozzle

2.

Side defroster duct

3.

Side ventilator duct

4.

A/C unit

5.

Center ventilator duct

6.

Front floor duct

7.

Rear floor duct

MTC-16

LUBRICANT
LUBRICANT
Maintenance of Lubricant Quantity in Compressor

PFP:KLG00

A
BJS000DB

The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compressor when replacing any component or after a large refrigerant leakage occurred. It is important to maintain the
specified amount.
If lubricant quantity is not maintained properly, the following malfunctions may result:
●
Lack of lubricant: May lead to a seized compressor.
●
Excessive lubricant: Inadequate cooling (thermal exchange interference)

B

C

LUBRICANT
D

Name

Gasoline engine

K9K engine

Nissan A/C System Oil Type R

Nissan A/C System Oil Type S

KLH00 — PAGR0

KLH00 — PAGS0

Parts number

E

LUBRICANT RETURN OPERATION
Adjust the lubricant quantity according to the test group shown below.

F

1. CHECK LUBRICANT RETURN OPERATION
Can lubricant return operation be performed?
●
A/C system works properly.
●
There is no evidence of a large amount of lubricant leakage.
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant return operation.
OK or NG
OK
>> GO TO 2.
NG
>> GO TO 3.

2. PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS
1.
–
–
–
–
–

2.
3.

Start engine, and set the following conditions:
Engine speed: Idling to 1,200 rpm
A/C switch: ON
Blower speed: Max. position
Temp. control: Optional (Set so that intake air temperature is 25 to 30°C.)
Intake position: Recirculation (REC)
Perform lubricant return operation for about 10 minutes.
Stop engine.
>> GO TO 3.

3. CHECK REPLACEMENT PART
Should the compressor be replaced?
YES >> GO TO MTC-18, «LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT» .
NO
>> GO TO MTC-18, «LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR» .

MTC-17

G

H

I

MTC

K

L

M

LUBRICANT
LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR
After replacing any of the following major components, add the correct amount of lubricant to the system.
Amount of lubricant to be added
Lubricant to be added to system
Part replaced

Amount of lubricant
m
(Imp fl oz.)

Remarks

Evaporator

35 (1.2)

—

Condenser

15 (0.5)

—

Liquid tank

5 (0.2)

—

30 (1.1)

Large leak

—

Small leak *1

In case of refrigerant leak
*1: If refrigerant leak is small, no addition of lubricant is needed.

LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT
1.
2.
3.
4.
5.
6.
7.

Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If
NG, recover refrigerant from equipment lines.
Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into
the recovery/recycling equipment.
Drain the lubricant from the old (removed) compressor into a graduated container and recover the amount
of lubricant drained.
Drain the lubricant from the new compressor into a separate, clean container.
Measure an amount of new lubricant installed equal to amount drained from old compressor. Add this
lubricant to new compressor through the suction port opening.
Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant
to new compressor through the suction port opening.
If the liquid tank also needs to be replaced, add another 5 m (0.2 Imp fl oz.) of lubricant at this time.
Do not add this 5 m (0.2 Imp fl oz.) of lubricant only when replaces the compressor.

MTC-18

LUBRICANT
A

B

C

D

E

F

G

H

I

SJIA0596E

MTC

K

L

M

MTC-19

AIR CONDITIONER CONTROL
AIR CONDITIONER CONTROL
Control Operation

PFP:27500
BJS000DC

SJIA0699E

FAN CONTROL DIAL
This dial turns the fan ON and OFF, and controls fan speed.

TEMPERATURE CONTROL DIAL
This dial allows you to adjust the temperature of the discharge air.

MODE CONTROL DIAL
This dial controls the outlet air flow.

INTAKE DOOR LEVER
●
●

Recirculation (REC) position: Interior air is recirculated inside the vehicle.
Fresh (FRE) position: Outside air is drawn into the passenger compartment.

REAR WINDOW DEFOGGER SWITCH
When illumination is ON, rear window is defogged.

A/C SWITCH
The A/C switch controls the air conditioner system. When the switch is depressed with the fan ON, the compressor will turn ON. The indicator lamp also illuminates.

MTC-20

AIR CONDITIONER CONTROL
Discharge Air Flow

BJS000JC

A

B

C

D

E

F

G

H

I

MTC

K

L

M

MJIB0512E

MTC-21

AIR CONDITIONER CONTROL
System Description

BJS000DE

SWITCHES AND THEIR CONTROL FUNCTION

MJIB0507E

SJIA0701E

CAN Communication System Description

BJS000DF

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only. For details, refer to LAN-27,
«CAN Communication Unit» .

MTC-22

TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
CONSULT-II Function (BCM)

PFP:00004

A
BJS000DG

CONSULT-II can display diagnostic item using the diagnostic test modes shown following.
System part

Check item, diagnosis mode

BCM

Data monitor

B

Description
Displays BCM input data in real time.

C

CONSULT-II BASIC OPERATION
Refer to GI-36, «CONSULT-II Start Procedure» .

DATA MONITOR
Operation Procedure
1.

D

Touch “AIR CONDITIONER” on “SELECT TEST ITEM” screen.
E

F

G
MJIB0465E

2.

H

Touch “DATA MONITOR” on “SELECT DIAG MODE” screen.

I

MTC

K
MJIB0466E

3.

Touch either “ALL SIGNALS” or “SELECTION FROM MENU” on
“DATA MONITOR” screen.

All signals

Monitors all the items.

Selection from menu

Selects and monitors the individual item selected.

4.

5.
6.

L

M

When “SELECTION FROM MENU” is selected, touch items to
be monitored. When “ALL SIGNALS” is selected, all the items
will be monitored.
Touch “START”.
Touch “RECORD” while monitoring, then the status of the monitored item can be recorded. To stop recording, touch “STOP”.

RJIA1111E

Display Item List
Monitor item name
“operation or unit”

Contents

IGN ON SW

“ON/OFF”

Displays “IGN Position (ON)/OFF, ACC Position (OFF)” status as judged from ignition switch signal.

FAN ON SIG

“ON/OFF”

Displays “FAN (ON)/FAN (OFF)” status as judged from blower fan motor switch signal.

AIR COND SW

“ON/OFF”

Displays “COMP (ON)/COMP (OFF)” status as judged from air conditioner switch signal.

MTC-23

TROUBLE DIAGNOSIS
How to Perform Trouble Diagnosis for Quick and Accurate Repair

BJS000DH

WORK FLOW

SHA900E

*1

MTC-34, «Operational Check»

SYMPTOM TABLE
Symptom

Reference Page
MTC-36, «Mode Door»

Air outlet does not change.

Go to Trouble Diagnosis Procedure for mode door.

Discharge air temperature does not
change.

Go to Trouble Diagnosis Procedure for Air Mix Door.

MTC-37, «Air Mix
Door»

Intake door does not change.

Go to Trouble Diagnosis Procedure for Intake Door.

MTC-38, «Intake Door»

Blower motor operation is malfunctioning.

Go to Trouble Diagnosis Procedure for Blower Motor.

MTC-39, «Blower
Motor Circuit»

Magnet clutch does not engage.

Go to Trouble Diagnosis Procedure for Magnet Clutch.

MTC-43, «Magnet
Clutch Circuit»

Insufficient cooling

Go to Trouble Diagnosis Procedure for Insufficient Cooling.

MTC-52, «Insufficient
Cooling»

Insufficient heating

Go to Trouble Diagnosis Procedure for Insufficient Heating.

MTC-59, «Insufficient
Heating»

Noise

Go to Trouble Diagnosis Procedure for Noise.

MTC-24

MTC-60, «Noise»

TROUBLE DIAGNOSIS
Component Parts and Harness Connector Location

BJS000DI

A

B

C

D

E

F

G

H

I

MTC

K

L

M

MJIB0491E

1.

Compressor
(CR & HR engine F28)
(K9K engine F129)

2.

Refrigerant pressure sensor
(CR & HR engine E21)
(K9K engine E65)

3.

Heater control panel M62

4.

Blower motor M56

5.

Fan resistor M29

6.

Thermo control amp. M44

MTC-25

TROUBLE DIAGNOSIS
Wiring Diagram — HEATER —

BJS000DK

MJWA0265E

MTC-26

TROUBLE DIAGNOSIS
Wiring Diagram — A/C — CR Engine Models

BJS000IM

A

B

C

D

E

F

G

H

I

MTC

K

L

M

MJWA0266E

MTC-27

TROUBLE DIAGNOSIS

MJWA0267E

MTC-28

TROUBLE DIAGNOSIS
Wiring Diagram — A/C — HR Engine Models

BJS000IN

A

B

C

D

E

F

G

H

I

MTC

K

L

M

MJWA0268E

MTC-29

TROUBLE DIAGNOSIS

MJWA0269E

MTC-30

TROUBLE DIAGNOSIS
Wiring Diagram — A/C — K9K Engine Models

BJS000IO

A

B

C

D

E

F

G

H

I

MTC

K

L

M

MJWA0270E

MTC-31

TROUBLE DIAGNOSIS

MJWA0271E

MTC-32

TROUBLE DIAGNOSIS
Wiring Diagram — PTC/H —

BJS000IP

A

B

C

D

E

F

G

H

I

MTC

K

L

M

MJWA0272E

PTC heater function is intended to improve the heating performance with CTP electrical system for air heating
system which is broken down into several stages controlled by relays.

MTC-33

TROUBLE DIAGNOSIS
Operational Check

BJS000DL

The purpose of the operational check is to confirm that the system operates properly.
Conditions

: Engine running at usual operating temperature

CHECKING BLOWER
1.

Turn fan control dial to 1-speed. Blower should operate on low
speed.
2. Then turn fan control dial to 2-speed, and continue checking
blower speed until all speeds are checked.
3. Leave blower on Max. speed.
If NG, go to trouble diagnosis procedure for MTC-39, «Blower Motor
Circuit» .
If OK, continue the check.
SJIA0704E

CHECKING DISCHARGE AIR
1.

Turn mode control dial to each position.

SJIA0705E

2.

Confirm that discharge air comes out according to the air distribution table. Refer to MTC-21, «Discharge Air Flow» .
If NG, go to trouble diagnosis procedure for MTC-36, «Mode Door» .
If OK, continue the check.

MJIB0374E

CHECKING RECIRCULATION
1.
2.
3.

Set intake door lever to REC position.
Operate intake door lever to FRE position.
Listen for intake door position change (you should hear blower
sound change slightly).
If NG, go to trouble diagnosis procedure for MTC-38, «Intake Door» .
If OK, continue the check.

SJIA0708E

MTC-34

TROUBLE DIAGNOSIS
CHECKING TEMPERATURE DECREASE
A

1.

Turn temperature control dial counterclockwise until full cold
position.
2. Check for cold air at discharge air outlets.
If NG, go to trouble diagnosis procedure for MTC-52, «Insufficient
Cooling» .
If OK, continue the check.

B

C

SJIA0710E

D

CHECKING TEMPERATURE INCREASE
1. Turn temperature control dial clockwise until full hot position.
2. Check for hot air at discharge air outlets.
If NG, go to trouble diagnosis procedure for MTC-59, «Insufficient
Heating» .
If OK, continue the check.

E

F

G

SJIA0711E

H

CHECKING A/C SWITCH
1.
2.
3.

Turn fan control dial to the desired (1 to 4 speed) position.
Press A/C switch.
A/C switch indicator will turn ON.
● Confirm that the compressor clutch engages (sound or visual
inspection).
If NG, go to trouble diagnosis procedure for MTC-43, «Magnet Clutch
Circuit» .
If all operational checks are OK (symptom cannot be duplicated), go
to Incident Simulation Tests in GI-25, «How to Perform Efficient Diagnosis for an Electrical Incident» and perform tests as outlined to
simulate driving conditions environment. If symptom appears, refer
to MTC-24, «SYMPTOM TABLE» and perform applicable trouble diagnosis procedures.

I

MTC

K
SJIA0713E

L

M

MTC-35

TROUBLE DIAGNOSIS
Mode Door

BJS000DM

SYMPTOM: Air outlet does not change.

INSPECTION FLOW

MJIB0493E

*1

MTC-21, «Discharge Air Flow»

*4

MTC-24, «SYMPTOM TABLE»

*2

MTC-34, «Operational Check»

MTC-36

*3

MTC-72, «Mode Door Cable Adjustment»

TROUBLE DIAGNOSIS
Air Mix Door

BJS000DN

A

SYMPTOM: Air mix door does not change.

INSPECTION FLOW
B

C

D

E

F

G

H

I

MTC

K

L

M

SJIA0720E

*1

MTC-34, «Operational Check»

*2

MTC-71, «Air Mix Door Cable Adjust- *3
ment»

MTC-37

MTC-24, «SYMPTOM TABLE»

TROUBLE DIAGNOSIS
Intake Door

BJS000DO

SYMPTOM:
Intake door does not change.

INSPECTION FLOW

SJIA0722E

*1

MTC-34, «Operational Check»

*2

MTC-70, «Intake Door Cable
Adjustment»

MTC-38

*3

MTC-24, «SYMPTOM TABLE»

TROUBLE DIAGNOSIS
Blower Motor Circuit

BJS000DP

A

SYMPTOM: Blower motor operation is malfunctioning.

INSPECTION FLOW
B

C

D

E

F

G

H

I

SJIA0723E

*1

MTC-34, «Operational Check»

*2

MTC-39, «DIAGNOSTIC PROCE- *3
DURE FOR BLOWER MOTOR»

MTC

MTC-24, «SYMPTOM TABLE»

K

DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR
SYMPTOM: Blower motor operation is malfunctioning.

L

M

MJIB0521E

1. CHECK BLOWER MOTOR OPERATION
1. Turn ignition switch ON.
2. Check blower motor operation at each fan speed.
OK or NG
Blower motor does not operate at all speed.>>GO TO 2.
Blower motor does not operate at one of speeds 1-4.>>GO TO 6.

MTC-39

TROUBLE DIAGNOSIS

2. CHECK POWER SUPPLY FOR BLOWER MOTOR
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect blower motor connector.
Turn ignition switch ON.
Check voltage between blower motor harness connector and
ground.
Terminals
(+)

Voltage
(Approx.)

(−)

Connector

Terminal

Blower
motor: M56

1

Ground
Battery voltage

MJIB0516E

OK or NG
OK
>> GO TO 3.
NG
>> Check power supply circuit and 15A fuses (Nos. 18 and 20, located in the fuse block). Refer to
PG-95, «FUSE BLOCK» .
● If fuses are OK, check harness for open circuit. Repair or replace if necessary.
● If fuses are NG, replace fuse and check harness for short circuit. Repair or replace if necessary.

3. CHECK GROUND CIRCUIT FOR BLOWER MOTOR
1.
2.

Turn ignition switch OFF.
Check continuity between blower motor harness connector and
ground.

Connector

Terminal

Blower
motor:
M56

2

Continuity
Ground
Yes

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 5.

MJIB0519E

4. CHECK BLOWER MOTOR
Check continuity between blower motor harness connector terminal
1 and 2.
Connector
Blower motor: M56

Terminals
1

Continuity
2

Yes

OK or NG
OK
>> GO TO 9.
NG
>> Replace blower motor.
MJIB0517E

MTC-40

TROUBLE DIAGNOSIS

5. CHECK CIRCUIT CONTINUITY BETWEEN BLOWER MOTOR AND BLOWER FAN RESISTOR
1.
2.

A

Disconnect fan resistor connector.
Check continuity between blower motor harness connector (A)
and fan resistor harness connector (B).
A

B

B

Continuity

Connector

Terminal

Connector

Terminal

Blower
motor:
M56

2

Fan resistor:
M29

4

C
Yes

D

OK or NG
OK
>> GO TO 6.
NG
>> Repair harness or connector.

MJIB0522E

E

6. CHECK BLOWER FAN RESISTOR
1.
2.
3.

F

Turn ignition switch OFF.
Disconnect fan resistor connector.
Check resistance between fan resistor connector terminal 4 and
1, 2, 3.
Connector

Terminals

Fan resistor: M29

4

G

Resistance
1

Approx. 2.15Ω

2

Approx. 1.10Ω

3

Approx. 0.46Ω

OK or NG
OK
>> GO TO 7.
NG
>> Replace fan resistor.

H

SJIA0730E

I

MTC

7. CHECK FAN SWITCH
1.
2.

Disconnect heater control panel connector.
Check continuity between heater control panel connector terminal 9 and 10, 11, 12, 13, 14.

Connector

Heater
control
panel: M62

Terminals

9

Condition

14

Fan control dial: OFF

10

Fan control dial: 1-speed

11

Fan control dial: 2-speed

12

Fan control dial: 3-speed

13

Fan control dial: 4-speed

K

L

Continuity

M
Yes

SJIA0732E

OK or NG
OK
>> GO TO 8.
NG
>> Replace heater control panel.

MTC-41

TROUBLE DIAGNOSIS

8. CHECK CIRCUIT CONTINUITY BETWEEN HEATER CONTROL PANEL AND BLOWER FAN RESISTOR
Check continuity between heater control panel harness connector
(A) and blower fan resistor harness connector (B).
A
Connector

B
Terminal

Connector

10
Heater
control
panel: M62

11
12

Continuity
Terminal
1

Fan resistor:
M29

13

2

Yes.

3
4

OK or NG
OK
>> Check harness connector and connector for open circuit.
NG
>> Repair harness and connector.

SJIA0733E

9. CHECK FAN SWITCH GROUND CIRCUIT
1.
2.

Disconnect heater control panel connector.
Check continuity between heater control panel harness connector and ground.

Connector

Terminal

Heater
control
panel: M62

9

Continuity
Ground

Yes

OK or NG
OK
>> INSPECTION END
NG
>> Repair harness and connector.
SJIA0734E

COMPONENT INSPECTION
Blower Motor
Confirm smooth rotation of the blower motor (1).
●
Ensure that there are no foreign particles inside the A/C unit
assembly.

MJIB0494E

MTC-42

TROUBLE DIAGNOSIS
Magnet Clutch Circuit

BJS000DQ

A

SYMPTOM: Magnet clutch does not engage.

INSPECTION FLOW
B

C

D

E

F

G

H

I

MTC

K

L

M

SJIA0740E

*1

MTC-34, «Operational Check»

*2

CR: EM-14, «Checking drive Belts»
HR: EM-114, «Checking Drive Belts»
K9K: EM-242, «Checking Drive
Belts»

*4

MTC-24, «SYMPTOM TABLE»

*5

MTC-56, «TROUBLE DIAGNOSIS
FOR UNUSUAL PRESSURE»

MTC-43

*3

MTC-44, «DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH»

TROUBLE DIAGNOSIS
SYSTEM DESCRIPTION
Thermo control amp. controls compressor operation by intake air temperature and signal from ECM.

Low Temperature Protection Control
When intake air temperatures are higher than 4°C (39°F), the compressor turns ON. The compressor turns OFF when intake air temperatures are lower than 2°C (36°F).

SJIA0741E

DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH
SYMPTOM: Magnet clutch does not engage when A/C switch and fan switch are ON.

MJIB0495E

1. PERFORM AUTO ACTIVE TEST
Refer to PG-22, «Auto Active Test» .
Does the magnet clutch operate?
YES >> ●
WITH CONSULT-II
GO TO 6.
●
WITHOUT CONSULT-II
GO TO 7.
NO
>> GO TO 2.

MTC-44

TROUBLE DIAGNOSIS

2. CHECK POWER SUPPLY FOR COMPRESSOR
1.
2.
3.
4.
5.

A

Turn ignition switch OFF.
Disconnect compressor connector.
Start the engine.
Turn fan control dial and A/C switch ON.
Check voltage between compressor harness connector and
ground.

B

C

Terminals
(+)
Engine

Voltage
(Approx.)

(−)

Connector

Terminal

CR and HR

Compressor: F28

K9K

Compressor: F129

D
MJIB0405E

Ground
1

E

12V

OK or NG
OK
>> GO TO 4.
NG
>> Check 10A fuse (No. 51, located in the fuse block)
● If fuse is OK, GO TO 3.
● If fuse is NG, replace fuse and GO TO 3.

F

G

3. CHECK CIRCUIT CONTINUITY BETWEEN IPDM E/R AND COMPRESSOR
1.
2.
3.

A
Engine

Connector

CR and HR

Compressor:
F28

K9K

Compressor:
F129

4.

H

Turn ignition switch OFF.
Disconnect IPDM E/R connector.
Check continuity between compressor harness connector (A)
and IPDM E/R harness connector (B).
B

Continuity

Terminal

Connector

Terminal

1

IPDM E/R: E7

41

CR and HR

Compressor: F28

K9K

Compressor: F129

K
MJIB0406E

A
Connector

MTC

Yes

Check continuity between compressor harness connector (A) and ground.

Engine

I

L

Continuity
Terminal
1

Ground
NO.

OK or NG
OK
>> GO TO 4.
NG
>> Repair harness and connector.

MTC-45

M

TROUBLE DIAGNOSIS

4. CHECK COMPRESSOR GROUND CIRCUIT
Check continuity between compressor harness connector and
ground.
Connector
Compressor: F129

Terminal

Ground

Continuity

2

Yes

OK or NG
OK
>> GO TO 5.
NG
>> Repair harness and connector.
MJIB0519E

5. CHECK COMPRESSOR
Check for operation sound when applying battery voltage direct current to terminal.
OK or NG
OK
>> 1. Check harness and connector for open circuit.
2. Repair or replace if necessary.
NG
>> 1. Replace magnet clutch.
2. Go to operational check. Refer to MTC-35, «CHECKING A/C SWITCH» . Confirm that magnet clutch operation is usual.

MJIB0407E

6. CHECK BCM INPUT (COMPRESSOR ON) SIGNAL
Check compressor ON/OFF signal. Refer to MTC-23, «CONSULT-II
Function (BCM)» .
A/C SW ON
A/C SW OFF

: AIR COND SW ON
: AIR COND SW OFF

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

RJIA1111E

MTC-46

TROUBLE DIAGNOSIS

7. CHECK CIRCUIT CONTINUITY BETWEEN HEATER CONTROL PANEL AND BCM
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect heater control panel and BCM connector.
Check continuity between heater control panel harness connector (A) and BCM harness connector (B).
A

B

B

Connector

Terminal

Connector

Terminal

Heater
control
panel: M62

1

BCM: M58

61

Continuity

C

Yes

D
MJIB0492E

OK or NG
OK
>> GO TO 8.
NG
>> Repair harness or connector.

E

8. CHECK REFRIGERANT PRESSURE SENSOR
1.
2.
3.

1.
2.
3.

F

WITH CONSULT-II
Reconnect heater control panel connector and BCM connector.
Start the engine.
Check voltage of refrigerant pressure sensor.
CR (WITH EURO–OBD): Refer to EC-112, «CONSULT-II Reference Value in Data Monitor Mode» .
CR (WITHOUT EURO–OBD): Refer to EC-527, «CONSULT-II Reference Value in Data Monitor Mode» .
HR (WITH EURO–OBD): Refer to EC-902, «CONSULT-II Reference Value in Data Monitor» .
HR (WITHOUT EURO–OBD): Refer to EC-1321, «CONSULT-II Reference Value in Data Monitor» .
K9K: Refer to EC-1694, «CONSULT-II Reference Value in Data Monitor Mode» .
*For further information refer to EC-21, «APPLICATION NOTICE» .
WITHOUT CONSULT-II
Reconnect heater control panel connector and BCM connector.
Start the engine.
Check voltage between ECM harness connector and ground.

G

H

I

MTC

K

Terminals
(+)

Engine

Connector

(−)

ECM: F2

69

HR

ECM: F51

41

K9K

ECM: F134

89

●

NG

>> ●
●
●
●
●

Voltage
(Approx.)

L

Terminal

CR

OK or NG
OK
>> ●

Condition

Ground

A/C switch: ON
(Blower motor operates.)

1 — 4V

M

WITH CONSULT-II
GO TO 9.
WITHOUT CONSULT-II
GO TO 10.
CR (WITH EURO–OBD): Refer to EC-443 …
CR (WITHOUT EURO–OBD): Refer to EC-794 .
HR (WITH EURO–OBD): Refer to EC-1231 .
HR (WITHOUT EURO–OBD): Refer to EC-1590 .
K9K: Refer to EC-1811 .
MJIB0410E

MTC-47

TROUBLE DIAGNOSIS

9. CHECK BCM INPUT (FAN ON) SIGNAL
Check FAN ON/OFF signal. Refer to MTC-23, «CONSULT-II Function (BCM)» .
FAN CONTROL DIAL ON
FAN CONTROL DIAL OFF

: FAN ON SIG ON
: FAN ON SIG OFF

OK or NG
OK
>> Stop the engine and GO TO 14.
NG
>> GO TO 10.

RJIA1111E

10. CHECK BCM INPUT (FAN ON) SIGNAL
1.
2.
3.

Stop the engine and turn ignition switch ON.
Turn fan control dial to 1-speed.
Confirm fan on signal between heater control panel harness
connector and ground using oscilloscope.
Terminals
Voltage
(Approx.)

(+)
Connector

Terminal

(-)

SJIA0750E

Heater control
panel: M62

14

Ground

ZJIA0583J

OK or NG
OK
>> Turn ignition switch OFF and disconnect heater control panel connector, GO TO 12.
NG
>> GO TO 11.

11. CHECK CIRCUIT CONTINUITY BETWEEN BCM AND HEATER CONTROL PANEL
1.
2.
3.

Turn ignition switch OFF.
Disconnect heater control panel connector and BCM connector.
Check continuity between BCM harness connector (A) and
heater control panel harness connector (B).
A

B

Continuity

Connector

Terminal

Connector

Terminal

BCM: M58

50

Heater
control
panel: M62

14

Yes
MJIB0497E

OK or NG
OK
>> GO TO 12.
NG
>> Repair harness or connector.

MTC-48

TROUBLE DIAGNOSIS

12. CHECK FAN SWITCH CIRCUIT
1.
2.

A

Turn fan control dial to the OFF position.
Check continuity between heater control panel connector terminal 9 and 14.
Connector

Terminals

Heater control panel: M62

9

B

Continuity
14

C

Yes

OK or NG
OK
>> GO TO 13.
NG
>> Replace heater control panel.

D
SJIA0753E

13. CHECK HEATER CONTROL PANEL GROUND CIRCUIT

E

Check continuity between heater control panel harness connector
and ground.
Connector

Terminal

Heater control panel: M62

9

F

Continuity

Ground

Yes

G

OK or NG
OK
>> GO TO 14.
NG
>> Repair harness or connector.

H
SJIA0754E

14. CHECK BCM INPUT (COMPRESSOR ON) SIGNAL
1.
2.
3.

I

Reconnect BCM connector and heater control panel connector.
Turn ignition switch ON.
Confirm compressor on signal between heater control panel harness connector and ground using oscilloscope.

MTC

K
Terminals
(+)
Connector

Terminal

(-)

Voltage
(Approx.)

L
SJIA0755E

Heater control
panel: M62

M
1

Ground

ZJIA0584J

OK or NG
OK
>> GO TO 15.
NG
>> GO TO 17.

MTC-49

TROUBLE DIAGNOSIS

15. CHECK A/C SWITCH CIRCUIT
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect heater control panel connector.
Pressing A/C switch.
Check continuity between heater control panel connector terminal 1 and 8.
Connector

Terminals

Heater control
panel: M62

1

8

Condition

Continuity

Pressing A/C
switch.

Yes

OK or NG
OK
>> GO TO 16.
NG
>> Replace heater control panel.

SJIA0756E

16. CHECK HEATER CONTROL PANEL GROUND CIRCUIT
Check continuity between heater control panel harness connector
and ground.
Connector

Terminal

Heater
control
panel: M62

8

Continuity
Ground

Yes

OK or NG
OK
>> GO TO 19.
NG
>> Repair harness or connector.
SJIA0758E

17. CHECK POWER SUPPLY THERMO CONTROL AMP.
1.
2.

Turn ignition switch ON.
Check voltage thermo control amp. harness connector and
ground.
Terminals
(+)

(−)

Connector

Terminal

Thermo control
amp.: M44

1

Ground

Voltage
(Approx.)

Battery voltage

MJIB0498E
OK or NG
OK
>> GO TO 18.
NG
>> Check power supply circuit and 10A fuse (No. 19, located in the fuse block). Refer to PG-95,
«FUSE BLOCK» .
● If fuse is OK, check harness for open circuit. Repair or replace if necessary.
● If fuse is NG, replace fuse and check harness for short circuit. Repair or replace if necessary.

MTC-50

TROUBLE DIAGNOSIS

18. CHECK CIRCUIT CONTINUITY THERMO CONTROL AMP. AND BCM
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect BCM connector.
Check continuity thermo control amp. harness connector (A)
and BCM harness connector (B).
A

B

B

Connector

Terminal

Connector

Terminal

Thermo
control
amp.: M44

2

BCM: M57

35

C

Continuity

D

Yes
MJIB0499E

OK or NG
OK
>> GO TO 19.
NG
>> Repair harness or connector.

E

19. CHECK CAN COMMUNICATION

F

Check CAN communication. Refer to BCS-17, «CAN Communication Inspection With CONSULT-II (Self-Diagnosis)» .
●
BCM – ECM
●
ECM – IPDM E/R
OK or NG
OK
>> Replace BCM.
NG
>> Repair or replace malfunction part(s).

COMPONENT INSPECTION
Refrigerant Pressure Sensor

G

H

I

MTC

K

L
MJIB0457E

1.

Refrigerant pressure sensor

4.

Air guide

2.

Condenser

3.

M

Liquid tank

The refrigerant pressure sensor (1) is attached to the condenser.
Make sure that the A/C refrigerant pressure and the sensor output
voltage are within the specified range as shown in the A/C operating
condition figure.
CR (WITH EURO–OBD): Refer to EC-443 .
CR (WITHOUT EURO–OBD): Refer to EC-794 .
HR (WITH EURO–OBD): Refer to EC-1231 .
HR (WITHOUT EURO–OBD): Refer to EC-1590 .
K9K: Refer to EC-1811 .
*For further information refer to EC-21, «APPLICATION NOTICE» .
RJIA2954E

MTC-51

TROUBLE DIAGNOSIS
Insufficient Cooling

BJS000DR

SYMPTOM: Insufficient cooling

INSPECTION FLOW

SJIA0766E

*1

MTC-34, «Operational Check»

*2

CR: EM-14, «Checking drive Belts»
HR: EM-114, «Checking Drive Belts»
K9K: EM-242, «Checking Drive Belts»

*3

MTC-71, «Air Mix Door Cable Adjustment»

*4

MTC-55, «Test Reading»

*5

MTC-24, «SYMPTOM TABLE»

*6

CR (WITH EURO–OBD): EC-345
CR (WITHOUT EUROOBD): EC-662
HR (WITH EUROOBD): EC-1130
HR (WITHOUT EUROOBD): EC-1451
K9K: EC-1864

*7

MTC-53, «PERFORMANCE TEST
DIAGNOSIS»

*For further information refer to EC-21, «APPLICATION NOTICE» .

MTC-52

TROUBLE DIAGNOSIS
PERFORMANCE TEST DIAGNOSIS
A

B

C

D

E

F

G

H

I

MTC

K

L

M

RJIA1601E

*1

MTC-55, «PERFORMANCE CHART» *2

*4

MTC-71, «Air Mix Door Cable Adjustment»

MTC-55, «PERFORMANCE CHART» *3

MTC-53

MTC-56, «TROUBLE DIAGNOSIS
FOR UNUSUAL PRESSURE»

TROUBLE DIAGNOSIS

RJIA3107E

*1

MTC-87, «CHECK DISC TO PULLEY *2
CLEARANCE»

MTC-39, «Blower Motor Circuit»

MTC-54

*3

CR: EM-14, «Checking drive Belts»
HR: EM-114, «Checking Drive Belts»
K9K: EM-242, «Checking Drive
Belts»

TROUBLE DIAGNOSIS
PERFORMANCE CHART
Test Condition

A

Testing must be performed as follows:
Vehicle condition

Indoors or in the shade (in a well-ventilated place)

Doors

Closed

Door window

Open

Hood

Open

TEMP.

Max. COLD

Mode control dial

C

(Ventilation) set

Intake door lever

B

D

(Recirculation) set
Max. speed set

Fan (blower) speed
Engine speed

E

Idle speed

Operate the air conditioning system for 10 minutes before taking measurements.

Test Reading

F

Recirculating-to-discharge Air Temperature Table
Inside air (Recirculating air) at blower assembly inlet
Relative humidity
%

Discharge air temperature at center ventilator
°C (°F)

Air temperature
°C (°F)

50 — 60

60 — 70

20 (68)

7.2 — 9.1 (45 — 48)

25 (77)

11.4 — 13.8 (53 — 57)

30 (86)

15.5 — 18.4 (60 — 65)

35 (95)

20.3 — 23.7 (69 — 75)

20 (68)

9.1 — 10.9 (48 — 52)

25 (77)

13.8 — 16.2 (57 — 61)

30 (86)

18.4 — 21.3 (65 — 70)

35 (95)

23.7 — 27.1 (75 — 81)

Relative humidity
%

50 — 70

High-pressure (Discharge side)

Low-pressure (Suction side)

Air temperature
°C (°F)

kPa (bar, kg/cm2 , psi)

kPa (bar, kg/cm2 , psi)

20 (68)

843 — 1,036 *1
(11.08 — 13.63, 8.6 — 10.6, 122 — 150)

159.0 — 194.0
(1.59 — 1.94, 1.62 — 1.98, 23.1 — 28.1)

25 (77)

1,094 — 1,338 *1
(10.94 — 13.38, 11.2 — 13.6, 159 — 194)

196.3 — 240.0
(1.96 — 2.40, 2.00 — 2.45, 28.5 — 34.8)

30 (86)

1,298 — 1,590 *1
(12.98 — 15.90, 13.2 — 16.2, 188 — 231)

248.0 — 302.7
(2.48 — 3.03, 2.53 — 3.09, 36.0 — 43.9)

35 (95)

1,383 — 1,688 *2
(13.83 — 16.88, 14.1 — 17.2, 201 — 245)

308.8 — 377.4
(3.09 — 3.77, 3.15 — 3.85, 44.8 — 54.7)

40 (104)

1,628 — 1,988 *2
(16.28 — 19.88, 16.6 — 20.3, 236 — 288)

377.4 — 461.2
(3.77 — 4.61, 3.85 — 4.70, 54.7 — 66.8)

*1: In the motor fan low-speed control
*2: In the motor fan high-speed control

MTC-55

H

I

MTC

K

Ambient Air Temperature-to-operating Pressure Table
Ambient air

G

L

M

TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE
Whenever system’s high and/or low side pressure(s) is/are unusual, diagnose using a manifold gauge. The
marker above the gauge scale in the following tables indicates the standard (usual) pressure range. Since the
standard (usual) pressure, however, differs from vehicle to vehicle, refer to above table (Ambient air temperature-to-operating pressure table).

Both High- and Low-pressure Sides are Too High
Gauge indication

Refrigerant cycle

Probable cause

Pressure is reduced soon
after water is splashed on
condenser.

Air suction by cooling fan is
insufficient.

Excessive refrigerant charge in
refrigeration cycle.
Insufficient condenser cooling performance.
↓
1. Condenser fins are clogged.

Corrective action
Reduce refrigerant until
specified pressure is
obtained.

●

Clean condenser.

●

Check and repair cooling
fan if necessary.

2. Improper fan rotation of cooling
fan.
Both high- and low-pressure
sides are too high.

●

Low-pressure pipe is not
cold.

●

When compressor is
stopped high-pressure
value quickly drops by
approximately 196 kPa
(1.96 bar, 2 kg/cm2 , 28
psi). It then decreases
gradually thereafter.

AC359A

Engine tends to overheat.

●

●

An area of the low-pressure pipe is colder than
areas near the evaporator
outlet.
Plates are sometimes covered with frost.

Poor heat exchange in condenser
(After compressor operation stops,
high-pressure decreases too
slowly.).
↓
Air in refrigeration cycle.

Evacuate repeatedly and
recharge system.

Engine cooling systems malfunction.

Check and repair each
engine cooling system.

●

Excessive liquid refrigerant on lowpressure side.

●

Excessive refrigerant discharge
flow.

●

Expansion valve is open a little
compared with the specification.

Replace expansion valve.

↓
Improper expansion valve adjustment.

High-pressure Side is Too High and Low-pressure Side is Too Low
Gauge indication

Refrigerant cycle

Probable cause

Upper side of condenser and
high-pressure side are hot,
however, liquid tank is not so
hot.

High-pressure tube or parts located
between compressor and condenser
are clogged or crushed.

Corrective action

High-pressure side is too high
and low-pressure side is too low.

AC360A

MTC-56

●

Check and repair or
replace malfunctioning
parts.

●

Check lubricant for
contamination.

TROUBLE DIAGNOSIS
High-pressure Side is Too Low and Low-pressure Side is Too High
Gauge indication
High-pressure side is too low
and low-pressure side is too
high.

Refrigerant cycle

Probable cause

High- and low-pressure sides
become equal soon after compressor operation stops.

Compressor pressure operation
is improper.
↓
Damaged inside compressor
packings.

No temperature difference
between high- and low-pressure sides.

Compressor pressure operation
is improper.
↓
Damaged inside compressor
packings.

AC356A

Corrective action

Replace compressor.

A

B

C
Replace compressor.

D

Both High- and Low-pressure Sides are Too Low
Gauge indication

Refrigerant cycle
●

Liquid tank inlet and expansion valve are frosted.

●

Temperature of expansion
valve inlet is extremely low as
compared with areas near liquid tank.

●

AC353A

There is a big temperature
difference between liquid tank
outlet and inlet. Outlet temperature is extremely low.

●

●

Both high- and low-pressure
sides are too low.

Probable cause

Expansion valve inlet may be
frosted.

Liquid tank inside is slightly
clogged.

Corrective action

●

Replace liquid tank.

●

Check lubricant for contamination.

There is a big temperature difference between expansion
valve inlet and outlet while the
valve itself is frosted.

High-pressure pipe located
between liquid tank and expansion valve is clogged.

●

Check and repair malfunctioning parts.

●

Check lubricant for contamination.

Low refrigerant charge.
↓
Leaking fittings or components
Expansion valve closes a little
compared with the specification.
↓
1. Improper expansion valve
adjustment.
2. Malfunctioning expansion
valve.

Check refrigerant for leaks.
Refer to MTC-93, «Checking
for Refrigerant Leaks» .

Air flow volume is not enough or
is too low.

Low-pressure pipe is clogged or
crushed.

Evaporator is frozen.

MTC-57

H

I

MTC

K
●

Remove foreign particles by
using compressed air.

●

Replace expansion valve.

●

Check lubricant for contamination.

3. Outlet and inlet may be
clogged.
An area of the low-pressure
pipe is colder than areas near
the evaporator outlet.

F

G

Temperature difference
occurs somewhere in highpressure side.

Expansion valve and liquid tank
are warm or only cool when
touched.

E

●

Check and repair malfunctioning parts.

●

Check lubricant for contamination.

●

Check thermo control amp.
Refer to MTC-43, «Magnet
Clutch Circuit» .

●

Replace compressor.

●

Repair evaporator fins.

●

Replace evaporator.

●

Refer to MTC-39, «Blower
Motor Circuit» .

L

M

TROUBLE DIAGNOSIS
Low-pressure Side Sometimes Becomes Negative
Gauge indication
Low-pressure side sometimes
becomes negative.

Refrigerant cycle
●

●

AC354A

Air conditioning system
does not function and does
not cyclically cool the compartment air.
The system constantly functions for a certain period of
time after compressor is
stopped and restarted.

Probable cause
Refrigerant does not discharge cyclically.
↓
Moisture is frozen at expansion valve outlet and inlet.
↓
Water is mixed with refrigerant.

Corrective action

●

Drain water from refrigerant
or replace refrigerant.

●

Replace liquid tank.

Low-pressure Side Becomes Negative
Gauge indication

Refrigerant cycle

Probable cause

Corrective action
Leave the system at rest until
no frost is present. Start it
again to check whether or not
the malfunction is caused by
water or foreign particles.
●

If water is the cause, initially
cooling is okay. Then the
water freezes causing a
blockage. Drain water from
refrigerant or replace refrigerant.

●

If due to foreign particles,
remove expansion valve
and remove the particles
with dry and compressed air
(not shop air).

●

If either of the above methods cannot correct the malfunction, replace expansion
valve.

●

Replace liquid tank.

●

Check lubricant for contamination.

Low-pressure side becomes negative.
Liquid tank or front/rear side of
expansion valve’s pipe is
frosted or dewed.

High-pressure side is closed
and refrigerant does not flow.
↓
Expansion valve or liquid tank
is frosted.

AC362A

MTC-58

TROUBLE DIAGNOSIS
Insufficient Heating

BJS000DS

A

SYMPTOM: Insufficient heating

INSPECTION FLOW
B

C

D

E

F

G

H

I

MTC

K

L

M

SJIA0767E

*1 MTC-34, «Operational Check»

*2 CR: CO-9, «Changing Engine coolant»
HR: CO-28, «Changing Engine coolant»
K9K: CO-49, «Changing Engine Coolant»

*3 CR: CO-15 or CO-16
HR: CO-34 or CO-35
K9K: CO-53

*4 CR (WITH EURO–OBD): EC-166
CR (WITHOUT EURO–OBD): EC-565
HR (WITH EURO–OBD): EC-947
HR: (WITHOUT EURO–OBD): EC-1361
K9K: EC-1727

*5 MTC-24, «SYMPTOM TABLE»

*6 MTC-71, «Air Mix Door Cable
Adjustment»

*For further information refer to EC-21, «APPLICATION NOTICE» .

MTC-59

TROUBLE DIAGNOSIS
Noise

BJS000DT

SYMPTOM: Noise

INSPECTION FLOW

SJIA0843E

MTC-60

TROUBLE DIAGNOSIS
*1

MTC-34, «Operational Check»

*4

CR: EM-14, «Checking drive Belts»
HR: EM-114, «Checking Drive Belts»
K9K: EM-242, «Checking Drive
Belts»

*2

MTC-87, «CHECK DISC TO PULLEY *3
CLEARANCE»

MTC-17, «Maintenance of Lubricant
Quantity in Compressor»

A

B

C

D

E

F

G

H

I

MTC

K

L

M

MTC-61

CONTROLLER
CONTROLLER
Removal and Installation

PFP:28074
BJS000E2

REMOVAL
1.
2.
3.

Remove intake door lever knob. Refer to MTC-63, «Disassembly and Assembly» .
Remove controller mounting clips (A) using remover tool, and
then remove controller finisher (1).
Disconnect front passenger air bag OFF indicator harness connector.

ZJIA0850J

4.

Remove mounting screws, and then pull out controller.

ZJIA0851J

5.
6.
7.

Remove instrument panel & pad. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove air mix door cable, mode door cable and intake door cable from A/C unit assembly.
Disconnect connector, and then remove controller.

INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
Adjust the door cables during installation. Refer to MTC-70, «Intake Door Cable Adjustment» , MTC-71,
«Air Mix Door Cable Adjustment» and MTC-72, «Mode Door Cable Adjustment» .

MTC-62

CONTROLLER
Disassembly and Assembly

BJS000E3

A

B

C

D

E

F
ZJIA0106J

1.

Air mix door cable

2.

Intake door cable

3.

Mode door cable

4.

A/C controller assembly

5.

Mode control dial

6.

Rear DEF button

7.

A/C button

8.

Temperature control dial

9.

Illumination bulb

10. Intake door lever knob

G

H

11. Fan control dial

CAUTION:
Install inner cable of each door cable to the corresponding
lever, as shown in the figure. Press outer cable until it hooks on
the tabs and becomes fixed.

I

MTC

K

MJIA0038E

L

M

MTC-63

THERMO CONTROL AMPLIFIER
THERMO CONTROL AMPLIFIER
Removal and Installation

PFP:27675
BJS000E4

REMOVAL
1.

2.

Remove evaporator. Refer to MTC-91, «Removal and Installation for Evaporator» .
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
Remove thermo control amp. (1) from evaporator (2).

MJIB0459E

INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
●
Replace O-rings for A/C piping with new ones, and then apply compressor oil to it when installing
it.
●
Mark the mounting position of thermo control amp.
●
When recharging refrigerant, check for leaks.

MTC-64

A/C UNIT ASSEMBLY
A/C UNIT ASSEMBLY
Removal and Installation

PFP:27110

A
BJS000E5

REMOVAL
1.
2.

3.
4.
5.

Use a refrigerant collecting equipment (for HFC-134a) to discharge refrigerant.
Drain coolant from cooling system.
CR: Refer to CO-9, «Changing Engine coolant» .
HR: Refer to CO-28, «Changing Engine coolant» .
K9K: Refer to CO-49, «Changing Engine Coolant» .
Remove cowl top cover. Refer to EI-12, «Removal and Installation» .
Remove lower dash insulator.
Remove mounting bolt (A), and then disconnect low-pressure
flexible hose (1) and high-pressure pipe (2) from evaporator.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.

B

C

D

E

F

G
MJIB0471E

6.

Remove clamps (A), and then disconnect heater hoses (1) from
heater core.

H

I

MTC

MJIB0472E

7.
8.

Remove console box assembly. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove mounting nuts (A) and harness clamps (B), and then
remove instrument stay (1).

K

L

M

MJIB0473E

MTC-65

A/C UNIT ASSEMBLY
9.

Disconnect thermo control amp. connector (1).

MJIB0474E

10.
11.
12.
13.

Remove instrument panel & pad. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove side ventilator ducts. Refer to MTC-78, «Removal of Side Ventilator Ducts» .
Remove center ventilator ducts. Refer to MTC-78, «Removal of Center Ventilator Ducts» .
Remove A/C unit assembly mounting bolts (A), steering member mounting bolts (B), steering column
mounting nuts (C) and harness clips.

MJIB0435E

14. Remove steering member, and then remove A/C unit assembly.

INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
●
Replace O-rings for A/C piping with new ones, and then apply compressor oil to it when installing
it.
●
When recharging refrigerant, check for leaks.
NOTE:
●
When filling radiator with coolant.
CR: Refer to CO-9, «Changing Engine coolant» .
HR: Refer to CO-28, «Changing Engine coolant» .
K9K: Refer to CO-49, «Changing Engine Coolant» .
●
Recharge the refrigerant.
A/C unit assembly mounting bolt
Tightening torque
: 6.9 N·m (0.7 kg-m, 61 in-lb)
Steering member mounting bolt
Tightening torque
: 12 N·m (1.25 kg-m, 9 ft-lb)

MTC-66

A/C UNIT ASSEMBLY
Steering column mounting nut
Tightening torque
: 12 N·m (1.25 kg-m, 9 ft-lb)

A

Disassembly and Assembly

BJS000E6

B

C

D

E

F

G

H

I

MTC

K

L

M

MJIB0506E

1.

Center defroster duct

2.

Seal

3.

4.

Insulator

5.

Nut

6.

Blower unit

7.

Air conditioner filter

8.

Evaporator assembly

9.

Foot duct assembly (RH)

MTC-67

Intake case

A/C UNIT ASSEMBLY
10. Ventilator-defroster door lever

11.

Rod

12. Foot door lever

13. Air mix door link

14.

Main link

15. Foot door link

16. A/C controller assembly

17.

Clip

18. Heater cover

19. Lower blower case

20.

Heater core assembly

21. PTC heater

22. Foot duct assembly (LH)

23.

Heater hose cover

24. Air mix door lever

25. Blower fan resistor

26.

Intake door link

27. Intake door lever

28. Heater pipe packing

29.

Cover

30. Expansion valve assembly

31. O-ring

32.

Evaporator valve block

33. Expansion valve cover

34. Thermal control amplifier

35.

Drain hose

36. Blower case (RH)

37. Blower case (LH)

38.

Ventilator-defroster door

39. Air mix door 1

40. Air mix door 2

41.

Foot duct

42. Foot door link

MTC-68

BLOWER MOTOR
BLOWER MOTOR
Removal and Installation

PFP:27226

A
BJS000E7

REMOVAL
1.
2.
3.
4.

Remove instrument panel & pad. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove side ventilator duct (right). Refer to MTC-78, «Removal of Side Ventilator Ducts» .
Disconnect blower motor connector (1).
Push flange holding hook (A), and then remove blower motor (2)
from A/C unit assembly (3).
CAUTION:
When blower fan and blower motor are assembled, the balance is adjusted, so do not replace the individual parts.

B

C

D

E
MJIB0440E

INSTALLATION

F

Installation is basically the reverse order of removal.
CAUTION:
Correctly install blower motor flange holding hook in A/C unit assembly.

G

H

I

MTC

K

L

M

MTC-69

INTAKE DOOR
INTAKE DOOR
Intake Door Cable Adjustment
1.
2.
3.
4.

5.

PFP:27245
BJS000E8

Remove instrument lower finisher. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove outer cable of intake door cable (1) from clamp (A).
Set intake door lever to REC position.
Push intake door link (2) in the direction shown by the arrow,
and then carefully pulling outer cable to controller side, and
install clamp (A).
Operate intake door lever to insure that inner cable moves
smoothly.
CAUTION:
When clamping the outer cable, do not move the inner
cable.

MTC-70

MJIB0500E

AIR MIX DOOR
AIR MIX DOOR
Air Mix Door Cable Adjustment
1.
2.
3.
4.

5.

PFP:27180

A
BJS000E9

Remove steering member. Refer to MTC-65, «A/C UNIT ASSEMBLY» .
Remove outer cable of air mix door cable (1) from clamp (A).
Set temperature control dial to full cold position.
Push air mix door lever (2) in the direction shown by arrow, and
then carefully pull outer cable toward controller side, and install
clamp (A).
Operate temperature control dial to insure that inner cable
moves smoothly.
CAUTION:
When clamping the outer cable, do not move the inner
cable.

B

C

D

MJIB0501E

E

F

G

H

I

MTC

K

L

M

MTC-71

MODE DOOR
MODE DOOR
Mode Door Cable Adjustment
1.
2.
3.
4.
5.

PFP:27181
BJS000EA

Remove glove box assembly and instrument lower cover (RH). Refer to IP-4, «INSTRUMENT PANEL
ASSEMBLY» .
Remove outer cable of mode door cable (1) from clamp (A).
Set mode control dial to VENT position.
Push main link (2) in the direction shown by the arrow, and then
carefully pull outer cable to controller side, and install clamp (A).
Operate mode control dial to insure that inner cable moves
smoothly.
CAUTION:
When clamping the outer cable, do not move the inner
cable.
MJIB0502E

MTC-72

BLOWER FAN RESISTOR
BLOWER FAN RESISTOR
Removal and Installation

PFP:27150

A
BJS000EB

REMOVAL
1.
2.
3.

Remove instrument panel & pad. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Disconnect blower fan resistor connector.
Remove mounting screws (A), and then remove blower fan
resistor (1).

B

C

D

E
MJIB0503E

INSTALLATION
Installation is basically the reverse order of removal.

F

G

H

I

MTC

K

L

M

MTC-73

HEATER CORE
HEATER CORE
Removal and Installation

PFP:27140
BJS000EC

REMOVAL
1.
2.
3.
4.

Remove A/C unit assembly. Refer to MTC-65, «A/C UNIT ASSEMBLY» .
Remove foot duct (left). Refer to MTC-78, «Removal of Foot Ducts» .
Remove mounting screws (A).
Slide heater core (1) to leftward.

MJIB0439E

INSTALLATION
Installation is basically the reverse order of removal.

MTC-74

AIR CONDITIONER FILTER
AIR CONDITIONER FILTER
Removal and Installation

PFP:27277

A
BJS000ED

FUNCTION
Air inside passenger compartment is kept clean at either recirculation or fresh mode by installing air conditioner filter into A/C unit
assembly.

B

C

D

SJIA0651E

E

REPLACEMENT TIMING
Replace air conditioner filter.
Refer to MA-55, «CHASSIS AND BODY MAINTENANCE» .
Caution label is fixed inside glove box.

F

REPLACEMENT PROCEDURES
1.
2.
3.
4.
5.

G

Remove glove box assembly. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Compress air conditioner filter downward while sliding it to the
right side of the vehicle.
Turn the bottom of air conditioner filter upward, and then remove
it.
Replace with new one and reinstall on A/C unit assembly.
Reinstall glove box assembly.

H

I

MTC
MJIB0446E

K

L

M

MTC-75

DUCTS AND GRILLES
DUCTS AND GRILLES
Removal and Installation

PFP:27860
BJS000EE

REMOVAL

MJIB0447E

1.

Side defroster duct (right)

2.

Defroster nozzle

3.

Side defroster duct (left)

4.

Side defroster grille (left)

5.

Instrument side panel (left)

6.

Instrument panel & pad

7.

Side ventilator assembly (left)

8.

Cluster lid C

9.

Side ventilator assembly (right)

10. Instrument finisher E

11. Instrument side panel (right)

Removal of Center Ventilator Grilles
1.
2.

Remove cluster lid C. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove center ventilator grilles (1) mounting screws (A) using a
screwdriver (B), and then remove center ventilator grilles (1).

MJIB0448E

MTC-76

DUCTS AND GRILLES
Removal of Side Ventilator Grilles
1.

Remove instrument pad assembly (left). Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .

2.

Side ventilator grille (left) (1) mounting pawl (
side ventilator grille (left)(1) is pulled out.

A

) is pushed, and
B

C

D
MJIB0449E

3.

Remove instrument pad assembly (right). Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .

4.

Side ventilator grille (right) (1) mounting pawl (
and side ventilator grille (right)(1) is pulled out.

E

) is pushed,
F

G

H
MJIB0450E

Removal of Defroster Nozzle and Ducts
1.
2.

Remove instrument upper finisher. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove mounting screws (A) and then remove side defroster duct (right) (1) and side defroster duct (left)
(2).

I

MTC

K

L

M

MJIB0451E

3.

Remove mounting screws (B), and then remove defroster nozzle (3).

MTC-77

DUCTS AND GRILLES
Removal of Side Ventilator Ducts
1.
2.

Remove instrument panel & pad. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove mounting screws (A) and clip (B), and then remove
side ventilator duct (left) (1).

MJIB0475E

3.

Remove mounting screw (A) and clip (B), and then remove side
ventilator duct (right) (1).

MJIB0476E

Removal of Center Ventilator Ducts
1.
2.

Remove instrument panel & pad. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove mounting screws (A), and then remove center ventilator ducts (1).

MJIB0477E

Removal of Foot Ducts
1.
2.
3.

Remove A/C unit assembly. Refer to MTC-65, «A/C UNIT ASSEMBLY» .
Remove intake door motor (2). Refer to MTC-70, «INTAKE DOOR» .
Remove mounting screws (A), and then remove foot duct (left)
(1).

MJIB0452E

MTC-78

DUCTS AND GRILLES
4.

Remove mounting screws (A), and then remove foot duct (right)
(1).

A

B

C
MJIB0453E

D

Removal of Floor Ducts

E

F

G

H

I

MJIB0454E

1.
2.

1.

Front floor duct

4.

Rear floor duct (right)

2.

Rear floor duct (left)

3.

MTC

Clip

K

Remove front seat and center console assembly. Refer to SE-8, «Removal and Installation»
«INSTRUMENT PANEL ASSEMBLY» .
Disengage claws (A), and then remove front floor duct (1).

and IP-4,
L

M

MJIB0455E

3.

Peel back floor trim to a point where floor duct is visible.

MTC-79

DUCTS AND GRILLES
4.

Remove mounting clips (A), and then remove rear floor duct
(left) (1) and rear floor duct (right) (2).

MJIB0456E

INSTALLATION
Installation is basically the reverse order of removal.

MTC-80

REFRIGERANT LINES
REFRIGERANT LINES
HFC-134a (R-134a) Service Procedure

PFP:92600

A
BJS000EF

SETTING OF SERVICE TOOLS AND EQUIPMENT
Discharging Refrigerant

B

WARNING:
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If
accidental system discharge occurs, ventilate work area before resuming service. Additional health
and safety information may be obtained from refrigerant and lubricant manufacturers.

C

D

E

F

G

H

I
SHA539DE

Evacuating System and Charging Refrigerant

MTC

K

L

M

SHA540DC

MTC-81

REFRIGERANT LINES

RJIA2143E

*1

MTC-17, «LUBRICANT RETURN
OPERATION»

*4

MTC-53, «PERFORMANCE TEST
DIAGNOSIS»

*2

MTC-93, «Checking for Refrigerant
Leaks»

MTC-82

*3

MTC-95, «CHECKING PROCEDURE»

REFRIGERANT LINES
Components

BJS000IQ

A

CR ENGINE MODELS

B

C

D

E

F

G

H

I
MJIB0436E

1.

High-pressure flexible hose

2.

Radiator (Condenser)

3.

Liquid tank

4.

Compressor

5.

High-pressure pipe

6.

Low-pressure flexible hose

MTC

K

L

M

MTC-83

REFRIGERANT LINES
HR ENGINE MODELS

MJIB0437E

1.

High-pressure flexible hose

2.

Radiator (Condenser)

3.

Liquid tank

4.

Compressor

5.

High-pressure pipe

6.

Low-pressure flexible hose

7.

Service valve (High pressure)

8.

Service valve (Low pressure)

9.

Refrigerant pressure sensor

10. Condenser

MTC-84

REFRIGERANT LINES
K9K ENGINE MODELS
A

B

C

D

E

F

G

H

I

MTC

K

L
MJIB0438E

1.

High-pressure flexible hose

2.

Refrigerant pressure sensor

3.

Liquid tank

4.

Radiator (Condenser)

5.

Condenser

6.

Compressor

7.

Service valve (Low pressure)

8.

Low-pressure flexible hose

9.

High-pressure pipe

10. Service valve (High pressure)

MTC-85

M

REFRIGERANT LINES
Removal and Installation of Compressor

BJS000IR

REMOVAL
1.
2.
3.

Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
Remove engine undercover, using power tools.
Remove low-pressure flexible hose mounting nut and high-pressure flexible hose mounting bolt from
compressor.

MJIB0273E

4.

5.
6.

CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
Remove A/C compressor belt.
CR: Refer to EM-14, «DRIVE BELTS» .
HR: Refer to EM-114, «DRIVE BELTS» .
K9K: Refer to EM-242, «DRIVE BELTS» .
Disconnect compressor connector.
Remove mounting bolts from compressor, using power tools.

MJIB0134E

7.

Remove compressor downward of the vehicle.

INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
●
Replace O-rings of low-pressure flexible hose and high-pressure flexible hose with a new ones,
and then apply compressor oil to it when installing it.
●
When recharging refrigerant, check for leaks.
Compressor mounting bolt
Tightening torque

: 20.0 N·m (2.05 kg-m, 14.8 ft-lb)

MTC-86

REFRIGERANT LINES
CHECK DISC TO PULLEY CLEARANCE
A

Check clearance around entire periphery of clutch disc.
Disc to pulley
clearance

: 0.3 — 0.6 mm (0.012 — 0.024 in)
B

If specified clearance is not obtained, replace compressor.

C

RHA087E

Removal and Installation for Pipe and Hose

D

BJS000IS

REMOVAL
1.
2.
3.

4.

5.
6.

7.

E
Use recovery/recycling recharging equipment [for HFC-134a (R-134a)] to discharge refrigerant.
Remove the low-pressure flexible hose bracket mounting bolt and nut.
Remove the high-pressure pipe and low-pressure flexible hose mounting bolts (air conditioner unit side).
F
CAUTION:
Seal the connecting points of the pipe and hose with caps and vinyl tape, etc. to prevent them from
being exposed to the atmosphere.
G
Remove the low-pressure flexible hose mounting bolt or nut (compressor side) and then remove the lowpressure flexible hose.
CAUTION:
H
Seal the connecting points of the hose with caps and vinyl tape, etc. to prevent them from being
exposed to the atmosphere.
Remove the front bumper and air guide (RH). Refer to EI-4, «Removal and Installation» and BL-13,
I
«Removal and Installation» .
Remove the high-pressure pipe mounting bolt (liquid tank side) and then remove the high-pressure pipe.
CAUTION:
MTC
Seal the connecting points of the pipe with caps and vinyl tape, etc. to prevent them from being
exposed to the atmosphere.
Remove the high-pressure flexible hose mounting bolts and then remove the high-pressure flexible hose.
K
CAUTION:
Seal the connecting points of the hoses with caps and vinyl tape, etc. to prevent them from being
exposed to the atmosphere.
L

INSTALLATION

CAUTION:
●
Replace the O-rings on the high-pressure pipe, low-pressure flexible hose, and high-pressure flexible hose with new ones, and apply compressor lubricant to O-rings before installing.
●
When charging refrigerant, check for refrigerant leaks.
High-pressure pipe mounting bolt
Tightening torque
: 4.4 N·m (0.45 kg-m, 39.0 in-lb)
Low-pressure flexible hose and high-pressure pipe mounting bolts (evaporator side)
Tightening torque
: 4.4 N·m (0.45 kg-m, 39.0 in-lb)
Low-pressure flexible hose mounting bolt (compressor side)
Tightening torque
: 13.7 N·m (1.4 kg-m, 10.1 ft-lb)
Low-pressure flexible hose bracket mounting bolt/nut
Tightening torque
: 4.2 N·m (0.43 kg-m, 37.2 in-lb)
High-pressure flexible hose mounting bolt
Tightening torque
: 13.7 N·m (1.4 kg-m, 10.1 ft-lb)

MTC-87

M

REFRIGERANT LINES
Removal and Installation for Refrigerant Pressure Sensor

BJS000IT

MJIB0457E

1.

Refrigerant pressure sensor

4.

Air guide

2.

Condenser

3.

Liquid tank

REMOVAL AND INSTALLATION
1.
2.
3.

Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant.
Remove the front bumper and air guide (RH) (4). Refer to EI-4, «Removal and Installation» and BL-13,
«Removal and Installation» .
Use a adjustable wrench A or other tool to hold the refrigerant pressure sensor mounting block, and then
remove the refrigerant pressure sensor from the condenser (CR and HR engine models) or the high-pressure flexible hose (K9K engine models).
CAUTION:
● Be careful when working so as not to damage the condenser core.
● When installing refrigerant pressure sensor, apply compressor lubricant to the O-rings.
Refrigerant pressure sensor
Tightening torque
: 10.8 N·m (1.1 kg-m, 8.0 ft-lb)

Removal and Installation for Condenser (Models without Integrated Condenser)
BJS000IU

REMOVAL
1.
2.
3.

4.

Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant.
Remove the front bumper and air guide (RH). Refer to EI-4, «Removal and Installation» and BL-13,
«Removal and Installation» .
Disconnect the high-pressure flexible hose and high-pressure
pipe from the condenser.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmosphere.
Disconnect the refrigerant pressure sensor connector, and then
remove the harness clip (CR engine models).

MJIA0059E

MTC-88

REFRIGERANT LINES
5.

6.
7.

Use cord, etc., to hold the condenser and radiator to each radiator core support upper.
NOTE:
To prevent the condenser and radiator from being dropped when
the radiator core lower support is removed.
Remove the mounting bolts, and then remove the radiator core
lower support.
Remove the condenser from underneath the vehicle.
CAUTION:
Do not damage the condenser core.

A

B

C
MJIA0060E

D

INSTALLATION
CAUTION:
●
Replace O-rings on the high-pressure pipe and high-pressure flexible hose with new ones. Apply
compressor lubricant to O-rings when installing them.
●
When charging refrigerant, check for refrigerant leaks.
High-pressure flexible hose bolt
Tightening torque : 13.7 N·m (1.4 kg-m, 10.1 ft-lb)
High-pressure pipe mounting bolt
Tightening torque : 4.4 N·m (0.45 kg-m, 39.0 in-lb)
Radiator core lower support mounting bolts.
Tightening torque : 51.1 N·m (5.3 kg-m, 37.7 ft-lb)

E

F

G

H

Removal and Installation for Condenser (Models with Integrated Condenser)
BJS000IV

REMOVAL
1.
2.
3.

4.

I
Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant.
Remove the front bumper and air guide (RH). Refer to EI-4, «Removal and Installation» and BL-13,
«Removal and Installation» .
MTC
Disconnect the high-pressure flexible hose from the condenser.
Disconnect the high-pressure pipe from the liquid tank.
CAUTION:
K
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmosphere.
L
Remove the radiator assembly.
CR: Refer to CO-12, «RADIATOR» .
HR: Refer to CO-31, «RADIATOR» .
M
CAUTION:
MJIA0214E
Do not damage the radiator and condenser core.

INSTALLATION
CAUTION:
●
Replace O-rings on the high-pressure pipe and high-pressure flexible hose with new ones. Apply
compressor lubricant to O-rings when installing them.
●
When charging refrigerant, check for refrigerant leaks.

MTC-89

REFRIGERANT LINES
Removal and Installation for Liquid Tank (HR Engine with A/T Models)

BJS000IW

REMOVAL
1.
2.
3.
4.

Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
Remove condenser. Refer to MTC-88, «Removal and Installation
for Condenser (Models without Integrated Condenser)» .
Clean around the liquid tank to remove foreign material and corrosion.
Remove the liquid tank bracket (upper/lower) mounting bolts.

MJIA0061E

5.
6.

Lift up the liquid tank bracket, and remove it from the condenser
protruding area.
Lift up the liquid tank and remove it.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmosphere.

MJIA0062E

INSTALLATION
Install the liquid tank, and then install liquid tank bracket to the condenser.
CAUTION:
●
Make sure the liquid tank bracket is correctly inserted into
the condenser’s protruding area (the liquid tank bracket
does not move below the center of the liquid tank).
●
Replace the condenser pipe O-rings with new ones. Apply a
coat of compressor lubricant to the O-rings prior to installation.
MJIA0063E

Liquid tank bracket (upper) mounting bolt
Tightening torque : 3.38 N·m (0.35 kg-m, 30.0 in-lb)
Liquid tank bracket (lower) mounting bolt
Tightening torque : 5.74 N·m (0.58 kg-m, 50.8 in-lb)

Removal and Installation for Liquid Tank (Except HR Engine with A/T Models)
BJS000IX

REMOVAL
1.
2.
3.
4.
5.

Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
Clean around the liquid tank to remove foreign material and corrosion.
Remove the high-pressure pipe from the liquid tank.
Remove the condenser pipe mounting bolt from the liquid tank,
and remove pipe from the condenser protruding area.
Remove the liquid tank bracket bolts and then remove the liquid
tank.
MJIA0215E

MTC-90

REFRIGERANT LINES
CAUTION:
Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being
exposed to the atmosphere.

A

INSTALLATION
Install the liquid tank, and then install liquid tank bracket to the condenser.
CAUTION:
Replace the condenser pipe O-rings with new ones. Apply a coat of compressor lubricant to the Orings prior to installation.

Removal and Installation for Evaporator

B

C

BJS000IY

REMOVAL
1. Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant.
2. Remove the A/C unit. Refer to MTC-65, «A/C UNIT ASSEMBLY» .
CAUTION:
Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being
exposed to the atmosphere.
3. Remove the air conditioner filter, mode door motor, and foot duct (RH). Refer to MTC-75, «AIR CONDITIONER FILTER» , MTC-72, «MODE DOOR» and MTC-78, «Removal of Foot Ducts» .
4. Remove the lower blower case and expansion valve cover.
5. Slide the evaporator (1) and lower blower case (2) downward,
and remove the intake sensor (3).
6. Remove the evaporator from the lower blower case.

D

E

F

G

H

I

MJIB0462E

MTC

INSTALLATION
CAUTION:
●
Replace low-pressure flexible hose and high-pressure pipe O-rings with new ones. Apply a coat of
compressor lubricant prior to installation.
●
When installing a new evaporator, install the thermistor of intake air temperature in the same position as the removed intake sensor.
●
When removing and installing the intake sensor, do not rotate the thermistor insertion part.
Mounting bolts for the low-pressure flexible hoses and high-pressure pipes.
Tightening torque
: 4.4 N·m (0.45 kg-m, 39.0 in-lb)

Removal and Installation for Expansion Valve

L

M
BJS000IZ

REMOVAL
1.

Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
2. Disconnect the low-pressure flexible hose and high-pressure
pipe from the evaporator.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmosphere.
3. Remove the two bolts (A) from the expansion valve, and then
remove the expansion valve (1).
MJIB0460E

MTC-91

K

REFRIGERANT LINES
INSTALLATION
CAUTION:
Replace the removed O-rings with new ones. Apply a coat of compressor lubricant to the O-rings prior
to installation.
Expansion valve mounting bolts
Tightening torque : 4.0 N·m (0.41 kg-m, 35.4 in-lb)
Mounting bolts for the low-pressure flexible hoses and high-pressure pipes.
Tightening torque : 4.4 N·m (0.45 kg-m, 39.0 in-lb)

MTC-92

REFRIGERANT LINES
Checking for Refrigerant Leaks

BJS000J0

Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent
dye leak detector.
If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was
repaired and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electronic leak detector probe slower and closer to the suspected leak area will improve
the chances of finding a leak.

Checking System for Leaks Using the Fluorescent Leak Detector

A

B

C

D

E
BJS000J1

1.

Check A/C system for leaks using the UV lamp and safety goggles [SST: J-42220] in a low sunlight area
(area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a F
bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indicates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
G
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using refrigerant dye cleaner [SST: J-43872] to prevent
future misdiagnosis.
H
4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant
leak detector.
NOTE:
I
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Clean with a dry cloth or blow off with shop air.
MTC
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.

Dye Injection

BJS000J2

(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1.
2.
3.
4.
5.

6.

7.

Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm2 , 50
psi).
Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool [SST: J-41459].
Connect the injector tool to the A/C low-pressure side service fitting.
Start engine and switch A/C ON.
When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture’s operating instructions).
With the engine still running, disconnect the injector tool from the service fitting.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system
connection and proceed with the service procedures.
Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.

MTC-93

K

L

M

REFRIGERANT LINES
Electronic Refrigerant Leak Detector

BJS000J3

PRECAUTIONS FOR HANDLING LEAK DETECTOR
When performing a refrigerant leak check, use an A/C electrical leak
detector (SST) or equivalent. Ensure that the instrument is calibrated
and set properly per the operating instructions.
The leak detector is a delicate device. In order to use the leak detector properly, read the operating instructions and perform any specified maintenance.

SHA705EB

1.

Position probe approximately 5 mm (3/16 in) away from point to
be checked.

SHA707EA

2.

When testing, circle each fitting completely with probe.

SHA706E

3.

Move probe along component approximately 25 to 50 mm (1 to
2 in)/sec.

SHA708EA

MTC-94

REFRIGERANT LINES
CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette
smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Turn engine OFF.
2. Connect a suitable A/C manifold gauge set to the A/C service ports.
3.

4.

Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm2 , 50 psi) above 16°C. If
less than specification, recover/evacuate and recharge the system with the specified amount of refrigerant.
NOTE:
At temperatures below 16°C, leaks may not be detected since the system may not reach 345 kPa (3.45
bar, 3.52 kg/cm2 , 50 psi).
Perform the leak test from the high-pressure side (compressor discharge a to evaporator inlet f) to the
low-pressure side (evaporator drain hose g to shaft seal k). Refer to MTC-83, «Components» . Perform a
leak check for the following areas carefully. Clean the component to be checked and move the leak
detected probe completely around the connection/component.
Compressor
Check the fitting of high- and low-pressure flexible hoses, relief valve and shaft seal.

A

B

C

D

E

F

Condenser
Check the fitting of high-pressure flexible hose and pipe, refrigerant pressure sensor.

G

Liquid tank
Check the refrigerant connection.

H

Service valves
I
Check all around the service valves. Ensure service valve caps are secured on the service valves (to prevent leaks).
NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any MTC
false readings by leak detector.

5.
6.
7.
8.
a.
b.
c.
d.
e.
9.

Cooling unit (Evaporator)
With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the
cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended
procedure for actual wait time) before inserting the leak detector probe into the drain hose.
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water
or dirt that may be in the drain hose.
If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected
leak, then repeat check as outlined above.
Do not stop when one leak is found. Continue to check for additional leaks at all system components.
If no leaks are found, perform steps 7-10.
Start engine.
Set the heater A/C control as follows;
A/C switch: ON
MODE door position: VENT (Ventilation)
Intake door position: Recirculation
Temperature control dial: Max. cold
Fan speed: High
Run engine at 1,500 rpm for at least 2 minutes.

MTC-95

K

L

M

REFRIGERANT LINES
10. Turn engine off and perform leak check again following steps 4
through 6 above.
Refrigerant leaks should be checked immediately after stopping
the engine. Begin with the leak detector at the compressor. The
pressure on the high-pressure side will gradually drop after
refrigerant circulation stops and pressure on the low-pressure
side will gradually rise, as shown in the graph. Some leaks are
more easily detected when pressure is high.
11. Before connecting ACR4 to vehicle, check ACR4 gauges. No
refrigerant pressure should be displayed. If pressure is displayed, recover refrigerant from equipment lines.
12. Discharge A/C system using approved refrigerant recovery
equipment. Repair the leaking fitting or component if necessary.
13. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks.
14. Perform A/C performance test to ensure system works properly.

MTC-96

SHA839E

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
COMPRESSOR
Model

PFP:00030

A
BJS000J4

CR engine models

HR engine models

K9K engine models

ZEXEL VALEO CLIMATE
CONTROL make KC59G

CR-10

SANDEN make SD6V12

Type

Vane rotary

Displacement

Max.

cm3 (cu
in)/rev

Min.

Cylinder bore × stroke mm (in)

Variable volume piston

80 (4.88)
Theoretical displacement

96 (5.86)
Theoretical displacement

125.1 (7.63)
6.2 (0.38)

5 vanes, φ51.0 × 7.28

5 vanes, φ50.2 × 8.5

—

Direction of rotation
Poly V (4grooves)

V-Ribbed (7 grooves)

E
Poly V (6 grooves)

LUBRICANT

BJS000J5

F
CR engine models

HR engine models

K9K engine models

ZEXEL VALEO CLIMATE CONTROL make KC59G

CR-10

SANDEN make SD6V12

Name
Part number
Capacity
m (lmp fl
oz)

Nissan A/C System Oil Type R

Nissan A/C System Oil Type S

KLH00-PAGR0

KLH00-PAGS0

Total in system

—

—

135 (4.75)

Compressor
(Service part)
charging
amount

—

—

135 (4.75)

REFRIGERANT
Model

G

H

I

BJS000J6

MTC

CR engine models

HR engine models

K9K engine models

ZEXEL VALEO CLIMATE CONTROL make KC59G

CR-10

SANDEN make SD6V12

K

0.55 ± 0.05 (1.21 ± 0.11)

L

Type
Capacity
kg (lb)

C

D

Clockwise (viewed from drive end)

Drive belt

Model

B

HFC-134a (R-134a)
0.475 ± 0.025 (1.04 ± 0.055)

0.475 ± 0.025 (1.04 ± 0.055)

ENGINE IDLING SPEED

BJS000J7

M

Refer to EC-449, «SERVICE DATA AND SPECIFICATIONS (SDS)» . CR (WITH EURO−OBD).
Refer to EC-801, «SERVICE DATA AND SPECIFICATIONS (SDS)» . CR (WITHOUT EURO−OBD).
Refer to EC-1237, «SERVICE DATA AND SPECIFICATIONS (SDS)» . HR (WITH EURO−OBD).
Refer to EC-1597, «SERVICE DATA AND SPECIFICATIONS (SDS)» . HR (WITHOUT EURO−OBD).
Refer to EC-1870, «SERVICE DATA AND SPECIFICATIONS (SDS)» . K9K.

BELT TENSION

BJS000J8

Refer to EM-14, «Tension Adjustment» . (CR engine models).
Refer to EM-114, «Tension Adjustment» . (HR engine models).
Refer to EM-242, «Tension Adjustment» . (K9K engine models).

MTC-97

SERVICE DATA AND SPECIFICATIONS (SDS)

MTC-98

MANUAL TRANSAXLE

C TRANSMISSION/TRANSAXLE

SECTION

MT

MANUAL TRANSAXLE

A

B

MT

D

E

CONTENTS
PRECAUTIONS …………………………………………………. 3
Cautions …………………………………………………………. 3
PREPARATION ………………………………………………….. 4
Special Service Tools ……………………………………….. 4

JH3
DESCRIPTION …………………………………………………… 6
Cross-sectional View ………………………………………… 6
REMOVAL AND INSTALLATION …………………………. 7
Removal …………………………………………………………. 7
Installation ………………………………………………………. 7
TIGHTENING TORQUES ……………………………………. 8
Description ……………………………………………………… 8
COMPONENTS …………………………………………………. 9
Gear Components ……………………………………………. 9
Differential Gear …………………………………………….. 10
Shift Control Components ……………………………….. 10
Case Components …………………………………………..11
Clutch Housing ………………………………………………..11
CONTROL LINKAGE ……………………………………….. 12
Removal and Installation of Control Device and
Cable ……………………………………………………………. 12
REMOVAL ………………………………………………….. 12
INSTALLATION …………………………………………… 12
RATIOS …………………………………………………………… 13
NISSAN Gearbox …………………………………………… 13
CONSUMABLES ……………………………………………… 14
Description ……………………………………………………. 14
CAPACITIES — LUBRICANTS ……………………………. 15
Description ……………………………………………………. 15
TROUBLE DIAGNOSIS …………………………………….. 16
Symptom Chart ……………………………………………… 16
Back-Up Lamp Switch …………………………………….. 16
Park/Neutral Position Switch ……………………………. 16
PRECAUTIONS ……………………………………………….. 17
Precautions …………………………………………………… 17
PARTS TO BE REPLACED SYSTEMATICALLY ….. 18
Description ……………………………………………………. 18

CHECKING ……………………………………………………… 19
Bearings ……………………………………………………….. 19
Gearing …………………………………………………………. 19
Synchronizer Ring ………………………………………….. 19
Sliding Gear Hub ……………………………………………. 19
SEPARATING THE HOUSINGS …………………………. 20
Removal ……………………………………………………….. 20
REPAIRING THE GEARBOX …………………………….. 22
Removal ……………………………………………………….. 22
MAINSHAFT ……………………………………………………. 24
Removal ……………………………………………………….. 24
Refitting ………………………………………………………… 25
TRANSAXLE CASE BEARING ………………………….. 26
Removal ……………………………………………………….. 26
Refitting ………………………………………………………… 26
CLUTCH HOUSING BEARING ………………………….. 27
Removal ……………………………………………………….. 27
Refitting ………………………………………………………… 27
SELECTOR SHAFT RINGS ……………………………….. 28
Removal ……………………………………………………….. 28
Refitting ………………………………………………………… 28
DIFFERENTIAL BEARINGS ………………………………. 29
Removal and Installation …………………………………. 29
SELECTOR SHAFT ………………………………………….. 30
Removal ……………………………………………………….. 30
Refitting ………………………………………………………… 30
ASSEMBLY ……………………………………………………… 31
Refitting ………………………………………………………… 31
HOUSING ASSEMBLY ……………………………………… 33
Assembly ………………………………………………………. 33

JR5
DESCRIPTION …………………………………………………. 36
Cross-Sectional View ……………………………………… 36
REMOVAL AND INSTALLATION ……………………….. 37
Removal ……………………………………………………….. 37
Installation …………………………………………………….. 37
TIGHTENING TORQUES …………………………………… 38
Description …………………………………………………….. 38

MT-1

F

G

H

I

J

K

L

M

COMPONENTS ………………………………………………… 39
Gear Components ………………………………………….. 39
Differential Gear ……………………………………………… 40
Shift Control Components ………………………………… 40
Case Components ………………………………………….. 41
Clutch Housing ………………………………………………. 41
CONTROL LINKAGE ………………………………………… 42
Removal and Installation of Control Device and
Cable ……………………………………………………………. 42
REMOVAL ………………………………………………….. 42
INSTALLATION ……………………………………………. 42
RATIOS …………………………………………………………… 43
NISSAN Gearbox …………………………………………… 43
CONSUMABLES ………………………………………………. 44
Description …………………………………………………….. 44
CAPACITIES — LUBRICANTS …………………………….. 45
Description …………………………………………………….. 45
TROUBLE DIAGNOSIS …………………………………….. 46
Symptom Chart ………………………………………………. 46
Back-Up Lamp Switch …………………………………….. 46
Park/Neutral Position Switch ……………………………. 46
PRECAUTIONS ………………………………………………… 47
Precautions ……………………………………………………. 47
PARTS TO BE REPLACED SYSTEMATICALLY ….. 48
Description …………………………………………………….. 48
CHECKING ………………………………………………………. 49
Bearings ……………………………………………………….. 49
Gearing …………………………………………………………. 49

Synchronizer Ring ……………………………………………49
Sliding Gear Hub ……………………………………………..49
SEPARATING THE HOUSINGS …………………………..50
Removal …………………………………………………………50
REPAIRING THE GEARBOX ………………………………52
Removal …………………………………………………………52
Removing the Gearing ……………………………………..53
Checking Parts ………………………………………………..53
Refitting the Gearing ………………………………………..54
TRANSAXLE CASE BEARING …………………………..55
Removing the Bearing, Input Shaft Side ……………..55
Refitting ………………………………………………………….55
CLUTCH HOUSING BEARING ……………………………56
Removal and Installation …………………………………..56
SELECTOR SHAFT RINGS ………………………………..57
Removal …………………………………………………………57
Refitting ………………………………………………………….57
DIFFERENTIAL BEARINGS ……………………………….58
Removal and Installation …………………………………..58
SELECTOR SHAFT ……………………………………………59
Removal …………………………………………………………59
Refitting ………………………………………………………….59
REPAIRING THE GEARBOX ………………………………60
Setting the Pre-tensioning of the Output Shaft Bearings ……………………………………………………………….60
ASSEMBLY ………………………………………………………61
Refitting ………………………………………………………….61
HOUSING ASSEMBLY ……………………………………….63
Assembly ……………………………………………………….63

MT-2

PRECAUTIONS
PRECAUTIONS
Cautions
●
●
●
●

●

●

PFP:00001

A
BCS000L0

Do not reuse transaxle oil, once it has been drained.
B
Check oil level or replace oil with vehicle on level ground.
During removal or installation, keep inside of transaxle clear of dust or dirt.
Check the correct installation status prior to removal or disassembly. If mating marks are required, make
MT
sure that they do not interfere with the function of the parts they are applied to.
In principle, tighten nuts and bolts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
D
Be careful not to damage sliding surfaces and mating surfaces.

E

F

G

H

I

J

K

L

M

MT-3

PREPARATION
PREPARATION
Special Service Tools
Tool number
Tool name

PFP:00002
BCS000L1

Description

B. Vi. 1581
Transmission stand

Disassembly and assembly for transmission or
transaxle

YMT029

B. Vi. 31-01
Pin punch

Removing and installing retaining pin

YMT030

B. Vi. 1170
Puller

Removing 5th synchronizer

YMT031

B. Vi. 22-01
Puller

Removing 5th gear

B. Vi. 1000-01
Puller

Removing 5th gear

MCIB0026E

B. Vi. 1576
Mandrel

Removing input shaft bearing

YMT032

B. Vi. 1601
Mandrel

Installing bearing guide of mainshaft

YMT033

MT-4

PREPARATION
Tool number
Tool name

Description

A

B. Vi. 1554
Drift kit

Installing bearing race

B

MT
MCIA0151E

B. Vi. 1175
Installer

Installing 5th gear

D

E
YMT035

B. Vi. 1666
Drift

Installing differential oil seal

F

G
YMT036

B. Vi. 1165
Extractor

Removing mainshaft bearing

H

I

MCIA0152E

J

K

L

M

MT-5

DESCRIPTION
[JH3]

DESCRIPTION
Cross-sectional View
[JH3]

PFP:zzzzz
BCS000L2

MCIA0153E

MT-6

REMOVAL AND INSTALLATION
[JH3]

REMOVAL AND INSTALLATION
Removal

PFP:00000

A
BCS000L3

CAUTION:
Remove the crankshaft position sensor (POS) from transaxle assembly before separating transaxle B
from engine. Be careful not to damage sensor edge.
1. Remove battery.
2. Remove the air cleaner. Refer to EM-18, «AIR CLEANER AND AIR DUCT» (CR engine) or EM-245, «AIR MT
CLEANER AND AIR DUCT» (K9K engine).
3. Disconnect the cable end ball of the select cable, and the cable end of the shift cable. Refer to MT-12,
«CONTROL LINKAGE» .
D
4. Disconnect the clutch tube.
5. Remove the engine harness clamp.
6. Remove the starter. Refer to SC-51, «Removal and Installation (CR Engine Models)» , “STARTING SYS- E
TEM”.
7. Remove the engine mounting LH side installation bolt. Refer to EM-70, «ENGINE ASSEMBLY» (CR
engine) or EM-279, «ENGINE ASSEMBLY» (K9K engine).
F
8. Set the engine hanger.
G

H

I
MBIB0585E

9.
10.
11.
12.
13.
14.
15.
16.

17.
18.
19.

Lift up the vehicle and remove the front fender protectors (RH & LH).
Remove the undercover.
Remove the front exhaust pipe. Refer to EX-3, «Removal and Installation» , “EXHAUST SYSTEM”.
Remove the turbocharger outlet tube bracket from the transaxle.
Remove the RH and LH drive shafts. Refer to FAX-13, «Removal and Installation» , “FRONT DRIVE
SHAFT”.
Disconnect the ground cable from the transaxle.
Set the transmission jack.
Remove the rear engine mounting bracket. Then, remove the rear torque link from the transaxle. Refer to
EM-70, «ENGINE ASSEMBLY» (CR engine) or EM-279, «ENGINE ASSEMBLY» (K9K engine).
CAUTION:
Do not remove the rear torque link from the suspension member.
Remove the engine mounting bracket LH.
Disconnect the position switch connector.
Remove the transaxle mounting nuts and bolts, and remove the transaxle.

Installation

BCS000L4

Install in the reverse order of removal.

MT-7

J

K

L

M

TIGHTENING TORQUES
[JH3]

TIGHTENING TORQUES
Description

PFP:32010
BCS000L5

Tightening portion

N·m (kg-m, ft-lb)

Gearbox casing bolt

25 (2.6, 18)

Mainshaft bolt

70 (7.1, 52)

Input shaft nut

190 (19, 140)

Rear cover bolt

25 (2.6, 18)

Back-up lamp switch

25 (2.6, 18)

Concentric slave cylinder

21 (2.1, 15)

Selector shaft bolt

20 (2.0, 15)

Gear shift catch bolt

10 (1.0, 7)

Reverse gear fork support bolt

25 (2.6, 18)

Drain bolt

25 (2.6, 18)

Selector shaft balls

23 (2.3, 17)

MT-8

COMPONENTS
[JH3]

COMPONENTS
Gear Components

PFP:32010

A
BCS000L6

B

MT

D

E

F

G

H

I
MCIB0130E

1.

Oil channel

2.

Mainshaft front bearing

3.

Mainshaft

4.

1st main gear

5.

Baulk ring

6.

1st & 2nd synchronizer hub

7.

Spring

8.

Roller

9.

Stop ring

10. Adapter plate

11. 2nd main gear

12. 3rd main gear

13. 3rd & 4th synchronizer hub

14. 4th main gear

15. Support washer

16. Retaining clip

17. Mainshaft rear bearing

18. 5th main gear

19. Bolt

20. Bearing guide

21. Input shaft

22. Retaining clip

23. Input shaft rear bearing

24. Support washer

25. 2nd & 3rd gear bushing

26. 5th main gear

27. Baulk ring

28. Spread spring

29. 5th synchronizer hub

30. Spread spring

31. Friction cone

32. Baulk ring

33. Washer

34. Nut

MT-9

J

K

L

M

COMPONENTS
[JH3]

Differential Gear
1

Oil seal

2

Differential side bearing

3

Differential case

4

Pinion mate gear

5

Bevel side gear

6

Pinion mate shaft

7

Shaft retaining spring

8

Side gear thrust washer

BCS000L7

MCIA0170E

Shift Control Components
1

Control assembly

2

Gear shift catch

3

Reverse gear brake fork and shaft

4

Fork rod (For 5th)

5

Lock pin

6

Reverse idler gear assembly

7

Fork rod (For 3rd and 4th)

8

Ring

9

Lock pin

10

Fork rod (For 1st and 2nd)

11

Check ball cartridge

BCS000L8

12

Selector shaft bolt [20 N·m (2.0 kg-m, 15 ft-lb)]

13

Reverse gear fork shaft bolt [25 N·m (2.6 kg-m, 18 ft-lb)]

MCIA0155E

MT-10

COMPONENTS
[JH3]

Case Components

BCS000L9

A
1

Transaxle case

2

Filler plug

3

Dowel pin

4

Oil gutter

5

Breather pipe

6

Back-up lamp switch

7

O-ring

8

Transaxle case cover

9

Gearbox edge bolt [25 N·m (2.6 kg-m, 18 ft-lb)]

10

Fifth gear housing bolt [25 N·m (2.6 kg-m, 18 ft-lb)]

B

MT

D

E

F

G
MCIB0013E

Clutch Housing

BCS000LA

1

Clutch housing

2

Drain bolt [25 N·m (2.6 kg-m, 18 ft-lb)]

3

Magnet

4

Concentric slave cylinder

5

Concentric slave cylinder bolt [21 N·m (2.1 kg-m, 15 ft-lb)]

H

I

J

K

L

M

MCIB0014E

MT-11

CONTROL LINKAGE
[JH3]

CONTROL LINKAGE
Removal and Installation of Control Device and Cable

PFP:34103
BCS000LB

MCIB0167E

1.

Shift knob

2.

Shift lever

3.

Control device

4.

Selector lever

5.

Shift cable

6.

Clutch housing

7.

Cable bracket 1

8.

Cable bracket 2*

A.

Black color

B.

White color

*: Only for HR16DE
Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11 .

REMOVAL
1. Remove center console and shift boot. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
2. Remove control device mounting bolts.
3. Pressing release bottom of cable end, remove cable from either manual transmission shift lever.
4. Lift up cable and remove it from cable bracket 1.
5. Remove center muffler and heat plate. Refer to EX-3, «Removal and Installation» , “EXHAUST SYSTEM”.
6. Remove cable bracket 2 from the vehicle. (Only for HR16DE)
7. Remove front and rear claws of control device. Remove control device and cable from the vehicle.
NOTE:
If shift knob needs to be removed, pull it up to remove.

INSTALLATION
Note the following, and install in the reverse order of removal.
●
When installing, make sure to insert cable end into either manual transmission shift lever.
●
After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st, 2nd, or
Reverse.
●
After installation, make sure that the shift to each position works well.
●
When installing shift knob, press it onto selector lever.

MT-12

RATIOS
[JH3]

RATIOS
NISSAN Gearbox

PFP:32010

A
BCS000LC

Engine

Suffix

First

Second

Third

Fourth

Fifth

Reverse gear

Final drive

K9K (50 kw)

JH3-162

11:37

22:41

28:37

30:29

42:31

11:39

15:58

CR14DE

JH3-103

11:41

21:43

28:39

34:35

39:32

11:39

15:61

HR16DE

JH3-149

12:41

22:43

29:39

35:35

40:32

12:39

16:61

B

MT

D

E

F

G

H

I

J

K

L

M

MT-13

CONSUMABLES
[JH3]

CONSUMABLES
Description
Types

PFP:32010
BCS000LD

Packaging

Parts Department No.

Component

RHODORSEAL

100 g tubes

77 01 404 452

Housing assembly

LOCTITE 518

24 ml syringe

77 01 421 162

Back-up lamp switch threading

Gearbox oil

Cover all parts

MT-14

CAPACITIES — LUBRICANTS
[JH3]

CAPACITIES — LUBRICANTS
Description
Capacity
2.6

(4-5/8 Imp pt)

PFP:32010

A
BCS000LE

Grade

B

Nissan Genuine gear oil Passenger Car or
API GL-4 Viscosity 75W-80

Fill to the level of the oil filler cap hole.

MT

D
MCIB0015E

E

F

G

H

I

J

K

L

M

MT-15

TROUBLE DIAGNOSIS
[JH3]

TROUBLE DIAGNOSIS
Symptom Chart

PFP:00004
BCS000LF

Symptoms (after checking
the clutch)

Possible causes

Oil level
or grade

External
control

Synchronizer

Gear grinding

1

2

3

One or more gears
cannot be selected

1

2

3

Gear disengagement

2

4

One or more gears
locked

1

Symptoms

Noisy

Gearing

Sliding
gear hub

Fork and
balls

Bearings

Engine
mounting
— housing

4
4
4
4

1

3

3

1

2

3
2

NOTE:
The numbers indicate the order of priority for diagnostics.

Back-Up Lamp Switch
●

BCS000LG

Check continuity between terminals 1 and 2.
Gear position

Continuity

Reverse

Yes

Except reverse

No

MCIA0157E

Park/Neutral Position Switch
●

BCS000LH

Check continuity between terminals 2 and 3.
Gear position

Continuity

Neutral

Yes

Except neutral

No

MT-16

PRECAUTIONS
[JH3]

PRECAUTIONS
Precautions

PFP:00001

A
BCS000LI

Removing and handling the parts must be carried out on a workbench with a knockproof cover. (rubber or thick
plastic)
B
Cover all turning and synchronizer points in oil.
Observe the tightening torques.
Carefully carry out the specific settings and adjustments.
MT
Be sure to properly refit parts in the same order and position after removal.
Marking the position of the sliding rods in relation to the hubs before removal is recommended.
During refitting, make sure the inside of the box remains free of dust or impurities.
D

E

F

G

H

I

J

K

L

M

MT-17

PARTS TO BE REPLACED SYSTEMATICALLY
[JH3]

PARTS TO BE REPLACED SYSTEMATICALLY
Description
If they have been removed:
●
the lip seals,
●
the O-rings,
●
the gear supporting rings,
●
the roll pins,
●
the input shaft and mainshaft bearing circlips,
●
the sliding gear hub springs.

MT-18

PFP:32010
BCS000LJ

CHECKING
[JH3]

CHECKING
Bearings

PFP:32010

A
BCS000LK

Check that the bearings show no signs of damage and that they turn
evenly. Replace them if necessary.

B

MT

D
MCIB0017E

E

Gearing

BCS000LL

NOTE:
The inspection focuses mainly on the appearance of the teeth, especially in terms of claw chamfers.
1. Check that the teeth (A) are not broken or chipped.
2. Check that the claws (B) are not broken, chipped or worn.
3. Check that the friction cone (C) shows no scratches or blueness.

F

G

H

MCIB0018E

Synchronizer Ring

I

BCS000LM

Check that the grooves and ridges on the ring are not worn or damaged.
1. Check that the ring puts onto the gear cone.
2. Check that the ring rotates while applying force in the direction
of the cone (D).
3. Check that the ring should lock against the cone.
Otherwise, replace the synchronizer ring.

J

K

L

MCIB0019E

Sliding Gear Hub

BCS000LN

Make sure the sliding gear turns smoothly in the hub.
Check that the rollers or keys are in good condition.

MCIB0020E

MT-19

M

SEPARATING THE HOUSINGS
[JH3]

SEPARATING THE HOUSINGS
Removal

PFP:32010
BCS000LO

Fit the B. Vi. 1581 support plate on a Desvil stand.
Fit the gearbox on the B. Vi. 1581 support.

MCIB0021E

1.
2.

Remove the concentric slave cylinder.
Remove the bolts located inside the housing.

MCIB0022E

3.

Remove the rear housing. This must be removed along the horizontal axis of the gearbox because it has a lubrication spline
which is located in the input shaft bore.

MCIB0023E

4.
5.
6.
7.

Remove the two reverse gear fork support mounting bolts (A).
Drive in the 5th gear fork using B. Vi. 31-01.
Shift the 3rd gear on the gear selector lever and the 5th gear by
sliding the 5th gear fork on its shaft.
Remove the mainshaft bolt (B).
Remove the input shaft nut (C).
Remove the reverse gear synchronizer.
Remove the 5th gear fork and sliding gear.
MCIB0024E

MT-20

SEPARATING THE HOUSINGS
[JH3]
Remove the 5th gear hub using B. Vi. 1170.
To do this, fit the sliding gear B. Vi. 1170 and rotate it so that the
splines are opposite those of the input shaft hub.

A

B

MT
MCIB0025E

D

Remove the fixed 5th gear using B. Vi. 22-01 and B. Vi. 100001.
Remove the gearbox edge bolts.

E

F

G
MCIB0026E

H

Remove the back-up lamp switch (B).
Engage 3rd gear.
Lift and remove the mechanism housing.

I

J

K
MCIB0027E

L

M

MT-21

REPAIRING THE GEARBOX
[JH3]

REPAIRING THE GEARBOX
Removal
1.

PFP:32010
BCS000LP

Remove the 4th-gear pinion.

MCIB0028E

2.

Remove the 3rd/4th gear shaft/fork and sliding gear assembly
while gently lifting the mainshaft assembly.

MCIB0029E

3.

Remove input shaft assembly.

MCIB0030E

4.

Remove mainshaft assembly.

MCIB0031E

MT-22

REPAIRING THE GEARBOX
[JH3]
5.

Remove the 1st/2nd shaft and fork and the 5th gear shaft.
A

B

MT
MCIB0032E

D

6.

Remove the pin from the reverse gear and remove the reverse
gear.
E

F

G
MCIB0033E

H

I

J

K

L

M

MT-23

MAINSHAFT
[JH3]

MAINSHAFT
Removal
1.
2.

PFP:32241
BCS000LQ

Put the mainshaft in a vice with soft jaws.
Remove the 4th main gear and the 3rd/4th gear sliding gear
hub.

MCIA0158E

3.

Remove the stop ring (systematically replace) and the grooved
washer.

MCIA0159E

4.

Remove the 3rd main gear and the grooved washer.

MCIA0160E

5.

Remove the stop ring (systematically replace) and the grooved
washer.

MCIA0161E

MT-24

MAINSHAFT
[JH3]
6.

Remove the 2nd main gear and the grooved washer.
A

B

MT
MCIA0162E

D

7.

Remove the stop ring and the 1st/2nd gear sliding gear hub.
E

F

G
MCIA0163E

Refitting

BCS000LR

Proceed in the reverse order of removal.
The retaining rings must be systematically replaced.
Oil the synchronizer rings.
WARNING:
Make sure that the notches on the synchronizer double cones
are correctly positioned.

H

I

J

K
MCIA0164E

L

M

MT-25

TRANSAXLE CASE BEARING
[JH3]

TRANSAXLE CASE BEARING
Removal

PFP:32010
BCS000LS

Remove the circlips with circlip pliers and drive the bearing inside the
housing using tool B. Vi. 1576.

MCIA0165E

Refitting

BCS000LT

Place the new circlips in their respective housings.
Fit the bearings using tool B. Vi. 1576.
Knock the tool with the bearing using a small hammer.

MT-26

CLUTCH HOUSING BEARING
[JH3]

CLUTCH HOUSING BEARING
Removal

PFP:32010

A
BCS000LU

Cut the base of the plastic hollow needle located at the centre of the
bearing.
Fit tool B. Vi. 1165 and extract the bearing.

B

MT

D
MCIA0166E

E

Refitting
1.
2.

BCS000LV

Fit a new deflector, then the bearing on the press flush with the
inner surface of the housing.
Set the bearing with a mortise chisel.

F

G

H
MCIA0167E

I

3.

Remove the input shaft bearing guide using the press and a 38
mm (1.50 in) diameter tube.
J

K

L
MCIB0044E

4.

Refit the bearing guide using the press and tool B. Vi. 1601.

M

MCIB0045E

MT-27

SELECTOR SHAFT RINGS
[JH3]

SELECTOR SHAFT RINGS
Removal

PFP:32010
BCS000LW

Remove the rings with an inertia puller.

MCIB0046E

Refitting

BCS000LX

Refit the rings using a 14.5 mm (0.57 in) tube down to the thrust
bearing.

MCIB0047E

MT-28

DIFFERENTIAL BEARINGS
[JH3]

DIFFERENTIAL BEARINGS
Removal and Installation
1.

PFP:32010

A
BCS000LY

Remove the bearing using an antisticking pin.
B

MT

D
MCIB0048E

2.

E

Refit the bearings using a 40 mm (1.57 in) tube.

F

G

H
MCIB0049E

3.

Remove the bearing races using a roll pin punch.

I

J

K

MCIB0050E

4.

L

Refit the bearing races using tools C-F from the B. Vi. 1554 kit.
M

MCIB0051E

MT-29

SELECTOR SHAFT
[JH3]

SELECTOR SHAFT
Removal

PFP:32010
BCS000LZ

After removing the pin from the selector finger (B), remove the
mounting bolts (C) and remove the control shaft unit.

MCIB0052E

MCIB0053E

Refitting

BCS000M0

Proceed in the reverse order to removal.
NOTE:
Replace the O-ring (D).

MCIB0054E

MT-30

ASSEMBLY
[JH3]

ASSEMBLY
Refitting
1.

PFP:00000

A
BCS000M1

Fit the mainshaft and 1st/2nd gear fork assembly.
B

MT

D
MCIB0055E

2.

E

Fit the input shaft.

F

G

H
MCIB0056E

3.

Fit the reverse gear assembly.

I

J

K

MCIB0057E

4.

L

Fit the two locking shafts.
M

MCIB0058E

MT-31

ASSEMBLY
[JH3]
5.

Fit the 5th gear shaft and the 3rd/4th gear shaft/fork and sliding
gear assembly while gently lifting the input shaft assembly.
Rotate the reverse gear assembly to position the 5th gear fork
(A).

MCIB0059E

6.

Pin the reverse gear assembly.

MCIB0060E

7.

Shift to 3rd gear and insert the rollers and clawing springs.

MCIB0061E

8.

Refit the 4th main gear fitted with its synchronizer ring.

MCIB0028E

MT-32

HOUSING ASSEMBLY
[JH3]

HOUSING ASSEMBLY
Assembly
1.
2.

PFP:32010

A
BCS000M2

Fit the 1st/2nd, 3rd/4th, and 5th gear shaft ball cartridges into
the housing mechanism.
Engage 3rd gear.

B

MT

D
MCIB0062E

3.
4.

E

Check the positioning of the centring dowels (A).
Check the positioning of magnet (B).

F

G

H
MCIB0063E

5.
6.

Apply a line of LOCTITE 518 to the gasket face.
Offer up the housing while guiding the selector finger (C) into
fork (D) of the 3rd gear.

I

J

K

MCIB0064E

7.
8.
9.

Pretighten the peripheral bolts and rotate the input shaft to
check that they make contact with the bearings.
Tighten the bolts to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)].
Put three drops of LOCTITE Frenbloc on the splines of the fixed
5th gear and fit it using tool B. Vi. 1175.

M

MCIB0065E

MT-33

L

HOUSING ASSEMBLY
[JH3]
10. On the input shaft, fit the support washer (top side gear side).
11. On the input shaft, fit the sprocket bushing.
12. On the input shaft, fit the 5th main gear fitted with its synchronizer ring.
13. On the input shaft, fit the 5th gear hub fitted with its spring.

MCIB0066E

14. Refit the 5th gear fork/sliding gear/reverse gear fork assembly.
15. Fit the reverse gear synchronizer.
16. Screw on the reverse gear fork support and tighten the bolts (A)
to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)].
17. Slide the 5th gear fork on its shaft to engage 5th gear.

MCIB0067E

18. Tighten the gear bolt and nut to torque of:
output shaft bolt (B)
input shaft nut (C)

: [70 N·m (7.1 kg-m, 52 ft-lb)]
: [190 N·m (19 kg-m, 140 ft-lb)]

19. Reset to neutral and pin the 5th gear fork.

MCIB0024E

20. Fit a new O-ring, position the 5th gear cover and tighten the
bolts to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)].
21. Fit the back-up lamp switch (A) and tighten to a torque of [25
N·m (2.6 kg-m, 18 ft-lb)].

MCIB0068E

22. Refit the new differential output seals using B. Vi. 1666.

MCIB0069E

MT-34

HOUSING ASSEMBLY
[JH3]
23. Refit the concentric slave cylinder and tighten the bolts.
A

Tightening torque

: 21 N·m (2.1 kg-m, 15 ft-lb)
B

MT

MCIB0022E

D

E

F

G

H

I

J

K

L

M

MT-35

DESCRIPTION
[JR5]

DESCRIPTION
Cross-Sectional View
[JR5]

PFP:00000
BCS000M3

MCIA0168E

MT-36

REMOVAL AND INSTALLATION
[JR5]

REMOVAL AND INSTALLATION
Removal

PFP:00000

A
BCS000M4

CAUTION:
Remove the crankshaft position sensor (POS) from transaxle assembly before separating transaxle B
from engine. Be careful not to damage sensor edge.
1. Remove battery.
2. Remove the air cleaner. Refer to EM-245, «AIR CLEANER AND AIR DUCT» .
MT
3. Disconnect the cable end ball of the select cable, and the cable end of the shift cable. Refer to MT-42,
«CONTROL LINKAGE» .
4. Disconnect the clutch tube.
D
5. Remove the engine harness clamp.
6. Remove the starter. Refer to SC-51, «Removal and Installation (CR Engine Models)» , “STARTING SYSE
TEM”.
7. Remove the engine mounting LH side installation bolt. Refer to .
8. Set the engine hanger.
F

G

H

MBIB0585E

I

9.
10.
11.
12.
13.
14.
15.
16.

17.
18.
19.

Lift up the vehicle and remove the front fender protectors (RH & LH).
Remove the undercover.
Remove the front exhaust pipe. Refer to EX-3, «Removal and Installation» , “EXHAUST SYSTEM”.
Remove the turbocharger outlet tube bracket from the transaxle.
Remove the RH and LH drive shafts. Refer to FAX-13, «Removal and Installation» , “FRONT DRIVE
SHAFT”.
Disconnect the ground cable from the transaxle.
Set the transmission jack.
Remove the rear engine mounting bracket. Then, remove the rear torque link from the transaxle. Refer to
EM-279, «ENGINE ASSEMBLY» .
CAUTION:
Do not remove the rear torque link from the suspension member.
Remove the engine mounting bracket LH.
Disconnect the position switch connector.
Remove the transaxle mounting nuts and bolts, and remove the transaxle.

Installation

BCS000M5

Install in the reverse order of removal.

MT-37

J

K

L

M

TIGHTENING TORQUES
[JR5]

TIGHTENING TORQUES
Description

PFP:32010
BCS000M6

Tightening portion

N·m (kg-m, ft-lb)

Gearbox casing bolt

25 (2.6, 18)

Mainshaft bolt

70 (7.1, 52)

Input shaft nut

190 (19, 140)

Rear cover bolt

25 (2.6, 18)

Back-up lamp switch

25 (2.6, 18)

Concentric slave cylinder

21 (2.1, 15)

Selector shaft bolt

20 (2.0, 15)

Gear shift catch bolt

10 (1.0, 7)

Reverse gear fork support bolt

25 (2.6, 18)

Drain bolt

25 (2.6, 18)

Selector shaft balls

23 (2.3, 17)

MT-38

COMPONENTS
[JR5]

COMPONENTS
Gear Components

PFP:32010

A
BCS000M7

B

MT

D

E

F

G

H

I
MCIB0131E

1.

Oil channel

2.

Mainshaft front bearing

3.

Mainshaft

4.

1st main gear

5.

Synchronizer ring

6.

Spread spring

7.

1st & 2nd synchronizer hub

8.

Synchronizer ring

9.

Mainshaft bearing

10. 2nd main gear

11. Adapter plate

12. Mainshaft bearing

13. 3rd main gear

14. Baulk ring

15. 3rd & 4th synchronizer hub and
reverse gear

16. Baulk ring

17. Mainshaft bearing

18. 4th main gear

19. Adapter plate

20. Mainshaft rear bearing

21. 5th main gear

22. Bolt

23. Bearing guide

24. Input shaft

25. Retaining clip

26. Input shaft rear bearing

27. Adapter plate

28. 2nd & 3rd gear bushing

29. 5th main gear

30. Baulk ring

31. Spread spring

32. 5th synchronizer hub

33. Spread spring

34. Friction cone

35. Baulk ring

36. Washer

37. Nut

MT-39

J

K

L

M

COMPONENTS
[JR5]

Differential Gear
1

Oil seal

2

Differential side bearing

3

Differential case

4

Pinion mate gear

5

Bevel side gear

6

Pinion mate shaft

7

Shaft retaining spring

8

Side gear thrust washer

BCS000M8

MCIA0170E

Shift Control Components
1

Control assembly

2

Gear shift catch

3

Reverse gear brake fork and shaft

4

Fork rod (For 5th)

5

Lock pin

6

Reverse idler gear assembly

7

Fork rod (For 3rd and 4th)

8

Ring

9

Lock pin

10

Fork rod (For 1st and 2nd)

11

Check ball cartridge

BCS000M9

12

Selector shaft bolt [20 N·m (2.0 kg-m, 15 ft-lb)]

13

Reverse gear fork shaft bolt [25 N·m (2.6 kg-m, 18 ft-lb)]

MCIA0155E

MT-40

COMPONENTS
[JR5]

Case Components

BCS000MA

A
1

Transaxle case

2

Filler plug

3

Dowel pin

4

Oil gutter

5

Breather pipe

6

Back-up lamp switch

7

O-ring

8

Transaxle case cover

9

Gearbox edge bolt [25 N·m (2.6 kg-m, 18 ft-lb)]

10

Fifth gear housing bolt [25 N·m (2.6 kg-m, 18 ft-lb)]

B

MT

D

E

F

G
MCIB0013E

Clutch Housing

BCS000MB

1

Clutch housing

2

Drain bolt [25 N·m (2.6 kg-m, 18 ft-lb)]

3

Magnet

4

Concentric slave cylinder

5

Concentric slave cylinder bolt [21 N·m (2.1 kg-m, 15 ft-lb)]

H

I

J

K

L

M

MCIB0014E

MT-41

CONTROL LINKAGE
[JR5]

CONTROL LINKAGE
Removal and Installation of Control Device and Cable

PFP:34103
BCS000MC

MCIB0168E

1.

Shift knob

2.

Shift lever

3.

Control device

4.

Selector lever

5.

Shift cable

6.

Clutch housing

B.

White color

7.

Cable bracket 1

A.

Black color

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11 .

REMOVAL
1. Remove center console and shift boot. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
2. Remove control device mounting bolts.
3. Pressing release bottom of cable end, remove cable from either manual transmission shift lever.
4. Lift up cable and remove it from cable bracket 1.
5. Remove center muffler and heat plate. Refer to EX-3, «Removal and Installation» , “EXHAUST SYSTEM”.
6. Remove front and rear claws of control device. Remove control device and cable from the vehicle.
NOTE:
If shift knob needs to be removed, pull it up to remove.

INSTALLATION
Note the following, and install in the reverse order of removal.
●
When installing, make sure to insert cable end into either manual transmission shift lever.
●
After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st, 2nd, or
Reverse.
●
After installation, make sure that the shift to each position works well.
●
When installing shift knob, press it onto selector lever.

MT-42

RATIOS
[JR5]

RATIOS
NISSAN Gearbox

PFP:32010

A
BCS000MD

Engine

Suffix

First

Second

Third

Fourth

Fifth

Reverse gear

Final drive

K9K (63 kw)

JH5-140

11:41

21:43

28:37

35:34

42:31

11:39

15:56

B

MT

D

E

F

G

H

I

J

K

L

M

MT-43

CONSUMABLES
[JR5]

CONSUMABLES
Description
Types

PFP:32010
BCS000ME

Packaging

Parts Department No.

Component

RHODORSEAL

100 g tubes

77 01 404 452

Housing assembly

LOCTITE 518

24 ml syringe

77 01 421 162

Back-up lamp switch threading

Gearbox oil

Cover all parts

MT-44

CAPACITIES — LUBRICANTS
[JR5]

CAPACITIES — LUBRICANTS
Description
Capacity
2.6

(4-5/8 Imp pt)

PFP:32010

A
BCS000MF

Grade

B

Nissan Genuine gear oil Passenger Car or
API GL-4 Viscosity 75W-80

Fill to the level of the oil filler cap hole.

MT

D
MCIB0015E

E

F

G

H

I

J

K

L

M

MT-45

TROUBLE DIAGNOSIS
[JR5]

TROUBLE DIAGNOSIS
Symptom Chart

PFP:00004
BCS000MG

Symptoms (after checking
the clutch)

Possible causes

Oil level
or grade

External
control

Synchronizer

Gear grinding

1

2

3

One or more gears
cannot be selected

1

2

3

Gear disengagement

2

4

One or more gears
locked

1

Symptoms

Noisy

Gearing

Sliding
gear hub

Fork and
balls

Bearings

Engine
mounting
— housing

4
4
4
4

1

3

3

1

2

3
2

NOTE:
The numbers indicate the order of priority for diagnostics.

Back-Up Lamp Switch
●

BCS000MH

Check continuity between terminals 1 and 2.
Gear position

Continuity

Reverse

Yes

Except reverse

No

MCIA0157E

Park/Neutral Position Switch
●

BCS000MI

Check continuity between terminals 2 and 3.
Gear position

Continuity

Neutral

Yes

Except neutral

No

MT-46

PRECAUTIONS
[JR5]

PRECAUTIONS
Precautions

PFP:00001

A
BCS000MJ

Removing and handling the parts must be carried out on a workbench with a knockproof cover. (rubber or thick
plastic)
B
Cover all turning and synchronizer points in oil.
Observe the tightening torques.
Carefully carry out the specific settings and adjustments.
MT
Be sure to properly refit parts in the same order and position after removal.
Marking the position of the sliding rods in relation to the hubs before removal is recommended.
During refitting, make sure the inside of the box remains free of dust or impurities.
D

E

F

G

H

I

J

K

L

M

MT-47

PARTS TO BE REPLACED SYSTEMATICALLY
[JR5]

PARTS TO BE REPLACED SYSTEMATICALLY
Description
If they have been removed:
●
the lip seals,
●
the O-rings,
●
the gear supporting rings,
●
the roll pins,
●
the input shaft and mainshaft bearing circlips,
●
the sliding gear hub springs.

MT-48

PFP:32010
BCS000MK

CHECKING
[JR5]

CHECKING
Bearings

PFP:32010

A
BCS000ML

Check that the bearings show no signs of damage and that they turn
evenly. Replace them if necessary.

B

MT

D
MCIB0017E

E

Gearing

BCS000MM

NOTE:
The inspection focuses mainly on the appearance of the teeth, especially in terms of claw chamfers.
1. Check that the teeth (A) are not broken or chipped.
2. Check that the claws (B) are not broken, chipped or worn.
3. Check that the friction cone (C) shows no scratches or blueness.

F

G

H

MCIB0018E

Synchronizer Ring

I

BCS000MN

Check that the grooves and ridges on the ring are not worn or damaged.
1. Check that the ring puts onto the gear cone.
2. Check that the ring rotates while applying force in the direction
of the cone (D).
3. Check that the ring should lock against the cone.
Otherwise, replace the synchronizer ring.

J

K

L

MCIB0019E

Sliding Gear Hub

BCS000MO

Make sure the sliding gear turns smoothly in the hub.
Check that the rollers or keys are in good condition.

MCIB0020E

MT-49

M

SEPARATING THE HOUSINGS
[JR5]

SEPARATING THE HOUSINGS
Removal

PFP:32010
BCS000MP

Fit the B. Vi. 1581 support plate on a Desvil stand.
Fit the gearbox on the B. Vi. 1581 support.

MCIB0021E

1.
2.

Remove the concentric slave cylinder.
Remove the bolts located inside the housing.

MCIB0022E

3.

Remove the rear housing. This must be removed along the horizontal axis of the gearbox because it has a lubrication spline
which is located in the input shaft bore.

MCIB0023E

4.
5.
6.
7.

Remove the two reverse gear fork support mounting bolts (A).
Drive in the 5th gear fork using B. Vi. 31-01.
Shift the 3rd gear on the gear selector lever and the 5th gear by
sliding the 5th gear fork on its shaft.
Remove the mainshaft bolt (B).
Remove the input shaft nut (C).
Remove the reverse gear synchronizer.
Remove the 5th gear fork and sliding gear.
MCIB0024E

MT-50

SEPARATING THE HOUSINGS
[JR5]
Remove the 5th gear hub using B. Vi. 1170.
To do this, fit the sliding gear B. Vi. 1170 and rotate it so that the
splines are opposite those of the input shaft hub.

A

B

MT
MCIB0025E

D

Remove the fixed 5th gear using B. Vi. 22-01 and B. Vi. 100001.
Remove the gearbox edge bolts.

E

F

G
MCIB0026E

H

Remove the back-up lamp switch (B).
Engage 3rd gear.
Lift and remove the mechanism housing.

I

J

K
MCIB0027E

L

M

MT-51

REPAIRING THE GEARBOX
[JR5]

REPAIRING THE GEARBOX
Removal
1.

PFP:32010
BCS000MQ

Remove the 4th-gear pinion.

MCIB0028E

2.

Remove the 3rd/4th gear shaft/fork and sliding gear assembly
while gently lifting the mainshaft assembly.

MCIB0029E

3.

Remove input shaft assembly.

MCIB0030E

4.

Remove mainshaft assembly.

MCIB0031E

MT-52

REPAIRING THE GEARBOX
[JR5]
5.

Remove the 1st/2nd shaft and fork and the 5th gear shaft.
A

B

MT
MCIB0032E

D

6.

Remove the pin from the reverse gear and remove the reverse
gear.
E

F

G
MCIB0033E

Removing the Gearing

BCS000MR

NOTE:
The rings underneath the 2nd, 3rd and 4th gears are fitted tightened.
They will be systematically replaced during refitting.
1. Remove the ring/hub/3rd gear assembly with the press, resting
underneath the 3rd gear claw teeth.

H

I

J

K
MCIB0072E

2.

L

Remove the rings/1st and 2nd gears/hub/sliding gear assembly
with the press, resting underneath the 1st gear.

M

MCIB0073E

Checking Parts

BCS000MS

The sprocket teeth and the claws should not be chipped or excessively worn.
Also ensure that there are no signs of grating or abnormal wear on the surfaces of the shafts or the inner walls
of the sprockets.
It is advisable to mark the position of the sliding shafts in relation to the hub.

MT-53

REPAIRING THE GEARBOX
[JR5]

Refitting the Gearing

BCS000MT

A hot plate with a setting of 150°C (302°F) should be used for refitting.
Place the new rings on the cold hot plate. Heat them for 15 minutes
with a thermostat setting of 150°C (302°F).

MCIB0074E

Proceed in the reverse order to removal.
Refit the rings:
Remove a ring from the heating plate, using pliers, and use a tube
with an internal diameter of 33 mm (1.30 in) to fit it on the shaft until
it is resting on the hub.
NOTE:
The 1st/2nd gear has double-cone synchronizer, bring the notches
of the synchro rings together with those on the hubs and gears.

MCIB0075E

MT-54

TRANSAXLE CASE BEARING
[JR5]

TRANSAXLE CASE BEARING
Removing the Bearing, Input Shaft Side

PFP:32010

A
BCS000MU

Remove the circlips and drive the bearing inside the housing using
tool B. Vi. 1576.

B

MT

D
MCIB0076E

E

Refitting
1.
2.
3.

BCS000MV

Fit a new circlip.
Fit the bearing using tool B. Vi. 1576.
Remove the bearing race, output shaft side using a tube with a
diameter of 55 mm (2.17 in).

F

G

H
MCIB0077E

I

4.

Refit the race using a 60 mm (2.36 in) diameter tube.
J

K

L
MCIB0078E

M

MT-55

CLUTCH HOUSING BEARING
[JR5]

CLUTCH HOUSING BEARING
Removal and Installation
1.

PFP:32010
BCS000MW

Cut the base of the deflector plastic hollow needle located at the
centre of the bearing.
Drive out the cup using a puller.

MCIB0079E

2.

Fit a new deflector, then the bearing race using a 55 mm (2.17
in) diameter tube.

MCIB0080E

3.

Remove the input shaft bearing guide using the press and a 38
mm (1.50 in) diameter tube.

MCIB0044E

4.

Refit the bearing guide using the press and tool B. Vi. 1601.

MCIB0045E

MT-56

SELECTOR SHAFT RINGS
[JR5]

SELECTOR SHAFT RINGS
Removal

PFP:32010

A
BCS000MX

Remove the rings with an inertia puller.
B

MT

D
MCIB0046E

E

Refitting

BCS000MY

Refit the rings using a 14.5 mm (0.57 in) tube down to the thrust
bearing.

F

G

H
MCIB0047E

I

J

K

L

M

MT-57

DIFFERENTIAL BEARINGS
[JR5]

DIFFERENTIAL BEARINGS
Removal and Installation
1.

PFP:32010
BCS000MZ

Remove the bearing using an antisticking pin.

MCIB0048E

2.

Refit the bearings using a 40 mm (1.57 in) tube.

MCIB0049E

3.

Remove the bearing races using a roll pin punch.

MCIB0050E

4.

Refit the bearing races using tools C-F from the B. Vi. 1554 kit.

MCIB0051E

MT-58

SELECTOR SHAFT
[JR5]

SELECTOR SHAFT
Removal

PFP:32010

A
BCS000N0

After removing the pin from the selector finger (B), remove the
mounting bolts (C) and remove the control shaft unit.

B

MT

D
MCIB0052E

E

F

G

H
MCIB0053E

Refitting

BCS000N1

Proceed in the reverse order to removal.
NOTE:
Replace the O-ring (D).

I

J

K

L
MCIB0054E

M

MT-59

REPAIRING THE GEARBOX
[JR5]

REPAIRING THE GEARBOX
Setting the Pre-tensioning of the Output Shaft Bearings

PFP:32010
BCS000N2

NOTE:
This operation is carried out in the event of replacing the bearings,
housings or mainshaft.
Clutch housing without differential and without input shaft.
Fit the mainshaft in the clutch housing with the bearings and the presetting washer B. Vi. 1161, or equivalent, of 1.60 mm (0.06 in) (large
outer ý).
Fit the transaxle case assembly.
Fit and tighten to torque the box belt bolts.
Fit the dial gauge support plate B. Vi. 1161, or equivalent, on the tripod basin mountings.
MCIB0081E

1.
2.
3.

Fit the B. Vi. 1527 special spacer (A).
Fit the bolt (C).
Fit the dial gauge with its magnetic holder.
1

Rotate the mainshaft several times to fit the bearings.

2

Set the dial gauge to zero.

3

Pull the mainshaft upwards by making a lever out of two screwdrivers.

4

Take a reading from the dial gauge.

Repeat the operations several times (1 to 4).
MCIB0082E
Calculate the average of the readings.
Calculation of the value of the pre-load washer.
Prescribed value + value of the pre-setting washer + average of the readings on the dial gauge = value of the
pre-tensioning dial gauge washer.
Example: [Value in mm (in)]
0.26

+

0.49

+

1.60

=

2.35

↓

↓

↓

↓

Prescribed value

Average reading

Pre-setting washer value

Pre-load washer value

NOTE:
A set of pre-load washers of 2.15 mm (0.08 in) to 2.43 mm (0.10 in) from 0.04 mm (0.002 in) to 0.04 mm
(0.002 in) thickness is supplied as replacement parts.

MT-60

ASSEMBLY
[JR5]

ASSEMBLY
Refitting
1.

PFP:00000

A
BCS000N3

Fit the mainshaft and 1st/2nd gear fork assembly.
B

MT

D
MCIB0055E

2.

E

Fit the input shaft.

F

G

H
MCIB0056E

3.

Fit the reverse gear assembly.

I

J

K

MCIB0057E

4.

L

Fit the two locking shafts.
M

MCIB0058E

MT-61

ASSEMBLY
[JR5]
5.

Fit the 5th gear shaft and the 3rd/4th gear shaft/fork and sliding
gear assembly while gently lifting the input shaft assembly.
Rotate the reverse gear assembly to position the 5th gear fork
(A).

MCIB0059E

6.

Pin the reverse gear assembly.

MCIB0060E

7.

Shift to 3rd gear and insert the rollers and clawing springs.

MCIB0061E

8.

Refit the 4th main gear fitted with its synchronizer ring.

MCIB0028E

MT-62

HOUSING ASSEMBLY
[JR5]

HOUSING ASSEMBLY
Assembly
1.
2.

PFP:32010

A
BCS000N4

Fit the 1st/2nd, 3rd/4th, and 5th gear locking balls into the
transaxle case.
Engage 3rd gear.

B

MT

D
MCIB0062E

3.
4.

E

Check the positioning of the centring dowels (A).
Check the positioning of magnet (B).

F

G

H
MCIB0063E

5.
6.

Apply a line of LOCTITE 518 to the gasket face.
Offer up the housing while guiding the selector finger (C) into
fork (D) of the 3rd gear.

I

J

K

MCIB0064E

7.
8.
9.

Pretighten the peripheral bolts and rotate the input shaft to
check that they make contact with the bearings.
Tighten the bolts to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)].
Put three drops of LOCTITE Frenbloc on the splines of the fixed
5th gear and fit it using tool B. Vi. 1175.

M

MCIB0065E

MT-63

L

HOUSING ASSEMBLY
[JR5]
10. On the input shaft, fit the support washer (top side gear side).
11. On the input shaft, fit the sprocket bushing.
12. On the input shaft, fit the 5th main gear fitted with its synchronizer ring.
13. On the input shaft, fit the 5th gear hub fitted with its spring.

MCIB0066E

14. Refit the 5th gear fork/sliding gear/reverse gear fork assembly.
15. Fit the reverse gear synchronizer.
16. Screw on the reverse gear fork support and tighten the bolts (A)
to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)].
17. Slide the 5th gear fork on its shaft to engage 5th gear.

MCIB0067E

18. Tighten the gear bolt and nut to torque of:
output shaft bolt (B)
input shaft nut (C)

: [70 N·m (7.1 kg-m, 52 ft-lb)]
: [190 N·m (19 kg-m, 140 ft-lb)]

19. Reset to neutral and pin the 5th gear fork.

MCIB0024E

20. Fit a new O-ring, position the 5th gear cover and tighten the
bolts to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)].
21. Fit the back-up lamp switch (A) and tighten to a torque of [25
N·m (2.6 kg-m, 18 ft-lb)].

MCIB0068E

22. Refit the new differential output seals using B. Vi. 1666.

MCIB0069E

MT-64

HOUSING ASSEMBLY
[JR5]
23. Refit the concentric slave cylinder and tighten the bolts.
A

Tightening torque

: 21 N·m (2.1 kg-m, 15 ft-lb)
B

MT

MCIB0022E

D

E

F

G

H

I

J

K

L

M

MT-65

HOUSING ASSEMBLY
[JR5]

MT-66

PARKING BRAKE SYSTEM

F BRAKES

SECTION

PB

PARKING BRAKE SYSTEM

A

B

C

D

CONTENTS
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ………………………………………… 2
NVH Troubleshooting Chart ………………………………. 2
PARKING BRAKE SYSTEM ……………………………….. 3
On Board Inspection and Service ………………………. 3
LEVER STROKE …………………………………………… 3
Adjustment ……………………………………………………… 3

Components ……………………………………………………. 4
Removal and Installation …………………………………… 4
REMOVAL ……………………………………………………. 4
INSTALLATION …………………………………………….. 5
SERVICE DATA AND SPECIFICATIONS (SDS) …….. 6
Parking Brake ………………………………………………….. 6

E

PB

G

H

I

J

K

L

M

PB-1

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

PFP:00003
BFS0008T

PB-2

NVH in PS section
STEERING

X

NVH in WT section

X

ROAD WHEEL

—
Drum rust

X

NVH in WT section

X

TYRES

X

NVH in RSU section

X

SUSPENSION

Shimmy, Judder
X: Applicable

—

BR-28
Drum runout

X

Drum deflection

—
Drum damage

Shake

—

BR-28
Drum imbalance

X

Drum deformation

BR-27

X

NVH in RAX section

BRAKE

X

AXLE

Symptom

Return spring damaged

Noise

—

Possible cause and
SUSPECTED PARTS

Linings — uneven wear

BR-28

Reference page

Linings — damaged

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

PARKING BRAKE SYSTEM
PARKING BRAKE SYSTEM
On Board Inspection and Service

PFP:36010

A
BFS0008U

LEVER STROKE
●

Operate parking brake lever with a force of 196 N (20 kg, 44.1 lb). Check if stroke is within specified number of notches. (Check it by hearing clicks of ratchet.)
Lever stroke

: 8 — 9 notches
C

Adjustment
1.

2.

B

BFS0008V

Insert a socket wrench into opening of parking brake lever.
Rotate adjusting nut (1) to fully loosen cable (2), then return
parking brake lever.
Depress the foot brake several times (minimum 10 times) and
adjust the rear shoe clearance.
NOTE:
Be sure to securely depress the foot brake.

D

E

PB
MFIB9033E

G

3.
4.
a.
b.

Rotate the road wheels to make sure that there is no drag.
Use the following procedure to adjust the cable.
Pull the lever up to the position where a socket wrench can be
inserted.
Insert a socket wrench into the opening of the lever, and rotate
the adjusting nut to adjust lever stroke.
NOTE:
Do not reuse adjusting nut after removing it.

H

I

J
MAA0182D

c.
d.
5.
6.
7.

After operating the lever about 10 times with a force of 196 N (20 kg, 44.1 lb), make sure that the lever
stroke is within the specified number of notches.
With the lever completely returned, make sure that there is no drag on the rear brake.
Check brake warning lamp on Combination meter comes on when parking brake is applied by 1 notch or
less, and goes out again when parking brake lever returns to off position.
Check if the ratchet engages and releases securely and smoothly.
Check if initial free play of the lever is maximum 20 mm at the end of the release button and check operating force of release button is 4.9 N (0.50 kg, 1.10 lb) at full stroke point.

PB-3

K

L

M

PARKING BRAKE SYSTEM
Components

BFS0008W

MFIB9034E

1.

Device assembly

2.

Screw

3.

Warning lamp switch

4.

Adjusting nut

5.

Front cable

6.

Rear left cable

7.

Rear right cable

8.

Parking brake lever grip

9.

Rear cable mount

10. Back plate

Removal and Installation

BFS0008X

REMOVAL
1.
2.
3.
4.

Remove the center console. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Disconnect warning lamp switch connector.
Loosen adjusting nut and separate the rear left and rear right cable from front cable.
Remove device assembly tightening nuts, and remove device assembly from vehicle.

5.
6.

Remove tyre from vehicle.
Remove rear brake shoe assembly and remove cable from the operating lever. Refer to BR-27, «Components» .
Remove the center and rear heat plates. Refer to EX-3, «EXHAUST SYSTEM» .
Release fuel tank clips. Refer to FL-8, «FUEL TANK» (CR), FL-19, «FUEL TANK» (HR), FL-31, «FUEL
TANK» (K9K).
Remove rear cable mount fixing bolts and remove rear cables from the vehicle.

7.
8.
9.

PB-4

PARKING BRAKE SYSTEM
INSTALLATION
1.
2.

Install in the reverse order of removal. Tighten nuts and bolts to the specified torque.
Adjust the parking brake. Refer to PB-3, «Adjustment» .

A

B

C

D

E

PB

G

H

I

J

K

L

M

PB-5

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Parking Brake

PFP:00030
BFS0008Y

Control type

Center lever

Lever stroke [operating force 196 N (20 kg, 44.1 lb)]

8 — 9 notches

Full stroke

15 notches

Brake warning lamp stroke

1 notch or less

PB-6

POWER STEERING SYSTEM

G STEERING

SECTION

PS

POWER STEERING SYSTEM

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 2
Caution: ………………………………………………………….. 2
PREPARATION ………………………………………………….. 3
Special Service Tools ……………………………………….. 3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ………………………………………… 4
NVH Trouble Shooting Chart ……………………………… 4
STEERING WHEEL ……………………………………………. 5
On Board Inspection and Service ………………………. 5
PLAY INSPECTION ………………………………………. 5
NEUTRAL POSITION INSPECTION ……………….. 5
STEERING TORQUE INSPECTION ……………….. 5
STEERING ANGLE INSPECTION …………………… 5
Removal and Installation …………………………………… 6
REMOVAL ……………………………………………………. 6
INSTALLATION …………………………………………….. 6
STEERING COLUMN …………………………………………. 7
Removal and Installation …………………………………… 7
REMOVAL OF STEERING COLUMN ASSEM-

BLY ……………………………………………………………… 7
INSPECTION AFTER REMOVAL OF STEERING COLUMN ASSEMBLY …………………………….. 8
INSTALLATION OF STEERING COLUMN
ASSEMBLY ………………………………………………….. 8
CHECK AFTER STEERING COLUMN ASSEMBLY INSTALLATION ………………………………………. 8
POWER STEERING GEAR AND LINKAGE ………….. 9
Removal and Installation …………………………………… 9
REMOVAL ……………………………………………………. 9
INSTALLATION …………………………………………….. 9
Disassembly and Assembly ……………………………… 10
COMPONENT PARTS LOCATION (R24TTYPE)… 10
DISASSEMBLY …………………………………………… 10
INSPECTION AFTER DISASSEMBLY ……………. 10
ASSEMBLY ………………………………………………… 11
SERVICE DATA AND SPECIFICATIONS (SDS) …… 13
Wheel …………………………………………………………… 13
Steering Angle ……………………………………………….. 13
Steering Column …………………………………………….. 13
Steering Linkage …………………………………………….. 13
Tightening Torque …………………………………………… 14

E

F

PS

H

I

J

K

L

M

PS-1

PRECAUTIONS
PFP:00001
PRECAUTIONS
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

BGS0001O

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Caution:
●
–
–
–

–

–

–

BGS0001P

Always follow the warnings and the cautions below in disassembly procedures:
Work in a clean, dust-free place. No dustproof device is necessary.
Clean the outside of the unit before disassembly.
Clean the parts to be disassembled. Care must be taken not to allow any dirt or other foreign materials to
enter or come in contact with the parts.
Assemble the disassembled parts properly, following the order shown in the manual. If work has been
suspended in the middle of assembly, place a clean cover over the parts to prevent them from being contaminated.
Use paper towels when removing dirt and other foreign materials. Cloth shop towels can leave lint on the
cleaned parts that might affect the operation of the parts.
Clean disassembled parts with kerosene (except rubber parts), and then dry them thoroughly with an air
blower or paper towels.

PS-2

PREPARATION
PREPARATION
Special Service Tools

PFP:00002

A
BGS0001Q

Description

Application

B

Preload gauge
ST3127S000

●

Checking steering torque

●

Pinion gear rotating torque measurement
for steering gear

C

D

ZZA0806D

E
ST27180001
Steering wheel puller

Removing steering wheel

F
S-NT544

PS

H

I

J

K

L

M

PS-3

Symptom
STEERING
PS-5

Steering wheel play

×
×
×

×: Applicable
Judder

PS-4

PS-7
PS-7
PS-9
NVH in FAX, RAX, FSU, RSU section
NVH in WT section
NVH in WT section
NVH in FAX section
NVH in BR section

Improper installation or looseness of steering column
Steering linkage looseness
AXLE AND SUSPENSION
TYRES
ROAD WHEEL
DRIVE SHAFT
BRAKES

–

PS-7

Steering column deformation or damage

Mounting rubber deterioration

Improper installation or looseness or tilt lock lever

–

PS-9

Tie-rod ball joint end play

×
Improper steering wheel

PS-9

Noise
Tie-rod ball joint sliding torque

Possible cause and SUSPECTED PARTS
PS-9

Reference page

Tie-rod ball joint tensile force

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Trouble Shooting Chart

Shake
×
×
×

Vibration
×
×
×

Shimmy
×
×
×
×
×
×
×
×

×
×
×
×
×
×

×
×

PFP:00003
BGS0001R

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

×
×
×
×
×

×
×
×
×
×

×
×
×

STEERING WHEEL
STEERING WHEEL
On Board Inspection and Service

PFP:48430

A
BGS0001S

PLAY INSPECTION
1.

Turn steering wheel to the straight-ahead position. Start engine and lightly turn steering wheel clockwise
and counterclockwise until the front wheels start moving. Measure the travel to the starting point on the
circumference of steering wheel. If play is outside the specified range, check steering gear assembly, front
suspension, axles, and steering column for proper installation.
Steering wheel play inspection standard

2.

C

: 0 — 35 mm (0 — 1.38 in)

Check steering wheel for vertical, horizontal, or axial play.
Steering wheel axial end play

●

B

D

: 0 mm (0 in)

Lift vehicle and check steering gear nuts and bolts for looseness.
Tightening torque

E

: 94 N·m (9.6 kg-m, 69 ft-lb)

NEUTRAL POSITION INSPECTION
●

●
●

After wheel alignment inspection, perform neutral position inspection. Refer to FSU-6, «Wheel Alignment» F
.
Set vehicle to the straight-ahead position and confirm steering wheel is in the neutral position.
If it is not in the neutral position, loosen lock nut on tie-rod. Then adjust until the amount of left and right PS
becomes equal.

STEERING TORQUE INSPECTION
1.
2.
3.

Steering torque
4.

H

Stop vehicle on a dry flat paved road and apply parking brake.
Remove air bag module. Refer to SRS-36, «DRIVER AIR BAG MODULE» .
Start engine and use a preload gauge (SST) to check steering
wheel torque.

I

: 5.9 N·m (0.60 kg-m, 52 in-lb) or less

When torque is outside the standard, check steering column and
steering gear. If any non-standard condition is detected, replace
if necessary.

J

K

STA0005D

L

STEERING ANGLE INSPECTION
●

After toe-in inspection, check the steering angle. Place the front
wheels on turning radius gauges and the rear wheels on stands
so that the vehicle can be level. Check the maximum inner and
outer wheel steering angles for LH and RH road wheels.

M

FAA0016D

PS-5

STEERING WHEEL
●

●

With the engine at idle, turn steering wheel from stop to stop and
measure the steering angles.
Inner wheel

: 38°

Outer wheel

: 33°

+1°
-3°

Steering angles are not adjustable. If any of the steering angles
is different from the specified value, check steering gear, column
and front suspension components for wear or damage. If any
non-standard condition exists, replace if necessary.
SGIA0055E

Removal and Installation

BGS0001T

REMOVAL
NOTE:
When reconnecting spiral cable, fix cable with a tape so that fixing case and rotating part keep aligned. this will
omit neutral position alignment procedure during spiral installation.
1. Set vehicle to the straight-ahead position.
2. Remove driver air bag module. Refer to SRS-36, «DRIVER AIR BAG MODULE» .
3. Remove steering wheel lock bolt after steering is locked.
4. Remove steering wheel using the steering wheel puller (SST:
ST27180001).

SRS823

INSTALLATION
Reverse the removal procedure for installation attentive to the following operation.
NOTE:
Make sure that the spiral cable is in the neutral position. The neutral
position is detected by turning left 2.6 revolutions from the right end
position and ending with the locating pin (1) at the top.
CAUTION:
Do not run spiral cable idle needlessly. And do not turn it more
than necessary (or it leads to disconnection of the cable).

MGIB9046E

PS-6

STEERING COLUMN
STEERING COLUMN
Removal and Installation

PFP:48810

A
BGS0001U

B

C

D

E

F

PS

H

I
MGIB9047E

1.

Steering wheel

2.

Steering column assembly

4.

EPS control unit

5.

Intermediate shaft

3.

Bracket plate

CAUTION:
●
Care must be taken not to give axial impact to the steering column assembly during removal and
installation.
●
When steering wheel is turned repeatedly with the vehicle stopped, care must be taken because
motor and control unit may get too hot.
●
Steering column assembly is heavy (approximately 10 kg). Care must be taken when removing column from vehicle.
●
Steering column assembly cannot be disassembled. If any non-standard condition exists, replace
column assembly as a unit.

REMOVAL OF STEERING COLUMN ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.

Remove driver air bag module. Refer to SRS-36, «DRIVER AIR BAG MODULE» .
Remove steering wheel and spiral cable. Refer to SRS-38, «SPIRAL CABLE» .
Remove column cover and instrument panel & pad. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove front wiper and washer switch and light and turn signal lamp switch. Refer to SRS-38, «Removal
and Installation» in “Light and Turn Signal Switch”, and SRS-38, «Removal and Installation» .
Disconnect all the clamps and harness connectors from steering column assembly. Refer to PG-48, «Harness Layout» .
Remove intermediate shaft mounting bolt on steering gear, and disconnect the shaft from steering gear.
Remove harness connector of electric power steering. Refer to PG-48, «Harness Layout» .
Remove nut on steering column assembly, and make sure steering column moves freely.
Remove steering column assembly from vehicle.

PS-7

J

K

L

M

STEERING COLUMN
CAUTION:
● Be sure not to rotate column shaft by 360° or more. (Doing this causes error in steering angle
value memorized in electric power steering.)
● Do not disconnect intermediate shaft and steering column.

INSPECTION AFTER REMOVAL OF STEERING COLUMN ASSEMBLY
●

●

Check each part of column assembly and intermediate shaft for damage or other malfunctions. If any nonstandard condition exists, replace if necessary.
If vehicle has been involved in a minor collision, measure length
L as shown. If outside the standard, replace steering column
assembly.
Length L

●

: 464 mm (18.3 in)

Using preload gauge, measure steering column rotating torque.
If outside the standard, replace steering column assembly.
Rotating torque : 0 — 2.1 N·m (0 — 0.21 kg-m, 0 — 18 in-lb)
SGIA1016J

INSTALLATION OF STEERING COLUMN ASSEMBLY
Note the following, and install in the reverse order of removal. Tighten bolts and nuts to the specified torque.
●
Connect Pinion shaft (3) to yoke of intermediate shaft (1) and Steering column (2) assembly [RHD (4);
LHD (5)], and tighten bolt to the specified torque.
CAUTION:
● When tightening bolts, tighten them by hand first, and
make sure there is no feeling of sticking or galling before
final tightening.
● Insert bolts in the proper direction. (Do not insert them
from the other side.)
● Tighten bolts at connecting pinion shaft and intermediate
shaft side. Make sure there is no space between pinion
shaft and yoke, and between pinion shaft and cam nut.

MGIB9042E

CHECK AFTER STEERING COLUMN ASSEMBLY INSTALLATION
●

Rotating steering wheel, check for decentered condition, binding, noise or excessive steering effort.

PS-8

POWER STEERING GEAR AND LINKAGE
POWER STEERING GEAR AND LINKAGE
Removal and Installation

PFP:49001

A
BGS0001V

B

C

D

E

F

PS
MGIB9041E

1.

Steering gear assembly

2.

Suspension member

3.

Heat insulator

REMOVAL

H

1.
2.
3.
4.

I

5.

Lift vehicle and remove tyres.
Activate key lock of steering column.
Remove intermediate shaft mounting bolt on steering gear, and disconnect the shaft.
Remove tie-rod from steering knuckle. If tie-rod could not be
removed easily, use ball joint remover (commercial service tool).
CAUTION:
To avoid damage to threads and sudden disconnection of
ball joint remover (commercial service tool), temporarily
tighten lock nut.
Remove the exhaust front tube (CR engine models). Refer to
EX-3, «EXHAUST SYSTEM» .

J

K

L
SGIA0184J

6.

M

Remove steering gear mounting nuts and bolts, and remove the
steering gear through the right side of vehicle.
(Remove from left side for LHD models and from right side for
RHD models.)

MGIB9043E

INSTALLATION
Note the following, and install in the reverse order of removal. Tighten bolts and nuts to the specified torque.
●
Refer to PS-7, «Removal and Installation» .

PS-9

POWER STEERING GEAR AND LINKAGE
Disassembly and Assembly

BGS0001W

COMPONENT PARTS LOCATION (R24T TYPE)

MGIB9044E

1.

Outer socket

2.

Bulkhead sealing

3.

Seal ring

4.

Strap

5.

Dust boot

6.

Spring clip

7.

Lock nut

8.

Steering gear assembly

9.

Heat shield

DISASSEMBLY
1.
2.
3.

Disengage the tab of bulkhead seal, and remove it from steering
gear.
Loosen lock nut of tie-rod outer socket, and remove it from
steering gear.
Remove spring clip and strap (cutting off), and remove dust boot
and seal ring.
CAUTION:
When removing dust boot, be careful not to damage inner
socket and gear housing assembly.
MGIB9045E

INSPECTION AFTER DISASSEMBLY
Rack
Check rack gear, and, if any damage or wear exists, replace steering gear assembly.

Bulkhead Sealing
In case of broken tab, or torn sealing in bulkhead seal, replace the damaged part.

Tie-Rod Ball Joint
1.

Tensile force
● Hook a spring balance onto the point shown in the figure and
pull the balance. Make sure the balance reads the specified
value when ball stud and the inner socket start to move. If it is
outside the standard, replace both outer socket and steering
gear assembly.

MGIA0016E

PS-10

POWER STEERING GEAR AND LINKAGE

Measuring point of
spring balance
Tensile force
N·m (kg-m, in-lb)
Spring balance measurement
N (kg, lb)

2.

Outer socket

Inner socket

Edge of stud bolt

Measuring point

0.3 — 2.9
(0.03 — 0.29, 3 -25)

0.5 — 5.0
(0.05 — 0.51,
5 — 44)

5 — 54
(0.51 — 5.5,
1.1 — 12.1)

4 — 43
(0.41 — 4.4,
0.9 — 9.7)

A

B

C

Axial end play
Apply 490 N (50 kg, 110 lb) of load to the ball stud axially and
use a dial gauge to measure the amount of movement the
stud makes. Make sure the reading is within the range specified. If outside the standard, replace outer socket and steering
assembly.

D

●

Outer socket

No Free Play

Inner socket

No Free Play

3.

Using preload gauge (SST), measure rotating torque of pinion
gear. If the measurement is outside of the specified range,
replace steering gear.
Rotating torque of pinion
gear
Around neutral position
(Within ±100°) Average A
Other than the above: Maximum value C

E

F

PS
SGIA0057E

H

: 0.7 — 1.2 N·m (0.07 0.12 kg-m, 6 — 11 in-lb)
: 1.6 N·m (0.16 kg-m, 14
in-lb)

I

J
MGIA0017E

ASSEMBLY

K

Note the following, and assemble in the reverse order of disassembly
●
Apply multi-purpose grease to the sliding part of rack.
●
Securely fix dust boot and seal ring with strap. Caulk the strap,
and cut the excess of strap off.
●
Engage the tab of bulkhead seal to steering gear.

L

M

MGIA0018E

PS-11

POWER STEERING GEAR AND LINKAGE
●

Install lock nut and the outer socket to the inner socket and
tighten lock nut until the length of the tie-rod is within the standard (length before toe-in adjustment.)
Length of tie-rod (L)

: 57.8 mm (2.28 in)

CAUTION:
Perform toe-in adjustment after this procedure. Length
achieved after toe-in adjustment is not necessarily the
value given here.
SGIA0195J

PS-12

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Wheel

PFP:00030

A
BGS0001X

Steering wheel axial end play

0 mm (0 in)

Steering wheel free play

B

0 — 35 mm (0 — 138 in)

Steering Angle

BGS0001Y

38°

Inner wheel

C

+1°
-3°

Outer wheel

33°

D

Steering Column

BGS0001Z

Steering column length L

464 mm (18.3 in)

E

F

PS

H
SGIA1016J

Steering Linkage

Tie-rod ball joint outer
socket

BGS00020

Steering gear type

R24T

Tensile force

0.3 — 2.9 N·m (0.03 — 0.29 kg-m, 3 — 25 in-lb)

Spring balance measurement
(Upper edge of stud bolt)

Tie-rod ball joint inner
socket

J

5 — 54 N (0.51 — 5.5 kg, 1.1 — 12.1 lb)

Axial end play

No Free Play

Tensile force

I

K

0.5 — 5.0 N·m (0.05 — 0.51 kg-m, 5 — 44 in-lb)

Spring Balance measurement (measured
at * mark)

4 — 43 N (0.41 — 4.4 kg, 0.9 — 9.7 lb)

Axial end play

L

No Free Play

Tie-rod length L

57.8 mm (2.28 in)

M

STC1006D

PS-13

SERVICE DATA AND SPECIFICATIONS (SDS)
Tightening Torque

BGS00021

Unit: N·m (kg-m, ft-lb)
Steering wheel bolt

34.5 (3.5, 25)

Steering column to intermediate shaft to Steering gear

29.5 (3.0, 22)

Steering gear to Suspension member

94 (9.6, 69)

Outer socket to Steering knuckle

34.3 (3.5, 25)

Tie-rod outer socket lock nut

41.7 (4.3, 31)

PS-14

POWER SUPPLY, GROUND & CIRCUIT ELEMENTS

K ELECTRICAL

SECTION

PG

POWER SUPPLY, GROUND & CIRCUIT ELEMENTS

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 3
Maintenance Information …………………………………… 3
RHD MODELS ……………………………………………… 3
LHD MODELS ………………………………………………. 3
POWER SUPPLY ROUTING CIRCUIT …………………. 4
Schematic ………………………………………………………. 4
Wiring Diagram — POWER — …………………………… 5
BATTERY POWER SUPPLY — IGNITION SW.
IN ANY POSITION ………………………………………… 5
ACCESSORY POWER SUPPLY — IGNITION
SW. IN “ACC” OR “ON” ………………………………….11
IGNITION POWER SUPPLY — IGNITION SW.
IN “ON” AND/OR “START” ……………………………. 12
Fuse …………………………………………………………….. 17
Fusible Link …………………………………………………… 17
Circuit Breaker ………………………………………………. 17
IPDM E/R (INTELLIGENT POWER DISTRIBUTION
MODULE ENGINE ROOM) ……………………………….. 18
System Description ………………………………………… 18
SYSTEMS CONTROLLED BY IPDM E/R ……….. 18
CAN COMMUNICATION LINE CONTROL ……… 18
IPDM E/R STATUS CONTROL ……………………… 18
CAN Communication System Description ………….. 19
CAN Communication Unit ……………………………….. 19
Function of Detecting Ignition Relay Malfunction … 19
CONSULT-II Function (IPDM E/R) ……………………. 20
CONSULT-II BASIC OPERATION ………………….. 20
SELF-DIAG RESULTS …………………………………. 20
DATA MONITOR …………………………………………. 20
CAN DIAG SUPPORT MNTR ……………………….. 21
ACTIVE TEST …………………………………………….. 21
Auto Active Test …………………………………………….. 22
DESCRIPTION ……………………………………………. 22
OPERATION PROCEDURE …………………………. 22
INSPECTION IN AUTO ACTIVE TEST MODE… 23
Configuration …………………………………………………. 25
DESCRIPTION ……………………………………………. 25

READ CONFIGURATION PROCEDURE ………… 25
WRITE CONFIGURATION PROCEDURE ………. 27
Schematic ……………………………………………………… 31
IPDM E/R Terminal Arrangement ……………………… 32
Inspection With CONSULT-II (Self-Diagnosis) ……. 33
IPDM E/R Terminal Inspection ………………………….. 34
Check IPDM E/R Power Supply and Ground Circuit… 34
Diagnosis of IPDM E/R Integrated Relay …………… 36
Removal and Installation of IPDM E/R ………………. 37
REMOVAL ………………………………………………….. 37
INSTALLATION …………………………………………… 37
GROUND …………………………………………………………. 38
Ground Distribution …………………………………………. 38
MAIN HARNESS …………………………………………. 38
ENGINE ROOM HARNESS ………………………….. 41
ENGINE CONTROL HARNESS/CR AND HR
ENGINE MODELS ………………………………………. 45
BODY HARNESS ………………………………………… 46
HARNESS ……………………………………………………….. 48
Harness Layout ……………………………………………… 48
HOW TO READ HARNESS LAYOUT …………….. 48
HARNESS OUTLINE/CR AND HR ENGINE
MODELS ……………………………………………………. 49
HARNESS OUTLINE/K9K ENGINE MODELS … 50
MAIN HARNESS/LHD MODELS ……………………. 51
MAIN HARNESS/RHD MODELS …………………… 53
ENGINE ROOM HARNESS/CR ENGINE MODELS ……………………………………………………………. 55
ENGINE ROOM HARNESS/HR ENGINE MODELS ……………………………………………………………. 57
ENGINE ROOM HARNESS/K9K ENGINE MODELS ……………………………………………………………. 59
ENGINE CONTROL HARNESS/CR ENGINE
MODELS ……………………………………………………. 61
ENGINE CONTROL HARNESS/HR ENGINE
MODELS ……………………………………………………. 63
ENGINE CONTROL HARNESS/K9K ENGINE
MODELS ……………………………………………………. 65
BODY HARNESS (RH SIDE) ………………………… 67
BODY HARNESS (LH SIDE) ………………………… 69

PG-1

E

F

G

H

I

J

PG

L

M

ROOM LAMP HARNESS ……………………………… 71
FRONT DOOR HARNESS LH SIDE/LHD MODELS ……………………………………………………………. 72
FRONT DOOR HARNESS LH SIDE/RHD MODELS ……………………………………………………………. 73
FRONT DOOR HARNESS RH SIDE/LHD MODELS ……………………………………………………………. 74
FRONT DOOR HARNESS RH SIDE/RHD MODELS ……………………………………………………………. 75
REAR DOOR HARNESS LH SIDE ………………… 76
REAR DOOR HARNESS RH SIDE ………………… 77
BACK DOOR HARNESS ………………………………. 78
Wiring Diagram Codes (Cell Codes) ………………….. 79
ELECTRICAL UNITS LOCATION ……………………….. 82
Electrical Units Location ………………………………….. 82
ENGINE COMPARTMENT ……………………………. 82
PASSENGER COMPARTMENT/LHD MODELS… 84
PASSENGER COMPARTMENT/RHD MODELS… 86

HARNESS CONNECTOR …………………………………..88
Description ……………………………………………………..88
HARNESS CONNECTOR (TAB-LOCKING
TYPE) …………………………………………………………88
HARNESS CONNECTOR (SLIDE-LOCKING
TYPE) …………………………………………………………89
ELECTRICAL UNITS …………………………………………90
Terminal Arrangement ………………………………………90
SMJ (SUPER MULTIPLE JUNCTION) ………………….92
Terminal Arrangement ………………………………………92
STANDARDIZED RELAY ……………………………………93
Description ……………………………………………………..93
NORMAL OPEN, NORMAL CLOSED AND
MIXED TYPE RELAYS ………………………………….93
TYPE OF STANDARDIZED RELAYS ………………93
FUSE BLOCK ……………………………………………………95
Terminal Arrangement ………………………………………95
FUSE, FUSIBLE LINK AND RELAY BOX …………….96
Terminal Arrangement ………………………………………96

PG-2

PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

A

BKS00268

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Maintenance Information

B

C

D

E

F

BKS00269

If any of following part is replaced, always replace with new* one.
If it’s not (or fail to do so), the electrical system may not be operated properly.
*: New one means a virgin control unit that has never been energized on-board.

G

RHD MODELS

H

●
●
●
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM
IPDM E/R
Combination meter
EPS control unit

I

J

LHD MODELS
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM

PG

L

M

PG-3

POWER SUPPLY ROUTING CIRCUIT
POWER SUPPLY ROUTING CIRCUIT
Schematic

PFP:24110
BKS0025I

MKWA4392E

PG-4

POWER SUPPLY ROUTING CIRCUIT
Wiring Diagram — POWER —

BKS0025J

A

BATTERY POWER SUPPLY — IGNITION SW. IN ANY POSITION

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4393E

PG-5

POWER SUPPLY ROUTING CIRCUIT

MKWA4394E

PG-6

POWER SUPPLY ROUTING CIRCUIT
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4395E

PG-7

POWER SUPPLY ROUTING CIRCUIT

MKWA4396E

PG-8

POWER SUPPLY ROUTING CIRCUIT
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4397E

PG-9

POWER SUPPLY ROUTING CIRCUIT

MKWA4398E

PG-10

POWER SUPPLY ROUTING CIRCUIT
ACCESSORY POWER SUPPLY — IGNITION SW. IN “ACC” OR “ON”
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4399E

PG-11

POWER SUPPLY ROUTING CIRCUIT
IGNITION POWER SUPPLY — IGNITION SW. IN “ON” AND/OR “START”

MKWA4400E

PG-12

POWER SUPPLY ROUTING CIRCUIT
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4401E

PG-13

POWER SUPPLY ROUTING CIRCUIT

MKWA4402E

PG-14

POWER SUPPLY ROUTING CIRCUIT
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4403E

PG-15

POWER SUPPLY ROUTING CIRCUIT

MKWA4404E

PG-16

POWER SUPPLY ROUTING CIRCUIT
Fuse
●

●

●

●

BKS0025K

A

If fuse is blown, be sure to eliminate cause of malfunction before
installing new fuse.
Use fuse of specified rating. Never use fuse of more than specified rating.
Do not partially install fuse; always insert it into fuse holder properly.
Remove fuse for “ELECTRICAL PARTS (BAT)” if vehicle is not
used for a long period of time.

B

C

D
CEL083

Fusible Link

BKS0025L

A melted fusible link can be detected either by visual inspection or by
feeling with finger tip. If its condition is questionable, use circuit
tester or test lamp.
CAUTION:
●
If fusible link should melt, it is possible that critical circuit
(power supply or large current carrying circuit) is shorted.
In such a case, carefully check and eliminate cause of malfunction.
●
Never wrap outside of fusible link with vinyl tape. Important:
Never let fusible link touch any other wiring harness, vinyl
or rubber parts.

Circuit Breaker

E

F

G

H
CKIT0163E

BKS0025M

I

The PTC thermistor generates heat in response to current flow. The
temperature (and resistance) of the thermistor element varies with
current flow. Excessive current flow will cause the element’s temperature to rise. When the temperature reaches a specified level, the
electrical resistance will rise sharply to control the circuit current.
Reduced current flow will cause the element to cool. Resistance falls
accordingly and normal circuit current flow is allowed to resume.

J

PG

L
SEL109W

M

PG-17

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
PFP:284B7

System Description

BKS0025N

IPDM E/R (Intelligent Power Distribution Module Engine Room) integrates the relay box and fuse block
which were originally placed in engine compartment. It controls integrated relay via IPDM E/R control circuit.
●
IPDM E/R-integrated control circuit performs ON-OFF operation of relay, CAN communication control and
oil pressure switch signal reception, etc.
●
It controls operation of each electrical part via ECM, BCM and CAN communication lines.
CAUTION:
None of the IPDM E/R-integrated relays can be removed.
●

SYSTEMS CONTROLLED BY IPDM E/R
IPDM E/R receives a request signal from each Control unit with CAN communication. It controls each system.
Control system

Transmit control unit

Control part
●

Head lamps (HI,LO)

●

Tail lamps, parking and license plate lamps

●

Front fog lamps

BCM

●

Front wipers

Headlamp washer control

BCM

●

Headlamp washer

Rear window defogger control

BCM

●

Rear window defogger

A/C compressor control

ECM

●

A/C compressor

Cooling fan control

ECM

●

Cooling fan

Lamp control

BCM

Wiper control

CAN COMMUNICATION LINE CONTROL
With CAN communication, by connecting each control unit using two communication lines (CAN L-line, CAN
H-line), it is possible to transmit maximum amount of information with minimum wiring. Each control unit can
transmit and receive data, and reads necessary information only.

Fail-safe Control
●

●

When CAN communication with other control units is impossible, IPDM E/R performs fail-safe control.
After CAN communication recovers normally, it also returns to normal control.
Operation of control parts by IPDM E/R during fail-safe mode is as follows:
Controlled system

Fail-safe mode
●

With the ignition switch ON, the headlamp low is ON.

●

With the ignition switch OFF, the headlamp low is OFF.

●

With the ignition switch ON, the tail lamp is ON.

●

With the ignition switch OFF, the tail lamp is OFF.

●

With the ignition switch ON, the cooling fan HI operates.

●

With the ignition switch OFF, the cooling fan stops.

Headlamps
Tail, parking and
license plate lamps
Cooling fan
Front wiper

Until the ignition switch is turned off, the front wiper LO and HI remains in the same status it was in just
before fail−safe control was initiated.

Rear window defogger

Rear window defogger OFF

Front fog lamps

Front fog lamp OFF

Headlamp washer

Headlamp washer is OFF

A/C compressor

A/C compressor OFF

IPDM E/R STATUS CONTROL
In order to save power, IPDM E/R switches status by itself based on each operating condition.
1. CAN communication status
● CAN communication is normally performed with other control units.
● Individual unit control by IPDM E/R is normally performed.

PG-18

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
A status is changed into sleep transient status when receiving a sleep request signal from BCM while
all the systems controlled by IPDM E/R are under suspension.
Sleep transient status
● Process to stop CAN communication is activated.
● All systems controlled by IPDM E/R are stopped, when 3 seconds have elapsed after CAN communication with other control units is stopped, mode switches to sleep status.
Sleep status
● IPDM E/R operates in low power mode.
● CAN communication is stopped.
● When a change in CAN communication line is detected, mode switches to CAN communication status.
● When a change in ignition switch signal is detected, mode switches to CAN communication status.
●

2.

3.

CAN Communication System Description

A

B

C

D

BKS0025O

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Modern
vehicles are equipped with many electronic control units and each control unit shares information and links
with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission
with less wiring. Each control unit transmits/receives data but selectively reads required data only.

E

CAN Communication Unit

BKS0025P

G

BKS0027F

H

F

Refer to LAN-27, «CAN Communication Unit» .

Function of Detecting Ignition Relay Malfunction
●

●

When integrated ignition relay cannot be turned OFF and ignition switch is turned OFF, IPDM E/R turns
ON tail and parking lamps for 10 minutes. The lamps indicate ignition relay malfunction.
When a state of ignition relay having built-in does not agree with a state of Ignition switch signal input by a
CAN communication from BCM, IPDM E/R lets tail lamp relay operate.
Ignition switch signal

Ignition relay status

Tail lamp relay

ON

ON

—

OFF

OFF

—

ON

OFF

—

OFF

ON

ON (10 minutes)

NOTE:
When the ignition switch is turned ON, the tail lamps are OFF.

I

J

PG

L

M

PG-19

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
CONSULT-II Function (IPDM E/R)

BKS0025R

CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.
Inspection Item, Diagnosis Mode

Description

SELF-DIAG RESULTS

The IPDM E/R performs diagnosis of CAN communication and self-diagnosis.

DATA MONITOR

The input/output data of the IPDM E/R is displayed in real time.

CAN DIAG SUPPORT MNTR

The result of transmit/receive diagnosis of CAN communication can be read.

ACTIVE TEST

The IPDM E/R sends a drive signal to electronic components to check their operation.

CONFIGURATION

Performs IPDM E/R configuration read/write functions.

CONSULT-II BASIC OPERATION
Refer to GI-36, «CONSULT-II Start Procedure» .

SELF-DIAG RESULTS
Operation Procedure
1.
2.

Touch “SELF-DIAG RESULTS” on “SELECT DIAG MODE” screen.
Check display content in self-diagnostic results.

Display Item List
Display Items

CONSULT-II display code

Malfunction detecting condition

—

—

NO DTC IS
DETECTED.FURTHER TESTING
MAY BE
REQUIRED.

●

CAN COMM CIRC

U1000
●

If CAN communication reception/transmission
data has a malfunction, or if any of the control
units malfunction, data reception/transmission
cannot be confirmed.

TIME

Possible causes

CRNT

PAST

—

—

—

Any of or the items
below have errors.
×

×

When the data in CAN communication is not
received before the specified time

●

TRANSMIT DIAG

●

ECM

●

BCM

IGN RELAY ON

B2098

Where the ignition switch is not ON position, the
ignition relay in the IPDM E/R is ON.

×

×

Ignition relay (integrated in IPDM E/R)

IGN RELAY OFF

B2099

Where the ignition switch is ON position, the ignition relay in the IPDM E/R is OFF.

×

×

Ignition relay (integrated in IPDM E/R)

EEPROM

B2100

Malfunction is detected with the integrated
EEPROM memory diagnosis.

×

×

IPDM E/R

NOTE:

The details for display of the period are as follows:
●

CRNT: Error currently detected with IPDM E/R.

●

PAST: Error detected in the past and memorized with IPDM E/R.

DATA MONITOR
Operation Procedure
1.
2.

Touch “DATA MONITOR” on “SELECT MONITOR ITEM ” screen.
Touch “ALL SIGNALS”, “MAIN SIGNALS” or “SELECTION FROM MENU” on the “DATA MONITOR”
screen.

ALL SIGNALS

All items will be monitored.

MAIN SIGNALS

Monitor the predetermined item.

SELECTION FROM MENU

Select any item for monitoring.

3.

Touch the required monitoring item on “SELECTION FROM MENU”. In “ALL SIGNALS”, all items are
monitored. In “MAIN SIGNALS”, predetermined items are monitored.

PG-20

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
4.
5.

Touch “START”.
Touch “RECORD” while monitoring to record the status of the item being monitored. To stop recording,
touch “STOP”.

All Signals, Main Signals, Selection From Menu

A

B
Monitor item selection

Item name

CONSULT-II
screen display

Display or unit

ALL
SIGNALS

MAIN
SIGNALS

SELECTION
FROM
MENU

Description

C

Motor fan request

MOTOR FAN REQ

1/2/3/4

×

×

×

Signal status input from ECM

A/C Compressor
request

AC COMP REQ

ON/OFF

×

×

×

Signal status input from ECM

Tail & clearance
request

TAIL&CLR REQ

ON/OFF

×

×

×

Signal status input from BCM

Headlamp LO
request

HL LO REQ

ON/OFF

×

×

×

Signal status input from BCM

Headlamp HI
request

HL HI REQ

ON/OFF

×

×

×

Signal status input from BCM

Front fog lamp
request

FR FOG REQ

ON/OFF

×

×

×

Signal status input from BCM

Headlamp washer
request

HL WASHER REQ

ON/OFF

×

×

This item cannot be monitored.
(No change of display)

Front wiper request

FR WIP REQ

STOP/1LOW/
LOW/HI

×

×

×

Signal status input from BCM

Wiper auto stop

WIP AUTO STOP

ACT P/STOP P

×

×

×

Output status of IPDM E/R

Wiper protection

WIP PROT

OFF/BLOCK

×

×

×

Control status of IPDM E/R

Starter request

ST RLY REQ*

ON/OFF

×

×

Signal status input from BCM

Ignition relay status

IGN RLY

ON/OFF

×

×

×

Ignition relay status monitored
with IPDM E/R

Rear window defogger request

RR DEF REQ

ON/OFF

×

×

×

Signal status input from BCM

Rear window defogger stop request

DEF STOP REQ

ON/OFF

×

×

Input signal status

Alternator load

ALT LOAD

%

×

×

Alternator current

ALT CRNT

A

×

×

Alternator number

ALT NO

##

×

×

Battery voltage

BAT VOLT

V

×

×

Value measured with IPDM E/R

Engine coolant temperature

ENG COOL TEMP

°C

×

×

Signal status input from ECM

Oil pressure switch

OIL P SW

OPEN/CLOSE

×

×

Signal status input in IPDM E/R

Reverse switch

REV SW

OPEN/CLOSE

×

×

Signal status input in IPDM E/R

E

This item cannot be monitored
(No change of display)

NOTE:
● Perform monitoring of IPDM E/R data with the ignition switch ON. When the ignition switch is at ACC, the display may not be correct.
●

*: The vehicle without Intelligent Key system displays only ON without change.

CAN DIAG SUPPORT MNTR
Refer to LAN-15, «CAN Diagnostic Support Monitor» .

ACTIVE TEST
Operation Procedure
1.
2.
3.

D

Touch “ACTIVE TEST” on “SELECT DIAG MODE” screen.
Touch item to be tested.
Touch “START”, and confirm its operation.

PG-21

F

G

H

I

J

PG

L

M

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
4.

Touch “STOP” while testing to stop the operation.
Test item

CONSULT-II screen display

Description

Headlamp (HI, LO) output

HEAD LAMP

With a certain operation (OFF, HI ON, LO ON), the headlamp relay (Lo,
Hi) can be operated.

Front fog lamp output

FRONT FOG LAMP

With a certain ON-OFF operation, the fog lamp relay can be operated.

Tail lamp output

TAIL LAMP

With a certain ON-OFF operation, the tail lamp relay can be operated.

Rear window defogger operation

REAR DEFOGGER

With a certain ON-OFF operation, the rear window defogger relay can
be operated.

Front wiper (HI, LO) operation

FRONT WIPER

With a certain operation (OFF, HI ON, LO ON), the front wiper relay
(Lo, Hi) can be operated.

Cooling fan operation

MOTOR FAN

With a certain operation (1, 2, 3, 4), the cooling fan can be operated.

HEAD LAMP WASHER

With a certain ON-OFF operation, the headlamp washer can be operated.

Headlamp washer output

Auto Active Test

BKS0025S

DESCRIPTION
In auto active test mode, operation inspection can be performed when IPDM E/R sends a drive signal to the
following systems:
●
Rear window defogger
●
Front wiper (LO, HI)
●
Tail lamps, parking lamps, license plate lamps
●
Front fog lamps
●
Headlamps (LO, HI)
●
Headlamp washer
●
A/C compressor (magnetic clutch)
●
Cooling fan

OPERATION PROCEDURE
1.

2.
3.
4.
5.
6.

Close hood and front door (passenger side), and then lift wiper arms away from windshield (to prevent
glass damage by wiper operation).
NOTE:
When auto active test is performed with hood opened, sprinkle water on windshield beforehand.
Turn ignition switch OFF.
Turn ignition switch ON, and within 20 seconds, press driver’s door switch 10 times (close other doors).
Then turn ignition switch OFF.
Turn ignition switch ON within 10 seconds after ignition switch OFF.
When auto active test mode is actuated, horn chirps once. Oil pressure warning lamp starts blinking.
After a series of operations is repeated three times, auto active test is completed.
NOTE:
When auto active test mode has to be cancelled halfway, turn ignition switch OFF.
CAUTION:
Be sure to inspect BL-46, «Check Door Switch» when the auto active test cannot be performed.

PG-22

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
INSPECTION IN AUTO ACTIVE TEST MODE
A

When auto active test mode is actuated, the following nine steps are repeated three times.

B

C

D

E

F

MKIB2316E

G

(A): Oil pressure warning lamp is blinking when the auto active test operating.
Operation steps
Step

H
Test item

Operation time/ frequency

1

Rear window defogger

10 seconds

2

Front wiper

LO 5 seconds → HI 5 seconds

3

Tail lamps, parking lamps, license plate lamps

10 seconds

4

Front fog lamps

10 seconds

5

Headlamp (LO)

10 seconds

6

Headlamp (HI)

LO←→HI repeats every 2 seconds, 5 times

7

Headlamp washer

Left 1 seconds → Right 1 second

8

A/C compressor (magnetic clutch)

ON←→OFF repeat every 2 seconds, 5 times

9

Cooling fan

LO 5 seconds → HI 5 seconds (Petrol engine models with air conditioner and diesel engine models)
LO 10 seconds (Petrol engine models without air conditioner)

Concept of Auto Active Test
●

●

I

J

PG

L

M

IPDM E/R actuates auto active test mode when it receives door switch signal from BCM via CAN communication line. Therefore, when auto active test mode is activated successfully, CAN communication
between IPDM E/R and BCM is normal.
If any of systems controlled by IPDM E/R cannot be operated, possible cause can be easily diagnosed
using auto active test.

PG-23

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
Diagnosis Chart in Auto Active Test Mode
Symptom

Inspection contents

Rear window defogger does not operate.

Perform auto active
test. Does rear window defogger operate?

Front wiper does not
illuminate.

Either of parking
lamp, license plate
lamp and tail lamp
does not illuminate.

Front fog lamp does
not illuminate.

Perform auto active
test. Does rear window defogger operate?
Perform auto active
test. Does parking
lamp, license plate
lamp and tail lamp
illuminate?
Perform auto active
test. Does the front
fog lamp illuminate?

Possible cause
YES

NO

YES
NO
YES

NO

YES

NO

YES
Headlamp (Hi, Lo)
does not illuminate.

Headlamp washer
does not operate.

Perform auto active
test. Does
headlamp illuminate?
Perform auto active
test. Does the
headlamp washer
operate?

●

BCM signal input circuit malfunction

●

Harness/connector malfunction between IPDM E/R and rear window defogger

●

Open circuit of rear window defogger

●

IPDM E/R (integrated relay) malfunction (Rear window defogger relay)

●

BCM signal input circuit malfunction

●

Wiper motor malfunction

●

Front wiper motor ground.

●

BCM signal input circuit malfunction

●

Bulb

●

Harness/connector malfunction between IPDM E/R and parking, license plate
or tail lamp.

●

IPDM E/R (integrated relay) malfunction

●

BCM signal input circuit malfunction

●

Bulb

●

Harness/connector malfunction between IPDM E/R and front fog lamp

●

IPDM E/R (integrated relay) malfunction

●

BCM signal input circuit malfunction

●

Bulb

●

Headlamp ground system malfunction

●

Harness/connector malfunction between IPDM E/R and headlamps

●

IPDM E/R (integrated relay) malfunction (headlamp relay)

●

BCM signal input circuit malfunction

●

Harness/connector malfunction between IPDM E/R and headlamp washer

●

Headlamp washer relay is malfunction

●

CAN communication signal malfunction between ECM and IPDM E/R*

●

ECM signal input circuit malfunction

●

Cooling fan motor malfunction

●

Harness/connector malfunction between cooling fan motor and IPDM E/R

●

IPDM E/R (integrated relay) malfunction

●

CAN communication signal malfunction between BCM and ECM*

●

CAN communication signal malfunction between ECM and IPDM E/R*

●

BCM signal input circuit malfunction

●

ECM signal input circuit malfunction

●

Magnetic clutch inoperative

●

Harness/connector malfunction between IPDM E/R and magnetic clutch

●

IPDM E/R (integrated relay) malfunction

●

Harness/connector malfunction between IPDM E/R and oil pressure switch

●

Oil pressure switch malfunction

●

IPDM E/R malfunction

●

CAN communication signal malfunction between IPDM E/R and combination
meter *

●

Combination meter malfunction

NO

YES
NO

YES
Cooling fan does not
operate.

Perform auto active
test. Does magnetic
clutch operate?

NO

YES
A/C compressor is
inoperative.

Perform auto active
test. Does magnetic
clutch operate?
NO

Oil pressure warning
lamp does not operate.

Perform auto active
test. Does oil pressure warning lamp
blink?

YES

NO

*: Perform IPDM E/R self-diagnosis with CONSULT-II. Refer to PG-33, «Inspection With CONSULT-II (Self-Diagnosis)» .

PG-24

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
Configuration

BKS0026I

A

DESCRIPTION
There are two CONFIGURATION functions, as follows.
READ CONFIGURATION is a function for confirming the vehicle configuration written on IPDM E/R.
WRITE CONFIGURATION is a function for writing a vehicle configuration to IPDM E/R.
CAUTION:
●
When replacing IPDM E/R, completely perform WRITE CONFIGURATION with CONSULT-II.
●
Orderly complete the procedure of WRITE CONFIGURATION.
●
If you set incorrect WRITE CONFIGURATION, vehicle operation will not be correct.
●
Configuration is different by each vehicle model, confirm configuration in each case.

B

C

D

READ CONFIGURATION PROCEDURE
CAUTION:
If CONSULT-II is used with no connection of CONSULT CONVERTER, malfunctions might be detected
in self-diagnosis depending on control unit which carry out CAN communication.
1. With the ignition switch OFF, connect CONSULT-II and CONSULT-II CONVERTER to the data link connector, then turn the
ignition switch ON.

E

F

G

H
PAIA0070E

2.

I

Touch “START(NISSAN BASED VHCL)”.

J

PG

BCIA0029E

3.

Touch “IPDM E/R” on “SELECT SYSTEM” screen.
If “IPDM E/R” is not indicated, go to GI-38, «CONSULT-II Data
Link Connector (DLC) Circuit» .

M

BCIA0030E

PG-25

L

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
4.

Touch “CONFIGURATION” on “SELECT DIAG MODE” screen.

MKIB2361E

5.

Touch “K12”, and “OK” on “VEHICLE SELECT” screen.
For canceling, touch “CANCEL” on “VEHICLE SELECT” screen.
NOTE:
Confirm vehicle model on IDENTICATION PLATE, refer to GI
section.

MKIB2358E

6.

Touch “READ CONFIGURATION” on “SELECT CONFIG ITEM”
screen.

MKIB2362E

7.

Configuration of current IPDM E/R are printed out automatically.
Configuration of brand-new IPDM E/R before executing “WRITE
CONFIGURATION” is as follows.
MANUAL SET ITEM
Items

Setting Value

ALT TYPE

TYPE 1

AUTO SET ITEM
Items

Setting Value

STARTER MODE

MODE 1

MKIB2363E

PG-26

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
8.

Touch “BACK” on “ READ CONFIGURATION“screen.
A

B

C
MKIB0761E

D

WRITE CONFIGURATION PROCEDURE
CAUTION:
If CONSULT-II is used with no connection of CONSULT CONVERTER, malfunctions might be detected
in self-diagnosis depending on control unit which carry out CAN communication.
1. With the ignition switch OFF, connect CONSULT-II and CONSULT-II CONVERTER to the data link connector, then turn the
ignition switch ON.

E

F

G

H
PAIA0070E

2.

I

Touch “START(NISSAN BASED VHCL)”.

J

PG

BCIA0029E

3.

Touch “IPDM E/R” on “SELECT SYSTEM” screen.
If “IPDM E/R” is not indicated, go to GI-38, «CONSULT-II Data
Link Connector (DLC) Circuit» .

M

BCIA0030E

PG-27

L

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
4.

Touch “CONFIGURATION” on “SELECT DIAG MODE” screen.

MKIB2361E

5.

Touch “K12”, and “OK” on “VEHICLE SELECT” screen.
For canceling, touch “CANCEL” on “VEHICLE SELECT” screen.
NOTE:
Confirm vehicle model on IDENTICATION PLATE, refer to GI
section.

MKIB2358E

6.

Touch “WRITE CONFIGURATION” on “SELECT CONFIG
ITEM“screen.

MKIB2362E

7.

Touch “YES”.
For canceling, touch “NO”.

MKIB0762E

PG-28

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
8.

Touch “TYPE 1”, “TYPE 2” or “TYPE 3” on “WRITE CONFIGURATION”screen based on the following ITEM LIST.

A

< ITEM LIST>
ITEM

Alternator type

SET VAL

NOTE

B

TYPE 1

Petrol engine models

TYPE 2

Diesel engine models without PTC heater*

TYPE 3

Diesel engine models with PTC heater*

*: Models with PTC heater have PTC heater relays. Refer to Harness Layout,
PG-59, «ENGINE ROOM HARNESS/K9K ENGINE MODELS» , to confirm
whether PTC heater relays are equipped or not.

C
MKIB0763E

D

9.

For canceling, touch “CANCEL”.
Touch “CHNG SETTING” on “WRITE CONFIGURATION“screen.
CAUTION:
Make sure to touch “CHNG SETTING even if the indicated configuration of brand new IPDM E/R is
same as the desirable configuration.
If not, configuration which is set automatically by selecting vehicle model can not be memorized.

E

F

10. Touch “OK” on “WRITE CONFIGURATION”screen.
When touched “CANCEL”, go to previous screen.
G

H

I
MKIB0764E

11. Wait until the next screen during setting.

J

PG

L

MKIB0765E

PG-29

M

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
12. WRITE CONFIGURATION results are printed out automatically.
Check “WRITE CONFIGURATION” is correctly executed by
comparing sheet automatically printed out with desirable configuration.

MKIB2364E

13. Touch “OK” on “WRITE CONFIGURATION“screen.
WRITE CONFIGURATION is completed.

MKIB0767E

PG-30

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
Schematic

BKS0025T

A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4405E

PG-31

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
IPDM E/R Terminal Arrangement

BKS0025U

MKWA4445E

PG-32

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
Inspection With CONSULT-II (Self-Diagnosis)

BKS0025W

1. CHECK SELF DIAGNOSTIC RESULT

A

1.
2.
3.

B

Connect CONSULT-II and select “IPDM E/R” on the “SELECT SYSTEM” screen.
Select “SELF-DIAG RESULTS” on the “SELECT DIAG MODE” screen.
Check display content in self diagnostic results.
CONSULT-II display

NO DTC IS DETECTED.
FURTHER TESTING MAY BE REQUIRED.

TIME

CONSULT-II
display code

CRNT

PAST

—

—

—

Details of diagnosis result

C

No malfunction

D
Any of or several items below have errors.

CAN COM CIRC

U1000

×

×

●

TRANSMIT

●

RECEIVE (ECM)

●

RECEIVE (BCM)

IGN RELAY ON

B2098

×

×

Ignition relay malfunction (integrated in IPDM E/R)

IGN RELAY OFF

B2099

×

×

Ignition relay malfunction (integrated in IPDM E/R)

EEPROM

B2100

×

×

IPDM E/R malfunction

E

F

CAUTION:
G
If errors of the CAN communication system and the ignition relay ON or OFF are displayed at the
same time after the self-diagnostic result, replace the IPDM E/R and perform the self-diagnosis
again.
H
NOTE:
The details for display of the period are as follows:
● CRNT: Error currently detected with IPDM E/R.
I
● PAST: Error detected in the past and memorized with IPDM E/R.
Contents displayed
NO DTC IS DETECTED.FURTHER TESTING MAY BE REQUIRED.>>INSPECTION END
J
CAN COMM CIRC>>After print-out of the monitor items, refer to LAN-3, «Precautions When Using CONSULT-II» .
IGN RELAY ON>>Replace IPDM E/R.
PG
IGN RELAY OFF>>Replace IPDM E/R.
EEPROM>>Replace IPDM E/R.
L

M

PG-33

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
IPDM E/R Terminal Inspection

BKS0026O

CAUTION:
This is performed when the IPDM E/R is checked without removing the battery.
1. Remove the headlamp (LH). Refer to LT-32, «Removal and Installation» (Conventional type),LT-51,
«Removal and Installation» (Daytime light system).
2. Remove tabs of the IPDM E/R and place the IPDM E/R with its
connector facing upward. Check each terminal.

SKIA2151E

SKIA2152E

Check IPDM E/R Power Supply and Ground Circuit

BKS0025V

1. CHECK FUSE AND FUSIBLE LINK
Make sure that the following fusible links or IPDM E/R fuses are not blown.
Terminal No.

Power source

Fuse, fusible link No.

1

Battery

Letter C

2

Battery

Letter D

40

Ignition switch (ON)

5

OK or NG
OK
>> GO TO 2.
NG
>> Replace fuse or fusible link.

PG-34

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)

2. CHECK POWER SUPPLY CIRCUIT
1.
2.

A

Disconnect IPDM E/R harness connector.
Check voltage between IPDM E/R and ground.
B
Terminals

Ignition switch position

(+)
Connector

OFF

ACC

ON

C

1 (R)

Battery
voltage

Battery
voltage

Battery
voltage

D

2 (G)

Battery
voltage

Battery
voltage

Battery
voltage

0V

Battery
voltage

Terminal
(wire color)

(-)

E9
Ground

MKIB0534E

E7

40
(O)

0V

E

OK or NG
OK
>> GO TO 3.
NG
>> Check harness between fuse, fusible link and IPDM E/R.

F

3. CHECK GROUND CIRCUIT
1.
2.

G

Disconnect IPDM E/R harness connectors.
Check continuity between IPDM E/R harness connectors E11
terminal 3 (B), E12 terminal 54 (B) and ground.
3 (B) – Ground
54 (B) – Ground

H

:Continuity should exist.
:Continuity should exist.

I

OK or NG
OK
>> INSPECTION END.
NG
>> Repair harness for ground circuit.

J

MKIB1920E

PG

L

M

PG-35

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)
Diagnosis of IPDM E/R Integrated Relay

BKS0026P

1. CHECK SYMPTOM
Check the symptom of the malfunction relay.
What is the symptom?
No operation>>GO TO 2.
No stop>> GO TO 4.

2. CHECK RELAY TYPE
Which is the relay with error?
Front fog lamp relay, headlamp relay (Hi, Lo), tail lamp relay, front wiper relay (main, Hi/Lo), rear window
defogger relay, A/C relay, starter motor relay, cooling fan relay (Hi, Lo)>>GO TO 5.
Ignition relay>> Go to PG-33, «Inspection With CONSULT-II (Self-Diagnosis)»
ECM relay>>Go to EC-128, «POWER SUPPLY AND GROUND CIRCUIT» (CR engine models with EUROOBD), EC-543, «POWER SUPPLY AND GROUND CIRCUIT» (CR engine models without EUROOBD), EC-918, «POWER SUPPLY AND GROUND CIRCUIT» (HR engine models with EUROOBD), EC-1337, «POWER SUPPLY AND GROUND CIRCUIT» (HR engine models without
EURO-OBD) or EC-1698, «POWER SUPPLY AND GROUND CIRCUIT» (K9K engine models).
Throttle motor relay>>Go to EC-299, «DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY» (CR
engine models with EURO-OBD), EC-643, «DTC P1124, P1126 THROTTLE CONTROL MOTOR
RELAY» (CR engine models without EURO-OBD), EC-1090, «DTC P1124, P1126 THROTTLE
CONTROL MOTOR RELAY» (HR engine models with EURO-OBD) or EC-1439, «DTC P1124,
P1126 THROTTLE CONTROL MOTOR RELAY» (HR engine models without EURO-OBD).
Fuel pump relay>>Go to EC-427, «FUEL PUMP» (CR engine models with EURO-OBD), EC-750, «FUEL
PUMP» (CR engine models without EURO-OBD), EC-1215, «FUEL PUMP» (HR engine models
with EURO-OBD) or EC-1543, «FUEL PUMP» .(HR engine models without EURO-OBD).

3. CHECK RELAY
Send an operation signal to the relay using a diagnosis tool. Check the voltage at the input and output terminals of inoperative relays according to the table below or check for continuity between input and output terminals. Refer to PG-21, «ACTIVE TEST» or PG-22, «Auto Active Test» .
IPDM E/R terminal number
Relay name

Diagnosis tool
Voltage [V]

Output side

CONSULT-II
ACTIVE TEST

Auto
ACTIVE TEST

Front fog lamp relay

43, 44

×

×

Headlamp Hi relay

46, 47

×

×

Headlamp Lo relay

48, 50

×

×

15, 16, 45, 49

×

×

×

×

×

×

Input side

Tail lamp relay

1

Front wiper main relay

23

Front wiper HI/LO relay

24

A/C relay

41

Rear windows defogger relay
Cooling fan Lo relay
Cooling fan Hi relay

2
14

Battery
voltage

×

8

×

×

10

×

×

12

×

×

×: Applicable

OK or NG
OK
>> Check the control unit that controls the inoperative relay. (system)
NG
>> Replace the IPDM E/R. (malfunction of relay)

PG-36

IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)

4. CHECK RELAY TYPE

A

Which is the relay with error?
Front fog lamp relay, headlamp relay (Hi, Lo), tail lamp relay, front wiper relay (main, Hi/Lo), rear window
defogger relay, A/C relay, starter motor relay, cooling fan relay (Hi, Lo)>>GO TO 5.
Ignition relay>> Go to PG-33, «Inspection With CONSULT-II (Self-Diagnosis)»
ECM relay>>Go to EC-128, «POWER SUPPLY AND GROUND CIRCUIT» (CR engine models with EUROOBD), EC-543, «POWER SUPPLY AND GROUND CIRCUIT» (CR engine models without EUROOBD), EC-918, «POWER SUPPLY AND GROUND CIRCUIT» (HR engine models with EUROOBD), EC-1337, «POWER SUPPLY AND GROUND CIRCUIT» (HR engine models without
EURO-OBD) or EC-1698, «POWER SUPPLY AND GROUND CIRCUIT» (K9K engine models).
Throttle motor relay>>Go to EC-299, «DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY» (CR
engine models with EURO-OBD), EC-643, «DTC P1124, P1126 THROTTLE CONTROL MOTOR
RELAY» (CR engine models without EURO-OBD), EC-1090, «DTC P1124, P1126 THROTTLE
CONTROL MOTOR RELAY» (HR engine models with EURO-OBD) or EC-1439, «DTC P1124,
P1126 THROTTLE CONTROL MOTOR RELAY» (HR engine models without EURO-OBD).
Fuel pump relay>>Go to EC-427, «FUEL PUMP» (CR engine models with EURO-OBD), EC-750, «FUEL
PUMP» (CR engine models without EURO-OBD), EC-1215, «FUEL PUMP» (HR engine models
with EURO-OBD) or EC-1543, «FUEL PUMP» .(HR engine models without EURO-OBD).

5. CHECK INPUT SIGNAL

B

C

D

E

F

G

Check the control signal status of the relay on the IPDM E/R that receives from each control unit with the data
monitor of CONSULT-II. Refer to PG-20, «DATA MONITOR» .
What is the data monitor result?
Other than OFF>>Check the control unit that controls the relay (system) not deactivated.
OFF >> Replace the IPDM E/R. (error of relay ON)

Removal and Installation of IPDM E/R

H

I

BKS0025X

: Vehicle front

J

REMOVAL
1.

2.

Lift up the IPDM E/R while pushing and opening pawls (A) or
(B), and remove the IPDM E/R while pushing and opening the
other side pawls.
Disconnect harness connector.

PG

L

M
PKIC0917E

INSTALLATION
Installation is the reverse order of removal.

PG-37

GROUND
GROUND
Ground Distribution

PFP:00011
BKS0025Y

MAIN HARNESS

MKWA4382E

PG-38

GROUND
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4383E

PG-39

GROUND

MKWA4384E

PG-40

GROUND
ENGINE ROOM HARNESS
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4385E

PG-41

GROUND

MKWA4386E

PG-42

GROUND
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4387E

PG-43

GROUND

MKWA4388E

PG-44

GROUND
ENGINE CONTROL HARNESS/CR AND HR ENGINE MODELS
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4389E

PG-45

GROUND
BODY HARNESS

MKWA4390E

PG-46

GROUND
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4391E

PG-47

HARNESS
HARNESS
Harness Layout

PFP:00011
BKS0025Z

HOW TO READ HARNESS LAYOUT
The following Harness Layouts use a map style grid to help locate
connectors on the figures:
●
Main Harness
●
Engine Room Harness
●
Engine Control Harness
●
Body Harness
●
Room Lamp Harness
●
Front Door Harness
●
Rear Door Harness
●
Back Door Harness

SEL252V

To Use the Grid Reference
1. Find the desired connector number on the connector list.
2. Find the grid reference.
3. On the figure, find the crossing of the grid reference letter column and number row.
4. Find the connector number in the crossing zone.
5. Follow the line (if used) to the connector.
CONNECTOR SYMBOL
Main symbols of connector (in Harness Layout) are indicated in the below.

CKIT0108E

PG-48

HARNESS
HARNESS OUTLINE/CR AND HR ENGINE MODELS
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4406E

PG-49

HARNESS
HARNESS OUTLINE/K9K ENGINE MODELS

MKWA4407E

PG-50

HARNESS
MAIN HARNESS/LHD MODELS
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4408E

PG-51

HARNESS

MKWA4409E

PG-52

HARNESS
MAIN HARNESS/RHD MODELS
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4410E

PG-53

HARNESS

MKWA4411E

PG-54

HARNESS
ENGINE ROOM HARNESS/CR ENGINE MODELS
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4412E

PG-55

HARNESS

MKWA4413E

PG-56

HARNESS
ENGINE ROOM HARNESS/HR ENGINE MODELS
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4414E

PG-57

HARNESS

MKWA4415E

PG-58

HARNESS
ENGINE ROOM HARNESS/K9K ENGINE MODELS
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4416E

PG-59

HARNESS

MKWA4417E

PG-60

HARNESS
ENGINE CONTROL HARNESS/CR ENGINE MODELS
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4418E

PG-61

HARNESS

MKWA4419E

PG-62

HARNESS
ENGINE CONTROL HARNESS/HR ENGINE MODELS
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4420E

PG-63

HARNESS

MKWA4421E

PG-64

HARNESS
ENGINE CONTROL HARNESS/K9K ENGINE MODELS
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4422E

PG-65

HARNESS

MKWA4423E

PG-66

HARNESS
BODY HARNESS (RH SIDE)
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4424E

PG-67

HARNESS

MKWA4425E

PG-68

HARNESS
BODY HARNESS (LH SIDE)
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4426E

PG-69

HARNESS

MKWA4427E

PG-70

HARNESS
ROOM LAMP HARNESS
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4428E

PG-71

HARNESS
FRONT DOOR HARNESS LH SIDE/LHD MODELS

MKWA4429E

PG-72

HARNESS
FRONT DOOR HARNESS LH SIDE/RHD MODELS
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4430E

PG-73

HARNESS
FRONT DOOR HARNESS RH SIDE/LHD MODELS

MKWA4431E

PG-74

HARNESS
FRONT DOOR HARNESS RH SIDE/RHD MODELS
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4432E

PG-75

HARNESS
REAR DOOR HARNESS LH SIDE

MKWA4433E

PG-76

HARNESS
REAR DOOR HARNESS RH SIDE
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4434E

PG-77

HARNESS
BACK DOOR HARNESS

MKWA4435E

PG-78

HARNESS
Wiring Diagram Codes (Cell Codes)

BKS0026Q

Use the chart below to find out what each wiring diagram code stands for.
Refer to the wiring diagram code in the alphabetical index to find the location (page number) of each wiring
diagram.
Code

Section

Wiring Diagram Name

A/C

ATC

Air Conditioner

A/C

MTC

Air Conditioner

A/WIP

WW

Front Wiper and Washer System (With Rain Sensor)

ABS

BRC

Anti-lock Brake System

AP/SEN

EC

Absolute Pressure Sensor

APPS

EC

Accelerator Pedal Position Sensor

APPS1

EC

Accelerator Pedal Position Sensor

APPS2

EC

Accelerator Pedal Position Sensor

APPS3

EC

Accelerator Pedal Position Sensor

AT/IND

DI

A/T Indicator Lamp

AUDIO

AV

Audio

AUTO/L

LT

Auto Light Control

BA/FTS

AT

A/T Fluid Temperature Sensor and TCM Power Supply

BACK/L

LT

Back-up Lamp

BRK/SW

EC

Brake Switch

CAN

AT

CAN Communication Line

CAN

EC

CAN Communication Line

CAN

LAN

CAN System

CHARGE

SC

Charging System

CHIME

DI

Warning Chime

CIGAR

WW

Cigarette Lighter

CKPS

EC

Crankshaft Position Sensor

CMPS

EC

Camshaft Position Sensor

COMBSW

LT

Combination Switch

COOL/F

EC

Cooling Fan Control

CRFPS

EC

Common Rail Fuel Pressure Sensor

D/COMP

DI

Drive Computer

D/LOCK

BL

Power Door Lock

DEF

GW

Rear Window Defogger

DTRL

LT

Headlamp — With Daytime Light System

ECMRLY

EC

ECM Relay

ECM/PW

EC

ECM Power Supply For Back-up

ECTS

EC

Engine Coolant Temperature Sensor

EGRC/V

EC

EGR Control System

ENGSS

AT

Engine Speed Signal

EPS

STC

Electric Controlled Power Steering System

ESP

BRC

Electronic Stability Program System

ETC1

EC

Electric Throttle Control Function

ETC2

EC

Throttle Control Motor Relay

ETC3

EC

Throttle Control Motor

F/FOG

LT

Front Fog Lamp

PG-79

A

B

C

D

E

F

G

H

I

J

PG

L

M

HARNESS
Code

Section

Wiring Diagram Name

F/PUMP

EC

Fuel Pump

FRO2

EC

Front Heated Oxygen Sensor

FRPS

EC

Fuel Rail Pressure Sensor

FTS

AT

A/T Fluid Temperature Sensor

FTS

EC

Fuel Temperature Sensor

FUEL

EC

Fuel Injection System Function

GLOW

EC

Quick Glow System

H/AIM

LT

Headlamp Aiming Control System

H/LAMP

LT

Headlamp

H/SEAT

SE

Heated Seat

HEATER

MTC

Heater System

HLC

WW

Headlamp Washer

HO2S1

EC

Heated Oxygen Sensor 1

HO2S1H

EC

Heated Oxygen Sensor 1 Heater

HO2S2

EC

Rear Heated Oxygen Sensor 2

HO2S2H

EC

Rear Heated Oxygen Sensor 2 Heater

HORN

WW

Horn

I/KEY

BL

Intelligent Key System

IATS

EC

Intake Air Temperature Sensor

IATSEN

EC

Intake Air Temperature Sensor

IGNSYS

EC

Ignition System

ILL

LT

Illumination

IMV/D

EC

Fuel Flow Actuator

INJECT

EC

Fuel Injector

INT/L

LT

Stop, Vanity Mirror and Trunk Room Lamps

IVC

EC

Intake Valve Timing Control Solenoid Valve

KS

EC

Knock Sensor

LPSV

AT

Line Pressure Solenoid Valve

MAFS

EC

Mass Air Flow Sensor

MAIN

AT

Main Power Supply and Ground Circuit

MAIN

EC

Main Power Supply and Ground Circuit

METER

DI

Speed Meter, Tachometer, Temp, Oil and Fuel Gauge

MIL/DL

EC

MIL & Data Link Connector

MIRROR

GW

Door Mirror

MULTI

BL

Multi-remote Control System

NATS

BL

Nissan Anti-Theft System

NONDTC

AT

NON-detective Items

OVRCSV

AT

Overrun Clutch Solenoid Valve

PGC/V

EC

EVAP Canister Purge Volume Control Solenoid Valve

PHASE

EC

Camshaft Position Sensor (PHASE)

PNP/SW

AT

Park/Neutral Position Switch

PNP/SW

EC

Park/Neutral Position Switch

POS

EC

Crankshaft Position Sensor (CKPS) (POS)

POWER

PG

Power Supply Routing Circuit

PG-80

HARNESS
Code

Section

Wiring Diagram Name

PRGVLV

EC

EVAP Canister Purge Volume Control Solenoid Valve

PRWIRE

BL

After Market Alarm — Prewire

PTC/H

ATC

PTC Heater

PTC/H

MTC

PTC Heater

PT/SEN

AT

Turbine Revolution Sensor

R/FOG

LT

Rear Fog Lamp

RP/SEN

EC

Refrigerant Pressure Sensor

RRO2

EC

Rear Heated Oxygen Sensor 2

S/LOCK

BL

Power Door Lock-Super Lock

SEN/PW

EC

Sensor Power Supply

SHIFT

AT

A/T Shift Lock System

SRS

SRS

A

B

C

D

E

Supplemental Restraint System

SSV/A

AT

Shift Solenoid Valve A

SSV/B

AT

Shift Solenoid Valve B

START

SC

Starting System

STOP/L

LT

Stop Lamp

TAIL/L

LT

Parking, License Tail and Stop Lamps

TCBST

EC

TC Boost Pressure Sensor

TCC/V

EC

Turbocharger Boost Control Solenoid Valve

TCV

AT

Torque Converter Clutch Solenoid Valve

TPS1

EC

Throttle Position Sensor (Sensor 1)

TPS2

EC

Throttle Position Sensor (Sensor 2)

TPS3

EC

Throttle Position Sensor

TURN

LT

Turn Signal and Hazard Warning Lamps

VSSAT

AT

Vehicle Speed Sensor A/T (Revolution Senor)

VSSMTR

AT

Vehicle Speed Sensor MTR

WARN

DI

Warning Lamps

WINDOW

GW

Power Window

WIP/R

WW

Rear Wiper and Washer

F

G

H

I

J

PG

L

M

PG-81

ELECTRICAL UNITS LOCATION
ELECTRICAL UNITS LOCATION
Electrical Units Location

PFP:25230
BKS00261

ENGINE COMPARTMENT

MKWA4436E

PG-82

ELECTRICAL UNITS LOCATION
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4437E

PG-83

ELECTRICAL UNITS LOCATION
PASSENGER COMPARTMENT/LHD MODELS

MKWA4438E

PG-84

ELECTRICAL UNITS LOCATION
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4439E

PG-85

ELECTRICAL UNITS LOCATION
PASSENGER COMPARTMENT/RHD MODELS

MKWA4440E

PG-86

ELECTRICAL UNITS LOCATION
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4441E

PG-87

HARNESS CONNECTOR
HARNESS CONNECTOR
Description

PFP:00011
BKS00262

HARNESS CONNECTOR (TAB-LOCKING TYPE)
The tab-locking type connectors help prevent accidental looseness or disconnection.
The tab-locking type connectors are disconnected by pushing or lifting the locking tab(s). Refer to the figure below.
Refer to the next page for description of the slide-locking type connector.
CAUTION:
Never pull the harness or wires when disconnecting the connector.
●
●

[Example]

SEL769DA

PG-88

HARNESS CONNECTOR
HARNESS CONNECTOR (SLIDE-LOCKING TYPE)
A new style slide-locking type connector is used on certain systems and components, especially those
related to OBD.
●
The slide-locking type connectors help prevent incomplete locking and accidental looseness or disconnection.
●
The slide-locking type connectors are disconnected by pushing or pulling the slider. Refer to the figure
below.
CAUTION:
●
Do not pull the harness or wires when disconnecting the connector.
●
Be careful not to damage the connector support bracket when disconnecting the connector.
●

A

B

C

D

[Example]
E

F

G

H

I

J

PG

L

M

SEL769V

PG-89

ELECTRICAL UNITS
ELECTRICAL UNITS
Terminal Arrangement

PFP:00011
BKS00263

MKWA4443E

PG-90

ELECTRICAL UNITS
A

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4444E

PG-91

SMJ (SUPER MULTIPLE JUNCTION)
SMJ (SUPER MULTIPLE JUNCTION)
Terminal Arrangement

PFP:B4341
BKS00264

MKWA4442E

PG-92

STANDARDIZED RELAY
STANDARDIZED RELAY
Description

PFP:00011

A
BKS00265

NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS
Relays can mainly be divided into three types: normal open, normal closed and mixed type relays.

B

C

D

E

F

G

SEL881H

H

TYPE OF STANDARDIZED RELAYS
1M ···················· 1 Make

2M

1T ···················· 1 Transfer

1M·1B ···················· 1 Make 1 Break

···················· 2 Make

I

J

PG

L

M

SEL882H

PG-93

STANDARDIZED RELAY

SEL188W

PG-94

FUSE BLOCK
FUSE BLOCK
Terminal Arrangement

PFP:24010

A
BKS00266

B

C

D

E

F

G

H

I

J

PG

L

M

MKWA4446E

PG-95

FUSE, FUSIBLE LINK AND RELAY BOX
FUSE, FUSIBLE LINK AND RELAY BOX
Terminal Arrangement

PFP:24382
BKS00267

MKWA4447E

PG-96

REAR AXLE

D DRIVELINE/AXLE

SECTION

RAX

REAR AXLE

A

B

C

RAX

CONTENTS
PRECAUTIONS …………………………………………………. 2
Caution …………………………………………………………… 2
Precautions for Brake System ……………………………. 2
PREPARATION ………………………………………………….. 3
Special Service Tools ……………………………………….. 3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ………………………………………… 4
NVH Troubleshooting Chart ………………………………. 4
WHEEL HUB …………………………………………………….. 5
On-Vehicle Inspection ………………………………………. 5
REAR WHEEL BEARING ………………………………. 5

Removal and Installation …………………………………… 5
REMOVAL ……………………………………………………. 5
INSTALLATION …………………………………………….. 6
Disassembly and Assembly ……………………………….. 6
DISASSEMBLY …………………………………………….. 6
INSPECTION AFTER DISASSEMBLY ……………… 7
ASSEMBLY ………………………………………………….. 7
INSPECTION AFTER ASSEMBLY …………………… 7
SERVICE DATA AND SPECIFICATIONS (SDS) …….. 8
Wheel Bearing …………………………………………………. 8
Tightening Torque …………………………………………….. 8

E

F

G

H

I

J

K

L

M

RAX-1

PRECAUTIONS
PRECAUTIONS
Caution

PFP:00001
BDS00075

Observe the following precautions when disassembling and servicing drive shaft.
●
Perform work in a location which is as dust-free and dirt-free as possible.
●
Before disassembling and servicing, clean the outside of parts.
●
The disassembly and service location must be clean. Care must be taken to prevent parts from becoming
dirty and to prevent the entry of foreign objects.
●
Disassembled parts must be carefully reassembled in the correct order. If work is interrupted, a clean
cover must be placed over parts.
●
Paper shop cloths must be used. Fabric shop cloths must not be used because of the danger of lint adhering to parts.
●
Disassembled parts (except for rubber parts) should be cleaned with kerosene which shall be removed by
blowing with air or wiping with paper shop cloths.

Precautions for Brake System
●

●
●

●

BDS00076

When installing rubber parts, final tightening must be carried out
under unladen condition* with tyres on ground.
*: Fuel, radiator coolant and engine oil full. Spare tyre, jack,
hand tools and mats in designated positions.
Use flare nut wrench when removing or installing brake tubes.
After installing removed suspension parts, check wheel alignment and adjust if necessary.
Always tighten brake lines to the specified torque when installing.
SBR820BA

RAX-2

PREPARATION
PREPARATION
Special Service Tools

PFP:00002

A
BDS00077

Description

Application

B
Drift
ST30720000
a: 77 mm (3.03 in) dia.
b: 55 mm (2.17 in) dia.

Installing hub cap

RAX

ZZA0701D

Drift
ST33022000
a: 56 mm (2.20 in) dia.
b: 110 mm (4.33 in) dia.

C

●

Installing wheel bearing

●

Installing ABS sensor rotor

E

F
ZZA0881D

G

Drift
ST33710000
a: 30 mm (1.18 in) dia.
b: 23 mm (0.91 in) dia.

Removing wheel bearing

H
ZZA1234D

I
Flare nut torque wrench
GG94310000
a: 10 mm (0.39 in)

Removing and installing brake lines

J

NT406

K

L

M

RAX-3

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

PFP:00003
BDS00078

Refer to RAX-5, «REAR WHEEL BEARING»

NVH in FAX and FSU sections.

NVH in WT section.

NVH in WT section.

NVH in FAX section.

NVH in BR section.

NVH in PS section.

Wheel bearing damage

FRONT AXLE AND FRONT SUSPENSION

TYRES

ROAD WEEL

DRIVE SHAFT

BRAKES

STEERING

×

×

×

×

Parts interference

REAR AXLE

×

Noise

×

×

Shake

×

×

×

×

×

×

×

×

Vibration

×

×

×

×

Shimmy

×

×

×

×

×

×

×

Judder

×

×

×

×

×

×

Poor quality ride or handling

×

×

×

×

Possible cause and SUSPECTED PARTS

Symptom

×

Improper installation, looseness

Reference page

—

Refer to RAX-5, «REAR WHEEL BEARING»

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

×: Applicable

RAX-4

×

×

×

×

WHEEL HUB
WHEEL HUB
On-Vehicle Inspection

PFP:43202

A
BDS00079

Check rear axle for unusual play, cracking, excessive wear, or other
damage.
●
Turn rear wheels (left/right) and check the play.

B

C

RAX
SMA525A

E

REAR WHEEL BEARING
With the vehicle raised, inspect the following:
●
Manually move the wheel hub in axial direction to check wheel bearing for excessive play.
Axial end play
●

●

F

: 0.05 mm (0.0020 in)

Check for unusual noise by rotating wheel. If there are any non-standard conditions, replace the wheel
bearing.
If outside the standard or any other non-standard condition is found, replace wheel bearing assembly.

Removal and Installation

BDS0007A

G

H

I

J

K

L

M

MDIB9061E

1.

Back plate

2.

Spindle

3.

ABS sensor rotor

4.

Wheel bearing

5.

Snap rings

6.

Brake drum

7.

Hub cap

REMOVAL
1.
2.
3.
4.
5.

Lift up the vehicle and remove tyre from the vehicle. Release parking brake.
With hub cap pliers (commercial service tool), remove hub cap from brake drum (wheel hub)
Remove lock nut and separate brake drum from spindle.
Remove ABS sensor rotor from back plate part. Refer to BRC-36, «WHEEL SENSORS» .
Loosen self-locking nut. Refer to BR-27, «REAR DRUM BRAKE» . Separate parking brake rear cable from
rear brake. Refer to PB-4, «Components» .

RAX-5

WHEEL HUB
6.

7.

Separate brake tube from wheel cylinder. Refer to BR-11, «Removal and Installation of Front Brake Piping
and Brake Hose» .
CAUTION:
● Avoid smearing brake fluid on coated surfaces while removing brake tube.
● Never depress brake pedal while removing brake tube and brake drum.
Remove spindle mounting bolt. Separate back plate assembly and spindle from rear suspension trailing
arm.

INSTALLATION
●

●

●
●
●

●

For each tightening torque, refer to RAX-5, «Removal and Installation» and tighten in the reverse order of
removal.
For mounting of brake tube and tightening torque, refer to BR-11, «Removal and Installation of Front Brake
Piping and Brake Hose» .
For mounting parking brake and tightening torque, refer to PB-3, «PARKING BRAKE SYSTEM» .
For mounting ABS wheel sensor and tightening torque, refer to BRC-36, «WHEEL SENSORS» .
Using a drift (SST), mount hub cap on brake drum (wheel hub).
CAUTION:
Do not reuse hub cap.
Refill with new brake fluid and bleed air. Refer to BR-9, «BRAKE
FLUID» .

SDIA0766J

Disassembly and Assembly

BDS0007B

DISASSEMBLY
1.

Using snap ring pliers (commercial service tool), remove sensor
rotor

MDIA0062E

2.

Remove snap ring.

MDIA0056E

RAX-6

WHEEL HUB
3.

Press the wheel bearing out with a drift (SST) to remove.
A

B

C
MDIA0057E

RAX

INSPECTION AFTER DISASSEMBLY
●
●

Check trailing arm for deformed parts, cracks, or any other damage. Replace if necessary.
Check snap ring for wear or cracks. Replace if necessary.

E

ASSEMBLY
1.

2.

Press-fit the wheel hub with a drift (SST).
CAUTION:
Do not press and weight on wheel bearing inner lace and
sealing part.
NOTE:
Final press-loading guideline [50,000 N (5,100 kg, 11,240 lb)]
Install snap ring.

F

G

H
MDIA0058E

I

3.

Press-fit the sensor rotor on the brake drum with a drift (SST).
J

K

L
MDIA0059E

INSPECTION AFTER ASSEMBLY
1.

Tightening torque
2.
3.

M

After installing brake drum on spindle, tighten lock nut to the
standard torque.
: 175 N·m (18 kg-m, 129 ft-lb)

Rotate the wheel hub in both directions ten times each to check
for smooth movement.
At a rotating speed of 10 ± 2 rpm, place a spring balance on hub
bolt to measure torque.
Rotating
torque
Spring balance measurement

: 0.20 — 0.95 N·m (0.02 — 0.09 kg-m)
MDIA0060E

: 4 — 19 N (0.41 — 1.94 kg)

RAX-7

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Wheel Bearing
Axial end play

0.05 mm (0.0020 in)

Rotating torque

0.20 — 0.95 N·m (0.02 — 0.09 kg-m)

Spring balance measurement

Installation location of spring
scale

PFP:00030
BDS0007C

4 — 19 N (0.41 — 1.94 kg)

Hub bolt position

MDIA0061E

Tightening Torque
Hub lock nut

BDS0007D

175 N·m (18 kg-m, 129 ft-lb)

RAX-8

REAR SUSPENSION

E SUSPENSION

SECTION

RSU

REAR SUSPENSION

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 2
Cautions …………………………………………………………. 2
Precautions for Brake System ……………………………. 2
PREPARATION ………………………………………………….. 3
Special Service Tools ……………………………………….. 3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ………………………………………… 4
NVH Troubleshooting Chart ………………………………. 4
REAR SUSPENSION ASSEMBLY ……………………….. 5
Components ……………………………………………………. 5
On-Vehicle Inspection and Service …………………….. 5
Wheel Alignment ……………………………………………… 6
DESCRIPTION ……………………………………………… 6
PRELIMINARY INSPECTION …………………………. 6
CAMBER ……………………………………………………… 6
TOE-IN ………………………………………………………… 6

SHOCK ABSORBER ………………………………………….. 7
Removal and Installation …………………………………… 7
REMOVAL ……………………………………………………. 7
INSPECTION AFTER REMOVAL ……………………. 7
INSTALLATION …………………………………………….. 8
COIL SPRING ……………………………………………………. 9
Removal and Installation …………………………………… 9
REMOVAL ……………………………………………………. 9
INSPECTION AFTER REMOVAL ……………………. 9
INSTALLATION …………………………………………….. 9
REAR SUSPENSION BEAM ……………………………… 10
Removal and Installation …………………………………. 10
REMOVAL ………………………………………………….. 10
INSPECTION AFTER REMOVAL ………………….. 10
INSTALLATION …………………………………………… 10
SERVICE DATA AND SPECIFICATIONS (SDS) …… 11
Wheel Alignment ……………………………………………. 11
Tightening Torque …………………………………………… 11

RSU

F

G

H

I

J

K

L

M

RSU-1

PRECAUTIONS
PRECAUTIONS
Cautions
●

●

●
●

PFP:00001
BES0002U

Final tightening of bushings must be carried out under unladen condition with tyres on the ground. Oil will
shorten life of bushings. Be sure to wipe off any spilled oil.
“Unladen condition” means that fuel, coolant and lubricant are full and ready for drive. However, spare
tyre, jack, and hand tools should be unloaded.
After installing the removed suspension parts, always check wheel alignment and adjust if necessary.
Replace the caulking nut with a new one. Install a new nut without wiping the oil off before tightening.

Precautions for Brake System
●
●

BES0002V

Use flare nut wrench when removing or installing brake tubes.
Always tighten brake lines to specified torque when installing.

SBR820BA

RSU-2

PREPARATION
PREPARATION
Special Service Tools

PFP:00002

A
BES0002W

Tool number
Tool name

Description

GG94310000
Flare nut torque wrench
a: 10 mm (0.39 in)

B

Removing and installing brake lines

C

D
NT406

RSU

F

G

H

I

J

K

L

M

RSU-3

Symptom
Bushing or mounting deterioration
Parts interference

REAR SUSPENSION
Shock absorber deformation, damage or deflection

Possible cause and SUSPECTED PARTS
Improper installation, looseness

Reference page

×: Applicable

RSU-4

Noise
×
×
×
×

Shake
×
×
×
×

Vibration
×
×
×
×

Shimmy
×
×
×
×

Judder
×
×
×

Poor quality ride or
handling
×
×
×

Refer to RSU-6, «Wheel Alignment»

Incorrect wheel alignment
FRONT AXLE AND FRONT SUSPENSION
TYRES
ROAD WHEEL
DRIVE SHAFT
BRAKES
STEERING

×
×
×
×
×
×
×
×

×
×
×
×
×
×
×

×
×
×

×
×
×
×
×
×

×
×
×
×
×

×
×
×
×

×
×

NVH in PS section.

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

NVH in BR section.

NVH in FAX section.

NVH in WT section.

NVH in WT section.

NVH in FAX and FSU sections.

Refer to RSU-5, «Components»

—

Suspension looseness

×
Spring fatigue

—

—

Refer to RSU-7, «SHOCK ABSORBER»

Refer to RSU-5, «Components»

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
BES0002X

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

×

REAR SUSPENSION ASSEMBLY
REAR SUSPENSION ASSEMBLY
Components

PFP:55020

A
BES0002Y

B

C

D

RSU

F

G

H

I

J
MEIB9027E

K
1.

Bushing

2.

Bushing

3.

Distance tube

4.

Bound bumper cover

5.

Bound bumper

6.

Shock absorber

7.

Rear spring rubber seat

8.

Coil spring

9.

Rear spring rubber seat

10. Rear suspension beam

L

11. Rear suspension arm bracket

On-Vehicle Inspection and Service

BES0002Z

Check axle and suspension parts for excessive play, wear, and damage.
●
Move rear wheels (RH/LH) to check for unusual free play.
●
Retighten all nuts and bolts to the specified torque.
●
Check shock absorber for oil leakage and damage.

RSU-5

M

REAR SUSPENSION ASSEMBLY
Wheel Alignment

BES00030

DESCRIPTION
●

Measure wheel alignment under unladen conditions. “Unladen conditions” means that fuel, coolant, and
lubricant are full. However, spare tyre, jack, and hand tools should be unloaded.

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

Check the tyres for improper air pressure and wear.
Check road wheels for runout.
Check wheel bearing axial end play.
Check shock absorber operation.
Check each mounting point of axle and suspension for looseness and deformation.
Check each link and arm for cracks, deformation, and other damage.
Check the vehicle posture.

CAMBER
Camber is preset at factory and cannot be adjusted.
Camber
●

: -1°55′- -0°25′ (-1.92°- -0.42°)

If the camber is not within specification, inspect and replace any damaged or worn rear suspension parts.

TOE-IN
Toe-in is preset at factory and cannot be adjusted. Measure toe-in
using following procedure. If out of specification, inspect and replace
any damaged or worn rear suspension parts.
WARNING:
●
Always perform following procedure on a flat surface.
●
Make sure that no person is in front of the vehicle before
pushing it.
1. Bounce rear of vehicle up and down to stabilize the posture.
2. Push the vehicle straight ahead about 5 m (16 ft.).
3. Put a mark on base line of tread (rear side) of both tyres at the
same height as hub center. This mark is a measuring points.

AFA050

4.
5.

Measure distance “A” (rear side).
Push the vehicle slowly ahead to rotate the wheels 180 degrees
(1/2 turn).
If the wheels have rotated more than 180 degrees (1/2 turn), try the
above procedure again from the beginning. Never push vehicle
backward.
6. Measure distance “B” (front tyres).
Total toe-in:

In 0- 8 mm (0 — 0.31 in)
SFA234AC

RSU-6

SHOCK ABSORBER
SHOCK ABSORBER
Removal and Installation

PFP:56210

A
BES00031

REMOVAL
1.
2.

3.

Raise vehicle and remove tyre.
Using a flat screwdriver, remove luggage side lower finisher.
CAUTION:
Wrap the tip of a screwdriver with cloth to avoid damaging components.

B

C

Remove upper nuts of the shock absorber and remove washer,
bushing on the upper side of shock absorber.

D

RSU

F
SEIA0147J

G

4.
5.

Set a jack under trailing arm of rear suspension beam and support it. Remove lower bolts of the shock absorber.
Remove shock absorber from the vehicle.

H

I

J
SEIA0146J

INSPECTION AFTER REMOVAL
Shock Absorber
●

●
●

K

Check shock absorber for deformation, cracks, and other damage. Replace if any non-standard conditions are found.
Check piston rod for damage, uneven wear, and distortion, and replace shock absorber if necessary.
Check welded and sealed areas for oil leakage, and replace if necessary.

Bound Bumper and Bushing
●

L

M

Check bound bumper and bushing for cracks and damage. Replace if necessary.

RSU-7

SHOCK ABSORBER
INSTALLATION
●
●

Refer to RSU-5, «Components» for tightening torque. Install in the reverse order of removal.
When installing body side bushing, install the projection to the
vehicle side hole securely.

MEIA0028E

RSU-8

COIL SPRING
COIL SPRING
Removal and Installation

PFP:55020

A
BES00032

REMOVAL
1.
2.
3.

Raise vehicle and remove tyre.
Set a jack under trailing arm of rear suspension beam and support it. Remove lower side of the shock absorber. (left/right)
Remove jack. Remove coil spring and spring rubber seat.

B

C

D

RSU
SEIA0146J

INSPECTION AFTER REMOVAL
●

Check coil spring and spring rubber seat for deformation, cracks, and damage, and replace if necessary.

F

INSTALLATION
●
●

Refer to RSU-5, «Components» for tightening torque. Tighten in the reverse order of removal.
When installing spring, be sure to securely install the spring end
position aligned to flush of spring rubber seat as shown in the
figure.

G

H

I

J
SEIA0149J

K

L

M

RSU-9

REAR SUSPENSION BEAM
REAR SUSPENSION BEAM
Removal and Installation

PFP:55501
BES00034

REMOVAL
1.
2.
3.
4.

Raise vehicle, remove tyre and replace parking lever.
Install brake pedal press then open rear air bleeder. Refer to BR-10, «Bleeding Brake System» .
Drain brake fluid. Refer to BR-9, «Drain and Refill» .
Loosen self-locking nut, and separate parking brake rear cable from rear brake and rear suspension
beam. Refer to PB-3, «PARKING BRAKE SYSTEM» .
5. Remove ABS wheel sensor. Refer to BRC-36, «WHEEL SENSORS» .
6. Separate rear brake hose from brake piping. Refer to BR-11, «BRAKE PIPING AND HOSE» .
7. Remove shock absorber lower side (left/right), coil spring (left/right). Refer to RSU-7, «SHOCK
ABSORBER» , RSU-9, «COIL SPRING»
8. Set a jack under suspension beam, and remove mounting bolts
of suspension arm bracket and rear suspension beam.
9. Remove suspension beam.
10. Remove brake piping from rear suspension member beam.
Refer to BR-11, «BRAKE PIPING AND HOSE» .

MEIA0029E

11. Remove spindle bolts and rear axle assembly.
12. Remove rear suspension arm bracket nuts and bolts. Remove
rear suspension arm bracket from vehicle.

SEIA0151J

INSPECTION AFTER REMOVAL
●

Check suspension beam and bushing for deformation, cracks, and damage. Replace if necessary.

INSTALLATION
●
●

●
●
●

●

Refer to RSU-5, «Components» for tightening torque. Tighten in the reverse order of removal.
Refer to BR-11, «BRAKE PIPING AND HOSE» for installation of brake piping and brake hose and for
tightening torque.
Refer to PB-3, «PARKING BRAKE SYSTEM» for installation of parking brake and for tightening torque.
Tighten rear suspension arm bracket under unladen condition.
Refer to BRC-36, «WHEEL SENSORS» for installation of ABS
wheel sensor and for tightening torque.
Refill with new brake fluid and bleed air. Refer to BR-9, «BRAKE
FLUID» .

MEIA0030E

RSU-10

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Wheel Alignment
Camber

PFP:00030

A
BES00036

-1°55′ — -0°25′ (-1.92° — -0.42°)

Toe-in

B

In 0 — 8 mm (0 — 0.31 in)

Tightening Torque

BES00037

Unit: N·m (kg-m)
Shock absorber piston rod lock nut

C

20 (2.0, 15)

Rear suspension beam to rear suspension arm bracket

160 (16, 118)

Shock absorber to rear suspension beam

90 (9.2, 66)

Rear suspension arm bracket to body

50 (5.1, 37)

D

RSU

F

G

H

I

J

K

L

M

RSU-11

SERVICE DATA AND SPECIFICATIONS (SDS)

RSU-12

ROAD WHEELS & TYRES

E SUSPENSION

SECTION

WT

ROAD WHEELS & TYRES

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ………………………………………… 3
NVH Troubleshooting Chart ………………………………. 3
ROAD WHEEL …………………………………………………… 4
Inspection ……………………………………………………….. 4
ALUMINUM WHEEL ……………………………………… 4
STEEL WHEEL …………………………………………….. 4

ROAD WHEEL AND TYRE ASSEMBLY ……………….. 5
Balancing Wheels (Bonding Weight Type) …………… 5
REMOVAL ……………………………………………………. 5
WHEEL BALANCE ADJUSTMENT ………………….. 5
Balancing Wheels (Drive-in Weight Type) ……………. 6
WHEEL BALANCE ADJUSTMENT ………………….. 6
Rotation ………………………………………………………….. 7
SERVICE DATA …………………………………………………. 8
Road Wheel …………………………………………………….. 8
Tyre ………………………………………………………………… 8

WT

F

G

H

I

J

K

L

M

WT-1

PRECAUTIONS
PFP:00011
PRECAUTIONS
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

BES00038

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

WT-2

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

PFP:00003

A
BES00039

×

Shimmy

×

×

×

×

×

Judder

×

×

×

×

Poor quality ride
or handling

×

×

×

×

Noise

×

×

×

Shake

×

×

Shimmy, judder

×

Poor quality ride
or handling

×

×

×

×

×

×

×

×

×

×

×

×

×

Refer to ROAD WHEEL in this chart.

×

NVH in PS section.

NVH in BR section.

NVH in FAX section.

Refer to TYRES in this chart.

×

NVH in RAX and RSU sections.

—

STEERING

×

BRAKE

×

DRIVE SHAFT

×

ROAD WHEEL

×

×

C

H

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×: Applicable

WT-3

×

WT

G

×

×

D

F

TYRES

Shake

REAR AXLE AND REAR SUSPENSION

×

NVH in FAX and FSU sections.

×

FRONT AXLE AND FRONT SUSPENSION

×

NVH in MT, AT and CVT section.

×

B

DIFFERENTIAL

Non-uniformity

×

Incorrect tyre size

Deformation or damage

—

Uneven tyre wear

ROAD WHEEL

—

Incorrect tyre pressure

×

Vibration

Symptom

—

Imbalance

Noise

Possible cause and SUSPECTED PARTS

TYRES

—

Out-of-round

Reference page

—

Refer to WT-4, «ROAD WHEEL»

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

×

×

I

J

K

L

M

ROAD WHEEL
ROAD WHEEL
Inspection

PFP:40300
BES0003A

ALUMINUM WHEEL
1.
2.
a.
b.

Check tyres for wear and improper inflation.
Check wheels for deformation, cracks and other damage. If
deformed, remove wheel and check wheel runout.
Remove tyre from aluminum wheel and mount on a tyre balance
machine.
Set dial indicator as shown in the illustration.
Wheel runout (Dial indicator value):
Refer to WT-8, «SERVICE DATA»
SFA975B

STEEL WHEEL
1.
2.
a.
b.
c.
d.
e.

Check tyres for wear and improper inflation.
Check wheels for deformation, cracks and other damage. If
deformed, remove wheel and check wheel runout.
Remove tyre from steel wheel and mount wheel on a tyre balance machine.
Set two dial indicators as shown in the illustration.
Set each dial indicator to 0.
Rotate wheel and check dial indicators at several points around
the circumference of the wheel.
Calculate runout at each point as shown below.
Radial runout = (A + B)/2
Lateral runout = (C + D)/2

f.

: 0.5 mm (0.020 in)
: 0.8 mm (0.031 in)

Select maximum positive runout value and the maximum negative value.
Add the two values to determine total runout.
In case a positive or negative value is not available, use the
maximum value (negative or positive) for total runout.
If the total runout value exceeds the limit, replace steel wheel.
Wheel runout:
Refer to WT-8, «SERVICE DATA»

WT-4

MDIA0001E

ROAD WHEEL AND TYRE ASSEMBLY
ROAD WHEEL AND TYRE ASSEMBLY
Balancing Wheels (Bonding Weight Type)

PFP:40312

A
BES0003B

REMOVAL
1.

2.

Remove inner and outer balance weights from the road wheel.
CAUTION:
Be careful not to scratch the road wheel during removal procedures.
Using releasing agent, remove double-faced adhesive tape from the road wheel.
CAUTION:
Be careful not to scratch the road wheel during removal.
● After removing double-faced adhesive tape, wipe clean traces of releasing agent from the road wheel.

B

C

D

WHEEL BALANCE ADJUSTMENT
If a tyre balance machine has adhesion balance weight mode settings and drive-in weight mode setting,
WT
select and adjust a drive-in weight mode suitable for road wheels.
1. Set road wheel on wheel balancer using the center hole as a guide. Start the tyre balance machine.
2. When inner and outer unbalance values are shown on the wheel balancer indicator, multiply outer unbalance value by 5/3 to determine balance weight that should be used. Select the outer balance weight with F
a value closest to the calculated value above and install it to the designated outer position of, or at the
designated angle in relation to the road wheel.
CAUTION:
G
● Do not install the inner balance weight before installing the outer balance weight.
● Before installing the balance weight, be sure to clean the mating surface of the road wheel.
Indicated unbalance value × 5/3 = balance weight to be installed
H
Calculation example:
23 g (0.81 oz) × 5/3 = 38.33 g (1.35 oz) = 40 g (1.41 oz) balance
weight (closer to calculated balance weight value)
I
Note that balance weight value must be closer to the calculated balance weight value.
Example:
J
37.4 = 35 g (1.23 oz)
37.5 = 40 g (1.41 oz)
●

SMA054D

●
●

●

Attach weight as shown in figure.
When attaching weight to road wheel, align it with step on rear
surface of wheel, as shown in figure. Attach so that center of
weight and position (angle) of wheel balancer indicator are
aligned.
Do not attach more than 2 adhesive weights.

L

M

MDIA0002E

WT-5

K

ROAD WHEEL AND TYRE ASSEMBLY
If calculated value exceeds 50 g (1.76 oz), attach two weights
side by side, as shown in figure.
CAUTION:
When attaching two weights, do not attach them one on top of
the other.
3. Start the wheel balancer again.
4. As before, attach drive-in weight to inner side of road wheel,
according to amount and position (angle) of imbalance indicated
by wheel balancer.
5. Start wheel balancer. Check that residual imbalance amount is
10 g (0.35 oz) or less for both outer and inner sides.
● If residual imbalance exceeds 10 g (0.35 oz), then repeat procedure from start.
●

MDIA0003E

Permissible amount of residual imbalance
Dynamic (at lug)
: 10 g (0.35 oz) or less (one side)
Static (at lug)
: 20 g (0.71 oz) or less
Maximum balance weight correction : 100 g (3.53 oz)

Balancing Wheels (Drive-in Weight Type)

BES0003C

WHEEL BALANCE ADJUSTMENT
1.
2.
●

●

●

●

Remove wheel from vehicle.
Set road wheel on wheel balancer and start balancer machine.
Set with top/bottom reversed from vehicle installation position. After setting wheel on wheel balancer,
make mark on top surface of wheel.
Adjust wheel balance using a wheel balancer with straight cone attachment. Be sure cone contacts
reverse side of wheel.
If a general-purpose taper cone must be used to adjust wheel balance, place cone against reverse side of
wheel and support it.
Resin hammer must be used to drive in balance weights.
CAUTION:
Do not reuse balance weights after they are removed. Be sure to use new Nissan genuine weights
designed for use with steel wheels.
Permissible amount of residual imbalance
Dynamic (at lug)
: 10 g (0.35 oz) or less (one side)
Static (at lug)
: 20 g (0.71 oz) or less
Maximum balance weight correction : 60 g (2.12 oz)

3.
4.

Remove wheel from wheel balancer.
Install wheel to vehicle, with mark on lower side.
●
Minimize imbalance by keeping same relative positions between hub-wheel contact points when installing
to vehicle as when adjusting wheel balance.
CAUTION:
So as not to deform wheel, install by tightening at opposite angles, in 2 — 3 steps.
Tightening torque
of wheel nut

: 105 N·m (11 kg-m, 77 ft-lb)

WT-6

ROAD WHEEL AND TYRE ASSEMBLY
Rotation
●
●

●

BES0003D

A

After rotating the tyres, adjust the tyre pressure.
Retighten the wheel nuts when the vehicle has been driven for
1,000 km (600 miles) (also in cases of a flat tyre, etc).
Do not include the T-type spare tyre when rotating the tyres.
CAUTION:
When installing wheels, tighten them diagonally by dividing
the work two to three times in order to prevent the wheels
from developing any distortion.
Tightening torque
of wheel nut

B

C

: 105 N·m (11 kg-m, 77 ft-lb)

D
SMA829C

WT

F

G

H

I

J

K

L

M

WT-7

SERVICE DATA
SERVICE DATA
Road Wheel

PFP:00030
BES0003E

Kind of wheel

Aluminum

Steel

Lateral deflection

Less than 0.3 mm
(0.012 in)

Less than 0.5 mm
(0.020 in)

Vertical deflection

Less than 0.3 mm
(0.012 in)

Less than 0.8 mm
(0.031 in)

Deflection limit

Allowable quantity of residual unbalance

Dynamic
(On the ear part)

Less than 10 g (0.35 oz) (per side)

Static (On the ear part)

Less than 20 g (0.70 oz)

Tyre

BES0003F

Unit: kPa

(kg/cm2

, psi)

Air pressure
Tyre size

Front wheel
Normal condition

Rear wheel
Full load

Normal condition

Full load

216 (2.2, 31)

275 (2.8, 40)

175/65R15

226 (2.3, 33)

185/65R15

226 (2.3, 33)

206 (2.1, 30)

185/55R16
(Acenta grade with CR engine)

235 (2.4, 34)

216 (2.2, 31)

185/55R16
(except Acenta grade with CR engine)

245 (2.5, 36)

216 (2.2, 31)

T125/70D14
T125/70D15

412 (4.2, 60)

WT-8

SEAT BELTS

H RESTRAINTS

SECTION

SB

SEAT BELTS

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 2
Precaution for Seat Belt Service ………………………… 2
AFTER A COLLISION ……………………………………. 2
SEAT BELTS …………………………………………………….. 3
System Description ………………………………………….. 3
SEAT BELT WARNING LAMP ………………………… 3
SEAT BELT WARNING CHIME ………………………. 3
Removal and Installation of Front Seat Belt …………. 3
REMOVAL ……………………………………………………. 3

INSTALLATION …………………………………………….. 4
Removal and Installation of Rear Seat Belt ………….. 4
REMOVAL ……………………………………………………. 4
INSTALLATION …………………………………………….. 5
Inspection ……………………………………………………….. 5
POST-ACCIDENT INSPECTION …………………….. 5
INSPECTION FOR SEAT BELT RETRACTOR….. 5
INSPECTION OF ELR AND SEAT BELT WITH
CHILD SAFETY SEAT ANCHOR SYSTEM ………. 6
ISO FIX CHILD RESTRAINT ANCHORAGE ………….. 7
Removal and Installation …………………………………… 7

E

F

G

SB

I

J

K

L

M

SB-1

PRECAUTIONS
PFP:00001
PRECAUTIONS
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

BHS0002L

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Precaution for Seat Belt Service

BHS0002M

CAUTION:
●
Before removing the seat belt pre-tensioner assembly, turn the ignition switch off, disconnect the
battery ground cable and wait at least 3 minutes.
●
Do not use electrical test equipment for seat belt pre-tensioner connector.
●
After replacing or reinstalling seat belt pre-tensioner assembly, or reconnecting seat belt pretensioner connector, check the system function. Refer to SRS-18, «SRS Operation Check» .
●
Do not use disassemble buckle or seat belt assembly.
●
Replace anchor bolts if they are deformed or worn out.
●
Never oil tongue and buckle.
●
If any component of seat belt assembly is questionable, do not repair. Replace the whole seat belt
assembly.
●
If webbing is cut, frayed, or damaged, replace seat belt assembly.
●
When replacing seat belt assembly, use a genuine seat belt assembly.

AFTER A COLLISION
WARNING:
Inspect all seat belt assemblies including retractors and attaching hardware after any collision.
NISSAN recommends that all seat belt assemblies in use during a collision be replaced unless the collision was minor and the belts show no damage and continue to operate properly. Failure to do so
could result in serious personal injury in an accident. Seat belt assemblies not in use during a collision should also be replaced if either damage or improper operation is noted. Seat belt pre-tensioner
should be replaced even if the seat belts are not in use during a frontal collision in which the air bags
are deployed.
Replace any seat belt assembly (including anchor bolts) if:
●
The seat belt was in use at the time of a collision (except for minor collisions and the belts, retractors and
buckles show no damage and continue to operate properly).
●
The seat belt was damaged in an accident. (i.e. torn webbing, bent retractor or guide, etc.)
●
The seat belt attaching point was damaged in an accident. Inspect the seat belt attaching area for damage
or distortion and repair as necessary before installing a new seat belt assembly.
●
Anchor bolts are deformed or worn out.
●
The seat belt pre-tensioner should be replaced even if the seat belts are not in use during the collision in
which the air bags are deployed.

SB-2

SEAT BELTS
SEAT BELTS
System Description

PFP:86884

A
BHS0004Q

SEAT BELT WARNING LAMP
●
●
●

Fasten driver’s seat belt.
The seat belt warning lamp should go out.
If the seat belt warning lamp does not go out. Refer to DI-32, «WARNING LAMPS» .

B

C

SEAT BELT WARNING CHIME
●
●
●

Fasten driver’s seat belt.
The seat belt warning chime should not sound.
If the seat belt warning chime sounds. Refer to DI-52, «WARNING CHIME» .

D

Removal and Installation of Front Seat Belt

BHS0002N

E

F

G

SB

I

J
PHIA1076J

1.

Seat belt anchor plate (upper)

2.

Seat belt anchor plate (lower)

3.

Seat belt pre-tensioner

4.

Seat belt adjuster cover

5.

Anchor bolt

6.

Seat belt pre-tensioner connector

7.

Bolt

8.

Seat belt adjuster

CAUTION:
Before servicing SRS, turn ignition switch off, disconnect the battery ground cable and wait at least 3
minutes.

L

M

REMOVAL
Seat Belt Retractor
1.
2.
3.
4.
5.
6.

K

Remove bolt cover.
Remove shoulder anchor bolts.
Remove the center pillar lower garnish. Refer to EI-26, «Removal and Installation» in EI section.
Remove seat belt pre-tensioner connector on the seat belt retractor.
Remove anchor plate (lower) pre-tensioner connector (driver side only).
Remove pre-tensioner seat belt retractor mounting screw and floor anchor bolt. Then, remove seat belt
assembly.

SB-3

SEAT BELTS
Seat Belt Buckle
1.
2.
3.
4.

Remove front seat from vehicle body. Refer to SE-7, «FRONT SEAT» in SE section.
Separate clip of buckle switch harness connector from the bottom of seat cushion.
Remove seat cushion inner finisher. Refer to SE-10, «Disassembly and Assembly of Seat Cushion» in SE
section.
Remove anchor bolt (1) and buckle.

MHIB0004E

INSTALLATION
●
●

Install in the reverse order of removal.
Tighten anchor bolts to the specified torque.

Removal and Installation of Rear Seat Belt

BHS0002P

MHIB9026E

REMOVAL
Seat Belt Retractor (side seats)
1.
2.
3.
4.

Remove luggage side finisher. Refer to EI-33, «Luggage Side Finisher» .
Remove shoulder anchor bolt cap.
Remove shoulder and floor anchor bolt.
Remove the retractor.

SB-4

SEAT BELTS
Seat Belt Retractor (centre seat)
1.
2.
3.
4.

A

Remove seat cushion trim and pad. Refer to SE-13, «Rear Seat Disassembly and Assembly» .
Remove seatback trim and pad. Refer to SE-13, «Rear Seat Disassembly and Assembly» .
Remove shoulder anchor bolts (2) and floor anchor bolt.
Remove the retractor.

B

Seat Belt Buckle
1.
2.
3.

Remove seat cushion trim and pad. Refer to SE-13, «Rear Seat Disassembly and Assembly» .
Remove seat buckle anchor bolt.
Remove seat buckle.

C

D

INSTALLATION
●
●

Install in the reverse order of removal.
Tighten anchor bolts to the specified torque.

E

Inspection

BHS0002R

POST-ACCIDENT INSPECTION
After a collision, inspect for damage or distortion of retractor, seat belt anchor, floor anchor, or shoulder
anchor. Nissan recommends replacement of all seat belt assemblies in the following cases because these
impairments may lead to personal injury.
●
After a collision
●
When installation point of seat belt assembly on vehicle is damaged.
●
When it does not operate normally.

2.
3.
4.
a.
b.

c.
d.
5.

G

SB

INSPECTION FOR SEAT BELT RETRACTOR
1.

F

Using seat belt warning lamp, make sure it works normally.
Check the seat belt warning lamp/chime for proper operation as follows:
Switch ignition ON. The seat belt warning lamp should illuminate. Also, the seat belt warning chime should
sound for about six seconds.
Fasten driver’s seat belt. The seat belt warning lamp should go out and the chime (if sounding) should
stop. If warning lamp stay illuminated or warning chime combine to sound. Refer to DI-52, «WARNING
CHIME» . Refer to DI-32, «WARNING LAMPS» .
Check whether anchor bolts on seat belt retractor and buckle are securely tightened.
Confirm if the seat belt through anchor axis freely rotates, seat belt adjuster properly operates, or completely engages.
Retractor operation inspection
Pull out all webbing and check for twisting, cut, or other damage.
Retract webbing. Check if the webbing is retracted smoothly and completely into the retractor. When webbing is not retracted smoothly due to the dust or other reasons, carry out the following procedure with
“SEAT BELT, TAPE SET”.
Inspection for Front Seat Belt Shoulder Anchor.
1. Pull webbing out 50 cm or more.
2. Fix webbing near the belt exit with a clip.
3. Pass the thin wire into the through part of shoulder anchor and webbing. Remove the sticking materials
from the webbing by sliding the wire vertically along the surface of the webbing through part while pulling both sides of wire tightly.
4. Clean the remaining dirt by cleaning the webbing through part with a clean cloth.
5. Apply tape to the shoulder anchor belt through part where webbing touches.
NOTE:
Be careful to apply tape with no wrinkling or looseness.
6. Remove the seat belt fixing, and confirm webbing smoothly retracts.
Insert the seat belt into the buckle and confirm seat belt is firmly secured.
Remove the seat belt from buckle. Release the seat belt and confirm webbing and tongue are placed correctly.
Seat belt retractor unit inspection

SB-5

I

J

K

L

M

SEAT BELTS
a.
b.

Remove seat belt retractor.
As shown in the figure, without twisting retractor, recline the seat belt retractor at the position retractor is
mounted on the vehicle body. Slowly pull out the webbing.
● Webbing is able to pull out when reclining 15 degrees or less.
● Webbing is not able to pull out when reclining 35 degrees or more.

MHIB0006E

If it does not operate normally, replace seat belt assembly.

INSPECTION OF ELR AND SEAT BELT WITH CHILD SAFETY SEAT ANCHOR SYSTEM
ELR and Seat Belt With Child Safety Seat Anchor System
●

●

●

ELR is a system which locks retractor in emergency cases such as sudden braking so that the webbing is
not pulled out any further.
Child safety seat anchor system is applied at the 3-point seat belt (outside seat) of back seat. Child safety
seat anchor system functions when webbing is completely pulled out. Webbing is locked at certain point
when retracting webbing little by little.
There are 2 inspections: static and dynamic. Use the following procedures to check retractor for normal
operation.

ELR Static Inspection
Does retractor lock and webbing stop immediately when quickly pulling webbing forward?

Inspection for Child Safety Seat Anchor System
1.
2.
3.
4.

Fully pull out webbing until “clicking” is heard.
Is “clicking” operating sound heard when retracting webbing little by little?
Is webbing locked and no longer pulled out when under tension?
Is child safety seat anchor system released when webbing is completely retracted?

ELR Dynamic Inspection
WARNING:
●
The following tests should be carried out in a safe, open place free of traffic and obstacles.
●
The tests should be carried out on a dry paved road. Never attempt the tests on wet or unpaved
road, open road, or highway. (This may cause an accident or personal injury.)
●
Driver and passenger assume retractor will not lock and prepare themselves accordingly.
1. Tighten driver and passenger seat belts.
2. Drive at approximately 16 km/h (MPH).
3. Notify passenger of a sudden stop. Driver and passenger prepare themselves for the possibility of retractor not locking. Then, driver fully depresses the brake pedal to stop suddenly.
4. While car stops, confirm if retractor is locked and webbing is not pulled out any more. Check for only
retractor part if it is not locked.

SB-6

ISO FIX CHILD RESTRAINT ANCHORAGE
ISO FIX CHILD RESTRAINT ANCHORAGE
Removal and Installation

PFP:88840

A
BHS0004R

B

C

D

E

F

G
MHIB9029E

1.

Rear seat cushion frame assembly
: ISO fix child restraint anchor

SB

: Tether strap anchor

CAUTION:
ISO fix child restraint anchor and Tether strap anchor are not serviceable. If damaged, replace the rear
seat cushion frame assembly.

I

J

K

L

M

SB-7

ISO FIX CHILD RESTRAINT ANCHORAGE

SB-8

SEAT

I BODY

SECTION

SE

SEAT

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 2
Precautions …………………………………………………….. 2
CLIP AND FASTENER ……………………………………….. 3
List of Table …………………………………………………….. 3
HEATED SEAT ………………………………………………….. 4
Description ……………………………………………………… 4
Wiring Diagram — H/SEAT ……………………………….. 5
FRONT SEAT …………………………………………………….. 7
Component Parts Location ………………………………… 7
Removal and Installation …………………………………… 8

REMOVAL ……………………………………………………. 8
INSTALLATION …………………………………………….. 8
Disassembly and Assembly of Seatback ……………… 8
SEATBACK TRIM PAD …………………………………… 8
SEATBACK FRAME ………………………………………. 9
Disassembly and Assembly of Seat Cushion ……… 10
SEAT CUSHION TRIM PAD ………………………….. 10
SEAT CUSHION FRAME ……………………………… 10
REAR SEAT …………………………………………………….. 12
Removal and Installation …………………………………. 12
REMOVAL ………………………………………………….. 12
INSTALLATION …………………………………………… 12
Rear Seat Disassembly and Assembly ……………… 13

E

F

G

H

SE

J

K

L

M

SE-1

PRECAUTIONS
PFP:00001
PRECAUTIONS
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

BIS000U4

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Precautions

BIS000U5

When removing or disassembling any part, be careful not to damage or deform it. Protect parts, which
may get in the way with cloth.
●
When removing parts with a screwdriver or other tool, protect parts by wrapping them with vinyl or tape.
●
Keep removed parts protected with cloth.
●
If a clip is deformed or damaged, replace it.
●
If an unreusable part is removed, replace it with a new one.
●
Tighten bolts and nuts firmly to the specified torque.
●
After re-assembly has been completed, make sure each part functions correctly.
●
Remove stains in the following way.
Water-soluble stains:
Dip a soft cloth in warm water, and then squeeze it tightly. After wiping the stain, wipe with a soft dry cloth.
Oil stain:
Dissolve a synthetic detergent in warm water (density of 2 to 3% or less), dip the cloth, then clean off the stain
with the cloth. Next, dip the cloth in fresh water and squeeze it tightly. Then clean off the detergent completely.
Then wipe the area with a soft dry cloth.
●
Do not use any organic solvent, such as thinner or benzine.
●

SE-2

CLIP AND FASTENER
CLIP AND FASTENER
List of Table

PFP:76906

A
BIS000U6

B

C

D
MIIB0032E

E

F

G

H

SE

J

K

L

M

SE-3

HEATED SEAT
HEATED SEAT
Description
●
●
●

PFP:87335
BIS000U7

When handling seat, be extremely careful not to scratch heating unit.
To replace heating unit, seat trim and pad should be separated.
Do not use any organic solvent, such as thinner, benzene, alcohol, etc. to clean trims.

SBT314

SE-4

HEATED SEAT
Wiring Diagram — H/SEAT

BIS000U8

A

B

C

D

E

F

G

H

SE

J

K

L

M

MIWA0668E

SE-5

HEATED SEAT

MIWA0669E

SE-6

FRONT SEAT
FRONT SEAT
Component Parts Location

PFP:87000

A
BIS000U9

CAUTION:
When removing and installing seats, use shop cloths to protect the parts from damage.

B

C

D

E

F

G

H

SE

J

K

L

M
MIIB9345E

1.

Headrest

2.

4.

Seatback trim & pad

7.

Seatback frame (with active head rest)

Headrest holder (free)

3.

Headrest holder (locked)

5.

Side air bag module*

6.

Fixed inner cross rod*

8.

Seatback frame
(without active head rest)

9.

Armrest (driver only)

10. Seat slide outer finisher

11. Back table

12. Cushion pan undercover

13. Seat slide assembly

14. Seat slide inner finisher

15. Reclining inner finisher

16. Seat lifter lever

17. Reclining dial

18. Seat cushion trim & pad

19. Seat cushion frame

20. Front leg cover (inner)

21. Front leg cover (outer)

22. Rear leg cover (inner)

23. Rear leg cover (outer)

24. Belt buckle assembly**

*: Refer to SRS section (if equipped)
**: Refer to SB section
: Clip
: Always replace after every disassembly

SE-7

FRONT SEAT
: Sealing point
: Use recommended multi-purpose grease.
: Heated seat harness connector (if equipped)

Removal and Installation

BIS000UA

REMOVAL
CAUTION:
Disconnect both battery cables, and wait at least 3 minutes before beginning work.
1. Remove side air bag module connector and seatbelt buckle switch harness connector and heated seat
connectors (if equipped).
2. Remove front and rear leg covers.
3. Remove bolts (4), and remove seat from vehicle.
4. Remove headrest.
CAUTION:
When removing and installing, use shop cloths to protect
parts from damage and interference.

MIIB0034E

INSTALLATION
●
●

Install in the reverse order of removal.
Tighten front seat mounting bolts to the torque.
: 46.6 N·m (4.8 kg-m, 34 ft-lb)

CAUTION:
When removing and installing, use shop cloths to protect parts from damage and interference.

Disassembly and Assembly of Seatback

BIS000UB

SEATBACK TRIM PAD
Disassembly
1.
2.

Unfasten seatback fastener. (Vehicles with side air bags)
Remove retainer.

MIIB0035E

3.

Turn over seatback trim, remove nuts (2), and remove fixed
inner cross rod. (Vehicles with side air bags)

MIIB9097E

SE-8

FRONT SEAT
4.
5.

Use pincers, etc., to push up hooks shown by the arrows in the
figure, and remove headrest holder from seatback.
Remove seatback trim and pad from seatback frame.

A

B

C
MIIB0037E

D

Assembly
Install in the reverse order of removal.
CAUTION:
Before installing headrest holder, check its orientation (front/rear and right/left).

E

SEATBACK FRAME
Disassembly

F
Remove seatback trim&pad.
Pull out side air bag connector from back of seat cushion.
Remove seat lifter lever, reclining dial, seat slide out finisher, slide inner cover, and seat slide inner fin- G
isher.
4. Remove seatback frame bolts and remove seatback frame from seat slide assembly.
H
CAUTION:
When removing or installing, use safety gloves to protect hands and seat cushion.
5. Remove seatback seat trim and pad. Refer to SE-8, «SEATBACK TRIM PAD» .
SE
6. Remove side air bag module. Refer to SRS-42, «Removal and Installation» .
7. Remove seat slide inner finisher.
8. Remove fixing lockwasher from reclining shaft, then remove
J
reclining shaft and pulley from seatback frame.
9. Remove fixing bolts from seatback frame, then remove seatback
frame.
K

1.
2.
3.

L

M

MIIB9207E

SE-9

FRONT SEAT
10. Remove active headrest protector, then remove fixing bolt and
active headrest (if equipped).

MIIB9206E

Assembly
Install in the reverse order of removal.
CAUTION:
After assembling seatback frame, make sure reclining device operates.

Disassembly and Assembly of Seat Cushion

BIS000UC

SEAT CUSHION TRIM PAD
Disassembly
1.

Mark the location of harness connectors and routing of harness
before disassembly.

MIIB9344E

2.
3.
4.
5.

Remove seat lifter cover, seat lifter lever, reclining lever, seat slide out finisher, slide inner cover, and seat
slide inner finisher.
Remove seatback frame bolts, and the remove seat cushion assembly from seatback frame
Remove retainer from the back of cushion.
Remove seat cushion trim&pad from seat cushion frame.

MIIB0038E

Assembly
Install in the reverse order of removal.
CAUTION:
When assembling seat cushion assembly in seatback assembly, make sure the reclining device operates.

SEAT CUSHION FRAME
Disassembly
1.
2.

Remove short cushion trim&pad.
Remove bolts (4), and then remove seat cushion frame from seat slide assembly.

SE-10

FRONT SEAT
Assembly
A

Install in the reverse order of removal.

B

C

D

E

F

G

H

SE

J

K

L

M

SE-11

REAR SEAT
REAR SEAT
Removal and Installation

PFP:88300
BIS000UE

REMOVAL
1.
2.
3.

Slide the rear seat forward.
Remove seat rail cover LH and RH (1).
Remove slide seat rear mountings bolts from the rear floor.

MIIB9342E

4.
5.

Remove leg cover LH and RH (1).
Remove slide seat front mountings bolts.

MIIB9341E

6.

Recline the backseat and remove the slide seat assembly from
rear door.
NOTE:
This operation requires two workers.

MIIB9343E

INSTALLATION
●
●

Install in the reverse order of removal.
Tighten mountings bolts to the specified torque

SE-12

REAR SEAT
Rear Seat Disassembly and Assembly

BIS00161

A

B

C

D

E

F

G

H

SE

J

K

L

M

MIIB9340E

SE-13

REAR SEAT
1.

Headrest

2.

Seatback reclining cable RH

3.

Reclining cable clip

4.

Seatback reclining lever RH

5.

Seatback frame RH

6.

Headrest holder

7.

Seatback reclining lever LH

8.

Seat belt retractor centre

9.

Rope hook

10. Seatback frame RH

11. Seatback frame LH

12. Seatback reclining cable LH

13. Seatback trim and pad RH

14. Armrest carpet

15. Armrest

16. Bolt

17. Bush

18. Armrest cap RH

19. Armrest cap LH

20. Seatback trim and pad LH

21. Seat rail cover RH

22. Seat rail cover LH

23. Carpet finisher

24. Seat belt buckle RH

25. Release bracket

26. Reclining device RH

27. Seat belt buckle centre

28. Slide seat handle

29. Release cross tube

30. Seat belt buckle LH

31. Reclining device LH

32. Hinge cover RH outer

33. Hinge cover RH inner

34. Reclining device cover RH

35. Reclining device cover LH

36. Hinge cover LH inner

37. Hinge cover LH outer

38. Cushion bracket RH

39. Pin

40. Rail assembly RH

41. Strap

42. Cushion bracket LH

43. Rail assembly LH

44. Seat cushion trim and pad

45. Cross bar

46. Leg cover RH

47. Slide seat lever

48. Leg cover LH

49. Seat cushion frame

SE-14

STARTING & CHARGING SYSTEM

K ELECTRICAL

SECTION

SC

STARTING & CHARGING SYSTEM

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 3
PREPARATION ………………………………………………….. 4
Special Service Tools ……………………………………….. 4
BATTERY ………………………………………………………….. 5
How to Handle Battery ……………………………………… 5
METHODS OF PREVENTING OVER-DISCHARGE ……………………………………………………… 5
CHECKING ELECTROLYTE LEVEL ……………….. 5
SPECIFIC GRAVITY CHECK …………………………. 6
Battery Test and Charging Chart ………………………… 7
CHART I ………………………………………………………. 7
CHART II ……………………………………………………… 8
A: SLOW CHARGE ……………………………………….. 9
B: STANDARD CHARGE ……………………………….11
C: QUICK CHARGE …………………………………….. 12
Removal and Installation …………………………………. 14
REMOVAL ………………………………………………….. 14
INSTALLATION …………………………………………… 14
CHARGING SYSTEM ……………………………………….. 15
System Description (CR Engine Models) …………… 15
System Description (HR Engine Models) …………… 15
System Description (K9K Engine Models) …………. 15
Wiring Diagram — CHARGE —/CR Engine Models… 16
Wiring Diagram — CHARGE —/HR Engine Models… 17
Wiring Diagram — CHARGE —/K9K Engine Models ………………………………………………………………… 18
Trouble Diagnoses (CR Engine Models) ……………. 20
DIAGNOSIS PROCEDURE ………………………….. 20
PRE-DIAGNOSIS INSPECTION ……………………. 20
DIAGNOSIS CHART BY SYMPTOM ……………… 20
INSPECTION FLOW BY CHARGE WARNING
LAMP ………………………………………………………… 20
CHARGE WARNING LAMP LINE INSPECTION… 21
INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION ………………………… 22
INSPECTION OF EXCESSIVE ALTERNATOR
POWER GENERATION ……………………………….. 23

SC-1

DARK CURRENT INSPECTION ……………………. 23
OPERATION PROCEDURE OF CURRENT
MEASUREMENT PROBE FOR CONSULT-II ….. 24
Trouble Diagnoses (HR Engine Models) ……………. 25
DIAGNOSIS PROCEDURE ………………………….. 25
PRE-DIAGNOSIS INSPECTION ……………………. 25
DIAGNOSIS CHART BY SYMPTOM ……………… 25
INSPECTION FLOW BY CHARGE WARNING
LAMP …………………………………………………………. 25
CHARGE WARNING LAMP LINE INSPECTION… 26
VOLTAGE DETECTION LINE AND CHARGE
WARNING LAMP INSPECTION ……………………. 27
INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION ………………………… 28
INSPECTION OF EXCESSIVE ALTERNATOR
POWER GENERATION ……………………………….. 29
DARK CURRENT INSPECTION ……………………. 30
OPERATION PROCEDURE OF CURRENT
MEASUREMENT PROBE FOR CONSULT-II ….. 31
Trouble Diagnoses (K9K Engine Models) ………….. 32
DIAGNOSIS PROCEDURE ………………………….. 32
PRE-DIAGNOSIS INSPECTION ……………………. 32
DIAGNOSIS CHART BY SYMPTOM ……………… 32
INSPECTION FLOW BY CHARGE WARNING
LAMP …………………………………………………………. 32
CHARGE WARNING LAMP LINE INSPECTION… 33
VOLTAGE DETECTION LINE AND CHARGE
WARNING LAMP INSPECTION ……………………. 34
INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION ………………………… 36
INSPECTION OF EXCESSIVE ALTERNATOR
POWER GENERATION ……………………………….. 36
DARK CURRENT INSPECTION ……………………. 37
OPERATION PROCEDURE OF CURRENT
MEASUREMENT PROBE FOR CONSULT-II ….. 38
Removal and Installation (CR Engine Models) ……. 39
REMOVAL ………………………………………………….. 39
INSTALLATION …………………………………………… 40
Removal and Installation (HR Engine Models) ……. 40
REMOVAL ………………………………………………….. 40

E

F

G

H

I

J

SC

L

M

INSTALLATION ……………………………………………. 41
Removal and Installation (K9K Engine Models) ….. 42
REMOVAL ………………………………………………….. 42
INSTALLATION ……………………………………………. 42
Disassembly ………………………………………………….. 42
REAR COVER …………………………………………….. 42
REAR BEARING …………………………………………. 43
Inspection ……………………………………………………… 43
ROTOR CHECK ………………………………………….. 43
BRUSH CHECK ………………………………………….. 43
STATOR CHECK …………………………………………. 43
Assembly ………………………………………………………. 44
RING FITTING IN REAR BEARING ……………….. 44
REAR COVER INSTALLATION ……………………… 44
STARTING SYSTEM …………………………………………. 45
System Description …………………………………………. 45
M/T MODELS ……………………………………………… 45
A/T MODELS ………………………………………………. 45
Wiring Diagram — START — /CR and HR Engine
Models ………………………………………………………….. 46
Wiring Diagram — START — /K9K Engine Models… 48
Trouble Diagnoses ………………………………………….. 50
Removal and Installation (CR Engine Models) ……. 51

REMOVAL ……………………………………………………51
INSTALLATION …………………………………………….51
Removal and Installation (HR Engine Models) …….51
REMOVAL ……………………………………………………51
INSTALLATION …………………………………………….52
Removal and Installation (K9K Engine Models) ……52
REMOVAL ……………………………………………………52
INSTALLATION …………………………………………….52
Disassembly and Assembly ………………………………52
Inspection ……………………………………………………….55
MAGNETIC SWITCH CHECK ………………………..55
PINION/CLUTCH CHECK ……………………………..55
BRUSH CHECK ……………………………………………55
YOKE CHECK ……………………………………………..57
ARMATURE CHECK …………………………………….57
Assembly ……………………………………………………….58
PINION PROTRUSION LENGTH ADJUSTMENT ………………………………………………………….58
SERVICE DATA AND SPECIFICATIONS (SDS) ……60
Battery ……………………………………………………………60
Starter ……………………………………………………………60
Alternator ……………………………………………………….60

SC-2

PRECAUTIONS
PRECAUTIONS
PFP:00011
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

A

BKS000TY

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

B

C

D

E

F

G

H

I

J

SC

L

M

SC-3

PREPARATION
PREPARATION
Special Service Tools

PFP:00002
BKS000TZ

Tool number
Tool name

Description

EG1187 1900
Current measurement probe for
CONSULT-II

System diagnose and inspection

MKIA0065E

SC-4

BATTERY
BATTERY
How to Handle Battery

PFP:00011

A
BKS000U0

CAUTION:
●
If it becomes necessary to start the engine with a booster battery and jumper cables, use a 12-volt
booster battery.
●
After connecting battery cables, ensure that they are tightly clamped to battery terminals for good
contact.
●
Never add distilled water through the hole used to check specific gravity.

B

C

METHODS OF PREVENTING OVER-DISCHARGE
D

The following precautions must be taken to prevent over-discharging a battery.
●
The battery surface (particularly its top) should always be kept
clean and dry.
●
The terminal connections should be clean and tight.
●
At every routine maintenance, check the electrolyte level.
This also applies to batteries designated as “low maintenance”
and “maintenance-free”.

E

F

G
MEL040F

●

H

When the vehicle is not going to be used over a long period of
time, disconnect the negative battery terminal. (If the vehicle has
an extended storage switch, turn it off.)

I

J

SC
MEL041F

●

Check the charge condition of the battery.
Periodically check the specific gravity of the electrolyte. Keep a
close check on charge condition to prevent over-discharge.

L

M

MEL042F

CHECKING ELECTROLYTE LEVEL
WARNING:
Do not allow battery fluid to come in contact with skin, eyes, fabrics, or painted surfaces. After touching a battery, do not touch or rub your eyes until you have thoroughly washed your hands. If acid contacts eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention.

SC-5

BATTERY
●
●

Remove the cell plug using a suitable tool.
Add distilled water up to the MAX level.

MEL043F

Sulphation
A battery will be completely discharged if it is left unattended
for a long time and the specific gravity will become less than
1.100. This may result in sulphation on the cell plates.
To determine if a battery has been “sulphated”, note its voltage
and current when charging it. As shown in the figure, less current and higher voltage are observed in the initial stage of
charging sulphated batteries.
A sulphated battery may sometimes be brought back into service by means of a long, slow charge, 12 hours or more, followed by a battery capacity test.
SEL709E

SPECIFIC GRAVITY CHECK
1. Read hydrometer and thermometer indications at eye level.
2. Convert into specific gravity at 20°C (68°F).
Example:
●
When electrolyte temperature is 35°C (95°F) and specific gravity
of electrolyte is 1.230, converted specific gravity at 20°C (68°F)
is 1.240.
●
When electrolyte temperature is 0°C (32°F) and specific gravity
of electrolyte is 1.210, converted specific gravity at 20°C (68°F)
is 1.196.
MEL042FA

SEL007Z

SC-6

BATTERY
Battery Test and Charging Chart

BKS000U1

A

CHART I

B

C

D

E

F

G

H

I

J

SC

L

M

SEL754W

*1. SC-6, «SPECIFIC GRAVITY
CHECK»

*2. SC-8, «CHART II»

*4. SC-11, «B: STANDARD CHARGE»

*5. SC-12, «C: QUICK CHARGE»

SC-7

*3. SC-9, «A: SLOW CHARGE»

BATTERY
CHART II

SEL755W

*.
●

SC-7, «CHART I»

Check battery type and determine the specified current using the following table.

Fig. 1 Discharging Current (Load Tester)
Type

Current (A)

28B19R(L)

90

34B19R(L)

99

46B24R(L)

135

55B24R(L)

135

50D23R(L)

150

55D23R(L)

180

65D26R(L)

195

80D26R(L)

195

75D31R(L)

210

063 [YUASA type code]

210

95D31R(L)

240

115D31R(L)

240

025 [YUASA type code]

240

065 [YUASA type code]

255

027 [YUASA type code]

285

075 [YUASA type code]

300

110D26R(L)

300

95E41R(L)

300

067 [YUASA type code]

325

SC-8

BATTERY
Type

Current (A)

130E41R(L)

330

096 [YUASA type code]

375

096 [YUASA type code]

375

010S [YUASA type code]

360

LB1 FCM 047 620 [EXIDE type code]

420

LB2 FCM 055 622 [EXIDE type code]

510

LB2 FCM 050 622 [EXIDE type code]

600

A

B

C

A: SLOW CHARGE

D

E

F

G

H

I

J

SC

L
SEL756W

*1. SC-6, «SPECIFIC GRAVITY
CHECK»

*2. SC-8, «CHART II»

M

SC-9

BATTERY

130E41R(L)

010S [YUASA type code]

075 [YUASA type code]

096L [YUASA type code]

11.0
(A)

14.0 (A)

10.0 (A)

065 [YUASA type code]

95E41R(L)

110D26R(L)

115D31R(L)

95D31R(L)

75D31R(L)
9.0 (A)

8.0 (A)

067 [YUASA type code]

063 [YUASA type code]

80D26R(L)

65D26R(L)

027 [YUASA type code]

025 [YUASA type code]

50D23R(L)

55D23R(L)

7.0 (A)

096 [YUASA type code]

5.0 (A)

8.5 (A)

4.0 (A)

55B24R(L)

3.0
(A)

46B24R(L)

2.75
(A)

34B19R(L)

LB2 FCM 055 622
[EXIDE type code]

2.55
(A)

28B19R(L)

LB2 FCM 050 622
[EXIDE type code]

BATTERY TYPE

LB1 FCM 047 620
[EXIDE type code]

Below 1.100

CON-VERTED SPECIFIC GRAVITY

Fig. 2 Initial Charging Current Setting (Slow Charge)

Check battery type and determine the specified current using the table shown above.
After starting charging, adjustment of charging current is not necessary.

●
●

Fig. 3 Additional Charge (Slow Charge)

SEL757W

*.

SC-8, «CHART II»

CAUTION:
●
Set charging current to value specified in Fig. 2. If charger is not capable of producing specified
current value, set its charging current as close to that value as possible.
●
Keep battery away from open flame while it is being charged.
●
When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark.
●
If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°F).

SC-10

LB1 FCM 047 620 [EXIDE type code]

4.1(A)

3.4(A)

2.0 (A)

2.8(A)

2.0 (A)

2.1(A)

SC-11

4.0 (A)

8.0 (A)

5.0 (A)

6.0 (A)
13.0 (A)

7.0 (A)

11.0 (A)

9.0 (A)

9.0 (A)

3.0 (A)

8.0 (A)

7.0 (A)

5.0 (A)
8.0 (A)

4.0 (A)
10.0 (A)

7.0 (A)

6.0 (A)
9.0 (A)

6.0 (A)

5.0 (A)
130E41R(L)

010S [YUASA type code]

096L [YUASA type code]

075 [YUASA type code]

065 [YUASA type code]

95E41R(L)

110D26R(L)

115D31R(L)

95D31R(L)

75D31R(L)

096 [YUASA type code]

067 [YUASA type code]

063 [YUASA type code]

80D26R(L)

65D26R(L)

027 [YUASA type code]

025 [YUASA type code]

55D23R(L)

50D23R(L)

LB2 FCM 055 622 [EXIDE type code]

*1. SC-6, «SPECIFIC GRAVITY
CHECK»

5.0 (A)

2.0(A)

4.2(A)

2.0 (A)
7.0 (A)

3.3(A)

3.3(A)

3.0 (A)
6.0 (A)

2.4(A)

46B24R(L)

4.0(A)

4.0 (A)
55B24R(L)

LB2 FCM 050 622 [EXIDE type code]

4.8(A)
5.0 (A)

2.3(A)

34B19R(L)

28B19R(L)

1.130 — 1.160

3.0 (A)

1.160 — 1.190
CON-VERTED SPECIFIC GRAVITY

1.100 — 1.130
4.0 (A)

1.190 — 1.220

BATTERY

B: STANDARD CHARGE
A

B

C

D

E

F

*2. SC-8, «CHART II»
SEL758W

G

Fig. 4 Initial Charging Current Setting (Standard Charge)

BATTERY TYPE

H

I

J

SC

L

M

BATTERY
Check battery type and determine the specified current using the table shown above.
After starting charging, adjustment of charging current is not necessary.

●
●

Fig. 5 Additional Charge (Standard Charge)

SEL759W

*.

SC-8, «CHART II»

CAUTION:
●
Do not use standard charge method on a battery whose specific gravity is less than 1.100.
●
Set charging current to value specified in Fig. 4. If charger is not capable of producing specified
current value, set its charging current as close to that value as possible.
●
Keep battery away from open flame while it is being charged.
●
When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark.
●
If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°F).

C: QUICK CHARGE

SEL760W

*.

SC-8, «CHART II»

SC-12

BATTERY

CONVERTED SPECIFIC GRAVITY
Above 1.220 1.190 — 1.220 1.160 — 1.190

1.130 — 1.160

1.100 — 1.130

130E41R(L)

95E41R(L)

110D26R(L)

115D31R(L)

95D31R(L)

B
75D31R(L)

010S [YUASA type code]

096L [YUASA type code]

075 [YUASA type code]

065 [YUASA type code]

096 [YUASA type code]

067 [YUASA type code]

LB2 FCM 055 622 [EXIDE type code]

LB2 FCM 050 622 [EXIDE type code]

LB1 FCM 047 620 [EXIDE type code]

063 [YUASA type code]

027 [YUASA type code]

025 [YUASA type code]

80D26R(L)

65D26R(L)

55D23R(L)

50D23R(L)

55B24R(L)

46B24R(L)

34B19R(L)

28B19R(L)

A

C

D

20 (A)

25 (A)

30 (A)

40 (A)

15 (A)

24(A)

10 (A)

23(A)

E
21(A)

CURRENT [A]

BATTERY TYPE

Fig. 6 Initial Charging Current Setting and Charging Time (Quick Charge)

F

2.5 hours

G

H
2.0 hours

I

1.5 hours

J

SC
1.0 hours

L

0.75 hours (45 min.)

Check battery type and determine the specified current using the table shown above.
●
After starting charging, adjustment of charging current is not necessary.
CAUTION:
●
Do not use quick charge method on a battery whose specific gravity is less than 1.100.
●
Set initial charging current to value specified in Fig. 6. If charger is not capable of producing specified current value, set its charging current as close to that value as possible.
●
Keep battery away from open flame while it is being charged.
●
When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark.
●
Be careful of a rise in battery temperature because a large current flow is required during quickcharge operation.
If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°F).
●

SC-13

M

BATTERY
●

Do not exceed the charging time specified in Fig. 6, because charging battery over the charging
time can cause deterioration of the battery.

Removal and Installation

BKS000U2

REMOVAL
1.

2.
3.

Loosen battery terminal nuts (A), and disconnect both battery
cables from battery terminals.
CAUTION:
When disconnecting, disconnect the battery cable from the
negative terminal fist.
Loosen battery bracket mounting bolt (B), and remove battery
bracket (1).
Remove battery.
MKIB2317E

INSTALLATION
Installation is the reverse order of removal.
CAUTION:
When connecting, connect the battery cable to the positive terminal fist.
Battery bracket mounting bolt:
: 14.2 N·m (1.4 kg-m, 10 ft-lb)
Battery cable tightening nut:
: 5.15 N·m (0.53 kg-m, 46 in-lb)

SC-14

CHARGING SYSTEM
CHARGING SYSTEM
System Description (CR Engine Models)

PFP:00011

A
BKS000U3

The alternator provides DC voltage to operate the vehicle’s electrical system and to keep the battery charged.
The voltage output is controlled by the IC regulator.
Terminal B supplies power to charge the battery and operate the vehicle’s electrical system. The charging circuit is protected by the 100A link.
The alternator is grounded to the body.
With the ignition switch in the ON or START position, power is supplied
●
10A fuse [No. 4, located in the fuse block (J/B)]
●
to combination meter terminal 28 for the charge warning lamp.
Ground is supplied
●
to terminal 38 of the combination meter
●
through terminal 4 (L) of the alternator.
The charge warning lamp will illuminate. When the alternator is providing sufficient voltage with the engine
running, the ground is opened and the charge warning lamp will go off.
If the charge warning lamp illuminates with the engine running, a fault is indicated.

System Description (HR Engine Models)

B

C

D

E

F

BKS000U4

The alternator provides DC voltage to operate the vehicle’s electrical system and to keep the battery charged.
G
The voltage output is controlled by the IC regulator.
Power is supplied at all times to alternator terminal 3 through:
●
10A fuse [No. 36, located in the fuse block (J/B)].
Terminal B supplies power to charge the battery and operate the vehicle’s electrical system.The charging cir- H
cuit is protected by the 100A link.
The alternator is grounded to the body.
With the ignition switch in the ON or START position, power is supplied
I
●
10A fuse [No. 4, located in the fuse block (J/B)]
●
to combination meter terminal 28 for the charge warning lamp.
J
Ground is supplied
●
to terminal 38 of the combination meter
●
through terminal 2 (L) of the alternator.
SC
The charge warning lamp will illuminate. When the alternator is providing sufficient voltage with the engine
running, the ground is opened and the charge warning lamp will go off.
If the charge warning lamp illuminates with the engine running, a fault is indicated.
L

System Description (K9K Engine Models)

BKS000U5

The alternator provides DC voltage to operate the vehicle’s electrical system and to keep the battery charged.
The voltage output is controlled by the IC regulator.
With the ignition switch in the ON or START position, power is supplied to alternator terminal 4 (S) through:
●
IPDM E/R (Intelligent Power Distribution Module Engine Room)
Terminal B supplies power to charge the battery and operate the vehicle’s electrical system. Output voltage is
controlled by the IC regulator at terminal 4 (S) detecting the input voltage. The charging circuit is protected by
the 100A link.
The alternator is grounded to the body.
With the ignition switch in the ON or START position, power is supplied
●
10A fuse [No. 4, located in the fuse block (J/B)]
●
to combination meter terminal 28 for the charge warning lamp.
Ground is supplied
●
to terminal 38 of the combination meter
●
through terminal 3 (L) of the alternator.
The charge warning lamp will illuminate. When the alternator is providing sufficient voltage with the engine
running, the ground is opened and the charge warning lamp will go off.
If the charge warning lamp illuminates with the engine running, a fault is indicated.

SC-15

M

CHARGING SYSTEM
Wiring Diagram — CHARGE —/CR Engine Models

BKS000U6

MKWA4267E

SC-16

CHARGING SYSTEM
Wiring Diagram — CHARGE —/HR Engine Models

BKS000U7

A

B

C

D

E

F

G

H

I

J

SC

L

M

MKWA4268E

SC-17

CHARGING SYSTEM
Wiring Diagram — CHARGE —/K9K Engine Models

BKS000U8

MKWA4269E

SC-18

CHARGING SYSTEM
A

B

C

D

E

F

G

H

I

J

SC

L

M

MKWA4270E

SC-19

CHARGING SYSTEM
Trouble Diagnoses (CR Engine Models)

BKS000U9

DIAGNOSIS PROCEDURE
1.
2.
3.
4.
5.

Check malfunction symptoms or customer’s remarks.
Perform pre-diagnosis inspection. Refer to SC-20, «PRE-DIAGNOSIS INSPECTION» .
Perform trouble diagnosis for each trouble symptom. Refer to SC-20, «DIAGNOSIS CHART BY SYMPTOM»
Repair or replace parts indicated inspection flow based on the charge warning lamp. Refer to SC-20,
«INSPECTION FLOW BY CHARGE WARNING LAMP» .
End

PRE-DIAGNOSIS INSPECTION
1.
2.
3.
4.
5.
6.

Perform alternator belt inspection. Refer to EM-14, «DRIVE BELTS» .
Inspect battery.
Check alternator terminal B for loose or improper connection.
Check alternator connector and terminals for loose connection, disconnection and bend.
Check connecting condition of harness for charging system harness (fusible link terminal and battery terminal).
After performing 1 to 5 above, go to trouble diagnosis for symptoms. Refer to SC-20, «DIAGNOSIS
CHART BY SYMPTOM» .

DIAGNOSIS CHART BY SYMPTOM
Symptom

Reference page

Battery discharge
Charge warning lamp illuminates.

Refer to SC-20, «INSPECTION FLOW BY CHARGE WARNING LAMP» .

Other than the above symptoms (splashing out of battery fluid,
nasty smell and others)

Refer to SC-23, «INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION» .

INSPECTION FLOW BY CHARGE WARNING LAMP

1. CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch ON.
2. Check if charge warning lamp illuminates.
Does charge warning lamp illuminate?
YES >> GO TO 2.
NO
>> Go to SC-21, «CHARGE WARNING LAMP LINE
INSPECTION» .

MKIB0555E

2. CHARGE WARNING LAMP INSPECTION
1. Set engine speed at 2,500 rpm.
2. Check if charge warning lamp illuminates.
Does charge warning lamp illuminate?
YES >> Go to SC-23, «INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION» .
NO
>> Go to SC-22, «INSPECTION OF INSUFFICIENT
ALTERNATOR POWER GENERATION» .

MKIB0555E

SC-20

CHARGING SYSTEM
CHARGE WARNING LAMP LINE INSPECTION
A

CAUTION:
If open circuit is detected in L terminal, alternator cannot start generating.

INSPECTION PROCEDURE

B

1. CHARGE WARNING LAMP INSPECTION
1.
2.
3.

Turn ignition switch OFF.
Disconnect alternator connector
Connect alternator connector terminal 4 to ground.

C

D

E

MKIB1916E

4. Turn ignition switch ON.
Does charge warning lamp illuminate?
YES >> GO TO 4.
NO
>> GO TO 2.

F

G

H

I
MKIB0555E

2. CONNECTOR INSPECTION

J

1.
2.

Turn ignition switch OFF.
Check meter and terminals (meter side, and harness side) for damage, deformation or improper connec- SC
tion.
OK or NG
L
OK
>> GO TO 3.
NG
>> Repair terminals and connectors.

3. CONTINUITY INSPECTION
1.
2.

M

Disconnect combination meter connector.
Check continuity between combination meter connector terminal 38 and ground, and combination meter
connector terminal 38 and alternator connector terminal 4.
38 — Ground
38 — 4

: Continuity should not exist.
: Continuity should exist.

OK or NG
OK
>> Replace combination meter. (Do not replace alternator, since it is normal.)
NG
>> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)

SC-21

CHARGING SYSTEM

4. CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch OFF.
2. Connect alternator connector.
3. Turn ignition switch ON.
Does charge warning lamp illuminate?
YES >> Repair alternator connector. (Poor connection and intermittent problem) (Do not replace alternator, since it is
normal.)
NO
>> Replace alternator. (circuit malfunction in alternator)
MKIB0555E

INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION
CAUTION:
Check them using charged battery performed battery inspection.

1. VOLTAGE INSPECTION
1.
2.

Increase engine speed to 2,500 rpm.
Turn electrical load to ON. (Headlamp LO turns on, blower fan
motor maximum airflow amount)
3. Check battery voltage.
Is the inspection result 12.8V to 15.1V?
YES >> GO TO 2.
NO
>> Replace alternator. (Alternator power generation error.)

MKIA0067E

2. CURRENT INSPECTION
1.
2.
3.

Turn the ignition switch OFF.
Disconnect the battery ground cable.
Attach current measurement probe for CONSULT-II to the harness for alternator terminal B.
(If the probe can not be attached properly, then connect the subharness between alternator terminal B and the vehicle side harness as shown in figure, and attach the probe to sub-harness.)
4. Connect battery ground cable.
5. Increase engine speed to 2,500 rpm.
6. Turn electrical load to ON. (Headlamp LO turns on, blower fan
motor maximum airflow amount, rear window defogger)
7. Check alternator terminal B current.
CAUTION:
Be careful of rotating parts because the engine is running.
MKIA0068E
Is the inspection result 30A or more?
YES >> GO TO dark current inspection. Refer to SC-23, «DARK CURRENT INSPECTION» . (Alternator is
normal. Do not replace.)
NO
>> Replace alternator. (Alternator power generation error.)

SC-22

CHARGING SYSTEM
INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION
A

1. ALTERNATOR VOLTAGE INSPECTION
1. Increase engine speed to 2,500 rpm.
2. Check battery voltage.
Is the inspection result 16V or less?
YES >> Replace alternator. (Alternator power generation error.)
NO
>> Replace alternator. (Excessive alternator power generation.)

B

C

D
MKIA0067E

E

DARK CURRENT INSPECTION

Dark Current: Small current while ignition switch is “OFF”.
NOTE:
F
●
If battery ground cable is disconnected from battery terminal, a large dark current may not be reproduced.
When battery discharge occurs, never disconnect battery terminal while using ammeter.
●
Do not connect CONSULT-II CONVERTER to data link connector when measuring dark current. CON- G
SULT-II power should be supplied using AC adapter or internal battery.
1. Attach current measurement probe for CONSULT-II to battery
ground cable. Refer to SC-24, «OPERATION PROCEDURE OF
H
CURRENT MEASUREMENT PROBE FOR CONSULT-II» .
2. Check that all electrical equipment is turned OFF.
3. Remove key. Close and lock doors. Check that room lamp turns
I
off.
4. Measure dark current. Is it 50mA or less? Refer to SC-24,
«OPERATION PROCEDURE OF CURRENT MEASUREMENT
J
PROBE FOR CONSULT-II» .
NOTE:
MKIA0070E
Dark current stable time is different due to equipment and use of
the vehicle. If it is not 50mA or less after leaving for 1 minute, measure dark current again after leaving for SC
30 minutes or more.
If YES, GO TO 7. If NO, GO TO 5.
5. Remove and install fuses one by one. Search for the fuse that greatly changes dark current.
L
NOTE:
If dark current is greatly reduced when removing the fuse, and even if dark current is not greatly increased
when installing it again, the fuse circuit may be the cause.
M
6. Check that dark current changes when moving the suspect circuit harness. If dark current changes, check
harness for short. If dark current does not change, electronic unit in the circuit may not be entering the
energy-saving mode when it turns OFF. If it does not enter the energy-saving mode, replace electronic
unit.
7. No malfunction for alternator and electrical equipment. Electric load may be larger than alternator generating ability. Check the customer’s usage.

SC-23

CHARGING SYSTEM
OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II
For details, refer to the supplied “CONSULT-II Current Probe Operation Manual”.
1. Turn current probe power supply OFF and connect to CONSULT-II. (Red: CH1, Black: Ground)
2. Touch “SUB MODE”.
3. Touch “Extending Measurement Mode” on “SUB MODE” screen.
4. CAUTION is displayed, touch “OK”.

MKIA0071E

5.

6.

Set current probe range switch at the range to measure, turn
current probe power supply ON. When measuring dark current,
set 4A range. (Check that POWER indicator turns on. Refer to
CONSULT-II Current Probe Operation Manual.)
Touch the same measuring range at CONSULT-II.
NOTE:
If current probe measuring range is different from CONSULT-II
measuring range, incorrect value is displayed.

MKIA0072E

7.

Adjust 0 point of current probe or CONSULT-II. (Do not clamp
anything to probe.)
NOTE:
If 0 point is dislocated greatly, adjust at current probe side generally.

MKIA0073E

8.

Align current direction mark, clamp harness, and measure current. If current direction is incorrect, it is displayed negative
value.
NOTE:
● When current is measured, close probe joint securely.
● If multiple harnesses are clamped, measurement cannot be
performed. Always clamp only one.

MKIA0074E

SC-24

CHARGING SYSTEM
Trouble Diagnoses (HR Engine Models)

BKS000UA

DIAGNOSIS PROCEDURE

A

1.
2.
3.

B

4.
5.

Check malfunction symptoms or customer’s remarks.
Perform pre-diagnosis inspection. Refer to SC-25, «PRE-DIAGNOSIS INSPECTION» .
Perform trouble diagnosis for each trouble symptom. Refer to SC-25, «DIAGNOSIS CHART BY SYMPTOM» .
Repair or replace parts indicated inspection flow based on the charge warning lamp. Refer to SC-25,
«INSPECTION FLOW BY CHARGE WARNING LAMP» .
End

PRE-DIAGNOSIS INSPECTION
1.
2.
3.
4.
5.
6.

Perform alternator belt inspection. Refer to EM-114, «DRIVE BELTS» .
Inspect battery.
Check alternator terminal B for loose or improper connection.
Check alternator connector and terminals for loose connection, disconnection and bend.
Check connecting condition of harness for charging system harness (fusible link terminal and battery terminal).
After performing 1 to 5 above, go to trouble diagnosis for symptoms. Refer to SC-25, «DIAGNOSIS
CHART BY SYMPTOM» .

C

D

E

F

G

DIAGNOSIS CHART BY SYMPTOM
Symptom

Reference page

Battery discharge
Charge warning lamp illuminates.

Refer to SC-25, «INSPECTION FLOW BY CHARGE WARNING LAMP» .

Other than the above symptoms (splashing out of battery fluid,
nasty smell and others)

Refer to SC-29, «INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION» .

H

I

INSPECTION FLOW BY CHARGE WARNING LAMP

1. CHARGE WARNING LAMP INSPECTION

J

1. Turn ignition switch ON.
2. Check if charge warning lamp illuminates.
Does charge warning lamp illuminate?
YES >> GO TO 2.
NO
>> Go to SC-26, «CHARGE WARNING LAMP LINE
INSPECTION» .

SC

L

M
MKIB0555E

2. CHARGE WARNING LAMP INSPECTION
1. Start engine.
2. Check if charge warning lamp goes off.
Does charge warning lamp goes off?
YES >> GO TO 3.
NO
>> Go to SC-27, «VOLTAGE DETECTION LINE AND
CHARGE WARNING LAMP INSPECTION» .

MKIB0556E

SC-25

CHARGING SYSTEM

3. CHARGE WARNING LAMP INSPECTION
1. Set engine speed at 2,500 rpm.
2. Check if charge warning lamp illuminates.
Does charge warning lamp illuminate?
YES >> Go to SC-29, «INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION» .
NO
>> Go to SC-28, «INSPECTION OF INSUFFICIENT
ALTERNATOR POWER GENERATION» .

MKIB0555E

CHARGE WARNING LAMP LINE INSPECTION
CAUTION:
If open circuit is detected in L terminal, alternator cannot start generating.

INSPECTION PROCEDURE

1. CHARGE WARNING LAMP INSPECTION
1.
2.
3.

Turn ignition switch OFF.
Disconnect alternator connector
Connect alternator connector terminal 2 to ground.

MKIB1917E

4. Turn ignition switch ON.
Does charge warning lamp illuminate?
YES >> GO TO 4.
NO
>> GO TO 2.

MKIB0555E

2. CONNECTOR INSPECTION
1.
2.

Turn ignition switch OFF.
Check meter and terminals (meter side, and harness side) for damage, deformation or improper connection.
OK or NG
OK
>> GO TO 3.
NG
>> Repair terminals and connectors.

SC-26

CHARGING SYSTEM

3. CONTINUITY INSPECTION
1.
2.

A

Disconnect combination meter connector.
Check continuity between combination meter connector terminal 38 and alternator connector terminal 2.
38 — 2

B

: Continuity should exist.

OK or NG
OK
>> Replace combination meter. (Do not replace alternator, since it is normal.)
NG
>> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)

C

4. CHARGE WARNING LAMP INSPECTION

D

1. Turn ignition switch OFF.
2. Connect alternator connector.
3. Turn ignition switch ON.
Does charge warning lamp illuminate?
YES >> Repair alternator connector. (Poor connection and intermittent problem) (Do not replace alternator, since it is
normal.)
NO
>> Replace alternator. (circuit malfunction in alternator)

E

F

G
MKIB0555E

VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION
INSPECTION PROCEDURE

H

1. CHARGE WARNING LAMP INSPECTION
I

1. Turn ignition switch OFF.
2. Disconnect alternator connector.
3. Turn ignition switch ON.
Does charge warning lamp stay ON?
YES >> GO TO 5.
NO
>> GO TO 2.

J

SC

L
MKIB0555E

2. VOLTAGE INSPECTION

M

Check voltage between alternator connector terminal 3 and ground.
3 — Ground

: 12V or more

Is the inspection result 12V or more?
YES >> Replace alternator.
NO
>> GO TO 3.

MKIB1918E

SC-27

CHARGING SYSTEM

3. CONNECTOR INSPECTION
1.
2.

Turn ignition switch OFF.
Check alternator connector and terminal 3 (alternator side, and harness side) for damage, deformation or
improper connection.
OK or NG
OK
>> GO TO 4.
NG
>> Repair terminals and connectors.

4. CHECK FUSE
Check if alternator S terminal fuse #36 (10A) is blown.
OK or NG
OK
>> Repair harness between fuse #36 (10A) and alternator connector terminal 3. (Do not replace
alternator, since it is normal.)
NG
>> Replace fuse. (Do not replace alternator, since it is normal.)

5. CONTINUITY INSPECTION
1.
2.
3.

Turn ignition switch OFF.
Disconnect combination meter connector.
Check continuity between combination meter connector terminal 38 and ground, and combination meter
connector terminal 38 and alternator connector terminal 2.
38 — Ground
38 — 2

: Continuity should not exist.
: Continuity should exist.

OK or NG
OK
>> Replace combination meter. (Do not replace alternator, since it is normal.)
NG
>> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)

INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION
CAUTION:
Check them using charged battery performed battery inspection.

1. VOLTAGE INSPECTION
1.
2.

Increase engine speed to 2,500 rpm.
Turn electrical load to ON. (Headlamp LO turns on, blower fan
motor maximum airflow amount)
3. Check battery voltage.
Is the inspection result 12.8V to 15.1V?
YES >> GO TO 2.
NO
>> Replace alternator. (Alternator power generation error.)

MKIA0067E

SC-28

CHARGING SYSTEM

2. CURRENT INSPECTION

A

1.
2.
3.

Turn the ignition switch OFF.
Disconnect the battery ground cable.
Attach current measurement probe for CONSULT-II to the harness for alternator terminal B.
(If the probe can not be attached properly, then connect the subharness between alternator terminal B and the vehicle side harness as shown in figure, and attach the probe to sub-harness.)
4. Connect battery ground cable.
5. Increase engine speed to 2,500 rpm.
6. Turn electrical load to ON. (Headlamp LO turns on, blower fan
motor maximum airflow amount, rear window defogger)
7. Check alternator terminal B current.
CAUTION:
Be careful of rotating parts because the engine is running.
MKIA0068E
Is the inspection result 30A or more?
YES >> GO TO dark current inspection. Refer to SC-30, «DARK CURRENT INSPECTION» . (Alternator is
normal. Do not replace.)
NO
>> Replace alternator. (Alternator power generation error.)

B

C

D

E

F

G

INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION

1. ALTERNATOR VOLTAGE INSPECTION
H

1. Increase engine speed to 2,500 rpm.
2. Check battery voltage.
Is the inspection result 16V or less?
YES >> GO TO 2.
NO
>> Replace alternator. (Excessive alternator power generation.)

I

J

SC
MKIA0067E

2. BATTERY VOLTAGE INSPECTION
1.
2.
3.

L

Turn the ignition switch OFF.
Disconnect alternator connector.
Check voltage between alternator connector terminal 3 and
ground.
3 — Ground

M

: 12V or more

Is the inspection result 12V or more?
YES >> Replace alternator. (Alternator power generation error)
NO
>> GO TO 3.
MKIB1918E

3. FUSE CHECK
Check if fuse #36 (10A) is blown.
OK or N
OK
>> Repair harness between fuse #36 (10A) and alternator harness connector terminal 3. (Alternator
is normal. Do not replace.)
NG
>> Replace fuse. (Alternator is normal. Do not replace.)

SC-29

CHARGING SYSTEM
DARK CURRENT INSPECTION
Dark Current: Small current while ignition switch is “OFF”.
NOTE:
●
If battery ground cable is disconnected from battery terminal, a large dark current may not be reproduced.
When battery discharge occurs, never disconnect battery terminal while using ammeter.
●
Do not connect CONSULT-II CONVERTER to data link connector when measuring dark current. CONSULT-II power should be supplied using AC adapter or internal battery.
1. Attach current measurement probe for CONSULT-II to battery
ground cable. Refer to SC-31, «OPERATION PROCEDURE OF
CURRENT MEASUREMENT PROBE FOR CONSULT-II» .
2. Check that all electrical equipment is turned OFF.
3. Remove key. Close and lock doors. Check that room lamp turns
off.
4. Measure dark current. Is it 50mA or less? Refer to SC-31,
«OPERATION PROCEDURE OF CURRENT MEASUREMENT
PROBE FOR CONSULT-II» .
NOTE:
MKIA0070E
Dark current stable time is different due to equipment and use of
the vehicle. If it is not 50mA or less after leaving for 1 minute, measure dark current again after leaving for
30 minutes or more.
If YES, GO TO 7. If NO, GO TO 5.
5. Remove and install fuses one by one. Search for the fuse that greatly changes dark current.
NOTE:
If dark current is greatly reduced when removing the fuse, and even if dark current is not greatly increased
when installing it again, the fuse circuit may be the cause.
6. Check that dark current changes when moving the suspect circuit harness. If dark current changes, check
harness for short. If dark current does not change, electronic unit in the circuit may not be entering the
energy-saving mode when it turns OFF. If it does not enter the energy-saving mode, replace electronic
unit.
7. No malfunction for alternator and electrical equipment. Electric load may be larger than alternator generating ability. Check the customer’s usage.

SC-30

CHARGING SYSTEM
OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II
A

For details, refer to the supplied “CONSULT-II Current Probe Operation Manual”.
1. Turn current probe power supply OFF and connect to CONSULT-II. (Red: CH1, Black: Ground)
2. Touch “SUB MODE”.
3. Touch “Extending Measurement Mode” on “SUB MODE” screen.
4. CAUTION is displayed, touch “OK”.

B

C

D

E
MKIA0071E

5.

6.

Set current probe range switch at the range to measure, turn
current probe power supply ON. When measuring dark current,
set 4A range. (Check that POWER indicator turns on. Refer to
CONSULT-II Current Probe Operation Manual.)
Touch the same measuring range at CONSULT-II.
NOTE:
If current probe measuring range is different from CONSULT-II
measuring range, incorrect value is displayed.

F

G

H

MKIA0072E

I

7.

Adjust 0 point of current probe or CONSULT-II. (Do not clamp
anything to probe.)
NOTE:
If 0 point is dislocated greatly, adjust at current probe side generally.

J

SC

L
MKIA0073E

8.

Align current direction mark, clamp harness, and measure current. If current direction is incorrect, it is displayed negative
value.
NOTE:
● When current is measured, close probe joint securely.
● If multiple harnesses are clamped, measurement cannot be
performed. Always clamp only one.

M

MKIA0074E

SC-31

CHARGING SYSTEM
Trouble Diagnoses (K9K Engine Models)

BKS000UB

DIAGNOSIS PROCEDURE
1.
2.
3.
4.
5.

Check malfunction symptoms or customer’s remarks.
Perform pre-diagnosis inspection. Refer to SC-32, «PRE-DIAGNOSIS INSPECTION» .
Perform trouble diagnosis for each trouble symptom. Refer to SC-32, «DIAGNOSIS CHART BY SYMPTOM»
Repair or replace parts indicated inspection flow based on the charge warning lamp. Refer to SC-32,
«INSPECTION FLOW BY CHARGE WARNING LAMP» .
End

PRE-DIAGNOSIS INSPECTION
1.
2.
3.
4.
5.
6.

Perform alternator belt inspection. Refer to EM-242, «DRIVE BELTS» .
Inspect battery.
Check alternator terminal B for loose or improper connection.
Check alternator connector and terminals for loose connection, disconnection and bend.
Check connecting condition of harness for charging system harness (fusible link terminal and battery terminal).
After performing 1 to 5 above, go to trouble diagnosis for symptoms. Refer to SC-32, «DIAGNOSIS
CHART BY SYMPTOM» .

DIAGNOSIS CHART BY SYMPTOM
Symptom

Reference page

Battery discharge
Charge warning lamp illuminates.

Refer to SC-32, «INSPECTION FLOW BY CHARGE WARNING LAMP» .

Other than the above symptoms (splashing out of battery fluid,
nasty smell and others)

Refer to SC-36, «INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION» .

INSPECTION FLOW BY CHARGE WARNING LAMP

1. CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch ON.
2. Check if charge warning lamp illuminates.
Does charge warning lamp illuminate?
YES >> GO TO 2.
NO
>> Go to SC-33, «CHARGE WARNING LAMP LINE
INSPECTION» .

MKIB0555E

2. CHARGE WARNING LAMP INSPECTION
1. Start engine.
2. Check if charge warning lamp goes off.
Does charge warning lamp goes off?
YES >> GO TO 3.
NO
>> Go to SC-34, «VOLTAGE DETECTION LINE AND
CHARGE WARNING LAMP INSPECTION» .

MKIB0556E

SC-32

CHARGING SYSTEM

3. CHARGE WARNING LAMP INSPECTION

A

1. Set engine speed at 2,500 rpm.
2. Check if charge warning lamp illuminates.
Does charge warning lamp illuminate?
YES >> Go to SC-36, «INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION» .
NO
>> Go to SC-36, «INSPECTION OF INSUFFICIENT
ALTERNATOR POWER GENERATION» .

B

C

D
MKIB0555E

CHARGE WARNING LAMP LINE INSPECTION

E

CAUTION:
If open circuit is detected in L terminal, alternator cannot start generating.

INSPECTION PROCEDURE

F

1. CHARGE WARNING LAMP INSPECTION
1.
2.
3.

Turn ignition switch OFF.
Remove alternator connector.
Connect alternator connector terminal 3 to ground.

G

H

I

MKIB1919E

4. Turn ignition switch ON.
Does charge warning lamp illuminate?
YES >> GO TO 4.
NO
>> GO TO 2.

J

SC

L

M
MKIB0555E

2. CONNECTOR INSPECTION
1.
2.

Turn ignition switch OFF.
Check combination meter and terminals (meter side, and harness side) for damage, deformation or
improper connection.
OK or NG
OK
>> GO TO 3.
NG
>> Repair terminals and connectors.

SC-33

CHARGING SYSTEM

3. CONTINUITY INSPECTION
1.
2.

Disconnect combination meter connector.
Check continuity between combination meter connector terminal 38 and alternator connector terminal 3.
38 — 3

: Continuity should exist.

OK or NG
OK
>> Replace combination meter. (Do not replace alternator, since it is normal.)
NG
>> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)

4. CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch OFF.
2. Connect alternator connectors.
3. Turn ignition switch ON.
Does charge warning lamp illuminate?
YES >> Repair alternator connector. (Poor connection and intermittent problem) (Do not replace alternator, since it is
normal.)
NO
>> Replace alternator. (circuit malfunction in alternator)
MKIB0555E

VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION
INSPECTION PROCEDURE

1. CHARGE WARNING LAMP INSPECTION
1. Turn ignition switch OFF.
2. Disconnect alternator connector.
3. Turn ignition switch ON.
Does charge warning lamp stay ON?
YES >> GO TO 6.
NO
>> GO TO 2.

MKIB0555E

2. VOLTAGE INSPECTION
Check voltage between alternator connector terminal 4 and ground.
4 — Ground

: 12V or more

Is the inspection result 12V or more?
YES >> Replace alternator.
NO
>> GO TO 3.

MKIB1731E

SC-34

CHARGING SYSTEM

3. CONNECTOR INSPECTION

A

1.
2.

Turn ignition switch OFF.
Check alternator connector and terminal 4 (alternator side, and harness side) for damage, deformation or
improper connection.
OK or NG
OK
>> GO TO 4.
NG
>> Repair terminals and connectors.

B

C

4. CONNECTOR INSPECTION
Check IPDM E/R and terminals (IPDM E/R side, and harness side) for damage, deformation or improper connection.
OK or NG
OK
>> GO TO 5.
NG
>> Repair terminals and connectors.

D

E

5. CONTINUITY INSPECTION

F

1.
2.

G

Disconnect IPDM E/R connector.
Check continuity between IPDM E/R connector terminal 63 and alternator connector terminal 4.
63 — 4

: Continuity should exist.

OK or NG
OK
>> Replace IPDM E/R. (Do not replace alternator, since it is normal.)
NG
>> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)

H

6. CONTINUITY INSPECTION

I

1.
2.
3.

J

Turn ignition switch OFF.
Disconnect combination meter connector.
Check continuity between combination meter connector terminal 38 and ground, and combination meter
connector terminal 38 and alternator connector terminal 3.
38 — Ground
38 — 3

: Continuity should not exist.
: Continuity should exist.

OK or NG
OK
>> Replace combination meter. (Do not replace alternator, since it is normal.)
NG
>> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)

SC

L

M

SC-35

CHARGING SYSTEM
INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION
CAUTION:
Check them using charged battery performed battery inspection.

1. VOLTAGE INSPECTION
1.
2.

Increase engine speed to 2,500 rpm.
Turn electrical load to ON. (Headlamp LO turns on, blower fan
motor maximum airflow amount)
3. Check battery voltage.
Is the inspection result 12.8V to 15.1V?
YES >> GO TO 2.
NO
>> Replace alternator. (Alternator power generation error.)

MKIA0067E

2. CURRENT INSPECTION
1.
2.
3.

Turn ignition switch OFF.
Disconnect the battery ground cable.
Attach current measurement probe for CONSULT-II to the harness for alternator terminal B.
(If the probe can not be attached properly, then connect the subharness between alternator terminal B and the vehicle side harness as shown in figure, and attach the probe to sub-harness.)
4. Connect battery ground cable.
5. Increase engine speed to 2,500 rpm.
6. Turn electrical load to ON. (Headlamp LO turns on, blower fan
motor maximum airflow amount, rear window defogger)
7. Check alternator terminal B current.
CAUTION:
Be careful of rotating parts because the engine is running.
MKIA0068E
Is the inspection result 30A or more?
YES >> GO TO dark current inspection. Refer to SC-37, «DARK CURRENT INSPECTION» . (Alternator is
normal. Do not replace.)
NO
>> Replace alternator. (Alternator power generation error.)

INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION

1. ALTERNATOR VOLTAGE INSPECTION
1. Increase engine speed to 2,500 rpm.
2. Check battery voltage.
Is the inspection result 16V or less?
YES >> GO TO 2.
NO
>> Replace alternator. (Excessive alternator power generation.)

MKIA0067E

SC-36

CHARGING SYSTEM

2. BATTERY VOLTAGE INSPECTION
1.
2.
3.
4.

A

Turn ignition switch OFF.
Disconnect alternator connector.
Turn ignition switch ON.
Check voltage between alternator connector terminal 4 and
ground.
4 — Ground

B

C

: 12V or more

Is the inspection result 12V or more?
YES >> Replace alternator. (Alternator power generation error)
NO
>> GO TO 3.

D
MKIB1731E

3. CONNECTOR INSPECTION

E

1.
2.

Turn ignition switch OFF.
Check IPDM E/R and terminals (IPDM E/R side, and harness side) for damage, deformation or improper
connection.
OK or NG
OK
>> GO TO 4.
NG
>> Repair terminals and connectors.

4. CONTINUITY INSPECTION
1.
2.

F

G

H

Disconnect IPDM E/R connector.
Check continuity between IPDM E/R connector terminal 63 and alternator connector terminal 4.
63 — 4

: Continuity should exist.

OK or NG
OK
>> Replace IPDM E/R. (Do not replace alternator, since it is normal.)
NG
>> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.)

I

J

DARK CURRENT INSPECTION
SC
Dark Current: Small current while ignition switch is “OFF”.
NOTE:
●
If battery ground cable is disconnected from battery terminal, a large dark current may not be reproduced.
L
When battery discharge occurs, never disconnect battery terminal while using ammeter.
●
Do not connect CONSULT-II CONVERTER to data link connector when measuring dark current. CONSULT-II power should be supplied using AC adapter or internal battery.
M
1. Attach current measurement probe for CONSULT-II to battery
ground cable. Refer to SC-38, «OPERATION PROCEDURE OF
CURRENT MEASUREMENT PROBE FOR CONSULT-II» .
2. Check that all electrical equipment is turned OFF.
3. Remove key. Close and lock doors. Check that room lamp turns
off.
4. Measure dark current. Is it 50mA or less? Refer to SC-38,
«OPERATION PROCEDURE OF CURRENT MEASUREMENT
PROBE FOR CONSULT-II» .
NOTE:
MKIA0070E
Dark current stable time is different due to equipment and use of
the vehicle. If it is not 50mA or less after leaving for 1 minute, measure dark current again after leaving for
30 minutes or more.
If YES, GO TO 7. If NO, GO TO 5.
5. Remove and install fuses one by one. Search for the fuse that greatly changes dark current.

SC-37

CHARGING SYSTEM

6.

7.

NOTE:
If dark current is greatly reduced when removing the fuse, and even if dark current is not greatly increased
when installing it again, the fuse circuit may be the cause.
Check that dark current changes when moving the suspect circuit harness. If dark current changes, check
harness for short. If dark current does not change, electronic unit in the circuit may not be entering the
energy-saving mode when it turns OFF. If it does not enter the energy-saving mode, replace electronic
unit.
No malfunction for alternator and electrical equipment. Electric load may be larger than alternator generating ability. Check the customer’s usage.

OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II
For details, refer to the supplied “CONSULT-II Current Probe Operation Manual”.
1. Turn current probe power supply OFF and connect to CONSULT-II. (Red: CH1, Black: Ground)
2. Touch “SUB MODE”.
3. Touch “Extending Measurement Mode” on “SUB MODE” screen.
4. CAUTION is displayed, touch “OK”.

MKIA0071E

5.

6.

Set current probe range switch at the range to measure, turn
current probe power supply ON. When measuring dark current,
set 4A range. (Check that POWER indicator turns on. Refer to
CONSULT-II Current Probe Operation Manual.)
Touch the same measuring range at CONSULT-II.
NOTE:
If current probe measuring range is different from CONSULT-II
measuring range, incorrect value is displayed.

MKIA0072E

7.

Adjust 0 point of current probe or CONSULT-II. (Do not clamp
anything to probe.)
NOTE:
If 0 point is dislocated greatly, adjust at current probe side generally.

MKIA0073E

SC-38

CHARGING SYSTEM
8.

Align current direction mark, clamp harness, and measure current. If current direction is incorrect, it is displayed negative
value.
NOTE:
● When current is measured, close probe joint securely.
● If multiple harnesses are clamped, measurement cannot be
performed. Always clamp only one.

A

B

C
MKIA0074E

Removal and Installation (CR Engine Models)

D
BKS000UC

REMOVAL
1.
2.
3.
4.

Disconnect battery ground cable.
Remove fender protector from RH side.
Remove alternator drive belt. Refer to EM-16, «Removal and
Installation» .
Remove idler pulley bracket mounting bolts, and remove idler
pulley assembly.

E

F

G

MKIA0075E

5.

Disconnect alternator harness connector.
Terminal B mounting nut, ground wire mounting nut, and remove
harness clips.

H

I

J

SC
MKIA0076E

6.
7.

L

Remove engine mounting stay from RH side.
Remove alternator upper bracket mounting bolts, and alternator upper mounting bolt.

M

MKIA0077E

SC-39

CHARGING SYSTEM
8.
9.

Loosen alternator lower mounting bolt, and pull out from U-cut
portion on front cover.
Remove alternator assembly from engine.

MKIA0078E

INSTALLATION
Install in the reverse order of removal, taking care of the following point.
●
Install alternator, and check tension of belt. Refer to EM-14, «Tension Adjustment» .
CAUTION:
Be sure to tighten B terminal mounting nut carefully.
B terminal nut:

: 9.32 — 10.8 N·m (0.95 — 1.1 kg-m, 82 — 95 in-lb)

Ground bolt:

: 2.94 — 4.9 N·m (0.30 — 0.49 kg-m, 26 — 43 in-lb)

Alternator mounting bolt:

: 33.3 — 46.1 N·m (3.4 — 4.7 kg-m, 24 — 34 ft-lb)

Alternator upper bracket bolt:

: 33.3 — 46.1 N·m (3.4 — 4.7 kg-m, 24 — 34 ft-lb)

Engine mounting stay bolt:

: 40.0 — 50.0 N·m (4.1 — 5.1 kg-m, 30 — 37 ft-lb)

Idler pulley bracket bolt:

: 16.6 — 23.5 N·m (1.7 — 2.4 kg-m, 12 — 17 ft-lb)

Idler pulley nut:

: 25.5 — 33.3 N·m (2.6 — 3.3 kg-m, 19 — 24 ft-lb)

Removal and Installation (HR Engine Models)

BKS000UD

REMOVAL
1.
2.
3.
4.
5.

Disconnect battery ground cable.
Remove fender protector from RH side.
Remove alternator drive belt. Refer to EM-115, «Removal and Installation» .
Remove idler pulley assembly. Refer to EM-116, «Removal and Installation of Drive Belt Idler Pulley» .
Disconnect alternator harness connector.
● B terminal mounting nut, ground wire mounting nut, and
remove harness clips.

MKIB1996E

6.

Remove A/C compressor. Refer to ATC-140, «Removal and Installation of Compressor» (with auto A/C) or
MTC-86, «Removal and Installation of Compressor» (with manual A/C).

SC-40

CHARGING SYSTEM
7.

Remove torque rod bolt.
A

B

C
MKIB1997E

D

8.

Remove alternator mounting upper bolt.
E

F

G
MKIB1998E

9. Loosen alternator mounting lower bolt.
10. Remove alternator assembly from lower side the vehicle.

H

I

J

MKIB1999E

SC

INSTALLATION
Install in the reverse order of removal, taking care of the following point.
●
Install alternator, and check tension of belt. Refer to EM-114, «Tension Adjustment» .
CAUTION:
Be sure to tighten B terminal mounting nut carefully.

L

M

B terminal nut:

: 9.32 — 10.8 N·m (0.95 — 1.1 kg-m, 82 — 95 in-lb)

Ground bolt:

: 2.94 — 4.9 N·m (0.30 — 0.49 kg-m, 26 — 43 in-lb)

Alternator mounting bolt:

: 21.0 — 29.0 N·m (2.2 — 2.9kg-m, 16 — 21ft-lb)

Torque rod bolt:

: 40.0 — 50.0 N·m (4.1 — 5.1 kg-m, 30 — 37 ft-lb)

Idler pulley bolt:

: 24.0 — 32.0 N·m (2.5 — 3.2kg-m, 18 — 23ft-lb)

SC-41

CHARGING SYSTEM
Removal and Installation (K9K Engine Models)

BKS000UE

REMOVAL
1.
2.
3.
4.
5.

Disconnect battery ground cable.
Remove under cover and RH fender protector.
Remove front bumper. Refer to EI-4, «FRONT BUMPER» .
Remove alternator drive belt. Refer to EM-242, «DRIVE BELTS»
.
Disconnect alternator harness connector and B terminal nut.

MKIA0086E

6.

Remove alternator upper mounting bolt.

MKIA0087E

7.
8.

Remove alternator lower mounting bolt.
Remove alternator assembly from engine.

MKIA0088E

INSTALLATION
Install in the reverse order of removal, taking care of the following point.
●
Install alternator, and check tension of belt. Refer to EM-242, «DRIVE BELTS» .
CAUTION:
Be sure to tighten B terminal mounting nut carefully.

Disassembly

BKS000UF

REAR COVER

SEL032Z

SC-42

CHARGING SYSTEM
CAUTION:
Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. To facilitate removal of rear cover, heat just bearing box section with a 200W soldering iron.
Do not use a heat gun, as it can damage diode assembly.

A

REAR BEARING

B

CAUTION:
●
Do not reuse rear bearing after removal. Replace with a new one.
●
Do not lubricate rear bearing outer race.

C

Inspection

BKS000UG

ROTOR CHECK
1.

D

Resistance test
Resistance

: Refer to SC-60, «SERVICE DATA AND SPECIFICATIONS (SDS)» .

E

Not within the specified values… Replace rotor.
Insulator test
● Continuity exists… Replace rotor.
Check slip ring for wear.
●

2.
3.

Slip ring minimum
outer diameter
●

: Refer to SC-60, «SERVICE DATA AND SPECIFICATIONS (SDS)» .

F

G
SEL033Z

H

Not within the specified values… Replace rotor.

BRUSH CHECK
1.
2.

I

Check smooth movement of brush.
● Not smooth… Check brush holder and clean.
Check brush for wear.
● Replace brush if it is worn down to the limit line.

J

SC

SEL631DA

L

STATOR CHECK
1.

Continuity test
● No continuity… Replace stator.

M

SEL108E

SC-43

CHARGING SYSTEM
2.

Ground test
● Continuity exists… Replace stator.

SEL109E

Assembly

BKS000UH

RING FITTING IN REAR BEARING
Fix ring into groove in rear bearing so that it is as close to the
adjacent area as possible.
CAUTION:
Do not reuse rear bearing after removal.
●

SEL044Z

REAR COVER INSTALLATION
1.

Fit brush assembly, diode assembly, regulator assembly and
stator.

SEL048Z

2. Push brushes up with fingers and install them to rotor.
Take care not to damage slip ring sliding surface.

SEL049Z

SC-44

STARTING SYSTEM
STARTING SYSTEM
System Description

PFP:00011

A
BKS000UI

M/T MODELS
Power is supplied at all times
●
through 30A fusible link (letter L, located in the fuse and fusible link box)
●
to ignition switch terminal 1.
With the ignition switch in the ON or START position, power is supplied
●
through 10A fuse [No.60 located in the IPDM E/R]
●
to park/neutral position switch terminal 2
●
through 10A fuse [No.5, located in fuse block (J/B)]
●
through IPDM E/R terminal 21
●
to starter relay.
With the shift lever in the N position (under the ignition switch ON or START position)
Power is supplied
●
through park/neutral position switch terminal 2 and 3
●
to IPDM E/R terminal 31
and then starter relay is energized.
When ignition switch turn to START position, power is supplied
●
through ignition switch terminal 1 and 5
●
through IPDM E/R terminal 9 and 11
●
to starter motor terminal 1.
The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the
engine starts.

B

C

D

E

F

G

H

I

A/T MODELS
Power is supplied at all times
J
●
through 30A fusible link (letter L, located in the fuse and fusible link box)
●
to ignition switch terminal 1.
With the ignition switch in the ON or START position, power is supplied
SC
●
through 10A fuse [No. 60 located in the IPDM E/R]
●
to park/neutral position switch terminal 1.
With the selector lever in the P or N position (under the ignition switch ON or START position)
L
Power is supplied
●
through park/neutral position switch terminal 1 and 2
●
through IPDM E/R terminal 21
M
●
to starter relay.
●
through park/neutral position switch terminal 1 and 2
●
to IPDM E/R terminal 31.
and then starter relay is energized.
When ignition switch turn to START position, power is supplied
●
through ignition switch terminal 1 and 5
●
through IPDM E/R terminal 9 and 11
●
to starter motor terminal 1
The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the
engine starts.

SC-45

STARTING SYSTEM
Wiring Diagram — START — /CR and HR Engine Models

BKS000UJ

MKWA4271E

SC-46

STARTING SYSTEM
A

B

C

D

E

F

G

H

I

J

SC

L

M

MKWA4272E

SC-47

STARTING SYSTEM
Wiring Diagram — START — /K9K Engine Models

BKS000UK

MKWA4273E

SC-48

STARTING SYSTEM
A

B

C

D

E

F

G

H

I

J

SC

L

M

MKWA4274E

SC-49

STARTING SYSTEM
Trouble Diagnoses

BKS000UL

If any abnormality is found, immediately disconnect battery negative terminal.

SEL761W

SC-50

STARTING SYSTEM
Removal and Installation (CR Engine Models)

BKS000UM

REMOVAL

A

1.
2.
3.
4.
5.

B

Disconnect negative battery cable.
Remove starter motor mounting bolt from upper side.
Disconnect S terminal and B terminal from starter motor.
Remove starter motor mounting bolt from lower side.
Remove starter motor from lower side the vehicle.

C

D

E

F

G

MKIA0080E

H

INSTALLATION
Install in the reverse order of removal.
I

Removal and Installation (HR Engine Models)

BKS000UN

J

SC

L

M

PKIC0987E

1.

Cylinder block

4.

Starter motor

2.

B terminal harness
: N·m (kg-m, ft-lb)

3.

S terminal harness
: N·m (kg-m, in-lb)

: Engine front

REMOVAL
1.
2.
3.

Disconnect the battery cable from the negative terminal.
Remove air duct (inlet). Refer to EM-118, «AIR CLEANER AND AIR DUCT» .
Remove reservoir tank. Refer to.CO-31, «RADIATOR» .

SC-51

STARTING SYSTEM
4.
5.
6.
7.

Disconnect “S” terminal nut.
Remove “B” terminal nut.
Remove starter motor mounting bolts.
Remove starter motor upward from the vehicle.

INSTALLATION
Installation is the reverse order of removal.
CAUTION:
Be sure to tighten “B” terminal nut carefully.

Removal and Installation (K9K Engine Models)

BKS000UO

REMOVAL
1.
2.
3.
4.
5.

Disconnect negative battery cable.
Remove starter motor mounting bolt from upper side.
Disconnect S terminal and B terminal from starter motor.
Remove starter motor mounting bolt from lower side.
Remove starter motor from lower side the vehicle.

MKIA0089E

INSTALLATION
Install in the reverse order of removal.

Disassembly and Assembly

BKS000UP

MKIB1994E

1.

Gear case

2.

Sleeve bearing

3.

Shift lever

4.

Plate

5.

Packing

6.

Adjusting plate

7.

Magnetic switch assembly

8.

Stopper clip

9.

Pinion stopper

SC-52

STARTING SYSTEM
10. Pinion assembly

11. Internal gear

12. Pinion shaft

13. Planetary gear

14. Ball

15. Packing

16. Yoke

17. Armature

18. Brush holder assembly

19. Rear bearing

20. Rear cover

A

B

Through-bolt:
M0T84585
C

: 4.1 — 7.1 N·m (0.45 — 0.72 kg-m, 39.1 — 62.5 in-lb)

D

E

F

G

H

I
MKIB2318E

1.

Gear case

2.

Shift lever

3.

4.

Magnetic switch assembly

5.

Packing

6.

Armature

7.

Yoke

8.

Brush

9.

Brush holder

10. Spring

11. Plate

Spring

J

12. Rear cover

SC

13. Through-bolt

L

M

SC-53

STARTING SYSTEM

MKIB1995E

1.

Gear case

2.

Shift lever

3.

Plate

4.

Packing

5.

Magnetic switch assembly

6.

Ring

7.

Stopper

8.

Clutch gear assembly

9.

Internal gear assembly

10. Shaft assembly gear

11. Gear assembly

12. Packing

13. Though-bolt

14. Yoke assembly

15. Armature

16. Brush holder assembly

17. E-ring

18. Rear cover assembly

SC-54

STARTING SYSTEM
Inspection

BKS000UQ

A

MAGNETIC SWITCH CHECK
●
●

1.

Before starting to check, disconnect battery ground cable.
Disconnect “M” terminal of starter motor.
Continuity test (between “S” terminal and switch body).
● No continuity… Replace.

B

C

D

E
SEL555E

2.

Continuity test (between “S” terminal and “M” terminal).
● No continuity… Replace.

F

G

H
SEL556E

I

PINION/CLUTCH CHECK
1.

2.

3.

Inspect pinion teeth.
● Replace pinion if teeth are worn or damaged. (Also check
condition of ring gear teeth.)
Inspect reduction gear teeth (If equipped).
● Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)
Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
● If it locks or rotates in both directions, or unusual resistance is
evident…. Replace.

J

SC

L
MEL139L

BRUSH CHECK
Brush

M

Check wear of brush.
Wear limit length

●

: Refer to SC-60, «SERVICE DATA AND SPECIFICATIONS (SDS)» .

Excessive wear… Replace.

SEL014Z

SC-55

STARTING SYSTEM
Brush Spring Check
Check brush spring pressure with brush spring detached from brush.
Spring pressure (with
new brush)
●

: Refer to SC-60, «SERVICE DATA AND SPECIFICATIONS (SDS)» .

Not within the specified values… Replace.

SEL015Z

Brush Holder
1.

2.

Perform insulation test between brush holder (positive side) and
its base (negative side).
● Continuity exists…. Replace.
Check brush to see if it moves smoothly.
● If brush holder is bent, replace it; if sliding surface is dirty,
clean.

SEL016Z

SC-56

STARTING SYSTEM
YOKE CHECK
A

Magnet is secured to yoke by bonding agent. Check magnet to see
that it is secured to yoke and for any cracks. Replace malfunctioning
parts as an assembly.
CAUTION:
Do not clamp yoke in a vice or strike it with a hammer.

B

C

D

E

F

G
SEL018Z

H

ARMATURE CHECK
1.
2.

Continuity test (between two segments side by side).
● No continuity… Replace.
Insulation test (between each commutator bar and shaft).
● Continuity exists…. Replace.

I

J

SC
SEL019Z

3.

L

Check commutator surface.
● Rough… Sand lightly with No. 500 — 600 emery paper.

M

SEL020Z

SC-57

STARTING SYSTEM
4.

Check diameter of commutator.
Commutator minimum
diameter

: Refer to SC-60, «SERVICE DATA AND SPECIFICATIONS (SDS)» .

Less than specified value… Replace.
Check depth of insulating mold from commutator surface.
●

5.

SEL021Z

SEL022Z

●

Less than 0.2 mm (0.008 in)… Undercut to 0.5 to 0.8 mm (0.020 to 0.031 in)

Assembly

BKS000UR

Apply high-temperature grease to lubricate the bearing, gears and frictional surface when assembling the
starter.
Carefully observe the following instructions.

PINION PROTRUSION LENGTH ADJUSTMENT
Clearance
With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance “ ” between the front edge of
the pinion and the pinion stopper.
Clearance “ ”

: Refer to SC-60, «SERVICE DATA AND SPECIFICATIONS (SDS)» .

SEL026Z

SC-58

STARTING SYSTEM
●

Not in the specified value… Adjust by adjusting plate.
A

B

C
SEL633BA

D

E

F

G

H

I

J

SC

L

M

SC-59

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Battery

PFP:00030
BKS000US

Applied model

CR, HR, K9K
EXIDE type code

Type

LB1+ (420A)

LB2 (510A)

LB2+ (600A)

12 — 47

12 — 55

12 — 50

Capacity V-Ah

Starter

BKS000UT

Type

M0T84585

D7E 40

M0T32171

Mitsubishi make
Reduction gear type

Valeo make
Non reduction

Mitshubishi make
Reduction gear type

Applied model

CR

System voltage V

HR
12.0

Terminal voltage V

11.0

—

11.0

Less than 90

—

Less than 90

More than 2,800

—

More than 3,000

Minimum diameter of commutator mm (in)

28.8

—

28.8

Minimum length of brush mm (in)

5.5

—

5.5

15.0 — 20.4

—

15.0 — 20.4

Less than 0.2

—

Less than 0.2

0.5 — 2.0

—

0.5 — 2.0

No-load

Current A
Revolution rpm

Brush spring tension N (kg, lb)
Clearance between bearing metal and armature shaft mm (in)
Clearance “

” between pinion front edge and pinion stopper mm (in)

Alternator

BKS000UU

Type
Applied model
Nominal rating V-A

2542927

A002TJ0291ZE

Valeo make

Mitsubishi make

CR

HR

12 — 77

12 — 120

Ground polarity

Negative

Minimum revolutions under no-load (When 13.5V is applied) rpm

1200

1300

More than 39 / 1,800
More than 60 / 2,500
More than 76 / 5,000
More than 77 / 6,000

More than 27 / 1,300
More than 95 / 2,500
More than 116 / 5,000

14.25 — 14.85

14.1 — 14.7

Minimum length of brush mm (in)

10.5

5.00

Brush spring pressure N (g, oz.)

—

4.1 — 5.3

Slip ring minimum diameter mm (in)

—

22.1

Rotor coil resistance at 20° (68°F) Ω

3.01

1.8 — 2.2

Hot output current (When 13.5V is applied) A/rpm

Regulated output voltage V

SC-60

STEERING CONTROL SYSTEM

G STEERING

SECTION

STC

STEERING CONTROL SYSTEM

A

B

C

D

CONTENTS
EPS
PRECAUTIONS …………………………………………………. 2
Maintenance Information …………………………………… 2
RHD MODELS ……………………………………………… 2
LHD MODELS ………………………………………………. 2
SYSTEM DESCRIPTION …………………………………….. 3
Components ……………………………………………………. 3
Electric Power Steering Function ……………………….. 3
Fail-Safe Function ……………………………………………. 3
TROUBLE DIAGNOSIS ………………………………………. 4
How to Perform Trouble Diagnosis …………………….. 4
BASIC CONCEPT …………………………………………. 4
Component Parts Location ………………………………… 5
Schematic ………………………………………………………. 6
Wiring Diagram — EPS — ………………………………… 7
Control Unit Input/Output Signal Standard …………. 10
CIRCUIT TESTER REFERENCE VALUE ……….. 10
STANDARD BY CONSULT-II ………………………… 10
CONSULT-II Function (EPS) ……………………………..11
CONSULT-II MAIN FUNCTION ……………………….11
CONSULT-II START PROCEDURE …………………11
SELF-DIAGNOSIS ………………………………………..11
DATA MONITOR …………………………………………. 12
ECU PART NUMBER …………………………………… 13
CAN COMMUNICATION ………………………………. 13

For Fast and Accurate Trouble Diagnosis ………….. 13
Basic Inspection …………………………………………….. 13
BASIC INSPECTION 1: POWER SUPPLY CIRCUIT TERMINAL LOOSENESS AND BATTERY… 13
BASIC INSPECTION 2: EPS WARNING LAMP
INSPECTION ……………………………………………… 13
BASIC INSPECTION 3: EPS CONTROL UNIT
POWER SUPPLY CIRCUIT AND GROUND CIRCUIT INSPECTION ……………………………………… 14
Inspection 1: Battery Voltage Malfunction ………….. 15
Inspection 2: Torque Sensor Malfunction …………… 16
Inspection 3: Motor Malfunction ………………………… 17
Inspection 4: EEPROM Malfunction ………………….. 18
Inspection 5: Control unit malfunction ……………….. 18
Inspection 6: Vehicle Speed Signal Malfunction ….. 19
Inspection 7: Engine Signal Malfunction …………….. 19
Inspection 8: CAN Communication Circuit …………. 20
Symptom 1: Steering is Heavy or Light ……………… 20
Symptom 2: There is a Difference in the Steering
Turning/Returning Force of Left and Right (Biased
to One Side) ………………………………………………….. 21
Symptom 3: Steering Wheel Turning Force is
Uneven (Torque Variation) ……………………………….. 21
Symptom 4: EPS Warning Lamp Stays ON ………… 22

STC-1

E

F

STC

H

I

J

K

L

M

PRECAUTIONS
[EPS]

PRECAUTIONS
Maintenance Information
[EPS]

PFP:00001
BGS0004A

If any of following part is replaced, always replace with new* one.
If it’s not (or fail to do so), the electrical system may not be operated properly.
*: New one means a virgin control unit that has never been energized on-board.

RHD MODELS
●
●
●
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM
IPDM E/R
Combination meter
EPS control unit

LHD MODELS
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM

STC-2

SYSTEM DESCRIPTION
[EPS]

SYSTEM DESCRIPTION
Components

PFP:00000

A
BGS0002W

B

C

D

E

F

STC
SGIA1304E

1.

Steering wheel

2.

Motor

3.

EPS control unit

4.

Steering gear assembly

5.

Torque sensor

6.

Reduction gear

A.

Sensor processing signal

B.

Sensor signal

C.

Assist torque signal (motor drive)

F.

CAN (L)

D.

Ignition power

E.

CAN (H)

G.

Power supply

H.

Ground

I

Electric Power Steering Function

BGS0002X

Parts name

Electric power steering (EPS) control unit

Motor
Torque sensor
Reduction gear

EPS warning lamp

H

Function

J

●

Outputs optimum assist torque signal to motor by steering wheel turning force
(sensor signal) from torque sensor and vehicle speed signal from CAN communication.

●

Reduces output signals to motor and protects motor and EPS control unit when
using power steering continuously and excessively.

●

Under unusual conditions of electric system, fail-safe function starts, output signal to motor is turned off, and then changes to manual steering. EPS warning
lamp turns on to indicate system error.

●

Controls communication with other control units by using CAN communication.

●

Allows system diagnosis with CONSULT-II

●

Produces assist torque by control signal from EPS control unit.

●

Detects steering wheel turning force and outputs sensor signal to EPS control
unit.

●

Increases motor-produced assist torque by worm gear and transmits it to column
shaft.

●

Turns on when fail-safe function operates, and indicates manual steering state.

●

Turns on when key switch is turned on to check value, and turns off after engine
starts

Fail-Safe Function

L

M

BGS0002Y

In case an unusual condition is encountered in the system, fail-safe function stops EPS control and the system
enters a fail-safe state. EPS warning lamp turns on to indicate unusual state, and enters a manual steering
state. (Control turning force of steering wheel becomes heavy.)

STC-3

K

TROUBLE DIAGNOSIS
[EPS]

TROUBLE DIAGNOSIS
How to Perform Trouble Diagnosis

PFP:00004
BGS0002Z

BASIC CONCEPT
●

●

The most important point to perform trouble diagnosis is to understand systems (control and mechanism)
in vehicle thoroughly.
It is also important to clarify customer complaints before inspection.
First of all, reproduce symptom, and understand it fully.
Ask customer about his/her complaints carefully. In some cases,
it will be necessary to check symptom by driving vehicle with
customer.
CAUTION:
Customers are not professionals. Do not assume “maybe
customer means…” or “maybe customer mentioned this
symptom”.
SEF234G

●

●

●

It is essential to check symptoms right from beginning in order to
repair a malfunction completely.
For an intermittent malfunction, it is important to reproduce
symptom based on interview with customer and past examples.
Do not perform inspection on ad hoc basis. Most intermittent
malfunctions are caused by poor contacts. In this case, it will be
effective to shake suspected harness or connector by hand.
When repairs are performed without any symptom check, no
one can judge if malfunction has actually been eliminated.
After diagnosis, make sure to perform “ERASE MEMORY”.
Refer to STC-11, «Erase Memory» .
Always read “GI General Information” to confirm general precautions. Refer to GI-4, «General Precautions» .

STC-4

SEF233G

TROUBLE DIAGNOSIS
[EPS]

Component Parts Location

BGS00030

A

B

C

D

E

F

STC

H

I

J

K

L

M

MGIB0003E

1.

Motor

2.

EPS control unit

3.

4.

Reduction gear (built-in)

5.

EPS warning lamp

A. Sensor processing signal

B.

Sensor signal

C. Assist torque signal (motor drive)

D. Ignition power

E.

CAN (H)

F.

G. Power supply

H.

Ground

CAN (L)

STC-5

Torque sensor (built-in)

TROUBLE DIAGNOSIS
[EPS]

Schematic

BGS00031

MGWA0006E

STC-6

TROUBLE DIAGNOSIS
[EPS]

Wiring Diagram — EPS —

BGS00032

A

B

C

D

E

F

STC

H

I

J

K

L

M

MGWA0005E

STC-7

TROUBLE DIAGNOSIS
[EPS]

MGWA0007E

STC-8

TROUBLE DIAGNOSIS
[EPS]
A

B

C

D

E

F

STC

H

I

J

K

L

M

MGWA0008E

STC-9

TROUBLE DIAGNOSIS
[EPS]

Control Unit Input/Output Signal Standard

BGS00033

CIRCUIT TESTER REFERENCE VALUE
CAUTION:
When checked using a circuit tester for voltage measurement, connector terminals should not be
forcefully extended.
Terminal

Measuring point

Measuring condition

Standard

Torque sensor (sub)

Ignition switch ON, steering wheel in neutral position

Approx. 2.5 V

Torque sensor power supply

Ignition switch ON

Approx. 8 V

6 (G)

Torque sensor (main)

Ignition switch ON, steering wheel in neutral position

Approx. 2.5 V

7 (Y)

Torque sensor ground

–

Continuity exit

–

–

Ignition switch ON

Battery voltage
(Approx. 12 V)

Ignition switch OFF

Approx. 0 V

+ (wire color)

–

4 (V)
5 (BR)

Ground

9 (L)

–

CAN H

10 (O)

Ground

Ignition power

16 (Y)

–

CAN L

–

–

17 (R)

Ground

Battery power supply

Ignition switch ON or OFF

Battery voltage
(Approx. 12 V)

18 (B)

Ground

Ground

–

Continuity exit

Motor (+)

–

–

Motor (–)

–

–

19 (–)

–

20 (–)

STANDARD BY CONSULT-II
CAUTION:
The output signal indicates the EPS control unit calculation date. The normal values will be displayed
even in the event that the output circuit (harness) is open.
DATA MONITOR

Monitor item
Condition
Ignition switch
ON or engine
running

Malfunction inspection checklist

Reference values for normal operation
Battery voltage (Approx. 12 V)

STC-15, «Inspection 1: Battery
Voltage Malfunction»

Neutral (Steering force is zero): Approx. 0
N·m.
The value is changed according to steering
left or right.

STC-16, «Inspection 2: Torque
Sensor Malfunction»

Neutral (Steering force is zero and in vehicle
is in straight-ahead position): Approx. 0 A.
The value is changed according to steering
left or right.

STC-16, «Inspection 2: Torque
Sensor Malfunction», STC-17,
«Inspection 3: Motor Malfunction» , STC-18, «Inspection 5:
Control unit malfunction»

Almost in accordance with the speedometer
display. It is not a malfunction, though it
might not be corresponding just after ignition
switch is turned ON.

STC-19, «Inspection 6: Vehicle
Speed Signal Malfunction»

EPS warning lamp ON: ON
EPS warning lamp OFF: OFF

Warning lamp circuit inspection

DERATING STAT (ON/OFF)

Usually OFF. Turn ON when the stationary
steering is performed excessively. Return to
OFF when leaving it for a while.

This is normal.

ENGINE STATUS
(stop, stall, run, and crank)

Displays engine status.

STC-19, «Inspection 7: Engine
Signal Malfunction»

MOTOR VOL (V)

TORQUE SENSOR (Nm)

MOTOR SIG (A)

MOTOR CURRENT (A)

Turning steering wheel clockwise or counter
clockwise at
ignition switch
ON or running
engine

VEHICLE SPEED (km/h)

WARNING LAMP (ON/OFF)

Ignition switch
ON or engine
running

STC-10

TROUBLE DIAGNOSIS
[EPS]

CONSULT-II Function (EPS)

BGS00034

A

CONSULT-II MAIN FUNCTION
CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.
Mode

Function

Reference

SELF-DIAG RESULTS

Receives self-diagnosis results from EPS control unit and indicates DTCs.

STC-11, «SELF-DIAGNOSIS»

DATA MONITOR

Receives input/output signals from EPS control unit and indicates
and stores them to facilitate locating cause of malfunctions.

STC-12, «DATA MONITOR»

ECU PART NUMBER

Displays EPS control unit part number.

STC-13, «ECU PART
NUMBER»

CAN DIAG SUPPORT MNTR

Monitors transmitting/receiving status of CAN communication.

STC-13, «CAN COMMUNICATION»

CONSULT-II START PROCEDURE

B

C

D

E

Refer to GI-36, «CONSULT-II Start Procedure» .

SELF-DIAGNOSIS
Operation Procedure
1.
2.
3.
4.

5.
6.

F

Turn ignition switch OFF.
Connect CONSULT-II and CONSULT-II CONVERTER to data link connector.
STC
Turn ignition switch ON.
Touch “START (NISSAN BASED VHCL)” “EPS” “SELF-DIAG RESULTS”.
● If EPS is not displayed, print the “SELECT SYSTEM” screen. Then refer to LAN-3, «Precautions When
H
Using CONSULT-II» .
NOTE:
Just after starting engine, or turning ignition switch ON, it may not be displayed even if “START (NISI
SAN BASED VHCL)” is touched. In this case, reconnect CONSULT-II and CONSULT-II CONVERTER.
The self-diagnostic results are displayed. (Touch “PRINT” to print out the self-diagnostic results if necessary.) Check EPS warning lamp if “NO FAILURE” is displayed.
J
Perform the appropriate inspection from the display item list, and repair or replace the malfunctioning
component. Refer to STC-12, «Display Item List» .

Erase Memory
1.
2.

3.

K

Turn ignition switch OFF.
Start engine, and touch “START (NISSAN BASED VHCL)” “EPS” “SELF-DIAG RESULTS” and “ERASE”
in this order to erase the diagnostic memory.
CAUTION:
If memory cannot be erased, repeat step 1, 2.
Perform self-diagnosis again, and make sure that DTC memory is erased.

STC-11

L

M

TROUBLE DIAGNOSIS
[EPS]
Display Item List
CAUTION:
When malfunctions are detected in several system, including the “CAN COMM [U1000]”, inspect the
CAN communication system.
DTC code

Diagnostic item

Diagnostic item is detected when….

Check items

C1601

BATTERY_VOLT

Power supply malfunction supplied to EPS.

STC-15

C1604

TORQUE_SENSOR

Torque sensor malfunction assembled in column assembly.

STC-16

C1606

EPS_MOTOR

Motor driver malfunction of motor or EPS control unit.

STC-17

C1607

EEPROM

EEPROM malfunction of EPS control unit.

STC-18

C1608

CONTROL_UNIT

EPS control unit internal malfunction.

STC-18

C1609

CAN_VHCL_SPEED

Vehicle speed signal malfunction received via CAN communication.

STC-19

C1610

CAN_ENG_PRM

Engine signal malfunction received via CAN communication.

STC-19

U1000

CAN_COMM_CIRCUIT

Malfunction is detected in CAN communication circuit.

STC-20

DATA MONITOR
Operation Procedure
1.

2.
3.
4.

Touch “START (NISSAN BASED VHCL)” “EPS” “DATA MONITOR”.
● If EPS is not displayed, print the “SELECT SYSTEM” screen. Then refer to LAN-3, «Precautions When
Using CONSULT-II» .
NOTE:
Just after starting engine, or turning ignition switch ON, it may not be displayed even if “START (NISSAN BASED VHCL)” is touched. In this case, reconnect CONSULT-II and CONSULT-II CONVERTER.
Return to the monitor item selection screen, and touch any of “ALL SIGNALS”, “SELECTION FROM
MENU”.
Touch “START”.
“DATA MONITOR” screen is displayed.

Display Item List
Item (Display or Unit)

Remarks

MOTOR VOL (V)

Displays power supply voltage supplied EPS control unit

TORQUE SENSOR (Nm)

Displays steering wheel turning force detected by torque sensor

MOTOR SIG (A)

Displays command value of a current sent to motor
Displays current value used by EPS.

MOTOR CURRENT (A)

NOTE:
Quick steering may cause mismatch with a command value.
This is not a malfunction.

VEHICLE SPEED (km/h)

In close agreement with a vehicle speed read by speedometer. It
may not agree immediately after ignition key switch ON, however, this is not a malfunction.

WARNING LAMP (ON/OFF)

EPS warning lamp operation condition is displayed

DERATING STAT (ON/OFF)

Under normal conditions OFF. It turns on if the steering wheel is
turned excessively. When left standing, it recovers to OFF.

ENGINE STATUS (stop, stall, run, and crank)

Displays engine status

STC-12

TROUBLE DIAGNOSIS
[EPS]
ECU PART NUMBER
Operation Procedure
1.

2.

A

Touch “START (NISSAN BASED VHCL)” “EPS” “ECU PART NUMBER”.
● If EPS is not displayed, print the “SELECT SYSTEM” screen. Then refer to LAN-3, «Precautions When
Using CONSULT-II» .
NOTE:
Just after starting engine, or turning ignition switch ON, it may not be displayed even if “START (NISSAN BASED VHCL)” is touched. In this case, reconnect CONSULT-II and CONSULT-II CONVERTER.
The part number described on EPS control unit sticker is displayed.

CAN COMMUNICATION
System Description

For Fast and Accurate Trouble Diagnosis

BGS00035

Check the following items with the vehicle stopped
●
Is air pressure and size of tires proper?
●
Is the specified part used for the steering wheel?
●
Is control unit a genuine part?
●
Is the conditions (looseness of mounting bolts, damage on rod of main body, damage on boot or fire wall
seal and leakage of grease) of installation for steering column assembly and steering gear assembly are
normal?
●
Is the wheel alignment adjusted properly? Refer to FSU-6, «Wheel Alignment» .
●
Are there any damage or modification to suspension or body resulting in increased weight or altered
ground clearance?
●
Check each link installation condition of suspension and axle.
●
Is the battery voltage proper?
●
Check each connector connection condition.
Check the following items while driving the vehicle
●
Conditions when the error occurred (5W 1H).
●
Is the engine is normal?

Basic Inspection

BGS00036

BASIC INSPECTION 1: POWER SUPPLY CIRCUIT TERMINAL LOOSENESS AND BATTERY
Check battery terminals for looseness on both positive and negative ones and ground connection. Also make
sure that battery voltage does not drop.

BASIC INSPECTION 2: EPS WARNING LAMP INSPECTION

2.
3.

C

D

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only. Refer to LAN-21, «CAN
COMMUNICATION» .

1.

B

Make sure EPS warning lamp turns on when ignition switch is turned ON.
● If it does not turn on, refer to STC-20, «Inspection 8: CAN Communication Circuit» .
● Check combination meter if CAN communication is normal. Refer to DI-4, «COMBINATION METERS» .
Make sure that EPS warning lamp turns off when the engine is started after ignition switch is turned ON. If
it does not turn off, perform self-diagnosis. Refer to STC-11, «SELF-DIAGNOSIS» .
Always erase DTC memory after completing self-diagnosis. Refer to STC-11, «Erase Memory» .

STC-13

E

F

STC

H

I

J

K

L

M

TROUBLE DIAGNOSIS
[EPS]
BASIC INSPECTION 3: EPS CONTROL UNIT POWER SUPPLY CIRCUIT AND GROUND CIRCUIT INSPECTION

1. CHECK EPS CONTROL UNIT CONNECTOR
Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation,
disconnection, looseness, etc.
OK or NG
OK
>> GO TO 2.
NG
>> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal.

2. CHECK EPS CONTROL UNIT GROUND CIRCUIT
Disconnect EPS control unit harness connector M24, and then
check continuity between EPS control unit harness connector M24
and ground.
18 – Ground

: Continuity exist.

OK or NG
OK
>> GO TO 3.
NG
>> Ground circuit open or shorted. Repair or replace any
inoperative parts.
SGIA1306E

3. CHECK EPS CONTROL UNIT POWER SUPPLY CIRCUIT
1.
2.

Turn ignition switch on.
Check voltage between EPS control unit harness connector
M24, M25 and ground.
10, 17 – Ground

: Battery voltage (Approx. 12 V)

OK or NG
OK
>> Power supply and ground circuit are normal.
NG
>> Power supply circuit open or shorted. Repair or replace
any inoperative parts.

SGIA1307E

STC-14

TROUBLE DIAGNOSIS
[EPS]

Inspection 1: Battery Voltage Malfunction

BGS00037

1. CHECK EPS CONTROL UNIT CONNECTOR

A

1.

Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc.
2. Reconnect harness connector securely, and perform self-diagnosis.
Is “BATTERY_VOLT” indicated in self-diagnosis display?
YES >> GO TO 2.
NO
>> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal.

Turn ignition switch OFF.
Disconnect EPS control unit harness connector M24, and then
check continuity between EPS control unit harness connector
M24 and ground.
18 – Ground

C

D

2. CHECK EPS CONTROL UNIT GROUND CIRCUIT
1.
2.

B

E

F

: Continuity exist.

OK or NG
OK
>> GO TO 3.
NG
>> Ground circuit open or shorted. Repair or replace any
inoperative parts.

STC

H
SGIA1306E

3. CHECK EPS CONTROL UNIT POWER SUPPLY CIRCUIT
I

1.
2.

Turn ignition switch ON.
Check voltage between EPS control unit harness connector
M24, M25 and ground.
10, 17 – Ground

J

: Battery voltage (Approx. 12 V)

OK or NG
OK
>> GO TO 4.
NG
>> Connector terminal connection is loose, damaged,
open, or shorted. Repair or replace any inoperative
parts.

K

L
SGIA1307E

M

4. CHECK EPS CONTROL UNIT
1.
2.

Turn ignition switch OFF, disconnect EPS control unit harness connector. Start engine.
Check “MOTOR VOL” in CONSULT-II data monitor.
Voltage

: 10 – 16 V

OK or NG
OK
>> GO TO 5.
NG
>> EPS control unit malfunction. (Replace EPS control unit)

STC-15

TROUBLE DIAGNOSIS
[EPS]

5. CHECK POWER SUPPLY CIRCUIT
Turn head lamp, A/C, blower fan and rear window defogger OFF. Turn steering wheel until it stops. At that
time, check “MOTOR VOL” in CONSULT-II data monitor.
Voltage

: 10 – 16 V

OK or NG
OK
>> INSPECTION END
NG
>> Power supply circuit open or shorted. Repair or replace any inoperative pars.

Inspection 2: Torque Sensor Malfunction

BGS00038

1. CHECK EPS CONTROL UNIT CONNECTOR
1.

Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc.
2. Reconnect harness connector securely, and perform self-diagnosis.
Is “TORQUE SENSOR” indicated in self-diagnosis display?
YES >> GO TO 2.
NO
>> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal.

2. CHECK TORQUE SENSOR CONNECTOR
1.

Turn ignition switch OFF, disconnect torque sensor harness connector, and check terminal for deformation, looseness, etc.
2. Reconnect harness connector securely, and perform self-diagnosis.
Is “TORQUE SENSOR” indicated in self-diagnosis display?
YES >> GO TO 3.
NO
>> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal.

3. CHECK TORQUE SENSOR HARNESS
1.
2.

Turn ignition switch OFF, disconnect the harness connectors of EPS control unit and torque sensor.
Check continuity between EPS control unit harness connector
and torque sensor harness connector.
A
Connector

B
Terminal

Connector

4
EPS control unit: M25

5

Continuity
Terminal
3

Torque sensor: M26

2

6

1

7

4

Yes

MGIB0002E

OK or NG
OK
>> GO TO 4.
NG
>> Open or short in harness between EPS control unit and torque sensor. Repair applicable harness.

STC-16

TROUBLE DIAGNOSIS
[EPS]

4. CHECK TORQUE SENSOR POWER SUPPLY
1.
2.

A

Connect the harness connectors of EPS control unit and torque sensor. Turn ignition switch ON.
Turn steering to the neutral position (steering force: zero), and
then check voltage EPS control unit harness connector M25.

B

Torque sensor power supply
5–7
: Approx. 8 V

C

OK or NG
OK
>> GO TO 5.
NG
>> EPS control unit malfunction. (Replace EPS control unit)

D
SGIA1309E

E

5. CHECK TORQUE SENSOR SIGNAL
Turn steering to the neutral position (steering force: zero), and then
check voltage EPS control unit harness connector M25.

F

Torque sensor (sub)
4–7
: Approx. 2.5 V
Torque sensor (main)
6–7
: Approx. 2.5 V

STC

OK or NG
OK
>> EPS control unit malfunction. (Replace EPS control unit)
NG
>> Torque sensor malfunction. (Replace steering column
assembly [with motor, reduction gear, sensor])

Inspection 3: Motor Malfunction

H

SGIA1310E

I

BGS00039

1. CHECK EPS CONTROL UNIT CONNECTOR

J

1.

Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc.
2. Reconnect harness connector securely, and perform self-diagnosis.
Is “EPS MOTOR” indicated in self-diagnosis display?
YES >> GO TO 2.
NO
>> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal.

2. CHECK MOTOR RESISTANCE
1.
2.

L

M

Turn ignition switch OFF, disconnect motor harness connector M 351 from EPS control unit.
Check resistance between motor harness connector M351.
19 – 20

K

: Approx. 0.1 Ω or less

OK or NG
OK
>> EPS control unit malfunction. (Replace EPS control unit)
NG
>> Motor malfunction. (Replace steering column assembly
[with motor, reduction gear, sensor])

SGIA1311E

STC-17

TROUBLE DIAGNOSIS
[EPS]

Inspection 4: EEPROM Malfunction

BGS0003A

1. CHECK EPS CONTROL UNIT CONNECTOR
1.

Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc.
2. Reconnect harness connector securely, and perform self-diagnosis.
Is “EEPROM” indicated in self-diagnosis display?
YES >> EPS control unit malfunction. (Replace EPS control unit)
NO
>> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal.

Inspection 5: Control unit malfunction

BGS0003B

1. CHECK EPS CONTROL UNIT CONNECTOR
Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation,
disconnection, looseness, etc.
OK or NG
OK
>> GO TO 2.
NG
>> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal.

2. CHECK EPS CONTROL UNIT GROUND CIRCUIT
Disconnect EPS control unit harness connector M24, and then
check continuity between EPS control unit harness connector M24
and ground.
18 – Ground

: Continuity exist.

OK or NG
OK
>> GO TO 3.
NG
>> Ground circuit open or shorted. Repair or replace any
inoperative parts.
SGIA1306E

3. CHECK EPS CONTROL UNIT POWER SUPPLY CIRCUIT
1.
2.

Turn ignition switch turned ON.
Check voltage between EPS control unit harness connector
M24, M25 and ground.
10, 17 – Ground

: Battery voltage (Approx. 12 V)

OK or NG
OK
>> GO TO 4.
NG
>> Power supply circuit open or shorted. Repair or replace
any inoperative parts.

SGIA1307E

4. CHECK EPS CONTROL UNIT
Connect EPS control unit harness connector securely, and perform self-diagnosis.
Is “CONTROL UNIT” indicated in self-diagnosis display?
YES >> EPS control unit malfunction. (Replace EPS control unit)
NO
>> INSPECTION END.

STC-18

TROUBLE DIAGNOSIS
[EPS]

Inspection 6: Vehicle Speed Signal Malfunction

BGS0003C

1. CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) CIRCUIT

A

Perform self-diagnosis of ABS actuator and electric unit (control unit).
OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace the affect part.

B

C

2. CHECK SPEEDOMETER
Perform combination meter (speedometer) self-diagnosis.
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace the affect part.

D

E

3. CHECK EPS CONTROL UNIT CONNECTOR
1.
2.

Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc.
Reconnect harness connector securely, and perform self-diagnosis.

F

STC

SELF-DIAG RESULTS
CAN_VHCL_SPEED

H

CAN_COMM_CIRCUIT
Is above displayed on self-diagnosis display?
YES >> ● EPS control unit malfunction. (Replace EPS control unit)
● If “CAN_COMM_CIRCUIT” is displayed, refer to STC-20, «Inspection 8: CAN Communication
Circuit» .
NO
>> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal.

Inspection 7: Engine Signal Malfunction

K

Make sure that the engine speed signal in CONSULT II data monitor is the almost same as the tachometer.
OK or NG
OK
>> GO TO 2.
NG
>> Check tachometer and circuit. Refer to DI-4, «COMBINATION METERS» .

2. CHECK EPS CONTROL UNIT CONNECTOR
2.

J

BGS0003D

1. CHECK ENGINE SPEED SIGNAL

1.

I

Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc.
Reconnect harness connector securely, and perform self-diagnosis.
SELF-DIAG RESULTS
CAN_ENG_RPM
CAN_COMM_CIRCUIT

Is above displayed on self-diagnosis display?
YES >> ● EPS control unit malfunction. (Replace EPS control unit)
● If “CAN_COMM_CIRCUIT” is displayed, refer to STC-20, «Inspection 8: CAN Communication
Circuit» .
NO
>> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal.

STC-19

L

M

TROUBLE DIAGNOSIS
[EPS]

Inspection 8: CAN Communication Circuit

BGS0003E

1. CHECK EPS CONTROL UNIT CONNECTOR
1.

Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc.
2. Reconnect harness connector securely, and perform self-diagnosis.
Is “CAN COMM CIRCUIT” displayed on self-diagnosis display?
YES >> Print out the self-diagnosis results and refer to STC-20, «Inspection 8: CAN Communication Circuit» .
NO
>> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal.

Symptom 1: Steering is Heavy or Light

BGS0003F

1. CHECK SELF-DIAGNOSIS RESULTS
Check self-diagnosis results.
Are there malfunctioning systems in self-diagnosis results?
YES >> GO TO 2.
NO
>> GO TO 4.

2. CHECK EPS CONTROL UNIT CONNECTOR
1.

Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc.
2. Reconnect harness connector securely, and perform self-diagnosis.
Are there malfunctioning systems in self-diagnosis results?
YES >> Repair malfunctioning circuit, and GO TO 3.
NO
>> GO TO 3.

3. CHECK SYMPTOM
Make sure that the steering does not have the symptoms of “Heavy” or “Light”.
OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 4.

4. CHECK CAN COMMUNICATION CIRCUIT AGAIN
Check CAN communication circuit. Refer to STC-20, «Inspection 8: CAN Communication Circuit» .
OK or NG
OK
>> GO TO 5.
NG
>> Repair malfunctioning circuit.

5. CHECK EPS CONTROL UNIT POWER SUPPLY CIRCUIT
Check EPS control unit power supply circuit. Refer to STC-15, «Inspection 1: Battery Voltage Malfunction» .
OK or NG
OK
>> Check steering wheel turning force. Refer to PS-5, «STEERING TORQUE INSPECTION» .
NG
>> Repair power supply circuit.

STC-20

TROUBLE DIAGNOSIS
[EPS]

Symptom 2: There is a Difference in the Steering Turning/Returning Force of
Left and Right (Biased to One Side)

BGS0003G

A

1. CHECK SELF-DIAGNOSIS RESULTS
B

Check self-diagnosis results.
Are there malfunctioning systems in self-diagnosis results?
YES >> GO TO 2.
NO
>> GO TO 4.

C

2. CHECK EPS CONTROL UNIT CONNECTOR
1.

Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc.
2. Reconnect harness connector securely, and perform self-diagnosis.
Are there malfunctioning systems in self-diagnosis results?
YES >> Repair malfunctioning circuit, and GO TO3.
NO
>> GO TO 3.

D

E

F

3. CHECK SYMPTOM
Make sure that the steering does not have the symptoms of “Heavy” or “Light”.
OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 4.

STC

H

4. WHEEL ALIGNMENT INSPECTION
I

Check wheel alignment. Refer to FSU-6, «Wheel Alignment» .
OK or NG
OK
>> Check steering wheel turning force. Refer to PS-5, «STEERING TORQUE INSPECTION» .
NG
>> Adjust wheel alignment. Refer to FSU-6, «Wheel Alignment» .

Symptom 3: Steering Wheel Turning Force is Uneven (Torque Variation)

J
BGS0003H

1. CHECK SELF-DIAGNOSIS RESULTS

K

Check self-diagnosis results.
Are there malfunctioning systems in self-diagnosis results?
YES >> GO TO 2.
NO
>> GO TO 4.

L

2. CHECK EPS CONTROL UNIT CONNECTOR

M

1.

Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc.
2. Reconnect harness connector securely, and perform self-diagnosis.
Are there malfunctioning systems in self-diagnosis results?
YES >> Repair malfunctioning circuit, and GO TO 3.
NO
>> GO TO 3.

3. CHECK SYMPTOM
Make sure that the steering does not have the symptoms of “Heavy” or “Light”.
OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 4.

STC-21

TROUBLE DIAGNOSIS
[EPS]

4. CHECK EPS CONTROL UNIT POWER SUPPLY CIRCUIT
Check EPS control unit power supply circuit. Refer to STC-15, «Inspection 1: Battery Voltage Malfunction» .
OK or NG
OK
>> GO TO 5.
NG
>> Repair malfunctioning circuit.

5. CHECK STEERING COLUMN INTERMEDIATE SHAFT
1.

Check the connection between the intermediate shaft and the mounting part of steering column assembly
and steering gear assembly. Refer to PS-7, «STEERING COLUMN» .
2. Make sure that steering wheel turning force is uneven (torque variation).
OK or NG
OK
>> INSPECTION END.
NG
>> Check steering wheel turning force. Refer to PS-5, «STEERING TORQUE INSPECTION» .

Symptom 4: EPS Warning Lamp Stays ON

BGS0003I

1. CHECK SELF-DIAGNOSIS RESULTS
Check self-diagnosis results.
Are there malfunctioning systems in self-diagnosis results?
YES >> GO TO 2.
NO
>> GO TO 4.

2. CHECK EPS CONTROL UNIT CONNECTOR
1.

Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc.
2. Reconnect harness connector securely, and perform self-diagnosis.
Are there malfunctioning systems in self-diagnosis results?
YES >> Repair malfunctioning circuit, and GO TO 3.
NO
>> GO TO 3.

3. CHECK SYMPTOM
Make sure that the steering does not have the symptoms of “Heavy” or “Light”.
OK or NG
OK
>> INSPECTION END.
NG
>> GO TO 4.

4. CHECK EPS CONTROL UNIT POWER SUPPLY CIRCUIT
Check EPS control unit power supply circuit. Refer to STC-15, «Inspection 1: Battery Voltage Malfunction» .
OK or NG
OK
>> GO TO 5.
NG
>> Repair malfunctioning circuit.

5. CHECK STEERING WHEEL TURNING FORCE
Check the EPS assist force when the steering is operated. Refer to PS-5, «STEERING TORQUE INSPECTION» .
OK or NG
OK
>> Check CAN communication circuit. Refer to STC-20, «Inspection 8: CAN Communication Circuit» .
NG
>> EPS control unit malfunction.

STC-22

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

H RESTRAINTS

SECTION

SRS

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 3
Precautions for SRS “AIR BAG” and “SEAT BELT
PRE-TENSIONER” Service ………………………………. 3
PREPARATION ………………………………………………….. 4
Special Service Tools ……………………………………….. 4
Commercial Service Tools …………………………………. 4
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ……. 5
SRS Configuration …………………………………………… 5
Front Seat Belt Pre-tensioner with Load Limiter ….. 6
Front Side Air Bag ……………………………………………. 6
Side Curtain Air Bag …………………………………………. 6
Front Passenger Air Bag Cut OFF Switch …………… 6
Front Passenger Air Bag OFF Indicator ………………. 7
TROUBLE DIAGNOSIS ………………………………………. 8
Trouble Diagnosis Introduction …………………………… 8
DIAGNOSIS FUNCTION ………………………………… 8
HOW TO PERFORM TROUBLE DIAGNOSES
FOR QUICK AND ACCURATE REPAIR …………… 8
WORK FLOW ……………………………………………….. 9
Component Parts Location ………………………………. 10
Schematic ………………………………………………………11
Wiring Diagram — SRS — ………………………………. 12
CONSULT-II Function …………………………………….. 16
DIAGNOSIS MODE FOR CONSULT-II …………… 16
HOW TO CHANGE SELF-DIAGNOSIS MODE
WITH CONSULT-II ………………………………………. 16
HOW TO ERASE SELF-DIAGNOSIS RESULTS… 17
Self-Diagnosis Function (Without CONSULT-II) ….. 17
HOW TO CHANGE SELF-DIAGNOSIS MODE
WITHOUT CONSULT-II ……………………………….. 17
HOW TO ERASE SELF-DIAGNOSIS RESULTS… 17
SRS Operation Check …………………………………….. 18
DIAGNOSTIC PROCEDURE 1 ……………………… 18
Trouble Diagnosis with CONSULT-II …………………. 20
DIAGNOSTIC PROCEDURE 2 ……………………… 20
CONSULT-II DIAGNOSTIC CODE CHART

(“SELF-DIAG [CURRENT]”) ………………………….. 21
DIAGNOSTIC PROCEDURE 3 ……………………… 24
DIAGNOSTIC PROCEDURE 4 (CONTINUED
FROM DIAGNOSTIC PROCEDURE 2) ………….. 26
DIAGNOSTIC PROCEDURE 5 ……………………… 26
Trouble Diagnosis without CONSULT-II …………….. 30
DIAGNOSTIC PROCEDURE 6 ……………………… 30
WARNING LAMP FLASH CODE CHART ……….. 30
Trouble Diagnosis: “AIR BAG” Warning Lamp Does
Not Turn OFF ………………………………………………… 34
DIAGNOSTIC PROCEDURE 7 ……………………… 34
Trouble Diagnosis: “AIR BAG” Warning Lamp Does
Not Turn ON ………………………………………………….. 35
DIAGNOSTIC PROCEDURE 8 ……………………… 35
DRIVER AIR BAG MODULE ……………………………… 36
Removal and Installation …………………………………. 36
REMOVAL ………………………………………………….. 36
INSTALLATION …………………………………………… 37
SPIRAL CABLE ……………………………………………….. 38
Removal and Installation …………………………………. 38
REMOVAL ………………………………………………….. 38
INSTALLATION …………………………………………… 39
FRONT PASSENGER AIR BAG MODULE ………….. 40
Removal and Installation …………………………………. 40
REMOVAL ………………………………………………….. 40
INSTALLATION …………………………………………… 41
FRONT SIDE AIR BAG MODULE ………………………. 42
Removal and Installation …………………………………. 42
REMOVAL ………………………………………………….. 42
INSTALLATION …………………………………………… 43
SIDE CURTAIN AIR BAG MODULE …………………… 44
Removal and Installation …………………………………. 44
REMOVAL ………………………………………………….. 44
INSTALLATION …………………………………………… 44
CRASH ZONE SENSOR ……………………………………. 45
Removal and Installation …………………………………. 45
REMOVAL ………………………………………………….. 45
INSTALLATION …………………………………………… 45

SRS-1

E

F

G

SRS

I

J

K

L

M

SIDE AIR BAG (SATELLITE) SENSOR ………………. 46
Removal and Installation …………………………………. 46
REMOVAL ………………………………………………….. 46
INSTALLATION ……………………………………………. 46
SEAT BELT PRE-TENSIONER …………………………… 47
Removal and Installation …………………………………. 47
DIAGNOSIS SENSOR UNIT ………………………………. 48
Removal and Installation …………………………………. 48
REMOVAL ………………………………………………….. 48
INSTALLATION ……………………………………………. 48
ECU DISCRIMINATED NO. …………………………… 48
DISPOSALOFAIRBAGMODULEANDSEATBELT
PRE-TENSIONER …………………………………………….. 49
Caution for Air Bag Module and Seat Belt Pretensioner ……………………………………………………….. 49
CHECKING DEPLOYMENT TOOL ………………… 49
DEPLOYMENT PROCEDURES FOR AIR BAG
MODULE ……………… 50
DEPLOYMENT PROCEDURES FOR SEAT
BELT PRE-TENSIONER …………………………………………………………..54
DEPLOYMENT PROCEDURES FOR FRONT
SEAT BELT PRE-TENSIONER 2 (OUTSIDE OF
VEHICLE) ……………………………………………………55
DEPLOYMENT OF AIR BAG MODULE AND
SEAT BELT PRE-TENSIONER WHILE
MOUNTED IN VEHICLE ………………………………..57
DISPOSING OF AIR BAG MODULE AND SEAT
BELT PRE-TENSIONER ………………………………..57
COLLISION DIAGNOSIS ……………………………………58
For Frontal Collision …………………………………………58
SRS INSPECTION (FOR FRONTAL COLLISION) ………………………………………………………….58
For Side Collision …………………………………………….60
WHEN THE SIDE AIR BAG IS ACTIVATED IN
THE SIDE COLLISION: …………………………………60
WHEN SRS IS NOT ACTIVATED IN THE SIDE
COLLISION: …………………………………………………60
SRS INSPECTION (FOR SIDE COLLISION) ……60

SRS-2

PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

A

BHS0002S

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

B

C

D

E

F

Precautions for SRS “AIR BAG” and “SEAT BELT PRE-TENSIONER” Service
BHS0002T

●
●

●

●

●

●
●

G
Do not use electrical test equipment to check SRS circuits unless instructed to in this Service Manual.
Before servicing the SRS, turn ignition switch “OFF”, disconnect battery ground cable and wait at least 3
minutes.
For approximately 3 minutes after the cables is removed, it is still possible for the air bag and seat belt SRS
pre-tensioner to deploy. Therefore, do not work on any SRS connectors or wires until at least 3 minutes
have passed.
Diagnosis sensor unit must always be installed with their arrow marks “⇐” pointing towards the front of the
I
vehicle for proper operation. Also check diagnosis sensor unit for cracks, deformities or rust before installation and replace as required.
The spiral cable must be aligned with the neutral position since its rotations are limited. Do not attempt to J
turn steering wheel or column after removal of steering gear.
Handle air bag module carefully. Always place driver and front passenger air bag modules with the pad
side facing upward and place front side air bag module standing with stud bolt side setting bottom.
K
Conduct self-diagnosis to check entire SRS for proper function after replacing any components.
After air bag inflates, the front instrument panel assembly should be replaced if damaged.
L

M

SRS-3

PREPARATION
PREPARATION
Special Service Tools

PFP:00002
BHS0002U

Tool number
Tool name

Application

KV99105300
Air bag module bracket

Anchoring air bag module

S-NT354

KV99106400
Deployment tool

Disposing of air bag module

S-NT357

KV99109700
Deployment tool adapter for front
passenger air bag module

Connection between the deployment tool
and front passenger air bag module

SHIA0038J

KV99110500
●

Deployment tool adapter for pretensioner seat belt module

●

Deployment tool adapter for
driver air bag mmodule

●

Deployment tool adapter for side
curtain air bag module

●

Connection between the deployment tool
and pre-tensioner seat belt

●

Connection between the deployment tool
and driver air bag module

●

Connection between the deployment tool
and side curtain air bag module

PHIA0184E

KV99108300
Deployment tool adapter for front
side air bag module

Connection between the deployment tool
and front side air bag module

ZZA1166D

Commercial Service Tools

BHS0002V

Tool name

Application

Tamper resistant TORX bit

Size: T30

S-NT757

SRS-4

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
SRS Configuration

PFP:28556

A
BHS0002W

B

C

D

E

F

G

SRS

I
MHIB0115E

J

The air bag deploys if the diagnosis sensor unit activates while the ignition switch is in the ON or START position.
The collision modes for which supplemental restraint systems are activated are different among the SRS systems. For example, the driver air bag module and front passenger air bag module are activated in a frontal collision but not in a side collision.
SRS configurations which are activated for some collision modes are as follows;
SRS configuration

Frontal collision

Left side collision

Right side collision

Driver air bag module

×

—

—

Front passenger air bag module

×

—

—

Front LH seat belt pre-tensioner

×

—

—

Front RH seat belt pre-tensioner

×

—

—

Front LH side air bag module

—

×

—

Front RH side air bag module

—

—

×

LH side curtain air bag module

—

×

—

RH side curtain air bag module

—

—

×

SRS-5

K

L

M

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Front Seat Belt Pre-tensioner with Load Limiter
The seat belt pre-tensioner system with load limiter is installed for
both the driver’s seat and the front passenger’s seat. It operates
simultaneously with the SRS air bag system in the event of a frontal
collision with an impact exceeding a specified level.
When the frontal collision with an impact exceeding a specified level
occurs, seat belt slack resulting from clothing or other factors is
immediately taken up by the pre-tensioner. Vehicle passengers are
securely restrained.
When passengers in a vehicle are thrown forward in a collision and
the restraining force of the seat belt exceeds a specified level, the
load limiter permits the specified extension of the seat belt by the
twisting of the ELR shaft, and a relaxation of the chest-area seat belt
web tension while maintaining force.

Front Side Air Bag

BHS0002X

SRS444

BHS0002Y

Front side air bag is built-in type.
The front seatbacks with built-in type side air bag have the labels as
shown.

SHIA0170E

Side Curtain Air Bag

BHS0002Z

The side curtain air bags have the labels as shown.

PHIA0850J

Front Passenger Air Bag Cut OFF Switch

BHS00030

Operating the front passenger air bag cut OFF switch to ON or OFF
position will switch the front air bag to armed or disarmed state.
The front passenger air bag cut OFF switch is located in right hand
side of the instrument side mask for LHD model. (And oppositely for
the RHD model)

MHIB0118E

SRS-6

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Front Passenger Air Bag OFF Indicator

BHS00031

A

The front passenger air bag OFF indicator is arranged in the A/C
control panel.
Air bag OFF indicator — (1)

B

C

D
MHIB0132E

E

F

G

SRS

I

J

K

L

M

SRS-7

TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
Trouble Diagnosis Introduction

PFP:00004
BHS00032

CAUTION:
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.
●
Do not attempt to repair, splice or modify the SRS wiring harness. If the harness is damaged,
replace it with a new one.
●
Keep ground portion clean.

DIAGNOSIS FUNCTION
The SRS self-diagnosis results can be read by using “AIR BAG” warning lamp and/or CONSULT-II.
The User mode is exclusively prepared for the customer (driver). This mode warns the driver of a system malfunction through the operation of the “AIR BAG” warning lamp.
The Diagnosis mode allows the technician to locate and inspect the malfunctioning part.
The mode applications for the “AIR BAG” warning lamp and CONSULT-II are as follows:
User mode

Diagnosis mode

Display type

“AIR BAG” warning lamp

X

X

ON-OFF operation

CONSULT-II

—

X

Monitoring

HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR
A good understanding of the malfunction conditions can make troubleshooting faster and more accurate.
In general, each customer feels differently about a malfunction. It is important to fully understand the symptoms or conditions for a customer complaint.

Information from Customer
WHAT….. Vehicle model
WHEN….. Date, Frequencies
WHERE….. Road conditions
HOW….. Operating conditions, Symptoms

Preliminary Check
Check that the following parts are in good order.
●
Battery (Refer to SC-5, «How to Handle Battery» .)
●
Fuse (Refer to SRS-12, «Wiring Diagram — SRS —» .)
●
System component-to-harness connections

SRS-8

TROUBLE DIAGNOSIS
WORK FLOW
A

B

C

D

E

F

G

SRS

I

J

K

L
PHIA0710E

*1: SRS-8, «Preliminary Check»

*2: SRS-18, «SRS Operation Check»

*3: SRS-20, «DIAGNOSTIC PROCEDURE 2»

*4: SRS-30, «DIAGNOSTIC PROCEDURE 6»

*5

*6

SRS-24, «DIAGNOSTIC PROCEDURE 3»

SRS-9

SRS-30, «DIAGNOSTIC PROCEDURE 6»

M

TROUBLE DIAGNOSIS
Component Parts Location

BHS00033

MHIB0125E

1.

Driver air bag module

2.

Spiral cable

3.

Diagnosis sensor unit

4.

Side air bag (satellite) sensors

5.

Seat belt Pre-tensioners

6.

Front side air bag modules

7.

Front passenger air bag module

8.

Crash zone sensor

9.

Curtain air bag module

SRS-10

TROUBLE DIAGNOSIS
Schematic

BHS00034

A

B

C

D

E

F

G

SRS

I

J

K

L

M

MHWA0060E

SRS-11

TROUBLE DIAGNOSIS
Wiring Diagram — SRS —

BHS00035

MHWA0061E

SRS-12

TROUBLE DIAGNOSIS
A

B

C

D

E

F

G

SRS

I

J

K

L

M

MHWA0062E

SRS-13

TROUBLE DIAGNOSIS

MHWA0063E

SRS-14

TROUBLE DIAGNOSIS
A

B

C

D

E

F

G

SRS

I

J

K

L

M

MHWA0064E

SRS-15

TROUBLE DIAGNOSIS
CONSULT-II Function

BHS00036

DIAGNOSIS MODE FOR CONSULT-II
●

●

●

●

“SELF-DIAG [CURRENT]”
A current Self-diagnosis result (also indicated by the number of warning lamp flashes in the Diagnosis
mode) is displayed on the CONSULT-II screen in real time. This refers to a malfunctioning part requiring
repairs.
“SELF-DIAG [PAST]”
Diagnosis results previously stored in the memory are displayed on the CONSULT-II screen. The stored
results are not erased until memory erasing is executed.
“TROUBLE DIAG RECORD”
With TROUBLE DIAG RECORD, diagnosis results previously erased by a reset operation can be displayed on the CONSULT-II screen.
“ECU DISCRIMINATED NO.”
The diagnosis sensor unit for each vehicle model is assigned
with its own, individual classification number. This number will
be displayed on the CONSULT-II screen, as shown. When
replacing the diagnosis sensor unit, refer to the part number for
the compatibility. After installation, replacement with a correct
unit can be checked by confirming this classification number on
the CONSULT-II screen.
After repair, make sure the discriminated number of diagnosis
sensor unit installed to vehicle are same. Refer to SRS-48,
«ECU DISCRIMINATED NO.» .
PHIA0218E

HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT-II
From User Mode to Diagnosis Mode
After selecting “AIR BAG” on the “SELECT SYSTEM” screen, User mode automatically changes to Diagnosis
mode.

SRS803

From Diagnosis Mode to User Mode
To return to User mode from Diagnosis mode, touch “BACK” key of CONSULT-II until “SELECT SYSTEM”
appears, Diagnosis mode automatically changes to User mode.

SRS804

SRS-16

TROUBLE DIAGNOSIS
HOW TO ERASE SELF-DIAGNOSIS RESULTS
●

●

●

“SELF-DIAG [CURRENT]”
A current Self-diagnosis result is displayed on the CONSULT-II screen in real time.
After the malfunction is repaired completely, no malfunction is detected on “SELF-DIAG [CURRENT]”.
“SELF-DIAG [PAST]”
Return to the “SELF-DIAG [CURRENT]” CONSULT-II screen by touching “BACK” key of CONSULT-II and
select “SELF-DIAG [CURRENT]” in SELECT DIAG MODE. Touch “ERASE” in “SELF-DIAG [CURRENT]”
mode.
NOTE:
If the memory of the malfunction in “SELF-DIAG [PAST]” is not erased, the User mode shows the system
malfunction by the operation of the warning lamp even if the malfunction is repaired completely.
“TROUBLE DIAG RECORD”
The memory of “TROUBLE DIAG RECORD” cannot be erased.

A

B

C

D

E

F

G
SRS701

Self-Diagnosis Function (Without CONSULT-II)
●
●

BHS00037

The reading of these results is accomplished “User mode” and “Diagnosis mode”.
After a malfunction is repaired, turn ignition switch ON. Diagnosis mode returns to the User mode. At that
time, the self-diagnostic result is cleared.

HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT-II

SRS

I

J

K

L

M

PHIA0709E

HOW TO ERASE SELF-DIAGNOSIS RESULTS
After a malfunction is repaired, turn the ignition switch OFF for at least one second, then back ON. Diagnosis
mode returns to the User mode. At that time, the self-diagnostic result is cleared.

SRS-17

TROUBLE DIAGNOSIS
SRS Operation Check

BHS00038

DIAGNOSTIC PROCEDURE 1
Checking Air Bag Operation by Using “AIR BAG” Warning Lamp — User Mode
1.
2.

Turn the ignition switch from OFF to ON, and check that the air bag warning lamp blinks.
Compare the SRS air bag warning lamp blinking pattern with the
examples.

BF-1845D

SRS-18

TROUBLE DIAGNOSIS
Warning lamp examples
“AIR BAG” warning lamp operation-User mode-

SRS condition

Reference item

A

B

●

No malfunction is detected.

●

No further action is necessary.

—

C

D
SHIA0011E

E

F
●

The system is malfunctioning and
need to be repaired as indicated.

Go to SRS-20, «DIAGNOSTIC
PROCEDURE 2» or SRS-30,
«DIAGNOSTIC PROCEDURE 6» .

G

SRS

SHIA0012E

●

Air bag is deployed.

●

Seat belt pre-tensioner is deployed.

Go to SRS-58, «COLLISION DIAGNOSIS» .

I
●

Diagnosis sensor unit is malfunctioning.

●

Air bag power supply circuit is malfunctioning.

●

SRS air bag warning lamp circuit is
malfunctioning.

Go to SRS-34, «Trouble Diagnosis:
“AIR BAG” Warning Lamp Does Not
Turn OFF» .

J

K

SHIA0013E

L

●

●

Diagnosis sensor unit is malfunctioning.
Air bag warning lamp circuit is malfunctioning.

SHIA0014E

SRS-19

Go to SRS-35, «Trouble Diagnosis:
“AIR BAG” Warning Lamp Does Not
Turn ON» .

M

TROUBLE DIAGNOSIS
Trouble Diagnosis with CONSULT-II

BHS00039

DIAGNOSTIC PROCEDURE 2
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carry out CAN communication.
Refer to GI-36, «CONSULT-II Start Procedure» .
1. Touch “SELF-DIAG [CURRENT]”.

SRS697

2.

Diagnostic code is displayed on “SELF-DIAG [CURRENT]”.

SHIA0203E

a.

If no malfunction is detected on “SELF-DIAG [CURRENT]” even
though malfunction is detected in “SRS Operation Check”,
check the battery voltage. If the battery voltage is less than 9 V,
charge or replace the battery. SRS-24, «DIAGNOSTIC PROCEDURE 3» . If the battery voltage is OK, go to SRS-26, «DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC
PROCEDURE 2)» diagnose the following cases:
● Self-diagnostic result “SELF-DIAG [PAST]” (previously stored
in the memory) might not be erased after repair.
● The SRS system malfunctions intermittently.
SRS701

SRS-20

TROUBLE DIAGNOSIS
CONSULT-II DIAGNOSTIC CODE CHART (“SELF-DIAG [CURRENT]”)
Diagnostic item
NO DTC IS
DETECTED.

Repair order
“Recheck SRS at each replacement”

Explanation
When malfunction is
indicated by the “AIR
BAG” warning lamp in
User mode.

●

●

●

Low battery voltage (Less than 9V)
Self-diagnostic result “SELF-DIAG
[PAST]” (previously stored in the
memory) might not be erased after
repair.
Intermittent malfunction has been
detected in the past.

●

No malfunction is detected.

DRIVER AIRBAG
MODULE
[OPEN]

●

Driver air bag module circuit is open (including the spiral
cable).

DRIVER AIRBAG
MODULE
[VB-SHORT]

●

DRIVER AIRBAG
MODULE
[GND-SHORT]

●

Go to SRS-24, «DIAGNOSTIC PROCEDURE 3» after charging the battery.

B

●

Go to SRS-26, «DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM
DIAGNOSTIC PROCEDURE 2)» .

C

●

Go to SRS-26, «DIAGNOSTIC PROCEDURE 5» .

●

D
—

Driver air bag module circuit is shorted to a power supply circuit (including the spiral cable).
Driver air bag module circuit is shorted to ground (including
the spiral cable).
Driver air bag module circuit is shorted between lines.

1. Visually check the wiring harness connection.

E

2. Replace the harness if it has visible
damage.
3. Replace driver air bag module. (Before
disposal, it must be deployed.)

F

4. Replace the spiral cable.
5. Replace the diagnosis sensor unit.

G

6. Replace the related harness.

DRIVER AIRBAG
MODULE
[SHORT]

●

ASSIST A/B MODULE
[OPEN]

●

Front passenger air bag module circuit is open.

1. Visually check the wiring harness connection.

ASSIST A/B MODULE
[VB-SHORT]

●

Front passenger air bag module circuit is shorted to a power
supply circuit.

2. Replace the harness if it has visible
damage.

ASSIST A/B MODULE
[GND-SHORT]

●

Front passenger air bag module circuit is shorted to ground.

ASSIST A/B MODULE
[SHORT]

●

Front passenger air bag module circuit is shorted between
lines.

3. Replace front passenger air bag module. (Before disposal, it must be
deployed.)

SRS

●

Crash zone sensor

I

J

4. Replace the diagnosis sensor unit.
5. Replace the related harness.

CRASH ZONE SEN
[UNIT FAIL]
CRASH ZONE SEN
[COMM FAIL]
CRASH ZONE SEN
[UNMATCH]

A

K

1. Visually check the wiring harness connection.
2. Replace the harness if it has visible
damage.

L

3. Replace the crash zone sensor.
4. Replace the diagnosis sensor unit.
5. Replace the related harness.

SIDE MODULE LH
[OPEN]

●

Front LH side air bag module circuit is open.

1. Visually check the wiring harness connection.

SIDE MODULE LH
[VB-SHORT]

●

Front LH side air bag module circuit is shorted to a power
supply circuit.

2. Replace the harness if it has visible
damage.

SIDE MODULE LH
[GND-SHORT]

●

Front LH side air bag module circuit is shorted to ground.

SIDE MODULE LH
[SHORT]

●

Front LH side air bag module circuit is shorted between lines.

3. Replace front LH setback assembly
(front LH side air bag module).
(Before disposal, it must be deployed.)
4. Replace the diagnosis sensor unit.
5. Replace the related harness.

SRS-21

M

TROUBLE DIAGNOSIS
Diagnostic item

Explanation

Repair order
“Recheck SRS at each replacement”

SIDE MODULE RH
[OPEN]

●

Front RH side air bag module circuit is open.

1. Visually check the wiring harness connection.

SIDE MODULE RH
[VB-SHORT]

●

Front RH side air bag module circuit is shorted to some power
supply circuit.

2. Replace the harness if it has visible
damage.

SIDE MODULE RH
[GND-SHORT]

●

Front RH side air bag module circuit is shorted to ground.

SIDE MODULE RH
[SHORT]

●

Front RH side air bag module circuit is shorted between lines.

3. Replace front RH setback assembly
(front RH side air bag module).
(Before disposal, it must be deployed.)
4. Replace the diagnosis sensor unit.
5. Replace the related harness.

SATELLITE SENS LH
[UNIT FAIL]
SATELLITE SENS LH
[COMM FAIL]

●

LH side air bag (Satellite) sensor

1. Visually check the wiring harness connection.
2. Replace the harness if it has visible
damage.
3. Replace the LH side air bag (Satellite)
sensor.
4. Replace the diagnosis sensor unit.
5. Replace the related harness.

SATELLITE SENS RH
[UNIT FAIL]
SATELLITE SENS RH
[COMM FAIL]

●

RH side air bag (Satellite) sensor

1. Visually check the wiring harness connection.
2. Replace the harness if it has visible
damage.
3. Replace the RH side air bag (Satellite)
sensor.
4. Replace the diagnosis sensor unit.
5. Replace the related harness.

PRE-TEN FRONT LH
[OPEN]

●

Front LH pre-tensioner circuit is open.

1. Visually check the wiring harness connections.

PRE-TEN FRONT LH
[VB-SHORT]

●

Front LH pre-tensioner circuit is shorted to a power supply circuit.

2. Replace the harness if it has visible
damage.

PRE-TEN FRONT LH
[GND-SHORT]

●

Front LH pre-tensioner circuit is shorted to ground.

3. Replace front LH seat belt.
(Before disposal, it must be activated.)

PRE-TEN FRONT LH
[SHORT]

●

Front LH pre-tensioner circuit is shorted between lines.

4. Replace the diagnosis sensor unit.

PRE-TEN FRONT RH
[OPEN]

●

Front RH pre-tensioner circuit is shorted to a power supply
circuit.

1. Visually check the wiring harness connections.

PRE-TEN FRONT RH
[VB-SHORT]

●

Front RH pre-tensioner circuit is shorted to a power supply
circuit.

2. Replace the harness if it has visible
damage.

PRE-TEN FRONT RH
[GND-SHORT]

●

Front RH pre-tensioner circuit is shorted to ground.

3. Replace front RH seat belt.
(Before disposal, it must be activated.)

PRE-TEN FRONT RH
[SHORT]

●

Front RH pre-tensioner circuit is shorted between lines.

4. Replace the diagnosis sensor unit.

CURTAIN MODULE LH
[OPEN]

●

LH side curtain air bag module circuit is open.

1. Visually check the wiring harness connection.

CURTAIN MODULE LH
[VB-SHORT]

●

LH side curtain air bag module circuit is shorted to some
power supply circuits.

2. Replace the harness if it has visible
damage.

CURTAIN MODULE LH
[GND-SHORT]

●

LH side curtain air bag module circuit is shorted to ground.

CURTAIN MODULE LH
[SHORT]

●

LH side curtain air bag module circuit is shorted between
lines.

3. Replace LH side curtain air bag module.
(Before disposal, it must be deployed.)

5. Replace the related harness.

5. Replace the related harness.

4. Replace the diagnosis sensor unit.
5. Replace the related harness.

SRS-22

TROUBLE DIAGNOSIS
Diagnostic item

Explanation

Repair order
“Recheck SRS at each replacement”

CURTAIN MODULE RH
[OPEN]

●

RH side curtain air bag module circuit is open.

1. Visually check the wiring harness connection.

CURTAIN MODULE RH
[VB-SHORT]

●

RH side curtain air bag module circuit is shorted to a power
supply circuit.

2. Replace the harness if it has visible
damage.

CURTAIN MODULE RH
[GND-SHORT]

●

RH side curtain air bag module circuit is shorted to ground.

CURTAIN MODULE RH
[SHORT]

●

RH side curtain air bag module circuit is shorted between
lines.

3. Replace RH side curtain air bag module.
(Before disposal, it must be deployed.)

●

Diagnosis sensor unit is malfunctioning.

B

C

4. Replace the diagnosis sensor unit.
5. Replace the related harness.

CONTROL UNIT

A

D

1. Visually check the wiring harness connection.
2. Replace the harness if it has visible
damage.

E

3. Replace the diagnosis sensor unit.
PASS AIR BAG DEACT
SW

●

Front passenger air bag cut OFF switch unit is malfunctioning.

1. Visually check the wiring harness connection.
2. Replace the harness if it has visible
damage.

F

G

3. Replace the cut OFF switch.
4. Replace the diagnosis sensor unit.
PASS AIR BAG INDICATOR CKT

●

Front passenger air bag OFF indicator circuit is open, or
shorted each other or to ground.

1. Visually check the wiring harness connection.
2. Replace the harness if it has visible
damage.

SRS

I

3. Replace the cut OFF indicator.
4. Replace the diagnosis sensor unit.

NOTE:
Follow the procedures in numerical order when repairing malfunctioning parts. Confirm whether malfunction is
eliminated using air bag warning lamp or CONSULT-II each time repair is finished. If malfunction is still
observed, proceed to the next step. When malfunction is eliminated, further repair work is not required.

J

K

L

M

SRS-23

TROUBLE DIAGNOSIS
DIAGNOSTIC PROCEDURE 3
Final checking after repairing SRS by using CONSULT-II — Diagnosis mode
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carry out CAN communication.
1. Touch “SELF-DIAG [CURRENT]”.

SRS697

a.
If no malfunction is detected on “SELF-DIAG [CURRENT]”,
repair of SRS is completed. Go to step 2.
If any malfunction is detected on “SELF-DIAG [CURRENT]”, the
malfunctioning part is not repaired completely or another malfunctioning part is detected. Go to SRS-20, «DIAGNOSTIC
PROCEDURE 2» , and repair malfunctioning part completely.

SRS701

2.

Touch “ERASE”.
NOTE:
Touch “ERASE” to clear the memory of the malfunction (“SELFDIAG [PAST]”).
If the memory of the malfunction in “SELF-DIAG [PAST]” is not
erased, the User mode shows the system malfunction by the
operation of the warning lamp even if the malfunction is repaired
completely.

SRS773

3.

Touch “BACK” key of CONSULT-II to “SELECT DIAG MODE”
screen. Touch “SELF-DIAG [PAST]”.

SRS697

SRS-24

TROUBLE DIAGNOSIS
4.
5.
6.

Check that no malfunction is detected on “SELF-DIAG [PAST]”.
Touch “BACK” key of CONSULT-II until “SELECT SYSTEM”
appears in order to return to User mode from Diagnosis mode.
Turn ignition switch OFF then turn off and disconnect CONSULT-II. Go to SRS-18, «Checking Air Bag Operation by Using
“AIR BAG” Warning Lamp — User Mode» .

A

B

C
SRS702

D

E

F

G

SRS

I

J

K

L

M

SRS-25

TROUBLE DIAGNOSIS
DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2)
Inspecting SRS malfunctioning record

1. CONSIDER POSSIBILITY OF NOT ERASING SELF-DIAGNOSTIC RESULT AFTER REPAIRING
Is it the first time for maintenance of SRS?
YES or NO
YES >> Go to SRS-20, «DIAGNOSTIC PROCEDURE 2» .
NO
>> Self-diagnostic result “SELF-DIAG [PAST]” (previously stored in the memory) might not be erased
after repair. Go to SRS-24, «DIAGNOSTIC PROCEDURE 3» .

DIAGNOSTIC PROCEDURE 5
Inspecting SRS intermittent malfunction by using CONSULT-II — Diagnosis mode
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunction might be detected
in self-diagnosis depending on control unit which carry out CAN communication.
1. Touch “SELF-DIAG [PAST]”.

SRS697

a.

If diagnostic codes are displayed on “SELF-DIAG [PAST]”, go to
step 5.

SRS700

2.

If no malfunction is detected on “SELF-DIAG [PAST]”, touch
“BACK” and go back to “SELECT DIAG MODE”.

SRS702

SRS-26

TROUBLE DIAGNOSIS
3.

Touch “TROUBLE DIAG RECORD”.
NOTE:
With “TROUBLE DIAG RECORD”, diagnosis results previously
erased by a reset operation can be displayed.

A

B

C
SRS697

D
Diagnostic code is displayed on “TROUBLE DIAG RECORD”.
Touch “PRINT”.
E
Compare diagnostic codes to SRS-27, «CONSULT-II Diagnostic
Code Chart (“SELF-DIAG [PAST]” or “TROUBLE DIAG
RECORD”)» .
7. Touch “BACK” key of CONSULT-II until “SELECT SYSTEM”
F
appears.
8. Turn ignition switch OFF, then turn off and disconnect CONSULT-II, and both battery cables.
G
9. Repair the system as outlined by the “Repair order” in “IntermitSHIA0182E
tent Malfunction Diagnostic Code Chart”, that corresponds to the
self-diagnostic result. For replacement procedure of component parts, refer to the Removal and InstallaSRS
tion procedure for the appropriate component.
10. Go to SRS-24, «DIAGNOSTIC PROCEDURE 3» , for final checking.

4.
5.
6.

CONSULT-II Diagnostic Code Chart (“SELF-DIAG [PAST]” or “TROUBLE DIAG RECORD”)
Diagnostic item
NO DTC IS
DETECTED.

Explanation
When malfunction is
indicated by the “AIR
BAG” warning lamp in
User mode.

●

Low battery voltage (Less than 9V)

Repair order
“Recheck SRS at each replacement”
●

Go to SRS-24, «DIAGNOSTIC PROCEDURE 3» .

Go to SRS-24, «DIAGNOSTIC PROCEDURE 3» .

●

No malfunction is detected.

●

DRIVER AIRBAG
MODULE
[OPEN]

●

Driver air bag module circuit is open (including the spiral cable).

1. Visually check the wiring harness
connection.

DRIVER AIRBAG
MODULE
[VB-SHORT]

●

Driver air bag module circuit is shorted to a power supply circuit
(including the spiral cable).

DRIVER AIRBAG
MODULE
[GND-SHORT]

●

Driver air bag module circuit is shorted to ground (including the
spiral cable).

DRIVER AIRBAG
MODULE
[SHORT]

●

Driver air bag module circuit is shorted between lines.

ASSIST A/B MODULE
[OPEN]

●

Front passenger air bag module circuit is open.

1. Visually check the wiring harness
connection.

ASSIST A/B MODULE
[VB-SHORT]

●

Front passenger air bag module circuit is shorted to a power
supply circuit.

2. Replace the harness if it has visible
damage.

ASSIST A/B MODULE
[GND-SHORT]

●

Front passenger air bag module circuit is shorted to ground.

ASSIST A/B MODULE
[SHORT]

●

Front passenger air bag module circuit is shorted between lines.

3. If the harness check result is OK,
replace the diagnosis sensor unit
and front passenger air bag module
(Before disposal, it must be
deployed.).

SRS-27

I

2. Replace the harness if it has visible
damage.
3. If the harness check result is OK,
replace driver air bag module
(Before disposal, it must be
deployed.), diagnosis sensor unit
and spiral cable.

J

K

L

M

TROUBLE DIAGNOSIS
Diagnostic item
CRASH ZONE SEN
[UNIT FAIL]
CRASH ZONE SEN
[COMM FAIL]

Explanation
●

Crash zone sensor

Repair order
“Recheck SRS at each replacement”
1. Visually check the wiring harness
connection.
2. Replace the harness if it has visible
damage.
3. If the harness check result is OK,
replace crash zone sensor and diagnosis sensor unit.

SIDE MODULE LH
[OPEN]

●

Front LH side air bag module circuit is open.

1. Visually check the wiring harness
connection.

SIDE MODULE LH
[VB-SHORT]

●

Front LH side air bag module circuit is shorted to a power supply circuit.

2. Replace the harness if it has visible
damage.

SIDE MODULE LH
[GND-SHORT]

●

Front LH side air bag module circuit is shorted to ground.

SIDE MODULE LH
[SHORT]

●

Front LH side air bag module circuit is shorted between lines.

3. If the harness check result is OK,
replace the diagnosis sensor unit
and LH side air bag module. (Before
disposal, it must be deployed.).

SIDE MODULE RH
[OPEN]

●

Front RH side air bag module circuit is open.

1. Visually check the wiring harness
connection.

SIDE MODULE RH
[VB-SHORT]

●

Front RH side air bag module circuit is shorted to a power supply circuit.

2. Replace the harness if it has visible
damage.

SIDE MODULE RH
[GND-SHORT]

●

Front RH side air bag module circuit is shorted to ground.

SIDE MODULE RH
[SHORT]

●

Front RH side air bag module circuit is shorted between lines.

3. If the harness check result is OK,
replace the diagnosis sensor unit
and RH side air bag module
(Before disposal, it must be
deployed.)

SATELLITE SENS LH
[UNIT FAIL]
SATELLITE SENS LH
[COMM FAIL]

●

LH side air bag (Satellite) sensor

1. Visually check the wiring harness
connection.
2. Replace the harness if it has visible
damage.
3. If the harness check result is OK,
replace the diagnosis sensor unit
and LH side air bag (Satellite) sensor.

SATELLITE SENS RH
[UNIT FAIL]
SATELLITE SENS RH
[COMM FAIL]

●

RH side air bag (Satellite) sensor

1. Visually check the wiring harness
connection.
2. Replace the harness if it has visible
damage.
3. If the harness check result is OK,
replace the diagnosis sensor unit
and RH side air bag (Satellite) sensor.

PRE-TEN FRONT LH
[OPEN]

●

Front LH pre-tensioner circuit is open.

1. Visually check the wiring harness
connections.

PRE-TEN FRONT LH
[VB-SHORT]

●

Front LH pre-tensioner circuit is shorted to a power supply circuit.

2. Replace the harness if it has visible
damage.

PRE-TEN FRONT LH
[GND-SHORT]

●

Front LH pre-tensioner circuit is shorted to ground.

PRE-TEN FRONT LH
[SHORT]

●

Front LH pre-tensioner circuit is shorted between lines.

3. If the harness check result is OK,
replace the diagnosis sensor unit
and front LH seat belt
(Before disposal, it must be activated.)

SRS-28

TROUBLE DIAGNOSIS
Diagnostic item

Explanation

Repair order
“Recheck SRS at each replacement”

A

PRE-TEN FRONT RH
[OPEN]

●

Front RH pre-tensioner circuit is open.

1. Visually check the wiring harness
connections.

PRE-TEN FRONT RH
[VB-SHORT]

●

Front RH pre-tensioner circuit is shorted to a power supply circuit.

2. Replace the harness if it has visible
damage.

PRE-TEN FRONT RH
[GND-SHORT]

●

Front RH pre-tensioner circuit is shorted to ground.

PRE-TEN FRONT RH
[SHORT]

●

Front RH pre-tensioner circuit is shorted between lines.

3. If the harness check result is OK,
replace the diagnosis sensor unit
and front RH seat belt
(Before disposal, it must be activated.)

CURTAIN MODULE LH
[OPEN]

●

LH side curtain air bag module circuit is open.

1. Visually check the wiring harness
connection.

CURTAIN MODULE LH
[VB-SHORT]

●

LH side curtain air bag module circuit is shorted to a power supply circuits.

2. Replace the harness if it has visible
damage.

E

CURTAIN MODULE LH
[GND-SHORT]

●

LH side curtain air bag module circuit is shorted to ground.

3. If the harness check result is OK,
replace the diagnosis sensor unit
and LH side curtain air bag module.
(Before disposal, it must be
deployed.)

F

G

CURTAIN MODULE RH
[OPEN]

●

RH side curtain air bag module circuit is open.

1. Visually check the wiring harness
connection.

CURTAIN MODULE RH
[VB-SHORT]

●

RH side curtain air bag module circuit is shorted to a power supply circuit.

2. Replace the harness if it has visible
damage.

CURTAIN MODULE RH
[GND-SHORT]

●

RH side curtain air bag module circuit is shorted to ground.

CURTAIN MODULE RH
[SHORT]

●

RH side curtain air bag module circuit is shorted between lines.

3. If the harness check result is OK,
replace the diagnosis sensor unit
and RH side curtain air bag module.
(Before disposal, it must be
deployed.)

CONTROL UNIT

●

Diagnosis sensor unit is malfunctioning.

1. Visually check the wiring harness
connection.

B

C

D

SRS

I

J

2. Replace the harness if it has visible
damage.
3. Replace the diagnosis sensor unit.
PASS A/B DEACT SW

●

Front passenger air bag cut OFF switch unit is malfunctioning.

K

1. Visually check the wiring harness
connection.
2. Replace the harness if it has visible
damage.

L

3. Replace the cut OFF switch.
4. Replace diagnosis sensor unit.
PASS A/B INDCTR
CKT

●

Front passenger air bag OFF indicator circuit is open, or
shorted each other or to ground.

1. Visually check the wiring harness
connection.
2. Replace the harness if it has visible
damage.
3. Replace the cut OFF indicator.
4. Replace diagnosis sensor unit.

SRS-29

M

TROUBLE DIAGNOSIS
Trouble Diagnosis without CONSULT-II

BHS0003A

DIAGNOSTIC PROCEDURE 6
Inspecting SRS Malfunctioning Parts by Using “AIR BAG” Warning Lamp—Diagnosis Mode
NOTE:
SRS will not enter Diagnosis mode if no malfunction is detected in User mode.
1. Turn ignition switch ON.
2. After “AIR BAG” warning lamp lights for 7 seconds, turn ignition switch OFF within 1 second.
3. Wait more than 3 seconds.
4. Repeat the steps 1 to 3 two times.
5. Turn ignition switch ON.
SRS is now in Diagnosis mode.
“AIR BAG” warning lamp operates in Diagnosis mode as follows:

WARNING LAMP FLASH CODE CHART

SHIA0026E

PHIA0185E

SHIA0028E

SRS-30

TROUBLE DIAGNOSIS
A

B

C
SHIA0029E

D

E

F

G
SHIA0083E

SRS

I

J

K
SHIA0030E

L

M

SHIA0031E

SRS-31

TROUBLE DIAGNOSIS

SHIA0032E

SHIA0033E

SHIA0034E

SHIA0035E

SRS-32

TROUBLE DIAGNOSIS
A

B

C
SHIA0084E

D

E

F

G
SHIA0086E

SRS

I

J

K

L

M

SRS-33

TROUBLE DIAGNOSIS
Trouble Diagnosis: “AIR BAG” Warning Lamp Does Not Turn OFF

BHS0003B

DIAGNOSTIC PROCEDURE 7

1. CHECK THE DEPLOYMENT OF AIR BAG MODULE
Is air bag module deployed?
YES or NO
YES >> Refer to SRS-58, «COLLISION DIAGNOSIS» .
NO
>> GO TO 2.

2. CHECK THE AIR BAG FUSE
Check 10A fuse [No.3, located in fuse block (J/B)].
Refer to PG-4, «POWER SUPPLY ROUTING CIRCUIT» .
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3

3. CHECK AIR BAG FUSE AGAIN
Replace “AIR BAG” fuse and turn ignition switch ON.
Does the “AIR BAG” fuse blow again?
YES >> Repair or replace main harness.
NO
>> INSPECTION END

4. CHECK DIAGNOSIS SENSOR UNIT
Connect CONSULT-II and touch “START”.
Is “AIR BAG” displayed on CONSULT-II?
YES or NO
YES >> GO TO 5.
NO
>> Visually check the wiring harness connection of diagnosis sensor unit. If the harness connection check result is
OK, replace diagnosis sensor unit.

BCIA0030E

5. CHECK HARNESS CONNECTION
Is harness connection between warning lamp and diagnosis sensor unit OK?
OK or NG
OK
>> Replace diagnosis sensor unit.
NG
>> Connect “AIR BAG” warning lamp and diagnosis sensor unit connector properly. If “AIR BAG”
warning lamp still does not go off, replace harness.

SRS-34

TROUBLE DIAGNOSIS
Trouble Diagnosis: “AIR BAG” Warning Lamp Does Not Turn ON

BHS0003C

A

DIAGNOSTIC PROCEDURE 8

1. CHECK “METER” FUSE
Check 10A fuse [No.2, located in fuse block (J/B)].
Refer to PG-4, «POWER SUPPLY ROUTING CIRCUIT» .
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

B

C

2. CHECK “METER” FUSE AGAIN

D

Replace 10A fuse [No.2, located in fuse block (J/B)] and turn ignition switch ON.
Does the meter fuse blow again?
YES >> Repair or replace the related harness.
NO
>> INSPECTION END

E

3. CHECK HARNESS CONNECTION BETWEEN DIAGNOSIS SENSOR UNIT AND COMBINATION

F

METER
Disconnect diagnosis sensor unit connector and turn ignition switch ON.
Does “AIR BAG” warning lamp turn ON?
YES or NO
YES >> Replace diagnosis sensor unit.
NO
>> Replace combination meter assembly.

G

SRS

I

J

K

L

M

SRS-35

DRIVER AIR BAG MODULE
DRIVER AIR BAG MODULE
Removal and Installation

PFP:K8510
BHS0003D

PHIA1081J

1.

Side lid

2.

Driver air bag module

REMOVAL
CAUTION:
●
Before servicing SRS, turn the ignition switch OFF, disconnect both battery cables and wait at
least 3 minutes.
●
Always work from the side of driver air bag module.
●
Do not use air tools or electric tools for servicing.
1. Remove the side lids.
2. Remove the right and left side special bolts.
Special bolt
(TORX T30)

:

9.3 N·m (0.95 kg-m, 82.5 in-ib)

MIIB0243E

3.
4.

Disconnect the steering wheel switch sub-harness connector.
Disconnect the air bag harness connector, and remove the
driver air bag module.
CAUTION:
● For removing and installing air bag harness connector,
insert a flat-bladed screwdriver wrapped with a tape into
lock, and raise lock to remove connector.
● Install connector with lock raised, and push lock into
connector.
● Confirm the lock is fully pushed in after mounting connector.
MIIB0244E

SRS-36

DRIVER AIR BAG MODULE
CAUTION:
●
Always place driver air bag module with pad side facing
upward.
●
Do not insert any foreign objects (screwdriver, etc.) into
driver air bag module.
●
Do not attempt to disassemble driver air bag module.
●
Do not use old bolts after removal; replace with new ones.
●
Do not expose the driver air bag module to temperatures
exceeding 90°C (194°F).

A

B

C

MIIB0245E

●

●

Replace driver air bag module if it has been dropped or sustained an impact.
Do not allow oil, grease or water to come in contact with the
front passenger air bag module.

D

E

F

G
SBF814E

SRS

INSTALLATION
Install in the reverse order of removal.
CAUTION:
●
Always work from the side of driver air bag module.
●
Do not use air tools or electric tools for servicing.
●
After the work is completed, perform self-diagnosis to check that no malfunction is detected.
Refer to SRS-18, «SRS Operation Check» .

I

J

K

L

M

SRS-37

SPIRAL CABLE
SPIRAL CABLE
Removal and Installation

PFP:25554
BHS0003E

PHIA1083J

1.

Steering wheel

2.

Steering key cylinder escutcheon

3.

Steering column cover (lower/upper)

4.

Wiper and Washer switch

5.

Lighting and turn signal switch

6.

Spiral cable

REMOVAL
CAUTION:
●
Before servicing SRS, turn the ignition switch OFF, disconnect both battery cables and wait at
least 3 minutes.
●
Do not use air tools or electric tools for servicing.
1. Remove driver air bag module. Refer to SRS-36, «DRIVER AIR BAG MODULE» .
2. Set the steering wheel in the neutral position.
3. Remove horn switch connector.

MIIB0249E

4.
5.
6.
7.

Remove steering wheel. Refer to PS-5, «STEERING WHEEL» .
Remove steering column cover. Refer to IP-7, «F. Steering Column Cover Upper» .
Remove wiper and washer switch, lighting and turn signal switch.
Loosen screws. While pushing upper plastic tab, remove spiral cable.
CAUTION:
● Do not attempt to disassemble spiral cable.
● Do not apply lubricant to the spiral cable.

SRS-38

SPIRAL CABLE
8.

Remove horn switch connector, and then spiral cable connector.
A

B

C
SHIA0193E

D

INSTALLATION
Install in the reverse order of removal.
CAUTION:
●
Do not use air tools or electric tools for servicing.
●
The spiral cable may snap due to steering operation if the
cable is installed in an improper position.
●
Also, with the steering linkage disconnected the cable may
snap by turning the steering wheel beyond the limited number of turns. The spiral cable can be turned counterclockwise about 2.5 turns from the right end position.
●
After the work is completed, perform self-diagnosis to
check that no malfunction is detected. Refer to SRS-18,
«SRS Operation Check» .

E

F

G
PHIA0275E

SRS

I

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M

SRS-39

FRONT PASSENGER AIR BAG MODULE
FRONT PASSENGER AIR BAG MODULE
Removal and Installation

PFP:K8515
BHS0003F

REMOVAL
CAUTION:
●
Before servicing SRS, turn ignition switch OFF, disconnect both battery cables and wait at least 3
minutes.
●
Always work from the side of or under front passenger air bag module.
●
Do not use air tools or electric tools for servicing.
1. Remove glove box assembly. Refer to IP-5, «Removal and Installation» .
2. Remove air bag module mounting bolt.
Mounting bolt — (1)

:

24.5 N·m (2.5 kg-m, 18 ft-lb)

MHIB0126E

3.
4.
5.

Disconnect harness connector from the passenger air bag module.
Remove instrument assist upper panel. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove air bag module mounting screws.
Mounting screw — (1)
Air bag module — (2)

MHIB0127E

6.

Remove air bag module from the instrument assist upper panel.
NOTE:
Pull out and remove air bag module front tab and rear tab.
Front tab — (1)
Rear tab — (2)

MHIB0131E

SRS-40

FRONT PASSENGER AIR BAG MODULE
CAUTION:
●
Always place front passenger air bag module with warning
label side facing upward.
●
Do not insert any foreign objects (screwdriver, etc.) into
front passenger air bag module.
●
Do not attempt to disassemble front passenger air bag
module.
●
Do not use old bolts after removal; replace with new ones.

A

B

C

PHIA0167E

●

●

●

●

Replace front passenger air bag module if it has been
dropped or sustained an impact.
Do not expose the front passenger air bag module to temperature exceeding 90°C (194°F).
Do not allow oil, grease or water to come in contact with the
front passenger air bag module.
After front passenger air bag module inflates, the instrument panel assembly should be replaced.

D

E

F

G
SBF814E

SRS

INSTALLATION
Install in the reverse order of removal.
CAUTION:
●
Always work from the side of or under front passenger air bag module.
●
Do not use air tools or electric tools for servicing.
●
After the work is completed, perform self-diagnosis to check that no malfunction is detected.
Refer to SRS-18, «SRS Operation Check» .

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L

M

SRS-41

FRONT SIDE AIR BAG MODULE
FRONT SIDE AIR BAG MODULE
Removal and Installation

PFP:K8EH0
BHS0003G

MIIB0255E

REMOVAL
CAUTION:
●
Before servicing SRS, turn the ignition switch OFF, disconnect both battery cables and wait at
least 3 minutes.
●
Always work from the rear of the front side air bag module.
●
Do not use air tools or electric tools for servicing.
1. Remove the driver and/or passenger seat. Refer to SE-10, «Disassembly and Assembly of Seat Cushion»
.
2. Remove the seatback trim and pad. Refer to SE-8, «Disassembly and Assembly of Seatback» .
3. Remove the air bag module harness clips.
4. Remove the special nuts coated with bonding agent from the front side air bag module, and remove the
front side air bag module.
CAUTION:
●
Always place the front side air bag module standing with
the stud bolts side facing down.
●
Do not insert any foreign objects (screwdriver, etc.) into
front side air bag module.
●
Do not attempt to disassemble front side air bag module.
●
Do not use old bolts after removal; replace with new ones.

PHIA0169E

●

●

●

●

Replace front seatback assembly (side air bag module) if it
has been dropped or sustained an impact.
Do not expose front seatback assembly (side air bag module) to temperature exceeding 90°C (194°F).
Do not allow oil, grease or water to come in contact with the
front side air bag module.
After front side air bag module inflates, front seatback
assembly must be replaced.
SBF814E

SRS-42

FRONT SIDE AIR BAG MODULE
INSTALLATION
Install in the reverse order of removal.
CAUTION:
●
Always work from the side of or under front side air bag module.
●
Do not use air tools or electric tools for servicing.
●
After the work is completed, perform self-diagnosis to make sure that no malfunction is detected.
Refer to SRS-18, «SRS Operation Check» .

A

B

C

D

E

F

G

SRS

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SRS-43

SIDE CURTAIN AIR BAG MODULE
SIDE CURTAIN AIR BAG MODULE
Removal and Installation

PFP:985P0
BHS0003H

PHIA1075J

1.

Curtain air bag module

REMOVAL
CAUTION:
●
Before servicing SRS, turn the ignition switch OFF, disconnect both battery cables and wait at
least 3 minutes.
●
Always work from the side of the side curtain air bag module.
●
Do not use air tools or electric tools for servicing.
1. Remove headliner. Refer to EI-30, «HEADLINER» .
2. Disconnect curtain air bag module connector.
3. Remove the side curtain air bag module mounting bolts.
Mounting bolt

:

10.8 N·m (1.1 kg-m, 8 ft-lb)

4. Remove the side curtain air bag module.
CAUTION:
●
Always place the side curtain air bag module with the warning label facing upward.
●
Do not attempt to disassemble side curtain air bag module.
●
Do not insert any foreign objects (screw driver, etc.) into air bag module connector.
●
Replace side curtain air bag module if it has been dropped
or sustained an impact.
●
Do not expose the air bag module to temperatures exceeding 90°C (194°F).
●
Do not allow oil, grease or water to come in contact with the
side curtain air bag module.

SBF814E

INSTALLATION
Install in the reverse order of removal.
CAUTION:
●
Always work from the side of the side curtain air bag module.
●
Do not use air tools or electric tools for servicing.
●
After replacement of side curtain air bag module, perform self-diagnosis to check that no malfunction is detected. Refer to SRS-18, «SRS Operation Check» .

SRS-44

CRASH ZONE SENSOR
CRASH ZONE SENSOR
Removal and Installation

PFP:98582

A
BHS0003I

REMOVAL
CAUTION:
●
Before servicing SRS, turn ignition switch OFF, disconnect both battery cables and wait at least 3
minutes.
●
Do not use air tools or electric tools for servicing.
1. Disconnect crash zone sensor connector.
2. Remove mounting nuts, and then crush zone sensor.
Mounting nut — (1) :

B

C

D

10.8 N·m (1.1 kg-m, 8 ft-lb)

Crash zone sensor — (2)
E

F
MHIB0128E

CAUTION:
Replace crash zone sensor if it has been dropped or sustained an impact.
●
Do not attempt to disassemble crash zone sensor.
●
Do not use old bolts after removal; replace with new ones.
●

G

SRS

INSTALLATION
Install in the reverse order of removal.
CAUTION:
●
Check crash zone sensor for proper installation.
●
Do not use air tools or electric tools for servicing.
●
After the work is complete, perform self-diagnosis to check that no malfunction is detected. Refer
to SRS-18, «SRS Operation Check» .

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SRS-45

SIDE AIR BAG (SATELLITE) SENSOR
SIDE AIR BAG (SATELLITE) SENSOR
Removal and Installation

PFP:98830
BHS0003J

REMOVAL
CAUTION:
●
Before servicing SRS, turn ignition switch OFF, disconnect both battery cables and wait at least 3
minutes.
●
Do not use air tools or electric tools for servicing.
1. Remove front seat belt. Refer to SB-3, «Removal and Installation of Front Seat Belt» .
2. Remove side air bag (Satellite) sensor connector.
3. Remove mounting nuts, then remove side air bag (Satellite) sensor.
Mounting nut — (1)

:

10.8 N·m (1.1 kg-m, 8 ft-lb)

Satellite sensor — (2)
Satellite sensor connector — (3)

MHIB0130E

CAUTION:
●
Check side air bag (Satellite) sensor to ensure it is free of deformities, dents, cracks or rust. If it
shows any visible signs of damage, replace it with new one.
●
Do not attempt to disassemble side air bag (Satellite) sensor if it has been dropped or sustained
an impact.
●
Do not use old nuts after removal; replace with new ones.

INSTALLATION
Install in the reverse order of removal.
CAUTION:
●
Check side air bag (Satellite) sensor for proper installation.
●
Do not use air tools or electric tools for servicing.
●
After replacement of side air bag (Satellite) sensor, perform self-diagnosis to check that no malfunction is detected. Refer to SRS-18, «SRS Operation Check» .

SRS-46

SEAT BELT PRE-TENSIONER
SEAT BELT PRE-TENSIONER
Removal and Installation

PFP:86884

A
BHS0003K

For removal and installation procedures, refer to SB-3, «Removal and Installation of Front Seat Belt» .
B

C

D

E

F

G

SRS

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SRS-47

DIAGNOSIS SENSOR UNIT
DIAGNOSIS SENSOR UNIT
Removal and Installation

PFP:28556
BHS0003L

REMOVAL
CAUTION:
●
Before servicing SRS, turn ignition switch OFF, disconnect both battery cables and wait at least 3
minutes.
●
Do not use air tools or electric tools for servicing.
1. Disconnect each harness connector for air bag module and seat belt pre-tensioner.
2. Remove console box. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
3. Remove the diagnosis sensor unit connector.
4. Remove mounting bolts and ground bolt, then remove diagnosis
sensor unit.
Mounting bolt — (1)

:

24.5 N·m (2.5 kg-m, 18 ft-lb)

Ground bolt — (2)

:

6.9 N·m (0.7 kg-m, 61 in-lb)

MHIB0129E

CAUTION:
Do not use old bolts after removal; replace with new ones.
●
Check diagnosis sensor unit brackets to ensure it is free of deformities, dents, cracks or rust. if it
shows any visible signs of damage, replace it with new one.
●
Replace diagnosis sensor unit if it has been dropped or sustained an impact.
●

INSTALLATION
Install in the reverse order of removal.
CAUTION:
●
Do not use air tools or electric tools for servicing.
●
Check the diagnosis sensor unit for proper installation.
●
After replacement of diagnosis sensor unit, perform self-diagnosis to check that no malfunction is
detected. Refer to SRS-18, «SRS Operation Check» .

ECU DISCRIMINATED NO.
After replacing the diagnosis sensor unit, make sure that the diagnosis unit identification is correct for the vehicle as equipped.
Specification

Discriminated No.

2WD/LHD

Driver air bag module and Passenger air bag module, Seat belt pre-tensioner/pre-tensioner 2

A911

2WD/RHD

Driver air bag module and Passenger air bag module, Seat belt pre-tensioner/pre-tensioner 2

A912

2WD/LHD

Driver air bag module and Passenger air bag module, Seat belt pre-tensioner/pre-tensioner 2, and
front side air bag module

A913

2WD/RHD

Driver air bag module and Passenger air bag module, Seat belt pre-tensioner/pre-tensioner 2, and
front side air bag module

A914

2WD/LHD

Driver air bag module and Passenger air bag module, Seat belt pre-tensioner/pre-tensioner 2,
front side air bag module and side curtain air bag module

A915

2WD/RHD

Driver air bag module and Passenger air bag module, Seat belt pre-tensioner/pre-tensioner 2,
front side air bag module and side curtain air bag module

A916

SRS-48

DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER
DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER
Caution for Air Bag Module and Seat Belt Pre-tensioner
●

●

●

●

●
●

●
●
●
●

●
●

PFP:00014

A
BHS0003M

Before disposing of air bag module and seat belt pre-tensioner, or vehicles equipped with such systems,
deploy the systems. If such systems have already been deployed due to an accident, dispose of them as B
indicated inSRS-49, «DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER» .
When deploying the air bag module and seat belt pre-tensioner, always use the Special Service Tool;
Deployment tool (KV99106400).
C
When deploying the air bag module and seat belt pre-tensioner, stand at least 5 m (16 ft) away from the
deployment component.
When deploying air bag module and seat belt pre-tensioner, a fairly loud noise is made, followed by D
smoke being released. The smoke is not poisonous, however, be careful not to inhale smoke since it irritates the throat and can cause choking.
Always activate one air bag module at a time.
E
Due to heat, leave air bag module unattended for more than 30 minutes after deployment. Also leave seat
belt pre-tensioner unattended for more than 10 minutes after deployment.
Be sure to wear gloves when handling a deployed air bag module and seat belt pre-tensioner.
F
Never apply water to the deployed air bag module and seat belt pre-tensioner.
Wash your hands clean after finishing work.
Place the vehicle outdoors with an open space of at least 6 m (20 ft) on all sides when deploying air bag G
module and seat belt pre-tensioner while mounted in vehicle.
Use a voltmeter to make sure the vehicle battery is fully charged.
Do not dispose of the air bag module and seat belt pre-tensioner un-deployed.
SRS

CHECKING DEPLOYMENT TOOL
Connecting to Battery
CAUTION:
The battery must show voltage of 9.6 V or more.
Remove the battery from the vehicle and place it on dry wood blocks
approximately 5 m (16 ft) away from the vehicle.
●
Wait 3 minutes after the vehicle battery is disconnected before
proceeding.
●
Connect red clip of deployment tool to battery positive terminal
and black clip to negative terminal.
Make sure the polarity is correct. The right side lamp in the tool,
marked “deployment tool power”, should glow with a green
light. If the right side lamp glows red, reverse the connections
to the battery.

I

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L
PHIA0003E

M

Deployment Tool Check
Press the deployment tool switch to the ON position. The left side
lamp in the tool, marked “air bag connector voltage” should illuminate. If it does not illuminate, replace the tool.

SBF266H

SRS-49

DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER
Air Bag Deployment Tool Lamp Illumination Chart (Battery Connected)
Switch operation

Left side lamp, green*
“AIR BAG CONNECTOR
VOLTAGE”

Right side lamp, green*
“DEPLOYMENT TOOL
POWER”

OFF

OFF

ON

ON

ON

ON

*: If this lamp glows red, the tool is connected to the battery incorrectly. Reverse the connections and make sure the lamp glows green.

DEPLOYMENT PROCEDURES FOR AIR BAG MODULE
Unless the vehicle is being scrapped, deploying the air bag in the
vehicle is not recommended. This may cause damage to the vehicle
interior.
Anchor air bag module bracket (SST: KV99105300) in a vise
secured to a firm foundation during deployment.

SRS232-E

Deployment of Driver Air Bag Module
1.

Make an 8.5 mm (0.335 in) diameter hole in air bag module
bracket (SST: KV99105300) at the position shown in figure at
right.

MIIB0263E

2.

3.

Using wire, secure air bag module to air bag module bracket at
two places.
CAUTION:
Use wire of at least 1 mm (0.041 in) diameter.
Firmly secure air bag module bracket with air bag module
attached in a vise.

PHIA0551E

4.

Connect deployment tool adapter (SST: KV99110500) to deployment tool (SST: KV99106400) to air bag module connector.

PHIA0552E

SRS-50

DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER
5.

Connect red clip of deployment tool to battery positive terminal
and black clip to negative terminal.
6. The lamp on the right side of the tool, marked “deployment tool
power”, should glow green, not red.
7. Press the button on the deployment tool. The left side lamp on
the tool, marked “air bag connector voltage”, will illuminate and
the air bag module will deploy.
CAUTION:
When deploying the driver air bag module, stand at least 5 m
(16 ft) away from the air bag module.

A

B

C
SRS020-A

D

Deployment of Front Passenger Air Bag Module
1.

Make an 8.5 mm (0.335 in) diameter hole in air bag module
bracket (SST: KV99105300) at the position shown in figure at
right.

E

F

G
SHIA0064J

2.

SRS

Firmly secure air bag module bracket (SST: KV99105300) in a
vise.

I

J

SRS232-E

3.

Match a hole in air bag module bracket (held in vise) and front
passenger air bag module and fix them with a bolt [M8 × 25 — 30
mm (0.98 — 1.18 in)] and wire.
CAUTION:
If a gap exists between front passenger air bag module and
air bag module bracket, use a piece of wood inserted in the
gap to stabilize the air bag module.

L

M

MIIB0266E

SRS-51

K

DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER
4.

5.
6.

Connect deployment tool adapter (SST: KV99109700) to
deployment tool (SST: KV99106400) connector and front passenger air bag module connector.
Connect red clip of deployment tool to battery positive terminal
and black clip to negative terminal.
The lamp on the right side of the tool, marked “deployment tool
power”, should glow green, not red.

MIIB0267E

7.

Press the button on the deployment tool. The left side lamp on
the tool, marked “air bag connector voltage”, will illuminate and
the air bag module will deploy.
CAUTION:
●
When deploying the front passenger air bag module, do not
stand on the deploying side.
●
Stand at least 5 m (16 ft) away from the air bag module.

SRS020-A

Deployment of Front Side Air Bag Module
1.

Make 6.5 mm (0.256 in) diameter holes in air bag module
bracket (SST: KV99105300) at the position shown in figure at
right.

MIIB0268E

2.
3.

Firmly secure air bag module bracket (SST: KV99105300) in a
vise.
Insert the stud bolts of side air bag module into the two holes in
air bag module bracket (held in vise) and fix them with two M6
nuts.
CAUTION:
Side air bag module should be secured to air bag module
bracket (SST: KV99105300) in a vise with stud bolt side setting bottom.
MIIB0269E

SRS-52

DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER
4.

Connect deployment tool adapter (SST: KV99108300) and
deployment tool (SST: KV99106400) on side air bag module.

A

B

C
PHIA0008E

D

5.

Connect red clip of deployment tool to battery positive terminal
and black clip to negative terminal.
6. The lamp on the right side of the tool, marked “deployment tool
power”, should glow green, not red.
7. Press the button on the deployment tool. The left side lamp on
the tool, marked “air bag connector voltage”, will illuminate and
the air bag module will deploy.
CAUTION:
When deploying the front side air bag module, stand at least 5
m (16 ft) away from the air bag module.

E

F

G
PHIA0567E

Deployment of Side Curtain Air Bag Module··
1.

SRS

Cut the inflator from side curtain air bag module.

I

J

PHIA1311J

2.

Connect deployment tool (SST: KV99106400) connector to
deployment tool adapter (SST: KV99110500) the inflator.

K

L

M

PHIA1312J

SRS-53

DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER
3.

Put the inflator connected with the deployment tool adaptor
(SST: KV99110500) into a tire without wheel.
Inflator — (1)

PHIA1284J

4.

Put the tyre with the inflator onto another tyre without wheel.
Add an additional tyre without wheel and then a tyre mounted on
a wheel on top.
CAUTION:
Tie all tyres together with a strap in order keep them standing.
5. Connect red clip of deployment tool to battery positive terminal
and black clip to negative terminal.
6. The lamp on the right side of the tool, marked “deployment tool
power”, should glow green, not red.
MIIB0273E
7. Press the button on the deployment tool. The left side lamp on
the tool, marked “air bag connector voltage”, will illuminate and the air bag module will deploy.
CAUTION:
When deploying the side curtain air bag module, stand at least 5 m (16 ft) away from the side curtain
air bag module.

DEPLOYMENT PROCEDURES FOR SEAT BELT PRE-TENSIONER
1.

Firmly grip pre-tensioner in a vise.

PHIA0034E

2.

Cut the webbing off.

PHIA0035E

SRS-54

DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER
3.

Connect deployment tool adapter (SST: KV99110500) to deployment tool (SST: KV99106400) connector and front seat belt pretensioner connector.

A

B

C
PHIA0556E

D

4.

Connect red clip of deployment tool to battery positive terminal
and black clip to negative terminal.
5. The lamp on the right side of the tool, marked “deployment tool
power”, should glow green, not red.
6. Press the button on the deployment tool. The left side lamp on
the tool, marked “seat belt pre-tensioner connector voltage”, will
illuminate and the seat belt pre-tensioner will deploy.
CAUTION:
When deploying the front seat belt pre-tensioner, stand at least
5 m (16 ft) away from the seat belt pre-tensioner.

E

F

G
SRS242-D

DEPLOYMENT PROCEDURES FOR FRONT SEAT BELT PRE-TENSIONER 2 (OUTSIDE OF
VEHICLE)
1.

SRS

Cut off the webbing.
Seat belt — (1)
Inflator — (2)

I

J

K
PHIA1167E

2.

Connect deployment tool and deployment tool adapter yellow
connector to front seat belt pre-tensioner.
Deployment tool — A
Deployment tool adapter — C
Yellow connector — (c)

L

: KV99106400
: KV99110500

M

PHIA1168E

SRS-55

DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER
3.

Put the pre-tensioner connected with the deployment tool into a
tire without a wheel.
Inflator — (1)

PHIA1288J

4.
5.
6.

Connected red clip of deployment tool to battery positive terminal and back clip to negative terminal.
The lamp on the right side of the tool, marked «deployment tool
power» , should glow green, not red.
Press the button on the deployment tool. The left side lamp on
the tool, marked «seat beltpre-tensioner connector voltage» , will
illuminate and the seat belt pre-tensioner will deploy.
Inflator — (1)
Deployment tool — A

: KV99106400
PHIA1173E

CAUTION:
When deploying the front seat belt pre-tensioner, stand at least 5 m (16 ft) away from the seat belt pretensioner.

SRS-56

DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER
DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER WHILE MOUNTED IN
VEHICLE

A
When disposing of a vehicle, deploy air bag module and seat belt pre-tensioners while they are mounted in
vehicle.
B
CAUTION:
When deploying air bag module or seat belt pre-tensioner, ensure vehicle is empty.
1. Disconnect both the vehicle battery cables and wait 3 minutes.
C
2. Disconnect air bag module and seat belt pre-tensioner connector.
3. Connect deployment tool (SST: KV99106400 ) to air bag module.
For driver air bag module, attach deployment tool adapter (SST: KV99110500) to the tool connector.
For front passenger air bag module, attach deployment tool adapter (SST: KV99109700) to the tool con- D
nector.
For front side air bag module, attach deployment tool adapter (SST: KV99108300) to the tool connector.
For seat belt pre-tensioner, attach deployment tool adapter (SST: KV99110500) to the tool connector.
E
For side curtain air bag module, attach deployment tool adapter (SST: KV99110500) to the tool connector.
4. Connect red clip of deployment tool to battery positive terminal
and black clip to negative terminal.
F
5. The lamp on the right side of the tool, marked “deployment tool
power”, should glow green, not red.
6. Press the button on the deployment tool. The left side lamp on
G
the tool, marked “air bag connector voltage”, will illuminate and
the air bag module or seat belt pre-tensioner will deploy.
CAUTION:
SRS
Activate only one air bag module or seat belt pre-tensioner
at a time.
SRS006

DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER
Deployed air bag module and seat belt pre-tensioner are very hot. Before disposing of air bag module, and
seat belt pre-tensioner wait at least 30 minutes, and 10 minutes, respectively. Seal them in a plastic bag
before disposal.
CAUTION:
●
Never apply water to a deployed air bag module and seat
belt pre-tensioner.
●
Be sure to wear gloves when handling a deployed air bag
module and seat belt pre-tensioner.
●
No poisonous gas is produced upon air bag module
deployment. However, be careful not to inhale gas since it
irritates throat and can cause choking.
●
Do not attempt to disassemble air bag module and seat belt
pre-tensioner.
●
Air bag module and seat belt pre-tensioner cannot be
SBF276H
reused.
●
Wash your hands clean after finishing work.

SRS-57

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M

COLLISION DIAGNOSIS
COLLISION DIAGNOSIS
For Frontal Collision

PFP:00015
BHS0003N

To repair the SRS, perform the following steps.
When SRS (except the front side air bag and side curtain air bag modules) is activated in a collision:
1. Replace the diagnosis sensor unit.
2. Remove the air bag modules (except the front side air bag modules and side curtain air bag modules),
crash zone sensor assembly, bracket and seat belt pre-tensioner assemblies.
3. Check the SRS components using the table below:
–
Replace any SRS components showing visible signs of damage (dents, cracks and deformation).
4. Install new air bag modules (except the front side air bag modules and side curtain air bag modules) crash
zone sensor assembly, bracket and seat belt pre-tensioner assemblies.
5. Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to SRS-18, «SRS Operation
Check» for details. Ensure entire SRS operates properly.
When SRS is not activated in a collision:
1. Check the SRS components using the table below:
–
Replace any SRS components showing visible signs of damage (dents, cracks and deformation).
2. Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to SRS-18, «SRS Operation
Check» for details. Ensure entire SRS operates properly.

SRS INSPECTION (FOR FRONTAL COLLISION)
Part

SRS is activated

SRS is NOT activated

Air bag module
(driver and front passenger air bag module)

REPLACE
Install with new bolts.

1. Remove air bag module. Check harness cover and connectors for damage, terminals for deformities, and harness for binding.
2.
–

Install driver air bag module into the steering wheel to check fit and alignment with
the wheel.

–

Install passenger air bag module into the instrument panel to check fit with the
instrument panel.

3. No damage found, reinstall with new bolts.
4. If damaged—REPLACE air bag modules with new special bolts.
Air bag must be deployed before disposal.
Crash zone sensor

REPLACE the crash
zone sensor and
bracket with new
nuts.

1. Remove the crash zone sensor. Check harness connectors for damage, terminals
for deformities, and harness for binding.
2. Check for visible signs of damage (dents, cracks, deformation) of the crash zone
sensor and bracket.
3. Install the crash zone sensor to check fit.
4. No damage found, reinstall with new bolts.
5. If damaged—REPLACE the crash zone sensor and bracket with new nuts.

Seat belt pretensioner assemblies

REPLACE
Install seat belt pretensioner with new
bolts.

1. Remove seat belt pre-tensioners.
Check harness cover and connectors for damage, terminals for deformities, and
harness for binding.
2. Check belts for damage and anchors for loose mounting.
3. Check retractor for smooth operation.
4. Check seat belt adjuster for damage.
5. If no damage is found, reinstall seat belt pre-tensioner assembly with new bolts.
6. If damaged—REPLACE seat belt pre-tensioners with new bolts.
Seat belt pre-tensioners must be deployed before disposal.

Diagnosis sensor unit

REPLACE
Install with new bolts.

1. Check case for dents, cracks or deformities.
2. Check connectors for damage, and terminals for deformities.
3. If no damage is found, reinstall with new bolts and ground bolt.
4. If damaged—REPLACE diagnosis sensor unit with new bolts and ground bolt.

SRS-58

COLLISION DIAGNOSIS
Part
Steering wheel

SRS is activated

SRS is NOT activated

1. Visually check steering wheel for deformities.

A

2. Check harness (built into steering wheel) and connectors for damage, and terminals for deformities.
3. Install air bag module to check fit or alignment with steering wheel.
4. Check steering wheel for excessive free play.

B

5. If no damage is found, reinstall with nut.
6. If damaged—REPLACE.
Spiral cable

C

1. Visually check spiral cable and combination switch for damage.
2. Check connectors and protective tape for damage.
3. Check steering wheel for noise, binding or heavy operation.

D

4. If no damage is found, reinstall with screws.
5. If damaged—REPLACE.
Harness and connectors

1. Check connectors for poor connection, damage, and terminals for deformities.
2. Check harness for binding, chafing, cuts, or deformities.
3. If no damage is found, reinstall the harness and connectors.
4. If damaged—REPLACE damaged section of harness. Do not attempt to repair, splice or modify any SRS
harness.

Instrument panel

E

1. Visually check instrument panel for damage.
2. If no damage is found, reinstall the instrument panel.

F

G

3. If damaged—REPLACE the instrument panel with bolts.

SRS

I

J

K

L

M

SRS-59

COLLISION DIAGNOSIS
For Side Collision

BHS0003O

WHEN THE SIDE AIR BAG IS ACTIVATED IN THE SIDE COLLISION:
1.
–

–
–
–

2.
–

3.

Replace the following components:
All parts of front seatback (including front seatback frame) with front side air bag module (on the side on
which front side air bag is activated)
Curtain air bag module (on the side on which side curtain air bag is activated)
Diagnosis sensor unit
Satellite sensor (on the side on which side air bag and side curtain air bag is activated)
Check the SRS components and the related parts using the following table.
Replace any SRS components and the related parts showing visible signs of damage (dents, cracks,
deformation).
Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to SRS-18, «SRS Operation
Check» . Ensure entire SRS operates properly.

WHEN SRS IS NOT ACTIVATED IN THE SIDE COLLISION:
1.
–

2.

Check the SRS components and the related parts using the following table.
Replace any SRS components and the related parts showing visible signs of damage (dents, cracks,
deformation).
Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to SRS-18, «SRS Operation
Check» . Ensure entire SRS operates properly.

SRS INSPECTION (FOR SIDE COLLISION)
Part

(LH or RH) side curtain air bag module

Front (LH or RH) side
air bag module

(LH or RH) side air
bag (Satellite) sensor

Diagnosis sensor unit

Front side air bag and
side curtain air bag is
activated

REPLACE the side
curtain air bag module.
(Repair the center pillar inner, etc. before
installing new one if
damaged.)

Front side air bag and side curtain air bag is NOT activated
1. Check for visible signs of damage (dents, tears, deformation) of the center pillar on
the collision side.
2. If damaged— Remove the side curtain air bag module.
3. Check for visible signs of damaged (tears etc.) of the side curtain air bag module.
4. Check harness and connectors for damage, and terminals for deformities.
5. If no damage is found, reinstall the side curtain air bag module with new bolts.
6. If damaged—REPLACE the side curtain air bag module with new bolts.
Air bag must be deployed before disposal.

REPLACE all parts of
seatback with
deployed front side
air bag module.

1. Check for visible signs of damage (dents, tears, deformation) of the seatback on
the collision side.

REPLACE the side
air bag (Satellite) sensor on the collision
side with new nuts.
(Repair the center pillar inner, etc. before
installing new one if
damaged.)

1. Remove the side air bag (Satellite) sensor on the collision side. Check harness
connectors for damage, terminals for deformities, and harness for binding.

REPLACE the diagnosis sensor unit with
the new bolts.

1. Check case and bracket for dents, cracks or deformities.

2. Check harness and connectors for damage, and terminals for deformities.
3. If damaged—REPLACE the front seatback assembly.
Air bag must be deployed before disposal.

2. Check for visible signs of damage (dents, cracks, deformation) of the side air bag
(Satellite) sensor.
3. Install the side air bag (Satellite) sensor to check fit.
4. If no damage is found, reinstall the side sir bag (Satellite) sensor with new nuts.
5. If damaged—REPLACE the side air bag (Satellite) sensor with new nuts.

2. Check connectors for damage, and terminals for deformities.
3. If no damage is found, reinstall the diagnosis sensor unit with new bolts and ground
bolt.
4. If damaged—REPLACE the diagnosis sensor unit with new bolts and ground bolt.

SRS-60

COLLISION DIAGNOSIS

Part
Seat belt pretensioner assembly

Front side air bag and
side curtain air bag is
activated

Front side air bag and side curtain air bag is NOT activated

1. Check if the seat belt can be extended smoothly.
If the seat belt cannot be extended smoothly,
–

Check for deformities of the center pillar inner.

–

If the center pillar inner has no damage, Replace the seat belt pre-tensioner assembly.

2. Remove the seat belt pre-tensioner assembly on the collision side. Check harness cover and connectors
for damage, terminals for deformities, and harness for binding.

A

B

C

3. Check for visible signs of damage (dents, cracks, deformation) of the seat belt pre-tensioner assembly.
4. Check seat belt adjuster for damage.

D

5. If no damage is found, reinstall the seat belt pre-tensioner assembly.
6. If damaged—REPLACE the seat belt pre-tensioner assembly with new bolts.
The seat belt pre-tensioner assembly must be deployed before disposal.
Seat with front side
air bag

REPLACE all parts of
front seatback
(including front
seatback frame)

E

1. Visually check the seat on the collision side.
2. Remove the seat on the collision side and check the following for damage and
deformities.
–

Harness, connectors and terminals

–

Frame and recliner (for front and rear seat), and also adjuster and slides (for front
seat)

F

G

3. If no damage is found, reinstall the seat.
4. If damaged—REPLACE the damaged seat parts using new bolts.
Center inner pillar

1. Check the center inner pillar on the collision side for damage (dents, cracks, deformation).

SRS

2. If damaged—REPAIR the center inner pillar.
Trim/headlining

1. Check for visible signs of damage (dents, cracks, deformation) of the interior trim on the collision side.
2. If damaged—REPLACE the damaged trim parts.

I

J

K

L

M

SRS-61

COLLISION DIAGNOSIS

SRS-62

WIPER, WASHER & HORN

K ELECTRICAL

SECTION

WW

WIPER, WASHER & HORN

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 3
Maintenance Information …………………………………… 3
RHD MODELS ……………………………………………… 3
LHD MODELS ………………………………………………. 3
PrecautionsforProcedureswithoutCowlTopCover….. 3
FRONT WIPER AND WASHER SYSTEM ……………… 4
Components Parts and Harness Connector Location ………………………………………………………………… 4
System Description ………………………………………….. 4
OUTLINE ……………………………………………………… 4
LOW SPEED WIPER OPERATION …………………. 5
HIGH SPEED WIPER OPERATION ………………… 5
INTERMITTENT OPERATION ………………………… 5
AUTO WIPER OPERATION (MODELS WITH
LIGHT AND RAIN SENSOR) ………………………….. 6
AUTO STOP OPERATION ……………………………… 6
MIST OPERATION ………………………………………… 6
WASHER OPERATION ………………………………….. 7
FAIL-SAFE FUNCTION ………………………………….. 7
COMBINATIONSWITCHREADING FUNCTION….. 8
CAN Communication ………………………………………..11
SYSTEM DESCRIPTION ……………………………….11
CAN Communication Unit …………………………………11
Schematic …………………………………………………….. 12
Wiring Diagram — WIPER — ………………………….. 13
Terminals and Reference Values for BCM …………. 16
Reference Values for BCM (Input) ……………………. 20
Terminals and Reference Values for IPDM E/R ….. 23
CONSULT-II Function (BCM) …………………………… 24
CONSULT-II BASIC OPERATION ………………….. 24
WORK SUPPORT ……………………………………….. 24
DATA MONITOR …………………………………………. 24
ACTIVE TEST …………………………………………….. 24
CONSULT-II Function (IPDM E/R) ……………………. 25
CONSULT-II BASIC OPERATION ………………….. 25
DATA MONITOR …………………………………………. 25
ACTIVE TEST …………………………………………….. 25

Diagnosis Chart by Symptom …………………………… 26
Front Wiper Does Not Operate …………………………. 28
Front Wiper Does Not Return to Stop Position (After
Front Wiper Operate for 10 Seconds, They Stop for
20 Seconds, and After Repeating the Operations
Five Times, They Become Inoperative) ……………… 31
Only Front Wiper Low Does Not Operate …………… 33
Only Front Wiper Hi Does Not Operate ……………… 35
Only Front Wiper Intermittent Does Not Operate … 37
Only Front Wiper Auto Dose Not Operate ………….. 38
Front Wiper Interval Time Is Not Controlled by Vehicle Speed ………………………………………………………. 40
Front Wiper Intermittent Operation Switch Position
Cannot Be Adjusted ………………………………………… 40
WiperDoesNotWipeWhenFrontWasherOperates
… 41
Front Wiper Does Not Stop ………………………………. 41
Removal and Installation of Front Wiper Arms,
Adjustment of Wiper Arms Stop Location …………… 42
REMOVAL ………………………………………………….. 42
INSTALLATION …………………………………………… 42
ADJUSTMENT ……………………………………………. 42
Removal and Installation of Front Wiper Drive
Assembly ………………………………………………………. 43
REMOVAL ………………………………………………….. 43
INSTALLATION …………………………………………… 44
Washer Nozzle Adjustment ……………………………… 44
Washer Tube Routing ……………………………………… 45
Removal and Installation of Front Washer Nozzle… 45
REMOVAL ………………………………………………….. 45
INSTALLATION …………………………………………… 45
Inspection for Washer Nozzle …………………………… 46
CHECK VALVE INSPECTION ……………………….. 46
InspectionofFrontWiperandWasherSwitchCircuit… 46
RemovalandInstallationofFrontWiperandWasher
Switch …………………………………………………………… 46
REMOVAL ………………………………………………….. 46
INSTALLATION …………………………………………… 46
Removal and Installation of Washer Tank ………….. 46
REMOVAL ………………………………………………….. 46

WW-1

E

F

G

H

I

J

WW

L

M

INSTALLATION ……………………………………………. 47
Removal and Installation of Front Washer Motor … 47
REMOVAL ………………………………………………….. 47
INSTALLATION ……………………………………………. 47
Removal and Installation of Light and Rain Sensor… 47
REMOVAL ………………………………………………….. 47
INSTALLATION OF RAIN SENSOR ……………….. 47
INSTALLATION OF LIGHT AND RAIN SENSOR
HOUSING …………………………………………………… 48
REAR WIPER AND WASHER SYSTEM ……………… 49
Components Parts and Harness Connector Location ……………………………………………………………….. 49
System Description …………………………………………. 49
OUTLINE ……………………………………………………. 49
REAR WIPER OPERATION ………………………….. 49
INTERMITTENT OPERATION ………………………. 50
AUTO STOP OPERATION ……………………………. 50
WASHER OPERATION ………………………………… 50
REAR WIPER REVERSE RANGE OPERATION
(IF AUTO WIPER IS EQUIPPED) ………………….. 50
COMBINATIONSWITCHREADING FUNCTION… 50
CAN Communication ………………………………………. 50
SYSTEM DESCRIPTION ……………………………… 50
CAN Communication Unit ………………………………… 50
Wiring Diagram — WIP/R — ……………………………. 51
WITHOUT RAIN SENSOR ……………………………. 51
Schematic ……………………………………………………… 53
WITH RAIN SENSOR …………………………………… 53
Wiring Diagram — WIP/R — ……………………………. 54
WITH RAIN SENSOR …………………………………… 54
Terminals and Reference Values for BCM ………….. 57
Reference Values for BCM (Input) …………………….. 60
Terminals and Reference Values for IPDM E/R …… 62
CONSULT-II Function (BCM) ……………………………. 63
Diagnosis Chart by Symptom …………………………… 64
Rear Wiper Does Not Operate …………………………. 65
Rear Wiper Does Not Return to Stop Position …….. 67
Only Rear Wiper ON Does Not Operate …………….. 68
Only Rear Wiper Intermittent Does Not Operate … 69
Wiper Does Not Wipe WhenRear Washer Operates… 69
Removal andInstallationofRear WiperArm,Adjustment of Wiper Arm Stop Location ……………………… 69
REMOVAL ………………………………………………….. 69
INSTALLATION ……………………………………………. 69
Removal and Installation of Rear Wiper Motor ……. 70
REMOVAL ………………………………………………….. 70
INSTALLATION ……………………………………………. 70
Rear Washer Nozzle Adjustment ………………………. 71
Rear Washer Tube Layout ……………………………….. 71
Removal and Installation of Rear Washer Nozzle… 71
REMOVAL ………………………………………………….. 71

INSTALLATION …………………………………………….71
CHECK VALVE INSPECTION ………………………..72
Inspection of Rear Wiper and Washer Switch Circuit…72
Removaland Installation of Rear Wiper and Washer
Switch ……………………………………………………………72
Removaland Installation of Rear Wiper and Washer
Tank ………………………………………………………………72
Removaland Installation of Rear Wiper and Washer
Pump ……………………………………………………………..72
HEADLAMP WASHER ……………………………………….73
Components Parts and Harness Connector Location ………………………………………………………………..73
System Description ………………………………………….73
OUTLINE …………………………………………………….73
HEADLAMP WASHER OPERATION ……………….74
CAN Communication ……………………………………….74
CAN Communication Unit …………………………………74
Wiring Diagram —HLC— ………………………………….75
Terminals and Reference Values for BCM …………..77
Reference Values for BCM (Input) ……………………..80
Terminals and Reference Values for IPDM E/R ……82
CONSULT-II Function (BCM) …………………………….83
CONSULT-II Function (IPDM E/R) ……………………..83
Diagnosis Chart by Symptom ……………………………83
Headlamp Washer Does Not Operate ………………..84
Removal and Installation for Headlamp Washer
Nozzle ……………………………………………………………88
REMOVAL ……………………………………………………88
INSTALLATION …………………………………………….88
Removal and Installation for Washer Tank …………..88
Removal and Installation for Headlamp Washer
Motor ……………………………………………………………..88
Headlamp Washer Tube Layout ………………………..88
HORN ………………………………………………………………89
Wiring Diagram —HORN— ………………………………89
Removal and Installation …………………………………..90
REMOVAL ……………………………………………………90
INSTALLATION …………………………………………….90
POWER SOCKET ……………………………………………..91
Wiring Diagram —P/SCKT— …………………………….91
Removal and Installation …………………………………..92
REMOVAL ……………………………………………………92
INSTALLATION …………………………………………….92
Removal and Installation of Console Power Socket…92
REMOVAL ……………………………………………………92
INSTALLATION …………………………………………….92
Removal and Installation of Luggage Room Power
Socket ……………………………………………………………92
REMOVAL ……………………………………………………92
INSTALLATION …………………………………………….92

WW-2

PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

A

BKS0010Y

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Maintenance Information

B

C

D

E

F

BKS0028L

If any of following part is replaced, always replace with new* one.
If it’s not (or fail to do so), the electrical system may not be operated properly.
*: New one means a virgin control unit that has never been energized on-board.

G

RHD MODELS

H

●
●
●
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM
IPDM E/R
Combination meter
EPS control unit

I

J

LHD MODELS
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM

Precautions for Procedures without Cowl Top Cover

WW

L
BKS0010Z

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

M

PIIB3706J

WW-3

FRONT WIPER AND WASHER SYSTEM
FRONT WIPER AND WASHER SYSTEM
Components Parts and Harness Connector Location

PFP:28810
BKS00111

MKIB2263E

: Vehicle front
1. IPDM E/R E10, E11, E12
[Engine room (left)]

2. BCM M57, M58, M59
(View with instrument panel removed)

3. Data link connector

4. Front wiper motor E39

5. Front and rear washer motor E24
(View with front bumper removed)

6. Combination switch (Wiper switch)
M38

7. Sun-visor

8. Light and rain sensor R2

System Description
●
●

●
●

BKS00112

Front wiper HI/LO relay and front wiper main relay are built into IPDM E/R.
Wiper switch (combination switch) is composed of a combination of 5 output terminals and 5 input terminals. Terminal combination status is read by BCM when switch is turned ON.
BCM controls front wiper LO, HI, and INT (intermittent) operation.
IPDM E/R operates wiper motor according to CAN communication signals from BCM.

OUTLINE
Power is supplied at all times
●
through 20A fuse (No.48, located in the IPDM E/R)
●
to front wiper main relay.
●
through 20A fuse (No.61 and 62, located in the IPDM E/R)
●
to IPDM E/R (CPU).
●
through 40A fusible link (letter J, located in fuse and fusible link box)
●
to BCM terminals 74 and 79.

WW-4

FRONT WIPER AND WASHER SYSTEM
When ignition switch ON or START position, power is supplied
●
through 10A fuse [No.5, located in fuse block (J/B)]
●
to BCM terminal 24,
●
through 10A fuse [No.3, located in fuse block (J/B)]
●
to combination switch terminal 14, and
●
to front wiper HI/LO relay, front wiper main relay and IPDM E/R (CPU)
Ground is supplied
●
to front wiper motor terminal 2 and,
●
to IPDM E/R terminals 3 and 54
●
through body grounds E28, E44 and E45, and
●
to combination switch terminal 12 and
●
to BCM terminals 2 and 70
●
through body grounds M21 and M66.

A

B

C

D

E

LOW SPEED WIPER OPERATION
When front wiper switch is placed in LO position, BCM reads combination switch condition (Refer to WW-8,
«COMBINATION SWITCH READING FUNCTION» ). And BCM sends front wiper request signal (LO) to IPDM
E/R with CAN communication line. When IPDM E/R receives front wiper request signal (LO), it turns ON front
wiper main relay (built into IPDM E/R).
Power is supplied
●
through front wiper main relay and front wiper HI/LO relay and
●
through IPDM E/R terminal 23
●
to front wiper motor terminal 1.
Ground is supplied
●
to front wiper motor terminal 2,
●
through body grounds E28, E44 and E45.
With power and ground are supplied, the front wiper motor operates at low speed.

F

G

H

I

J

HIGH SPEED WIPER OPERATION

When front wiper switch is placed in HI position, BCM reads combination switch condition (Refer toWW-8,
«COMBINATION SWITCH READING FUNCTION» ). And BCM sends front wiper request signal (HI) to IPDM
E/R with CAN communication line. When IPDM E/R receives front wiper request signal (HI), it turns ON front WW
wiper HI/LO relay and front wiper main relay (built into IPDM E/R).
Power is supplied
●
through front wiper main relay and front wiper HI/LO relay and,
L
●
through IPDM E/R terminal 24
●
to front wiper motor terminal 4.
M
Ground is supplied
●
to front wiper motor terminal 2
●
through body grounds E28, E44 and E45.
With power and ground are supplied, the front wiper motor operates at high speed.

INTERMITTENT OPERATION
Front wiper intermittent operation delay interval is determined by a combination of 3 switches (intermittent
operation dial position 1, 2, and 3) and by vehicle speed signal.
After each intermittent operation delay interval, BCM sends front wiper request signal to IPDM E/R.

WW-5

FRONT WIPER AND WASHER SYSTEM
Wiper Intermittent Dial Position Setting
Combination switch
Wiper intermittent dial position

Intermittent operation
interval

1

Short

Intermittent operation
dial position 1

Intermittent operation
dial position 2

Intermittent operation
dial position 3

ON

ON

ON

ON

ON

OFF

ON

OFF

OFF

OFF

OFF

OFF

5

OFF

OFF

ON

6

OFF

ON

ON

OFF

ON

OFF

2
3
4

7

↑
↓

Long

Example: For wiper intermittent dial position 1
Using combination switch reading function, BCM detects ON/OFF status of intermittent operation dial positions 1, 2, and 3.
When combination switch status is as listed below, BCM determines that it is wiper intermittent dial position 1.
●
Intermittent operation dial position 1: ON (Continuity exists between combination switch output 3 and input
1.)
●
Intermittent operation dial position 2: ON (Continuity exists between combination switch output 5 and input
1.)
●
Intermittent operation dial position 3: ON (Continuity exists between combination switch output 4 and input
2.)
BCM determines front wiper intermittent operation delay interval from wiper intermittent dial position 1 and
vehicle speed, and sends wiper request signal (INT) to IPDM E/R.

AUTO WIPER OPERATION (MODELS WITH LIGHT AND RAIN SENSOR)
When front auto wiper switch is toggled to AUTO position (light and rain sensor equipped), BCM reads the current combination switch condition/position (refer to WW-8, «COMBINATION SWITCH READING FUNCTION» )
and change light and rain sensor into 4stages of wiper sensitivity level.
When light and rain sensor detect rain with ignition switch ON and auto wiper switch in AUTO position the front
wiper will wipe the screen.
(Light and rain sensor will not react, if no raindrop is detected.)
●
from light and rain sensor terminal 2
●
to BCM terminal 63.
BCM send wiper request signal to IPDM E/R with CAN communication line. IPDM E/R operate front wiper.
Change the wiper speed by rainfall.
The light and rain sensor sensitivity is controlled by the wiper volume switch combined with front wiper and
washer switch and BCM.

AUTO STOP OPERATION
With wiper switch turned OFF, wiper motor will continue to operate until wiper arms reach stop position.
When wiper arms are not located at stop position with wiper switch OFF, power is supplied
●
from terminal 23 of the IPDM E/R
●
to front wiper motor terminal 1, in order to continue wiper motor operation at low speed.
Ground is supplied
●
to front wiper motor terminal 2
●
through body grounds E28 and E44.
When wiper arms reach stop position, front wiper motor terminals 2 and 5 are connected.
Then the IPDM E/R sends auto stop operation signal to BCM with CAN communication line.
When BCM receives auto-stop operation signal, BCM sends wiper stop signal to IPDM E/R with CAN communication line.
IPDM E/R stops wiper motor. Wiper motor will then stop wiper arms at the STOP position.

MIST OPERATION
When the front wiper switch is in mist position, low speed wiper operation cycles once and then stops.

WW-6

FRONT WIPER AND WASHER SYSTEM
For additional information about wiper operation under this condition, refer to WW-5, «LOW SPEED WIPER
OPERATION» .
If the front wiper switch is held in the mist position, low speed wiper operation continues.

A

WASHER OPERATION
When front wiper switch is pulled to washer position, power is supplied
●
through combination switch terminal 13
●
to washer motor terminal 1.
Ground is supplied
●
to washer motor terminal 2
●
through combination switch terminals 11 and 12, and
●
through body grounds M21 and M66.
With power and ground supplied, the washer motor operates, and at the same time,
When the wiper switch is pulled to the WASH position for 1 second or more. BCM sends front wiper request
signal (low) to IPDM E/R with CAN communication line. And the front wiper motor operates in low speed for 3
times to clean wind shield and then an additional wiping action will occur after 3 seconds to remove the moisture appear on the glass shortly after the wash/wipe action.

FAIL-SAFE FUNCTION
If CAN communication is malfunctioning, IPDM E/R maintains the condition of just before the fail-safe status
until ignition switch is turned OFF. (If wipers operate in LO just before the fail-safe status, operating in LO continues until ignition switch turns OFF.)
Refer to PG-18, «Fail-safe Control» .

B

C

D

E

F

G

H

I

J

WW

L

M

WW-7

FRONT WIPER AND WASHER SYSTEM
COMBINATION SWITCH READING FUNCTION
Description
●

●

BCM reads combination switch (wiper) status, and controls related systems such as headlamps and wipers, according to the results.
BCM reads information for a maximum of 20 switches by combining 5 output terminals (OUTPUT 1-5) and
5 input terminals (INPUT 1-5).

Operation Description
●

●

●

BCM activates transistors of output terminals (OUTPUT 1-5) periodically, and allows current to flow in
turn.
If any (1 or more) switches are turned ON, the circuit of output terminals (OUTPUT 1-5) and input terminals (INPUT 1-5) becomes active.
At this time, transistors of output terminals (OUTPUT 1-5) are activated to allow current to flow. When voltage of the input terminal (INPUT 1-5) corresponding to that switch changes, the interface in the BCM
detects a voltage change, and the BCM determines that the switch is ON.

MKIB2223E

BCM — Operation Table of Combination Switches
●

BCM reads operation status of the combination switch using combinations shown in the table below.

PKIC0420E

WW-8

FRONT WIPER AND WASHER SYSTEM
Sample Operation: (When Wiper Switch is Turned to LOW Position)
●

●

●

When wiper switch is turned to LOW position, front wiper LOW contact in combination switch turns ON. At
this time if OUTPUT 1 transistor is activated, BCM detects that voltage changes in INPUT 3.
When BCM detects that voltage changes in INPUT 3 while OUTPUT 1 transistor is ON, it judges that front
wiper switch is in LOW position. Then BCM sends front wiper request signal (LO) to IPDM E/R using CAN
communication.
If BCM detects that voltage changes in INPUT 3 when OUTPUT 1 transistor is activated again, it recognizes that wiper switch is still in LOW position.

A

B

C

D

E

F

G

H

MKIB2225E

NOTE:
Each OUTPUT terminal transistor is activated at 10 ms intervals. Therefore after switch is turned ON,
electrical loads are activated with time delay. But this time delay is so short that it cannot be detected by
human senses.

I

J

Operation Mode
Combination switch reading function has operation modes shown below.
1. Normal status
● When BCM is not in sleep status, output terminals (OUTPUT 1-5) send out ON signal every 10 ms.
2. Sleep status

WW

L

M

WW-9

FRONT WIPER AND WASHER SYSTEM
●

When BCM is in sleep status, BCM enters low power mode. Mean while out put terminals (OUTPUT 15) send out ON signal every 60ms, and accept only input from light switch system.

PKIC0832E

Intermittent Operation
Wiper intermittent operation delay interval is determined from a combination of 3 switches (intermittent operation dial position 1, intermittent operation dial position 2, and intermittent operation dial position 3) and vehicle
speed signal.
During each intermittent operation delay interval, BCM sends front wiper request signal to IPDM E/R.

WW-10

FRONT WIPER AND WASHER SYSTEM
CAN Communication

BKS00113

SYSTEM DESCRIPTION

A

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

B

CAN Communication Unit

C

BKS00114

Refer to LAN-27, «CAN Communication Unit» .

D

E

F

G

H

I

J

WW

L

M

WW-11

FRONT WIPER AND WASHER SYSTEM
Schematic

BKS00115

MKWA4279E

WW-12

FRONT WIPER AND WASHER SYSTEM
Wiring Diagram — WIPER —

BKS00116

A

B

C

D

E

F

G

H

I

J

WW

L

M

MKWA4280E

WW-13

FRONT WIPER AND WASHER SYSTEM

MKWA4281E

WW-14

FRONT WIPER AND WASHER SYSTEM
A

B

C

D

E

F

G

H

I

J

WW

L

M

MKWA4282E

WW-15

FRONT WIPER AND WASHER SYSTEM
Terminals and Reference Values for BCM

BKS00117

Measuring condition
Terminal
No.

Wire
color

2

B

Signal name

Ground

Signal
input/
output
—

Ignition
switch

Operation or condition

ON

—

Reference value [V]

0

OFF
(Wiper intermittent dial position 4)

PKIB8643J

Approx. 1.2V
Any of several conditions below
7

BR

Combination switch
output 5

Output

ON

●

Front fog lamp switch (Operates
only front fog lamp switch)
(Wiper intermittent dial position 4)

●

Rear fog lamp switch
(Wiper intermittent dial position 4)

●

Rear wiper ON
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 2

●

Wiper intermittent dial position 6

●

Wiper intermittent dial position 7

PKIB4956J

Approx. 1.0V

OFF
(Wiper intermittent dial position 4)

PKIB4958J

Approx. 1.2V
8

L

Combination switch
output 3

Output

ON

Any of several conditions below
●

Lighting switch 2ND
(Wiper intermittent dial position 4)

●

Lighting switch HI beam
(Operates only HI beam switch)
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 2

●

9

V

Combination switch
output 1

Output

ON

Wiper intermittent dial position 3

PKIB4959J

Approx. 1.0V

OFF
(Wiper intermittent dial position 4)

PKIB4958J

Approx. 1.2V

WW-16

FRONT WIPER AND WASHER SYSTEM
Measuring condition
Terminal
No.

Wire
color

Signal name

Signal
input/
output

A

Ignition
switch

Reference value [V]
Operation or condition

B
Any of several conditions below
●

Turn signal switch to right

●

Turn signal switch to left

●

Front wiper switch MIST

●

Front wiper switch LO

●

Front washer switch

C

PKIB4959J

D

Approx. 1.0V

13

14

15

19
24

GB

P

W

Combination switch
input 1

Combination switch
input 3

Combination switch
input 5

L

CAN H

O

Ignition power supply

Input

Input

Input

ON

●

OFF

●

Front wiper switch HI
(Wiper intermittent dial position 4)

●

Rear wiper switch INT
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 2

●

Wiper intermittent dial position 3

●

Wiper intermittent dial position 6

●

Wiper intermittent dial position 7

●

OFF

●

Lighting switch AUTO

●

Rear fog lamp switch

●

Front wiper switch MIST

●

Front wiper switch INT

●

Front wiper switch LO

●

OFF

●

Lighting switch 1ST

●

Lighting switch 2ND

●

Lighting switch HIGH beam
(Operates only HIGH beam
switch)

●

Turn signal switch to right

ON

ON

Input/
output

—

Input

ON

E

WW-20, «Reference Values for BCM
(Input)»

F

G

H

—

WW-20, «Reference Values for BCM
(Input)»

I

J

WW-20, «Reference Values for BCM
(Input)»

WW

L
—

M
—

WW-17

Battery voltage

FRONT WIPER AND WASHER SYSTEM
Measuring condition
Terminal
No.

Wire
color

Signal name

Signal
input/
output

Ignition
switch

Reference value [V]
Operation or condition

OFF
(Wiper intermittent dial position 4)

PKIB4958J

Approx. 1.2V
27

GR

Combination switch
output 4

Output

ON

Any of several conditions below
●

Lighting switch AUTO
(Wiper intermittent dial position 4)

●

Lighting switch 1ST
(The same result with
lighting switch 2ND)
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 5

●

Wiper intermittent dial position 6

PKIB4959J

Approx. 1.0V

OFF
(Wiper intermittent dial position 4)

PKIB4958J

28

G

Combination switch
output 2

Output

Approx. 1.2V

ON
Any of several conditions below
●

Lighting switch 2ND

●

Lighting switch PASSING
(Operates only PASSING switch)

●

Front wiper switch INT

●

Front wiper switch HI

PKIB4959J

Approx. 1.0V

33

R

Combination switch
input 2

Input

ON

●

OFF

●

Front washer switch
(Wiper intermittent dial position 4)

●

Rear wiper switch ON
(Wiper intermittent dial position 4) WW-20, «Reference Values for BCM
(Input)»
Rear washer switch ON
(Wiper intermittent dial position 4)

●

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 5

●

Wiper intermittent dial position 6

WW-18

FRONT WIPER AND WASHER SYSTEM
Measuring condition
Terminal
No.

34

39

Wire
color

Y

Y

Signal name

Combination switch
input 4

CAN L

Signal
input/
output

Input

Input/
output

A

Ignition
switch

ON

Reference value [V]
Operation or condition

B

●

OFF

●

Front fog lamp switch ON

●

Lighting switch 2ND

●

Lighting switch PASSING
(Operates only PASSING switch)

●

Turn signal switch to left

WW-20, «Reference Values for BCM
(Input)»

C

D
—

—

—

E

63

BR

Light and rain sensor signal

Input

ON

—

F

MKIB2017E

Approx. 8.9V
70

B

Ground

—

ON

—

0

73

V

Room lamp power
supply

Output

—

—

Battery voltage

74

Y

Power source
(Fusible link)

Input

OFF

—

Battery voltage

79

Y

Power source
(Fusible link)

Input

OFF

—

Battery voltage

G

H

I

J

WW

L

M

WW-19

FRONT WIPER AND WASHER SYSTEM
Reference Values for BCM (Input)

BKS001KE

CAUTION:
●
Check combination switch system terminal waveform under the loaded condition with lighting
switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded.
●
Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position.
Wiper dial position can be confirmed on CONSULT-II. Refer to WW-24, «DATA MONITOR» .
INPUT

Condition and reference value
OFF

Lighting switch 1ST

PKIB4956J

INPUT 5
(Wiper intermittent
dial position 4)

Lighting switch 2ND

PKIB8624J

Approx. 0.9V

Approx. 1.5 — 2.0V

Lighting switch HI beam
(Operates only HI beam switch)

Turn signal switch to right

PKIB8639J

Approx. 2.5 — 3.0V

—

PKIB8625J
PKIB8644J

Approx. 1.5 — 2.0V

Approx. 1.5 — 2.0V
Lighting switch 2ND

OFF

PKIB4958J

INPUT 4
(Wiper intermittent
dial position 4)

Turn signal switch to left

PKIB8628J

Approx. 1.0V

Approx. 1.5 — 2.0V

Front fog lamp switch
(Operates only front fog lamp
switch)

Lighting switch PASSING
(Operates only PASSING switch)

PKIB8630J

Approx. 2.0V

—

PKIB8629J
PKIB8627J

Approx. 1.5 — 2.0V

Approx. 2.0V

WW-20

FRONT WIPER AND WASHER SYSTEM
INPUT

Condition and reference value
OFF

Lighting switch AUTO

Front wiper switch INT

A

B

PKIB4958J

PKIB8631J

Approx. 1.0V
INPUT 3
(Wiper intermittent
dial position 4)

Approx. 2.0V

PKIB8632J

Approx. 2.0V

Any of several conditions below
● Front
● Front

wiper switch LO

C

D

Rear fog lamp switch

wiper switch MIST

E
—

F

PKIC1030E

Approx. 1.5V

PKIB8629J

Approx. 2.0V
OFF
(Wiper intermittent dial position 4)

Front washer switch
(Wiper intermittent dial position 4)

Rear washer switch
(Wiper intermittent dial position 4)

G

H

I
PKIB4958J

PKIB8632J

Approx. 1.0V

Approx. 2.0V

PKIB8631J

Approx. 2.0V

J

Any of the conditions below
INPUT 2
Rear wiper switch ON
(Wiper intermittent dial position 4)

● Wiper

intermittent dial position 1

● Wiper

intermittent dial position 5

● Wiper

intermittent dial position 6

WW
—

L
PKIB8634J

Approx. 1.5 — 2.0V

PKIB8633J

Approx. 2.0V

WW-21

M

FRONT WIPER AND WASHER SYSTEM
INPUT

Condition and reference value
Any of the conditions below
OFF
(Wiper intermittent dial position 4)

Front wiper switch HI
(Wiper intermittent dial position 4)

● Rear wiper switch INT
(Wiper intermittent dial position 4)
● Wiper

PKIB4958J

intermittent dial position 3

PKIB8635J

Approx. 1.0V

Approx. 2.0V

PKIB8636J

Approx. 2.0V

INPUT 1
Any of the conditions below

Any of the conditions below

● Wiper

intermittent dial position 1

● Wiper

intermittent dial position 6

● Wiper

intermittent dial position 2

● Wiper

intermittent dial position 7

—

PKIB8637J

Approx. 2.5 — 3.0V

PKIB8638J

Approx. 2.0V

WW-22

FRONT WIPER AND WASHER SYSTEM
Terminals and Reference Values for IPDM E/R

BKS00118

A
Terminal
No.

Wire
color

3

B

Ground

23

Y

24

LG

Measuring condition

Signal
input/
output

Ignition
switch

Operation or condition

—

ON

—

Low speed power
source

Output

ON

High speed power
source

Output

Signal name

ON

Reference value [V]

B

Wiper switch

Wiper switch

0
OFF

0

LO

Battery voltage

OFF

0

HI

Battery voltage

52

L

CAN H

Input/
output

—

—

—

54

B

Ground

—

—

—

0

Wiper operating

Battery voltage

Wiper stopped

0

—

—

55

OR

Wiper auto stop signal

Input

ON

58

W

CAN L

Input/
output

—

C

D

E

F

G

H

I

J

WW

L

M

WW-23

FRONT WIPER AND WASHER SYSTEM
CONSULT-II Function (BCM)

BKS0011B

CONSULT-II can display each diagnostic item using the diagnostic modes shown following.
BCM diagnosis position

Diagnosis mode

Changes the setting for each function.

DATA MONITOR

Displays BCM input data in real time.

WIPER

ACTIVE TEST
SELF-DIAG RESULTS

BCM

Description

WORK SUPPORT

CAN DIAG SUPPORT MNTR

Device operation can be checked by applying a drive signal to device.
BCM performs self-diagnosis of CAN communication.
The result of transmit/receive diagnosis of CAN communication can be read.

CONSULT-II BASIC OPERATION
Refer to GI-36, «CONSULT-II Start Procedure» .

WORK SUPPORT
Supported item

Description

RR WIP RVRS SET

Rear wiper reverse range operation setting can be changed.

DATA MONITOR
Monitor item “UNIT”

Contents

IGN ON SW

[ON/OFF]

Displays “ignition switch ON (ON)/Other OFF or ACC (OFF)” status as judged from ignition switch signal.

FR WIPER HI

[ON/OFF]

Displays “Front Wiper HI (ON)/Others (OFF)” status as judged from wiper switch signal.

FR WIPER LOW

[ON/OFF]

Displays “Front Wiper LOW (ON)/Others (OFF)” status as judged from wiper switch signal.

FR WIPER INT

[ON/OFF]

Displays “Front Wiper INT (ON)/Others (OFF)” status as judged from wiper switch signal.

FR WASHER SW

[ON/OFF]

Displays “Front Washer Switch (ON)/Others (OFF)” status as judged from wiper switch
signal.

[1 — 7]

Displays intermittent operation dial position setting (1 — 7) as judged from wiper switch
signal.

FR WIPER STOP

[ON/OFF]

Displays “Stopped (ON)/Operating (OFF)” status as judged from the auto-stop signal.

VEHICLE SPEED

[km/h]

INT VOLUME

Displays vehicle speed status as judged from vehicle speed signal.

H/L WASH SW

[ON/OFF]

Displays (Headlamp washer switch: ON/Others: OFF) as judged from headlamp washer
switch signal

H/L SW POS

[ON/OFF]

Displays (Headlamp switch: ON/Others: OFF) as judged from lighting switch signal

RR WIPER ON

[ON/OFF]

Displays “Rear Wiper ON (ON)/Others (OFF)” status as judged from wiper switch signal.

RR WIPER INT

[ON/OFF]

Displays “Rear Wiper INT (ON)/Others (OFF)” status as judged from wiper switch signal.

RR WASHER SW

[ON/OFF]

Displays “Rear Washer Switch (ON)/Others (OFF)” status as judged from wiper switch
signal.

RR WIPER STOP

[ON/OFF]

Displays “Rear Wiper Stop (ON)/Others (OFF)” status as judged from wiper switch signal.

REVERSE SW CAN

[ON/OFF]

Displays “Reverse position (ON)/Others (OFF)” status as judged from reverse signal.

R/WIP MTR SIG

[ON/OFF]

Displays “Rear wiper motor signal (ON)/Others (OFF)” status as judged to rear wiper
motor output signal.

ACTIVE TEST
Test item

Indication CONSULT-II
display

Description

Front wiper output
(HI, LOW)

FR WIPER

Front wiper can be operated by ON (HI, LO)–OFF operation.

Rear wiper output

RR WIPER

Rear wiper can be operated by any ON-OFF operation.

Head lamp washer output

HEAD LAMP WASHER

Head lamp washer can be operated by any ON-OFF operation.

WW-24

FRONT WIPER AND WASHER SYSTEM
CONSULT-II Function (IPDM E/R)

BKS0011C

CONSULT-II can display each diagnostic item using the diagnostic modes shown following.
Diagnosis Mode

A

Description

SELF−DIAG RESULTS

Refer to PG-20, «SELF-DIAG RESULTS» .

DATA MONITOR

The input/output data of IPDM E/R is displayed in real time.

CAN DIAG SUPPORT MNTR

The result of transmit/receive diagnosis of CAN communication can be read.

ACTIVE TEST

IPDM E/R sends a drive signal to electronic components to check their operation.

B

CONSULT-II BASIC OPERATION

C

D

Refer to GI-36, «CONSULT-II Start Procedure» .

DATA MONITOR
E

Monitor item selection
Item name

Display or unit

All
signals

HEADLAMP WASHER
REQUEST

ON/OFF

×

FR WIPER REQUEST

OFF/LO/HI

×

WIPER AUTO STOP

ON/OFF

×

WIPER PROTECTION

OFF/LS/HS/Block

Main
signal

Sele
ct
from
men
u

Description

F

×

Signal status input from BCM

×

×

Signal status input from BCM

×

×

IPDM E/R output status

×

IPDM E/R control status (LS: low speed operation/ HS: high speed operation/ BLOCK: wiper
arm is locked)

×

NOTE:
Perform monitoring of IPDM E/R data with ignition switch ON. When ignition switch is at ACC, the display may
not be correct.

G

H

I

J

ACTIVE TEST
Test item

Indication on CONSULT-II
display

Description

Front wiper (HI, LO)

FRONT WIPER

With a certain operation (HI, LO, OFF) front wiper relay can
be operated.

Headlamp washer

HEADLAMP WASHER

Headlamp washer relay can be operated by switching (ON
and OFF) optionally.

WW

L

M

WW-25

FRONT WIPER AND WASHER SYSTEM
Diagnosis Chart by Symptom
Symptom

Possible causes

BKS001HD

Possible malfunctioning system and part

Inspection procedure

Reference
page

BCM OUTPUT 2 — INPUT 1,
BCM OUTPUT 1 — INPUT 3 and
BCM OUTPUT 2 — INPUT 3 system
Combination
switch reading
function malfunction

Front wiper does

●

10A (M7) fuse

●

40A fusible link

CONSULT-II

●

Combination switch
(Front wiper HI, LOW, and INT systems malfunction)

●

●

Harness and connector between combination switch and BCM

●

BCM
CONSULT-II

not operateCAUTION 1

Front wiper
request signal
malfunction
(CAN)

BCM — IPDM E/R system
●

BCM (Transmission malfunction)

●

IPDM E/R (Receiving malfunction)

IPDM E/R — front wiper motor system
Front wiper HI/LO
output malfunction

Front wiper does
not return to stop
position (after front
wiper operate for
10 seconds, they
stop for 20 seconds, and after
repeating the
operations five
times, they
become inoperative)

DATA MONITOR
(BCM)

●

20A (#48, #62) fuse

●

Front wiper motor

●

Harness and connector between IPDM E/R
and front wiper motor

●

IPDM E/R

●

SELF-DIAGNOSIS
(BCM)

●

ACTIVE TEST (BCM)

●

DATA MONITOR
(IPDM E/R)

CONSULT-II
●

ACTIVE TEST (IPDM
E/R)

Other than CONSULT-II
●

Front wiper motor output inspection

CONSULT-II
IPDM E/R — front wiper motor system
Auto-stop signal
malfunction

●

Front wiper motor

●

Harness and connector between IPDM E/R
and front wiper motor

●

●

DATA MONITOR
(IPDM E/R)

Other than CONSULT-II
●

IPDM E/R

Auto-stop signal malfunction
Auto-stop signal system inspection

CAUTION 2

IPDM E/R — front wiper motor system
Only front wiper
LOW does not
operate

Front wiper LO
output malfunction

●

Front wiper motor

●

Harness and connector between IPDM E/R
and front wiper motor

●

IPDM E/R

Only front wiper HI
does not operate

Front wiper HI
output malfunction

●

Front wiper motor

●

Harness and connector between IPDM E/R
and front wiper motor

●

IPDM E/R

●

ACTIVE TEST (IPDM
E/R)

Other than CONSULT-II
Front wiper motor LO
output inspection

WW-33, «Only
Front Wiper
Low Does Not
Operate»

CONSULT-II
●

ACTIVE TEST (IPDM
E/R)

Other than CONSULT-II
●

WW-26

WW-31, «Front
Wiper Does
Not Return to
Stop Position
(After Front
Wiper Operate
for 10 Seconds, They
Stop for 20
Seconds, and
After Repeating the Operations Five
Times, They
Become Inoperative)»

CONSULT-II

●

IPDM E/R — Front wiper motor system

WW-28, «Front
Wiper Does
Not Operate»

Front wiper motor HI
output inspection

WW-35, «Only
Front Wiper Hi
Does Not
Operate»

FRONT WIPER AND WASHER SYSTEM
Symptom

Possible causes

Possible malfunctioning system and part

Inspection procedure

BCM OUTPUT 1 — INPUT 3 or
BCM OUTPUT 2 — INPUT 3 system
Only front wiper
INT does not operate

Combination
switch reading
function malfunction

●

Combination switch
(Front wiper INT systems malfunction)

●

Harness and connector between combination switch and BCM

●

BCM

CONSULT-II
●

DATA MONITOR
(BCM)

Reference
page

WW-37, «Only
Front Wiper
Intermittent
Does Not
Operate»

A

B

C

BCM — light and rain sensor
Only front wiper
AUTO does not
operate

Front wiper interval time is not controlled by vehicle
speed

Light and rain
sensor signal
malfunction

Vehicle speed
signal (meter)
malfunction
(CAN)

●

BCM

Other than CONSULT-II

●

Harness and connector between BCM and
light and rain sensor

●

●

Light and rain sensor

Combination meter — BCM (CAN communication) system
●

●

Front wiper intermittent operation
switch position
cannot be
adjusted

Combination meter
(Transmission malfunction)

Light and rain sensor
circuit inspection

●

CONSULT-II
●

SELF-DIAGNOSIS
(METER, BCM)

●

DATA MONITOR
(METER, BCM)

BCM (Receiving malfunction)

●

●

Combination switch
(Intermittent control 1, 2, and 3 systems malfunction)

WW-40, «Front
Wiper Interval
Time Is Not
Controlled by
Vehicle Speed»

Combination
switch reading
function malfunction

CONSULT-II
●

DATA MONITOR
(BCM)

Harness and connector between combination switch and BCM

WW-40, «Front
Wiper Intermittent Operation
Switch Position Cannot Be
Adjusted»

Combination switch
(Front washer system malfunction)

●

Harness and connector between combination switch and BCM

CONSULT-II
●

DATA MONITOR
(BCM)

WW-41, «Wiper
Does Not Wipe
When Front
Washer Operates»

Front wiper does
not stop

●

Combination switch
(Front wiper HI, LOW, and INT systems malfunction)

●

Harness and connector between combination switch and BCM

●

BCM

IPDM E/R — Front wiper motor system
Front wiper HI/LO
output malfunction

●

●

I

J

WW

BCM

BCM OUTPUT 2 — INPUT 1,
BCM OUTPUT 1 — INPUT 3 and
BCM OUTPUT 2 — INPUT 3 system
Combination
switch reading
function malfunction

H

BCM

●

●

F

G

BCM OUTPUT 1 — INPUT 2 system
Wiper does not
wipe when front
washer operates

D

E

BCM OUTPUT 3 — INPUT 1,
BCM OUTPUT 5 — INPUT 1 and
BCM OUTPUT 4 — INPUT 2 system
Combination
switch reading
function malfunction

WW-38, «Only
Front Wiper
Auto Dose Not
Operate»

Harness and connector between IPDM E/R
and front wiper motor
IPDM E/R

L
CONSULT-II
●

DATA MONITOR
(BCM)

M
WW-41, «Front
Wiper Does
Not Stop»

Other than CONSULT-II
●

Front wiper motor output inspection

CAUTION:
1. When the IPDM E/R is performing the fail-safe control, the front wiper may not be operated. Check if the system is not in
the fail-safe condition.
2. This phenomenon occurs when IPDM E/R judges that front wiper is locked. It stops wiper output while IPDM E/R is operating front wiper and auto stop signal does not change for at least 10 seconds.
In this state, use IPDM E/R data monitor to check if “wiper protection” item is “BLOCK”.

WW-27

FRONT WIPER AND WASHER SYSTEM
Front Wiper Does Not Operate

BKS001HL

CAUTION:
●
During IPDM E/R fail-safe control, front wipers may not operate. Refer to PG-18, «CAN COMMUNICATION LINE CONTROL» in “PG IPDM E/R” to make sure that it is not in fail-safe status.

1. CHECK FUSE
Check fuse and fusible link for blown-out.

●

Unit

Power source

Fuse No.

Ignition ON or START

3

Front wiper main relay

Battery

48

IPDM E/R

Battery

61, 62

Battery

J

Ignition switch ON or START position

5

Front and rear washer motor

BCM

Refer to WW-13, «Wiring Diagram — WIPER —» .
OK or NG
OK
>> GO TO 2.
NG
>> If fuse is blown, be sure to eliminate cause of problem before installing new fuse Refer to PG-4,
«POWER SUPPLY ROUTING CIRCUIT» .

2. CHECK BCM POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector.
Check voltage between BCM harness connector and ground.
Terminal

Ignition switch position

(+)
Connector

(–)
74

M59
79
M57

OFF

ACC

ON

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

0V

Battery
voltage

Terminal

Ground

24

0V

MKIB0352E

OK or NG
OK
>> GO TO 3.
NG
>> Check harness for open or short between fuse, fusible link and BCM.

3. CHECK IPDM E/R GROUND CIRCUIT
1.
2.

Disconnect IPDN E/R harness connector.
Check continuity between IPDM E/R harness connector and
ground.
Connector

Terminal

E11

3

E12

54

Continuity
Ground
Yes

OK or NG
OK
>> GO TO 4.
NG
>> Harness for open ground circuit.
MKIB2004E

WW-28

FRONT WIPER AND WASHER SYSTEM

4. CHECK BCM GROUND CIRCUIT

A

Check continuity between BCM harness connector and ground.
Connector

Terminal

M57

2

M59

70

Continuity
Ground

B

Yes

C

OK or NG
OK
>> GO TO 5.
NG
>> Check harness ground circuit.

D
MKIB0353E

5. ACTIVE TEST

E

With CONSULT-ll
Turn ignition switch ON.
Select “IPDM E/R” on CONSULT-II, and select “ACTIVE TEST”
on “SELECT DIAG MODE” screen.
3. Select “FRONT WIPER” on “SELECT TEST ITEM” screen.
4. Touch “LO” or “HI” screen.
1.
2.

F

G

Without CONSULT-ll
Start up auto active test. Refer to PG-22, «Auto Active Test» .
Does front wiper operate normally?
YES >> GO TO 6.
NO
>> GO TO 8.

H

I
SKIA3486E

6. CHECK CIRCUIT BETWEEN COMBINATION SWITCH AND BCM

J

With CONSULT-ll
Select “BCM” on CONSULT-II, and select “WIPER” on “SELECT
TEST ITEM” screen.
2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure that “FR WIPER INT”, “FR WIPER LOW”, and “FR
WIPER HI” turn ON-OFF according to wiper switch operation.
1.

Without CONSULT-ll
Refer to LT-125, «Combination Switch Inspection» .
OK or NG
OK
>> GO TO 7.
NG
>> Check combination switch (wiper switch). Refer to LT125, «Combination Switch Inspection» .

WW

L

M
PKIB0110E

7. CHECK CIRCUIT BETWEEN IPDM E/R AND BCM
Select “BCM” on CONSULT-II, and perform self-diagnosis for
“BCM”.
Displayed self-diagnosis results
NO DTC>>Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
CAN COMM CIRCUIT>>Check CAN communication line of BCM.
Refer to BCS-17, «CAN Communication Inspection With
CONSULT-II (Self-Diagnosis)» .

PKIA7627E

WW-29

FRONT WIPER AND WASHER SYSTEM

8. CHECK GROUND CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect front wiper motor connector.
Check continuity between front wiper motor harness connector
[A (LHD models) or B (RHD models)] and ground.
LHD models (A)

Front wiper
motor connector

Terminal

E39

5

Continuity
Ground
Yes

RHD models (B)
Front wiper
motor connector

Terminal

E66

2

Continuity
Ground
Yes

MKIB2303E

OK or NG
OK
>> GO TO 9.
NG
>> Repair harness or connector.

9. CHECK FRONT WIPER CIRCUIT
1.
2.

Disconnect IPDM E/R connector.
Check continuity between IPDM E/R harness connector (A) and
front wiper motor harness connector [B (LHD models) or C
(RHD models)].
LHD models
A
Connector

B
Terminal

Connector

Terminal

23
E10

Continuity

2
E39

24

Yes

1

RHD models
A
Connector

C
Terminal

Connector

23
E10

3.

Terminal

Continuity

1
E66

24

Yes

4

Check continuity between IPDM E/R harness connector (A) and
Ground.
A
Connector

23
E10

Continuity

Terminal
Ground

No

24

OK or NG
OK
>> GO TO 10.
NG
>> Repair harness or connector.

WW-30

MKIB2226E

FRONT WIPER AND WASHER SYSTEM

10. CHECK IPDM E/R
1.
2.
3.
4.
5.
6.

A

With CONSULT-ll
Connect IPDM E/R connector.
Turn ignition switch ON.
Select “IPDM E/R” by CONSULT-II, and select “ACTIVE TEST” on “SELECT DIAG MODE” screen.
Select “FRONT WIPER” on “SELECT TEST ITEM” screen.
Touch “LO” or “HI” screen.
Check voltage between IPDM E/R harness connector and
ground while front wiper (HI, LO) is operating.

B

C

D

Terminal
(+)
(-)

IPDM E/R
connector

Voltage

Stopped

Approx. 0V

LO operation

Battery voltage

Stopped

Approx. 0V

HI operation

Battery voltage

E

Terminal
23

E10

Ground
24

1.
2.
3.
4.

Condition

F
SKIA2170E

G

Without CONSULT-ll
Connect IPDM E/R connector.
Turn ignition switch ON.
Start up auto active test. Refer to PG-22, «Auto Active Test» .
Check voltage between IPDM E/R harness connector and ground while front wiper (HI, LO) is operating.

H

I

Terminal
(+)
IPDM E/R
connector

(-)

Condition

Voltage

Stopped

Approx. 0V

LO operation

Battery voltage

Stopped

Approx. 0V

HI operation

Battery voltage

J

Terminal
23

E10

Ground
24

WW

L

OK or NG
OK
>> Replace front wiper drive assembly. Refer to WW-43, «Removal and Installation of Front Wiper
Drive Assembly» .
NG
>> Replace IPDM E/R. Refer to PG-37, «Removal and Installation of IPDM E/R» .

Front Wiper Does Not Return to Stop Position (After Front Wiper Operate for 10
Seconds, They Stop for 20 Seconds, and After Repeating the Operations Five
Times, They Become Inoperative)

BKS001HM

CAUTION:
●
When auto-stop signal has not varied for 10 seconds or longer while IPDM E/R is operating front
wipers, IPDM E/R considers that front wipers are locked, and stops wiper output. That causes this
symptom.
●
This status can be checked by “DATA MONITOR” of “IPDM E/R” on which “WIPER PROT” item
shows “BLOCK”.

WW-31

M

FRONT WIPER AND WASHER SYSTEM

1. CHECK FRONT WIPER STOP SIGNAL
With CONSULT-ll
Select “IPDM E/R” on CONSULT-II. With “DATA MONITOR”, make
sure that “WIP AUTO STOP” turns “ACT P” — “STOP P” linked with
wiper operation.
Without CONSULT-ll
GO TO 2.
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-37, «Removal and
Installation of IPDM E/R» .
NG
>> GO TO 2.
PKIA7614E

2. CHECK IPDM E/R
Check voltage between IPDM E/R harness connector and ground
while front wiper motor is stopped and while it is operating.
Terminal
(+)
IPDM E/R
connector

Terminal

E12

55

Condition

Voltage

Wiper stopped

Approx. 0V

Wiper operating

Battery voltage

(-)

Ground

OK or NG
OK
>> Replace IPDM E/R. Refer to PG-37, «Removal and
Installation of IPDM E/R» .
NG
>> GO TO 3.

WW-32

SKIA2172E

FRONT WIPER AND WASHER SYSTEM

3. CHECK FRONT WIPER AUTO STOP CIRCUIT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect IPDM E/R connector and wiper motor connector.
Check continuity between IPDM E/R harness connector (A) and
front wiper motor harness connector [B (LHD models) or C
(RHD models)].

B

LHD models

C

A

B

Connector

Terminal

Connector

Terminal

E12

55

E39

4

Continuity

D

Yes

RHD models
A

4.

E

C

Connector

Terminal

Connector

Terminal

E12

55

E66

5

Continuity
Yes

F

Check continuity between IPDM E/R harness connector (A) and
Ground.
A
Connector

Terminal

E12

55

Ground

G

Continuity
No

OK or NG
OK
>> Replace front wiper drive assembly. Refer to WW-43,
«Removal and Installation of Front Wiper Drive Assembly» .
NG
>> Repair harness or connector.

Only Front Wiper Low Does Not Operate

H
MKIB2227E

I

BKS001HN

1. ACTIVE TEST
With CONSULT-ll
1. Select “IPDM E/R” on CONSULT-II, and select “ACTIVE TEST”
on “SELECT DIAG MODE” screen.
2. Select “FRONT WIPER” on “SELECT TEST ITEM” screen.
3. Touch “LO” screen.

WW

L

Without CONSULT-ll
Start up auto active test. Refer to PG-22, «Auto Active Test» .
Does front wiper operate normally?
YES >> Refer to LT-125, «Combination Switch Inspection» .
NO
>> GO TO 2.

M

SKIA3486E

WW-33

J

FRONT WIPER AND WASHER SYSTEM

2. CHECK FRONT WIPER MOTOR CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R connector and front wiper motor connector.
Check continuity between IPDM E/R harness connector (A) and
front wiper motor harness [B (LHD models) or C (RHD models)].
LHD models
A

B

Connector

Terminal

Connector

Terminal

E10

23

E39

2

Continuity
Yes

RHD models
A

4.

C

Connector

Terminal

Connector

Terminal

E10

23

E66

1

Continuity
Yes

Check continuity between IPDM E/R harness connector (A) and
ground.
A
Connector

Terminal

E10

23

Ground

Continuity
No

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

MKIB2228E

WW-34

FRONT WIPER AND WASHER SYSTEM

3. CHECK IPDM E/R
1.
2.
3.
4.
5.
6.

A

With CONSULT-ll
Connect IPDM E/R connector.
Turn ignition ON.
Select “IPDM E/R” on CONSULT-II, and select “ACTIVE TEST” on “SELECT DIAG MODE” screen.
Select “FRONT WIPER” on “SELECT TEST ITEM” screen.
Touch “LO” screen.
Check voltage between IPDM E/R harness connector terminal
and ground while front wiper LO is operating.

B

C

D

Terminal
(+)

Continuity

(-)

IPDM E/R
connector

Terminal

E10

23

Ground

E

Battery voltage

F

Without CONSULT-ll
MKIB0490E
1. Connect IPDM E/R connector.
2. Turn ignition ON.
3. Start up auto active test. Refer to PG-22, «Auto Active Test» .
4. Check voltage between IPDM E/R harness connector terminal and ground while front wiper LO is operating.

G

H

Terminal
(+)

Continuity

I

Battery voltage

J

(-)

IPDM E/R
connector

Terminal

E10

23

Ground

OK or NG
OK
>> Replace front wiper drive assembly. Refer to WW-43, «Removal and Installation of Front Wiper
WW
Drive Assembly» .
NG
>> Replace IPDM E/R. Refer to PG-37, «Removal and Installation of IPDM E/R» .

Only Front Wiper Hi Does Not Operate

BKS001HO

1. ACTIVE TEST
With CONSULT-ll
1. Select “IPDM E/R” on CONSULT-II, and select “ACTIVE TEST”
on “SELECT DIAG MODE” screen.
2. Select “FRONT WIPER” on “SELECT TEST ITEM” screen.
3. Touch “HI” screen.

M

Without CONSULT-ll
Start up auto active test. Refer to PG-22, «Auto Active Test» .
Does front wiper operate normally?
YES >> Refer to LT-125, «Combination Switch Inspection» .
NO
>> GO TO 2.

WW-35

L

SKIA3486E

FRONT WIPER AND WASHER SYSTEM

2. CHECK FRONT WIPER MOTOR CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R connector and front wiper motor connector.
Check continuity between IPDM E/R harness connector (A) and
front wiper motor harness connector [B (LHD models) or C
(RHD models)].
LHD models
A

B

Connector

Terminal

Connector

Terminal

E10

24

E39

1

Continuity
Yes

RHD models
A

4.

C

Connector

Terminal

Connector

Terminal

E10

24

E66

4

Continuity
Yes

Check continuity between IPDM E/R harness connector (A) and
ground.
A
Connector

Terminal

E10

24

Ground

Continuity
No

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

MKIB2229E

WW-36

FRONT WIPER AND WASHER SYSTEM

3. CHECK IPDM E/R
1.
2.
3.
4.
5.
6.

A

With CONSULT-ll
Connect IPDM E/R connector.
Turn ignition ON.
Select “IPDM E/R” on CONSULT-II, and select “ACTIVE TEST” on “SELECT DIAG MODE” screen.
Select “FRONT WIPER” on “SELECT TEST ITEM” screen.
Touch “HI” screen.
Check voltage between IPDM E/R harness connector terminal
and ground while front wiper HI is operating.

B

C

D

Terminal
(+)
(-)

IPDM E/R
connector

Terminal

E10

24

Ground

Continuity

E

Battery voltage

F

Without CONSULT-ll
SKIA2174E
1. Connect IPDM E/R connector.
2. Turn ignition ON.
3. Start up auto active test. Refer to PG-22, «Auto Active Test» .
4. Check voltage between IPDM E/R harness connector terminal and ground while front wiper HI is operating.

G

H

Terminal
(+)
(-)

IPDM E/R
connector

Terminal

E10

24

Ground

Continuity

I

Battery voltage

J

OK or NG
OK
>> Replace front wiper drive assembly. Refer to WW-43, «Removal and Installation of Front Wiper
WW
Drive Assembly» .
NG
>> Replace IPDM E/R. Refer to PG-37, «Removal and Installation of IPDM E/R» .

Only Front Wiper Intermittent Does Not Operate

BKS001HP

1. CHECK COMBINATION SWITCH
With CONSULT-ll
1. Select “BCM” on CONSULT-II, and select “WIPER” on “SELECT
TEST ITEM” screen.
2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure that “FR WIPER INT”, turn ON-OFF according to
wiper switch operation.
Without CONSULT-ll
Refer to LT-125, «Combination Switch Inspection» .
OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
NG
>> Check combination switch (wiper switch) Refer to LT125, «Combination Switch Inspection» .

WW-37

L

M

PKIB0110E

FRONT WIPER AND WASHER SYSTEM
Only Front Wiper Auto Dose Not Operate

BKS001KR

1. CHECK CONDITIONS OF WINDSHIELD (LIGHT AND RAIN SENSOR DETECTION AREA)
Check “light and rain sensor” detection area of windshield for dirt such as greases.
OK or NG
OK
>> GO TO 2.
NG
>> Clean “light and rain sensor” detection area of windshield fully.

2. CHECK LIGHT AND RAIN SENSOR SIGNAL
1.
2.

Turn ignition switch ON.
Check signal between BCM harness connector and ground with
oscilloscope.
(+)

Connector

Terminals
(Wire color)

(-)

Condition

M58

63

Ground

IGN ON

Signal
(Reference value.)

MKIB0664E

MKIB2017E

Approx. 8.9V

OK or NG
OK
>> Replace light and rain sensor. Refer to WW-47, «Removal and Installation of Light and Rain Sensor» . If front wiper does not operate, replace BCM. Refer to BCS-17, «Removal and Installation of
BCM» .
NG
>> GO TO 3.

3. CHECK LIGHT AND RAIN SENSOR POWER SUPPLY CIRCUIT
1.

Check continuity between BCM harness connector and “light
and rain sensor” harness connector.
BCM

2.

Light and rain sensor

Connector

Terminal

Connector

Terminal

M59

73

R2

1

Continuity
Yes

Check continuity between BCM harness connector and ground.
BCM

Continuity

Connector

Terminal

M59

73

Ground
MKIB1979E

No

OK or NG
OK
>> GO TO 4.
NG
>> Repair harness or connector.

WW-38

FRONT WIPER AND WASHER SYSTEM

4. CHECK LIGHT AND RAIN SENSOR POWER SUPPLY
1.
2.
3.
4.

A

Turn ignition switch OFF.
Disconnect “light and rain sensor” harness connector.
Turn ignition switch ON.
Check voltage between “light and rain sensor” harness connector and ground.

B

C
Terminal
(+)

Voltage

(-)

Light and rain sensor
connector

Terminal

R2

1

Ground

D

Battery voltage

OK or NG
OK
>> GO TO 5.
NG
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .

E
MKIB2262E

F

5. CHECK LIGHT AND RAIN SENSOR GROUND CIRCUIT
1.
2.

G

Turn ignition switch OFF.
Check continuity between “light and rain sensor” harness connector and ground.

Light and rain
sensor connector

Terminal

R2

3

H

Continuity
Ground

I

Yes

OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace harness.

J
MKIB2027E

6. CHECK LIGHT AND RAIN SENSOR SIGNAL CIRCUIT
1.
2.

Disconnect BCM connector.
Check continuity between BCM harness connector and “light
and rain sensor” harness connector.
BCM

3.

WW

L

Light and rain sensor

Connector

Terminal

Connector

Terminal

M58

63

R2

2

M

Continuity
Yes

Check continuity between BCM harness connector and ground.
BCM

Continuity

Connector

Terminal

M58

63

Ground
MKIB1978E

No

OK or NG
OK
>> Replace light and rain sensor. Refer to WW-47, «Removal and Installation of Light and Rain Sensor» .
NG
>> Repair or replace harness.

WW-39

FRONT WIPER AND WASHER SYSTEM
Front Wiper Interval Time Is Not Controlled by Vehicle Speed

BKS001HQ

1. CHECK WIPER SPEED SETTING
1.

Select “BCM” on CONSULT-II screen. Select “WIPER” on
“SELECT TEST ITEM” screen.
2. Select “WORK SUPPORT” on “SELECT DIAG MODE”. Select
“WIPER SPEED SETTING” on “SELECT WORK ITEM” screen.
Touch “START”.
3. Confirm “CURRENT SETTING” is “ON”.
OK or NG
OK
>> GO TO 2.
NG
>> Change “CURRENT SETTING” to “ON”.
SKIB6431E

2. CHECK FUNCTION OF COMBINATION METER
Confirm that speedometer operates normally.
Does front wiper operate normally?
YES >> GO TO 2.
NO
>> Combination meter vehicle speed system is malfunction. Refer to DI-16, «Check Vehicle Speed
Signal» .

3. CHECK CAN COMMUNICATION BETWEEN BCM AND COMBINATION METER
Select “BCM” on CONSULT-II, and perform self-diagnosis for
“BCM”.
Displayed self-diagnosis results
NO DTC>>Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
CAN COMM CIRCUIT>>Check CAN communication line of BCM.
Refer to BCS-17, «CAN Communication Inspection With
CONSULT-II (Self-Diagnosis)» .

PKIA7627E

Front Wiper Intermittent Operation Switch Position Cannot Be Adjusted

BKS001HR

1. CHECK CIRCUIT BETWEEN COMBINATION SWITCH AND BCM
With CONSULT-ll
Select “BCM” on CONSULT-II, and select “WIPER” on “SELECT
TEST ITEM” screen.
2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure that “INT VOLUME”, changes in order from 1 to 7
according to wiper switch operation.
1.

Without CONSULT-ll
Refer to LT-125, «Combination Switch Inspection» .
OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
NG
>> Check combination switch (wiper switch). Refer to LT125, «Combination Switch Inspection» .

WW-40

PKIB0110E

FRONT WIPER AND WASHER SYSTEM
Wiper Does Not Wipe When Front Washer Operates

BKS001HS

1. CHECK CIRCUIT BETWEEN COMBINATION SWITCH AND BCM

A

With CONSULT-ll
1. Select “BCM” on CONSULT-II, and select “WIPER” on “SELECT
TEST ITEM” screen.
2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure that “FR WASHER SW” turns ON-OFF according to
front wiper switch operation.
Without CONSULT-ll
Refer to LT-125, «Combination Switch Inspection» .
OK or NG
OK
>> Replace BCM Refer to BCS-17, «Removal and Installation of BCM» .
NG
>> Check front wiper switch. Refer to LT-125, «Combination
Switch Inspection» .

Front Wiper Does Not Stop

B

C

D

E
PKIB0110E

BKS001HT

F

1. CHECK CIRCUIT BETWEEN COMBINATION SWITCH AND BCM
With CONSULT-ll
1. Select “BCM” on CONSULT-II, and select “WIPER” on “SELECT
TEST ITEM” screen.
2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure that “FR WIPER INT”, “FR WIPER LOW”, “FR
WIPER HI”, and “FR WASHER SW” turns ON-OFF according to
front wiper switch operation.
Without CONSULT-ll
Refer to LT-125, «Combination Switch Inspection» .
OK or NG
OK
>> Replace IPDM E/R. Refer to PG-37, «Removal and
PKIB0110E
Installation of IPDM E/R» .
NG
>> Check combination switch (wiper switch). Refer to LT-125, «Combination Switch Inspection» .

G

H

I

J

WW

L

M

WW-41

FRONT WIPER AND WASHER SYSTEM
Removal and Installation of Front Wiper Arms, Adjustment of Wiper Arms Stop
Location

BKS0011L

REMOVAL
1.
2.
3.

Turn wiper switch ON to operate wiper motor, and then turn wiper switch OFF (auto stop).
Open hood, remove arm caps, and remove wiper arm nuts.
Raise wiper arm, and remove wiper arm from the vehicle.

INSTALLATION
1.
2.
3.

Clean up the pivot area as shown in the figure. This will reduce
possibility of wiper arm looseness.
Prior to wiper arm installation, turn on wiper switch to operate
wiper motor and then turn it “OFF” (auto stop).
Push wiper arm onto pivot shaft, paying attention to blind spline.

SEL024J

4.

5.
6.

Lift the blade up and then set it down onto glass surface to set
the blade center to clearance “L1” & “L2” immediately before
tightening nuts.
NOTE:
This illustration is for LHD models. The layout for RHD models is
symmetrically opposite.
Spray washer fluid. Turn on wiper switch to operate wiper motor
and then turn it “OFF”.
Make sure that wiper blades stop within clearance “L1” & “L2”.

Clearance “L1”

RHD
LHD

Clearance “L2”
●

48.0 ± 7.5 mm (1.890 ± 0.295 in)

RHD

46.0 ± 7.5 mm (1.811 ± 0.295 in)

LHD

43.0 ± 7.5 mm (1.693 ± 0.295 in)

Tighten wiper arm nuts to specified torque.
Front wiper arm nuts

7.

: 23.5 N·m (2.4 kg-m, 17 ft-lb)

Attach wiper arm caps.

ADJUSTMENT
Refer to WW-42, «INSTALLATION» .

WW-42

PKIA9951E

FRONT WIPER AND WASHER SYSTEM
Removal and Installation of Front Wiper Drive Assembly

BKS0011N

A

LHD models

B

C

D

E

F

MKIB2230E

1. Wiper arm and blade assembly (RH)

2. Wiper drive assembly mounting bolts

3. Wiper drive assembly

4. Wiper arm and blade assembly (LH)

5. Wiper arm mounting nuts

6. Wiper arm caps

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Should be lubricated with grease.

G

H

I

RHD models

J

WW

L

M

MKIB2231E

1. Wiper arm caps

2. Wiper arm mounting nuts

3. Wiper arm and blade assembly (RH)

4. Wiper drive assembly mounting bolts

5. Wiper drive assembly

6. Wiper arm and blade assembly (LH)

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

REMOVAL
1.
2.
3.

Operate front wiper motor, and stop at the auto stop position.
Remove wiper arms. Refer to WW-42, «REMOVAL» .
Remove cowl top cover. Refer to EI-12, «COWL TOP» .

WW-43

: Should be lubricated with grease.

FRONT WIPER AND WASHER SYSTEM
4.
5.

Disconnect wiper motor connector and remove connector clips.
Remove front wiper drive assembly mounting bolts (A), and
remove front wiper drive assembly (1) from the vehicle.

MKIB2237E

INSTALLATION
1.

Install front wiper drive assembly to the vehicle.
Front wiper drive assembly mounting bolts

2.
3.
4.
5.
6.

: 4.5 N- m (0.46kg-m, 40 in-lb)

Connect wiper motor connector. Turn wiper switch ON to operate wiper motor, then turn wiper switch OFF
(auto stop).
Install connector clips to the wiper frame, and install cowl top cover. Refer to EI-12, «COWL TOP» .
Attach wiper arms. Refer to WW-42, «INSTALLATION» .
Adjustment of wiper arm stop location.
Install arm caps.

Washer Nozzle Adjustment
●
●

BKS0011O

In this model, the washer nozzle has a non-adjustment nozzle and requires no adjusting.
If necessary, ensure that washer fluid spray covers at least the
area as shown in the figure.
h1:
h2:
h3:
h4:

320 mm (12.60 in)
115 mm (4.53 in)
160 mm (6.30 in)
315 mm (12.40 in)

NOTE:
This illustration is for LHD models. The layout for RHD models is
symmetrically opposite.
MKIB2217E
●
If the above is not satisfied, confirm that the washer nozzle is
installed correctly on the cowl top cover and/or cowl top cover is installed correctly on the body.
●
If they are installed correctly, and the fluid is still spraying out of the shooting target areas, replace them
with new washer nozzle and/or cowl top cover.
CAUTION:
Never adjust the washer nozzle (1) with needle pin. If attempts
are made to adjust the washer nozzle with needle pin, the nozzle may be damaged.

MKIB2216E

WW-44

FRONT WIPER AND WASHER SYSTEM
Washer Tube Routing

BKS0011P

A

B

C

D

E

F

G

H

I

J
MKIB2300E

1. Front washer tube

2. Clip

3. Front and rear washer tank

4. Front washer nozzle (LH)

5. Front washer nozzle (RH)

6. Check valve

7. Joint washer tube

8. Rear washer nozzle

9. Rear washer tube

Removal and Installation of Front Washer Nozzle

WW

BKS001C5

REMOVAL
1.
2.
3.

Remove cowl top cover. Refer to EI-12, «COWL TOP» .
Remove washer tube.
While pressing pawl (A) on the reverse side of front washer nozzle (1), remove front washer nozzle from cowl top cover.

M

MKIB2224E

INSTALLATION
Note the following, and installation is the reverse order of removal.
CAUTION:
Install left and right nozzle correctly. Incorrect side nozzle can be installed, but spray points wrong.

WW-45

L

FRONT WIPER AND WASHER SYSTEM
Inspection for Washer Nozzle

BKS001C6

CHECK VALVE INSPECTION
A check valve is provided in the washer fluid line. Be careful not to
connect check valve to washer tube in the wrong direction.

MKIB2218E

Inspection of Front Wiper and Washer Switch Circuit

BKS001C7

Refer to LT-125, «Combination Switch Inspection» .

Removal and Installation of Front Wiper and Washer Switch

BKS001C8

REMOVAL
1.
2.
3.

Remove steering column cover. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Disconnect the wiper and washer switch connector.
Pull wiper and washer switch (1) toward the passenger door
while pressing pawls (A) in direction shown by the arrow ( ) in
the figure, and remove it from the base.

SKIB5666E

INSTALLATION
Installation is the reverse order of removal.

Removal and Installation of Washer Tank

BKS001C9

REMOVAL
1.

Remove clip (A) and pull washer tank inlet (1) out of washer
tank.

–

: Vehicle front
Remove front bumper. Refer to EI-4, «FRONT BUMPER» .
Disconnect washer motor connector.

2.
3.

SKIB3755J

WW-46

FRONT WIPER AND WASHER SYSTEM
4.

Remove screws (A) and nut (B).

–

: Vehicle front
Remove washer tube (2), and remove washer tank (1) from
vehicle.

5.

A

B

C
MKIB2239E

D

INSTALLATION
Note the following, and installation is the reverse order of removal.
CAUTION:
After installation, add water up to the upper level of washer tank inlet, and check for water leaks.
Washer tank mounting nut

: 4.5 N·m (0.46 kg-m, 40 in-lb)

Washer tank mounting screws

: 4.5 N·m (0.46 kg-m, 40 in-lb)

Removal and Installation of Front Washer Motor

E

F
BKS001CA

G

REMOVAL
1.
2.

Remove fender protector (front) RH. Refer to EI-14, «FENDER PROTECTOR» .
Disconnect washer motor (1) connector and remove washer
tube.

3.

Pull out front washer motor in direction shown by the arrow (
in the figure. Remove front washer motor from washer tank.

H

)
I

J

MKIB2261E

INSTALLATION
Note the following, and installation is the reverse order of removal.
CAUTION:
When installing washer motor, there should be no packing twists, etc.

Removal and Installation of Light and Rain Sensor

L
BKS001KS

M

REMOVAL
1. Remove inside mirror. Refer to GW-104, «INSIDE MIRROR» .
2. Remove clip and pawl.
3. Pull out the light and rain sensor.
4. Remove light and rain sensor harness connector.
CAUTION:
Do not touch the electronic circuit board on rain sensor.

MKIB2028E

INSTALLATION OF RAIN SENSOR
Install in the reverse order of removal.

WW-47

WW

FRONT WIPER AND WASHER SYSTEM
INSTALLATION OF LIGHT AND RAIN SENSOR HOUSING
CAUTION:
When windshield is replaced, always replace rain sensor housing.
1. Clean the surface of bonded area on the windshield.
2. Fix rain sensor housing against light and rain sensor bracket
from the top, then press it in a downward motion until it is completely attach together.
CAUTION:
Do not touch the adhesive.

MKIB2029E

WW-48

REAR WIPER AND WASHER SYSTEM
REAR WIPER AND WASHER SYSTEM
Components Parts and Harness Connector Location

PFP:28710

A
BKS0012O

B

C

D

E

F

G
MKIB2264E

: Vehicle front
1. BCM M57, M58, M59
(View with instrument panel removed)

2. Data link connector

4. Rear wiper motor B45

5. Front and rear washer motor E24
(View with front bumper removed)

System Description
●

●

3. Combination switch (Wiper switch)
M38

H

I
BKS0012P

Wiper switch (combination switch) is composed of a combination of 5 output terminals and 5 input terminals. Terminal combination status is read by BCM when switch is turned ON.
BCM controls rear wiper and INT (intermittent) operation.

OUTLINE

J

WW

Power is supplied at all times
●
through 40A fusible link (letter J, located in fuse and fusible link box)
●
to BCM terminals 74 and 79.
When ignition switch turned ON or START position, power is supplied
●
through 10A fuse [No. 5 located in the fuse block (J/B)]
●
to BCM terminal 24.
●
through 10A fuse [No. 3 located in the fuse block (J/B)]
●
to combination switch terminal 14.
Ground is supplied
●
to BCM terminals 2 and 70,
●
to combination switch terminal 12.
●
through body grounds M21 and M66,
●
to rear wiper motor terminal 3.
●
through body ground B13, B28, B38 and B48

REAR WIPER OPERATION
When wiper switch is in the rear wiper ON position, BCM detect rear wiper ON signal by BCM wiper switch
reading function.
BCM operate rear wiper motor, power is supplied
●
through BCM terminal 71
●
to rear wiper motor terminal 1.

WW-49

L

M

REAR WIPER AND WASHER SYSTEM
Ground is supplied
●
to rear wiper motor terminal 3
●
through body grounds B13, B28, B38 and B48.
With power and ground supplied, the rear wiper motor operates.

INTERMITTENT OPERATION
The rear wiper motor operates the wiper arms at low speed approximately every 7 seconds.
When wiper switch is in the rear wiper INT position, BCM detect rear wiper INT signal by BCM wiper switch
reading function (Refer to WW-8, «COMBINATION SWITCH READING FUNCTION» ).
BCM operate rear wiper motor, power supplied
●
through BCM terminal 71.
●
to rear wiper motor terminal 1
Ground is supplied.
●
to rear wiper motor terminal 3
●
through body ground B13, B28, B38 and B48.
The wiper motor operates at intermittent.

AUTO STOP OPERATION
With rear wiper switch turned OFF, rear wiper motor will continue to operate until wiper arm reaches rear wiper
stopper.

WASHER OPERATION
When rear wiper switch is pushed to WASH position,
Power is supplied.
●
through combination switch terminal 11
●
to washer motor terminal 2.
Ground is supplied
●
to washer motor terminal 1
●
to combination switch terminals 12 and 13, and
●
through body grounds M21 and M66.
With power and ground supplied, the rear washer motor is operated, and at the same time,
When the wiper switch is pushed to the WASH position for 1 second or more, BCM reads combination switch
condition (Refer to WW-8, «COMBINATION SWITCH READING FUNCTION» ), rear wiper motor is operated
by BCM, and the rear wiper motor operates approximately 3 times after wiper switch is released.

REAR WIPER REVERSE RANGE OPERATION (IF AUTO WIPER IS EQUIPPED)
●

●

●

When front wiper is active in auto operation with shift in reverse position, front and rear wiping action is
synchronous. If front wiper becomes continuous, the rear wiper will intermittent, wiping every 7 seconds.
When shift is in reverse position then front wiper switch toggle from OFF to AUTO, rear wiping action will
occur once.
When front wiper switch is in auto position with shift is in reverse position, if front washer pull more than
0.4second, front wiper and rear wiper once.

COMBINATION SWITCH READING FUNCTION
Refer to WW-8, «COMBINATION SWITCH READING FUNCTION» .

CAN Communication

BKS0012Q

SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

CAN Communication Unit

BKS0012R

Refer to LAN-27, «CAN Communication Unit» .

WW-50

REAR WIPER AND WASHER SYSTEM
Wiring Diagram — WIP/R —

BKS0012S

A

WITHOUT RAIN SENSOR

B

C

D

E

F

G

H

I

J

WW

L

M

MKWA4283E

WW-51

REAR WIPER AND WASHER SYSTEM

MKWA4284E

WW-52

REAR WIPER AND WASHER SYSTEM
Schematic

BKS0012T

A

WITH RAIN SENSOR

B

C

D

E

F

G

H

I

J

WW

L

M

MKWA4285E

WW-53

REAR WIPER AND WASHER SYSTEM
Wiring Diagram — WIP/R —

BKS0012U

WITH RAIN SENSOR

MKWA4286E

WW-54

REAR WIPER AND WASHER SYSTEM
A

B

C

D

E

F

G

H

I

J

WW

L

M

MKWA4287E

WW-55

REAR WIPER AND WASHER SYSTEM

MKWA4288E

WW-56

REAR WIPER AND WASHER SYSTEM
Terminals and Reference Values for BCM

BKS0012V

A
Terminal
No.

Wire
color

2

B

Signal name
Ground

Measuring condition

Signal
input/
output

Ignition
switch

Operation or condition

Reference value [V]
(Approx.)

—

ON

—

0

B

C
OFF
(Wiper intermittent dial position 4)

D
PKIB8643J

Approx. 1.2V

E

Any of several conditions below
7

BR

Combination
switch output 5

Output

ON

●

Front fog lamp switch (Operates
only front fog lamp switch)
(Wiper intermittent dial position 4)

●

Rear fog lamp switch
(Wiper intermittent dial position 4)

●

Rear wiper ON
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 2

●

Wiper intermittent dial position 6

●

Wiper intermittent dial position 7

F

G

PKIB4956J

H

Approx. 1.0V

I

J
OFF
(Wiper intermittent dial position 4)

WW
PKIB4958J

Approx. 1.2V
8

L

Combination
switch output 3

Output

ON

Any of several conditions below
●

Lighting switch 2ND
(Wiper intermittent dial position 4)

●

Lighting switch HI beam
(Operates only HI beam switch)
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 2

●

9

V

Combination
switch output 1

Output

ON

Wiper intermittent dial position 3

L

M

PKIB4959J

Approx. 1.0V

OFF
(Wiper intermittent dial position 4)

PKIB4958J

Approx. 1.2V

WW-57

REAR WIPER AND WASHER SYSTEM
Terminal
No.

Wire
color

Signal name

Signal
input/
output

Measuring condition
Ignition
switch

Operation or condition

Reference value [V]
(Approx.)

Any of several conditions below
●

Turn signal switch to right

●

Turn signal switch to left

●

Front wiper switch MIST

●

Front wiper switch LO

●

Front washer switch

PKIB4959J

Approx. 1.0V

13

14

15

GB

P

W

Combination
switch input 1

Combination
switch input 3

Combination
switch input 5

Input

Input

Input

19

L

CAN-H

Input/
output

23

P

Rear wiper position detection signal

Input

Ignition power
supply

Input

24

O

ON

●

OFF

●

Front wiper switch HI
(Wiper intermittent dial position 4)

●

Rear wiper switch INT
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 2

●

Wiper intermittent dial position 3

●

Wiper intermittent dial position 6

●

Wiper intermittent dial position 7

●

OFF

●

Lighting switch AUTO

●

Rear fog lamp switch

●

Front wiper switch MIST

●

Front wiper switch INT

●

Front wiper switch LO

●

OFF

●

Lighting switch 1ST

●

Lighting switch 2ND

●

Lighting switch HIGH beam
(Operates only HIGH beam
switch)

●

Turn signal switch to right

ON

ON

—

WW-60, «Reference Values for BCM
(Input)»

WW-60, «Reference Values for BCM
(Input)»

WW-60, «Reference Values for BCM
(Input)»

—

Rear wiper operating

0

Rear wiper not operating

Battery voltage

—

Battery voltage

ON

ON

WW-58

REAR WIPER AND WASHER SYSTEM
Terminal
No.

Wire
color

Signal name

Signal
input/
output

Measuring condition
Ignition
switch

Operation or condition

Reference value [V]
(Approx.)

A

B
OFF
(Wiper intermittent dial position 4)

C

PKIB4958J

Approx. 1.2V
27

GR

Combination
switch output 4

Output

ON

D

Any of several conditions below
●

●

Lighting switch AUTO
(Wiper intermittent dial position 4)

E

Lighting switch 1ST
(The same result with
lighting switch 2ND)
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 5

●

Wiper intermittent dial position 6

F
PKIB4959J

G

Approx. 1.0V

H
OFF
(Wiper intermittent dial position 4)

I
PKIB4958J

28

G

Combination
switch output 2

Approx. 1.2V
Output

J

ON
Any of several conditions below
●

Lighting switch 2ND

●

Lighting switch PASSING
(Operates only PASSING switch)

●

Front wiper switch INT

●

Front wiper switch HI

WW

L
PKIB4959J

Approx. 1.0V

33

34

R

Y

Combination
switch input 2

Combination
switch input 4

Input

Input

ON

ON

●

OFF

●

Front washer switch
(Wiper intermittent dial position 4)

●

Rear wiper switch ON
(Wiper intermittent dial position 4)

●

Rear washer switch ON
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 5

●

Wiper intermittent dial position 6

●

OFF

●

Front fog lamp switch ON

●

Lighting switch 2ND

●

Lighting switch PASSING
(Operates only PASSING switch)

●

Turn signal switch to left

WW-59

M

WW-60, «Reference Values for BCM
(Input)»

WW-60, «Reference Values for BCM
(Input)»

REAR WIPER AND WASHER SYSTEM
Measuring condition

Terminal
No.

Wire
color

Signal
input/
output

39

Y

CAN-L

Input/
output

70

B

Ground

—

ON

71

BR

Output

ON

Signal name

Rear wiper operation signal

Ignition
switch

Operation or condition
—

Reference value [V]
(Approx.)
—

—

0

Rear wiper operating

Battery voltage

Rear wiper not operating

0

74

Y

Power source
(Fusible link)

Input

OFF

—

Battery voltage

79

Y

Power source
(Fusible link)

Input

OFF

—

Battery voltage

Reference Values for BCM (Input)

BKS001KP

CAUTION:
●
Check combination switch system terminal waveform under the loaded condition with lighting
switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded.
●
Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position.
Wiper dial position can be confirmed on CONSULT-II. Refer to WW-24, «DATA MONITOR» .
INPUT

Condition and reference value
OFF

Lighting switch 1ST

PKIB4956J

INPUT 5
(Wiper intermittent
dial position 4)

Lighting switch 2ND

PKIB8624J

Approx. 0.9V

Approx. 1.5 — 2.0V

Lighting switch HI beam
(Operates only HI beam switch)

Turn signal switch to right

PKIB8639J

Approx. 2.5 — 3.0V

—

PKIB8625J
PKIB8644J

Approx. 1.5 — 2.0V

Approx. 1.5 — 2.0V

WW-60

REAR WIPER AND WASHER SYSTEM
INPUT

Condition and reference value
OFF

Lighting switch 2ND

Turn signal switch to left

A

B

PKIB4958J

INPUT 4
(Wiper intermittent
dial position 4)

PKIB8628J

Approx. 1.0V

Approx. 1.5 — 2.0V

Front fog lamp switch
(Operates only front fog lamp
switch)

Lighting switch PASSING
(Operates only PASSING switch)

PKIB8630J

C

Approx. 2.0V

D

E

—

F
PKIB8629J
PKIB8627J

Approx. 1.5 — 2.0V
OFF

Approx. 2.0V
Lighting switch AUTO

Front wiper switch INT

G

H

PKIB4958J

Approx. 1.0V
INPUT 3
(Wiper intermittent
dial position 4)

PKIB8631J

Approx. 2.0V

PKIB8632J

I

Approx. 2.0V

Any of several conditions below
● Front
● Front

wiper switch LO

J

Rear fog lamp switch

wiper switch MIST

—

PKIC1030E
PKIB8629J

WW

L

Approx. 1.5V

Approx. 2.0V

M

WW-61

REAR WIPER AND WASHER SYSTEM
INPUT

Condition and reference value
OFF
(Wiper intermittent dial position 4)

Front washer switch
(Wiper intermittent dial position 4)

PKIB4958J

Rear washer switch
(Wiper intermittent dial position 4)

PKIB8632J

PKIB8631J

Approx. 2.0V

Approx. 2.0V

Approx. 1.0V

Any of the conditions below
INPUT 2
Rear wiper switch ON
(Wiper intermittent dial position 4)

● Wiper

intermittent dial position 1

● Wiper

intermittent dial position 5

● Wiper

intermittent dial position 6
—

PKIB8634J

Approx. 1.5 — 2.0V

PKIB8633J

Approx. 2.0V
Any of the conditions below
OFF
(Wiper intermittent dial position 4)

Front wiper switch HI
(Wiper intermittent dial position 4)

● Rear wiper switch INT
(Wiper intermittent dial position 4)
● Wiper

PKIB4958J

intermittent dial position 3

PKIB8635J

Approx. 1.0V

Approx. 2.0V

PKIB8636J

Approx. 2.0V

INPUT 1
Any of the conditions below

Any of the conditions below
● Wiper

intermittent dial position 1

● Wiper

intermittent dial position 6

● Wiper

intermittent dial position 2

● Wiper

intermittent dial position 7

—

PKIB8637J

PKIB8638J

Approx. 2.5 — 3.0V

Approx. 2.0V

Terminals and Reference Values for IPDM E/R
Ignition
switch

Operation or condition

Reference value [V]
(Approx.)

—

ON

—

0

Reverse switch signal

Input

ON

CAN H

Input/
output

Wire
color

3

B

Ground

18
30

L
R
L

Measuring condition

Signal
Input/
Output

Terminal No.

52

BKS0012W

Signal designation

Shift knob

—

WW-62

Reverse

Battery voltage

Other than above

0

—

—

REAR WIPER AND WASHER SYSTEM
Terminal No.

Wire
color

54

B

58

Y

Measuring condition

Signal
Input/
Output

Ignition
switch

Operation or condition

Reference value [V]
(Approx.)

Ground

—

—

—

0

CAN L

Input/
output

—

—

—

Signal designation

CONSULT-II Function (BCM)

A

B

BKS0012Z

C

Refer to WW-24, «CONSULT-II Function (BCM)» .
D

E

F

G

H

I

J

WW

L

M

WW-63

REAR WIPER AND WASHER SYSTEM
Diagnosis Chart by Symptom
Symptom

Possible causes

BKS001HE

Possible malfunctioning system and part

Inspection procedure

Reference
page

BCM OUTPUT 5 — INPUT 2 and
BCM OUTPUT 4 — INPUT 1 system
●

Combination switch
reading function
malfunction

Rear wiper does
not operate

Combination switch
(Rear wiper ON and INT systems malfunction)

●

Harness and connector between combination switch and BCM

●

BCM

BCM — Rear wiper motor system

Rear wiper motor
output malfunction

●

40A fusible link

●

10A fuse

●

Rear wiper motor

●

Harness and connector between BCM and
rear wiper motor

●

Harness and connector between rear wiper
motor and ground

●

BCM

CONSULT-II
●

DATA MONITOR (BCM)

CONSULT-II
●

ACTIVE TEST (BCM)

WW-65,
«Rear Wiper
Does Not
Operate»

Other than CONSULT-II
●

Rear wiper motor output
inspection

BCM — Rear wiper motor system
Rear wiper motor

CONSULT-II

●

Harness and connector between BCM and
rear wiper motor

●

●

Harness and connector between rear wiper
motor and ground

●

BCM

●

Rear wiper does
not return to stop
position

Auto-stop signal
malfunction

DATA MONITOR (BCM)

Other than CONSULT-II
●

Auto-stop signal system
inspection

WW-67,
«Rear Wiper
Does Not
Return to
Stop Position»

BCM OUTPUT 5 — INPUT 2 system
●

Only rear wiper
ON does not
operate

Combination switch
reading function
malfunction

Combination switch
(Rear wiper ON system malfunction)

●

Harness and connector between combination switch and BCM

●

BCM

CONSULT-II
●

DATA MONITOR (BCM)

BCM OUTPUT 4 — INPUT 1 system
Only rear wiper
INT does not
operate

Combination switch
reading function
malfunction

●

Combination switch
(Rear wiper INT system malfunction)

●

Harness and connector between combination switch and BCM

●

BCM

CONSULT-II
●

DATA MONITOR (BCM)

BCM OUTPUT 3 — INPUT 2 system
Wiper does not
wipe when rear
washer operates

Combination switch
reading function
malfunction

●

Combination switch
(Rear washer system malfunction)

●

Harness and connector between combination switch and BCM

●

BCM

WW-64

CONSULT-II
●

DATA MONITOR (BCM)

WW-68,
«Only Rear
Wiper ON
Does Not
Operate»

WW-69,
«Only Rear
Wiper Intermittent Does
Not Operate»
WW-69,
«Wiper Does
Not Wipe
When Rear
Washer
Operates»

REAR WIPER AND WASHER SYSTEM
Rear Wiper Does Not Operate

BKS001HG

1. CHECK FUSES

A

Check fuse and fusible link for blown-out.

●

UNIT

POWER SOURCE

FUSE No.

IPDM E/R

Battery

61, 62

Battery

J

Ignition switch ON or START position

5

Ignition switch (ON)

3

BCM
Combination switch

B

C

D

Refer to WW-51, «Wiring Diagram — WIP/R —» (without light and rain sensor), WW-54, «Wiring Diagram —
WIP/R —» (with light and rain sensor).
OK or NG
OK
>> GO TO 2.
NG
>> If fuse is blown, be sure to eliminate cause of malfunction before installing new fuse or fusible link.
Refer to PG-4, «POWER SUPPLY ROUTING CIRCUIT» .

E

F

2. CHECK BCM POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector.
Check voltage between BCM harness connector and ground.

G

H
Terminals

Ignition switch position

(+)
Connector

(–)
74

M59
79
M57

OFF

ACC

ON

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

0V

0V

Battery
voltage

I

Terminal

Ground

24

J
MKIB0352E

WW

OK or NG
OK
>> GO TO 3.
NG
>> Check harness for open or short between fuse, fusible link and BCM.

L

3. CHECK BCM GROUND CIRCUIT
M

Check continuity between BCM harness connector and ground.
Connector

Terminal

M57

2

M59

70

Continuity
Ground
Yes

OK or NG
OK
>> GO TO 4.
NG
>> Check harness ground circuit.
MKIB0353E

WW-65

REAR WIPER AND WASHER SYSTEM

4. CHECK CIRCUIT BETWEEN COMBINATION SWITCH AND BCM
With CONSULT-ll
Select “BCM” on CONSULT-II. Select “WIPER” on “SELECT
TEST ITEM” screen.
2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
3. Make sure that “RR WIPER ON”, turn ON-OFF according to
combination switch (wiper switch) operation.
1.

Without CONSULT-ll
Refer to LT-125, «Combination Switch Inspection» .
OK or NG
OK
>> GO TO 5.
NG
>> Check combination switch (wiper switch). Refer to LT125, «Combination Switch Inspection» .

SKIA5322E

5. ACTIVE TEST
With CONSULT-ll
Select “BCM” on CONSULT-II. Select “WIPER” on “SELECT
SYSTEM” screen.
2. Select “ACTIVE TEST” on “SELECT DIAG MODE” screen.
3. Select “REAR WIPER” on “SELECT TEST ITEM” screen.
4. Touch “ON” screen.
1.

Without CONSULT-ll
GO TO 6.
Does rear wiper operate normally?
YES >> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
NO
>> GO TO 6.

SKIA3503E

6. CHECK REAR WIPER MOTOR GROUND CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect rear wiper motor harness connector.
Check continuity between rear wiper motor harness connector
and ground.

Rear wiper motor
connector

Terminal

B45

4

Ground

Continuity
Yes

OK or NG
OK
>> GO TO 7.
NG
>> Repair harness or connector.
MKIB2232E

WW-66

REAR WIPER AND WASHER SYSTEM

7. CHECK CIRCUIT BETWEEN BCM AND REAR WIPER MOTOR
1.
2.

A

3.

A

Disconnect BCM harness connector.
Check continuity between BCM harness connector (A) and rear
wiper motor harness connector (B).
B

B

Continuity

Connector

Terminal

Connector

Terminal

M59

71

B45

2

C
Yes

Check continuity between BCM harness connector (A) and
ground.
A

Continuity

Connector

Terminal

M59

71

Ground

D
MKIB2233E

E
No

OK or NG
OK
>> GO TO 8.
NG
>> Repair harness or connector.

F

8. CHECK REAR WIPER MOTOR POWER SUPPLY

G

1.
2.
3.

Connect BCM harness connector.
Turn ignition switch ON.
Check voltage between rear wiper motor harness connector and
ground.

H

I

Terminal
(+)
Rear wiper
motor
connector

Terminal

B45

2

(-)

Ground

Condition

Voltage

J
Wiper stopped

Approx. 0V

Wiper operating

Battery voltage

WW
MKIB2234E

OK or NG
OK
>> Replace rear wiper motor. Refer to WW-70, «Removal and Installation of Rear Wiper Motor» .
NG
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .

Rear Wiper Does Not Return to Stop Position

L

BKS001HH

1. CHECK REAR WIPER MOTOR CIRCUIT

M

With CONSULT-ll
Select “BCM” on CONSULT-II. Select “WIPER” on “SELECT
TEST ITEM” screen.
2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen.
3. Make sure that “RR WIPER STOP”, turn ON-OFF linked with
rear wiper operation.
1.

Without CONSULT-ll
GO TO 2.
OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
NG
>> GO TO 2.

WW-67

SKIB6434E

REAR WIPER AND WASHER SYSTEM

2. CHECK REAR WIPER MOTOR AUTO STOP SIGNAL
Check voltage between BCM harness connector terminal and
ground while rear wiper motor is stopped and while it is operating.
Terminal
(+)
BCM
connector

Terminal

M57

23

Condition

Voltage

Wiper stopped

Battery voltage

Wiper operating

Approx. 0V

(-)

Ground

OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
NG
>> GO TO 3.

MKIB2235E

3. CHECK REAR WIPER AUTO STOP CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector and rear wiper motor connector.
Check continuity between BCM harness connector (A) and rear
wiper motor harness connector (B).
A

4.

B

Continuity

Connector

Terminal

Connector

Terminal

M57

23

B45

3

Yes

Check continuity between BCM harness connector (A) and
ground.
A

MKIB2236E

Continuity

Connector

Terminal

M57

23

Ground
No

OK or NG
OK
>> Replace rear wiper motor. Refer to WW-70, «Removal and Installation of Rear Wiper Motor» .
NG
>> Repair harness or connector.

Only Rear Wiper ON Does Not Operate

BKS001HI

1. CHECK COMBINATION SWITCH INPUT SIGNAL
1.
2.
3.

Select “BCM” on CONSULT-II.
Select “WIPER” on “SELECT TEST ITEM” screen. Then select
“DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure “RR WIPER ON” turns ON-OFF according to operation of combination switch (wiper switch).
When rear wiper switch is in
ON position

: RR WIPER ON

OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and InstallaSKIB6435E
tion of BCM» .
NG
>> Check combination switch (wiper switch). Refer to WW-8, «COMBINATION SWITCH READING
FUNCTION» .

WW-68

REAR WIPER AND WASHER SYSTEM
Only Rear Wiper Intermittent Does Not Operate

BKS001HJ

1. CHECK COMBINATION SWITCH INPUT SIGNAL
1.
2.
3.

A

Select “BCM” on CONSULT-II.
Select “WIPER” on “SELECT TEST ITEM” screen. Then select
“DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure “RR WIPER INT” turns ON-OFF according to operation of combination switch (wiper switch).
When rear wiper switch is in
INT position

B

C

: RR WIPER INT ON
D

OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and InstallaSKIB6436E
tion of BCM» .
NG
>> Check combination switch (wiper switch). Refer to WW-8, «COMBINATION SWITCH READING
FUNCTION» .

Wiper Does Not Wipe When Rear Washer Operates

BKS001HK

1. CHECK COMBINATION SWITCH INPUT SIGNAL
1.
2.
3.

Select “BCM” on CONSULT-II.
Select “WIPER” on “SELECT TEST ITEM” screen. Then select
“DATA MONITOR” on “SELECT DIAG MODE” screen.
Make sure “RR WASHER SW” turns ON-OFF according to operation of rear washer switch.
When rear wiper switch is in
WASHER position

H

: RR WASHER SW ON
I

Removal and Installation of Rear Wiper Arm, Adjustment of Wiper Arm Stop
Location

BKS00134

Turn rear wiper switch ON to operate wiper motor, and then turn rear wiper switch OFF (auto stop).
Remove rear wiper arm cap, and remove rear wiper arm nut.
Raise rear wiper arm, and remove rear wiper arm from the vehicle.

INSTALLATION

2.

Clean up the pivot area as shown in the figure. This will reduce
possibility of rear wiper arm nut looseness.
Prior to rear wiper arm installation, turn rear wiper switch ON to
operate wiper motor, and then turn rear wiper switch OFF (auto
stop).

SKIA0082J

WW-69

J

WW

REMOVAL

1.

F

G

OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and InstallaSKIB6437E
tion of BCM» .
NG
>> Check combination switch (wiper switch). Refer to WW-8, «COMBINATION SWITCH READING
FUNCTION» .

1.
2.
3.

E

L

M

REAR WIPER AND WASHER SYSTEM
3.
4.

Lift the blade up and then set it down onto glass surface to set
the blade center to lowest heat wire immediately.
Tighten rear wiper arm nut to specified torque.
Rear wiper arm nut

5.
6.
7.

:7.0 N·m (0.71 kg-m, 62 in-lb)

Spray washer fluid. Turn rear wiper switch ON to operate wiper
motor, and then turn rear wiper switch OFF (auto stop).
Make sure that wiper blade stop within lowest heat wire.
Install rear wiper arm cap.
MKIB2219E

Removal and Installation of Rear Wiper Motor

BKS00136

MKIB2220E

1. Rear wiper arm cap

2. Rear wiper arm

3. Rear wiper blade

4. Rear wiper motor mounting bolt

5. Rear wiper motor

6. Pivot seal

7. Rear wiper arm nut

REMOVAL
1.
2.
3.
4.
5.

Remove rear wiper arm. Refer to WW-69, «Removal and Installation of Rear Wiper Arm, Adjustment of
Wiper Arm Stop Location» .
Remove pivot seal.
Remove back door finisher. Refer to EI-22, «Removal and Installation» .
Disconnect rear wiper motor connector.
Remove rear wiper motor mounting bolts (A), and remove rear
wiper motor (1) from the vehicle.

SKIB3770J

INSTALLATION
CAUTION:
Never drop the rear wiper motor or cause it to interfere with other parts.
1. Install pivot seal.

WW-70

REAR WIPER AND WASHER SYSTEM
2.

Install rear wiper motor to the vehicle.
Rear wiper motor mounting bolts

3.
4.
5.

A

: 5.0 N·m (0.50 kg-m, 43 in-lb)

Connect rear wiper motor connector. Turn rear wiper switch ON to operate wiper motor, and then turn rear
wiper switch OFF (auto stop).
Install back door finisher. Refer to EI-22, «Removal and Installation» .
Install rear wiper arm and arm cap.

B

C

Rear Washer Nozzle Adjustment

BKS00137

Adjust spray position as shown in the figure.
Unit: mm (in)
Spray position

h (hight)

I (width)

φ
(spray point area)

A

140 (5.51)

38 (1.50)

60 (2.36)

D

E

F

MKIB2221E

Insert a needle or suitable tool into the nozzle hole and move it to
adjust the spray position.

G

H

I

J
MKIB0509E

Rear Washer Tube Layout

BKS00139

WW

Refer to WW-45, «Washer Tube Routing» .

Removal and Installation of Rear Washer Nozzle

BKS0013A

L

REMOVAL
1.
2.

3.

4.

Remove high-mounted stop lamp. Refer to LT-130, «Removal and Installation of High-Mounted Stop
Lamp» .
Disconnect washer tube (2) at the joint.
NOTE:
Washer tube can be accessed through the opening where the
high-mounted stop lamp was located.
While pressing pawl (B) on the reverse side of rear washer nozzle (1), remove rear washer nozzle from back door.
NOTE:
Rear washer nozzle can be accessed through the opening of the
back door inner panel (A).
Remove washer hose from washer nozzle.
SKIB3773J

INSTALLATION
Installation is the reverse order of removal. Adjust nozzle spray location. Refer to WW-71, «Rear Washer Nozzle Adjustment» .

WW-71

M

REAR WIPER AND WASHER SYSTEM
CHECK VALVE INSPECTION
Make sure air can pass through the hose by blowing forward (toward
the nozzle) and air cannot pass through by suction.

MKIB1984E

Inspection of Rear Wiper and Washer Switch Circuit

BKS0013B

Refer to LT-125, «Combination Switch Inspection» .

Removal and Installation of Rear Wiper and Washer Switch

BKS0013C

Refer to LT-128, «Removal and Installation» .

Removal and Installation of Rear Wiper and Washer Tank

BKS0013D

Refer to.WW-46, «Removal and Installation of Washer Tank» .

Removal and Installation of Rear Wiper and Washer Pump
Refer to WW-47, «Removal and Installation of Front Washer Motor» .

WW-72

BKS0013E

HEADLAMP WASHER
HEADLAMP WASHER
Components Parts and Harness Connector Location

PFP:28620

A
BKS001M3

B

C

D

E

F

G
MKIB2265E

: Vehicle front
1. IPDM E/R E10, E11, E12
[Engine room (left)]

2. BCM M57, M58, M59
(View with instrument panel removed)

4. Headlamp washer switch M18
(RHD models)

5. Headlamp washer motor E25
(View with front bumper removed)

System Description

H

3. Data link connector

I
BKS0013F

Headlamp washer operates under the following conditions.
J
●
When lighting switch is in 1ST position
●
When daytime light system is operating
●
When auto light system is operating (low beam is ON)
WW
When the headlamp washer switch is ON position the BCM (body control module) receives input signal
requesting the headlamp washer operates. The CPU (central processing unit) of the IPDM E/R (intelligent
power distribution module engine room) controls the headlamp washer relay coil. When activated this relay
L
directs power headlamp washer motor.

OUTLINE
Power is supplied at all times
●
through 30A fusible link (letter L, located in fuse and fusible link box).
●
to headlamp washer relay terminals 1 and 3.
●
through 40A fusible link (letter J, located in fuse and fusible link box).
●
to BCM terminals 74 and 79.
●
through 20A fuse (No.61, 62, located in IPDM E/R).
●
to IPDM E/R (CPU).
When ignition switch ON or START position, power is supplied
●
to IPDM E/R (CPU), and
●
through 10A fuse [No.5, located in fuse block (J/B)]
●
to BCM terminal 24.
Ground is supplied
●
to IPDM E/R terminals 3 and 54, and
●
to head lamp washer motor terminal 1,
●
through body grounds E28, E44 and E45.

WW-73

M

HEADLAMP WASHER
●
●
●

to BCM terminals 2 and 70, and
to head lamp washer switch terminal 2,
through body grounds M21 and M66.

HEADLAMP WASHER OPERATION
When lighting switch is placed in 2nd position, BCM read combination switch condition (Refer to WW-8,
«COMBINATION SWITCH READING FUNCTION» ).
And headlamp washer switch ON, ground is supplied.
●
to BCM terminal 62, and
●
through headlamp washer switch terminal 1 and 2.
●
through body grounds M21 and M66.
BCM sends headlamp washer request signal to IPDM E/R with CAN communication line.
And IPDM E/R is grounded to headlamp washer relay terminal 2 through IPDM E/R terminal 56.
Then headlamp washer relay is energized, power is supplied.
●
through headlamp washer relay terminal 5
●
to headlamp washer motor terminal 2.
Ground is supplied.
●
to terminal 1 of headlamp washer motor
●
through body grounds E28, E44 and E45.
With power and ground supplied, the headlamp washer operates.

CAN Communication

BKS0013G

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

CAN Communication Unit

BKS0013H

Refer to LAN-27, «CAN Communication Unit» .

WW-74

HEADLAMP WASHER
Wiring Diagram —HLC—

BKS0013I

A

B

C

D

E

F

G

H

I

J

WW

L

M

MKWA4289E

WW-75

HEADLAMP WASHER

MKWA4290E

WW-76

HEADLAMP WASHER
Terminals and Reference Values for BCM

BKS0013J

A
Measuring condition
Terminal
No.

Wire
color

2

B

Signal name

Ground

Signal
input/
output
—

Ignition
switch

Operation or condition

ON

—

Reference value [V]

B
0

C

OFF
(Wiper intermittent dial position 4)

D

PKIB8643J

Approx. 1.2V

E

Any of several conditions below
7

BR

Combination switch
output 5

Output

ON

●

Front fog lamp switch (Operates
only front fog lamp switch)
(Wiper intermittent dial position 4)

●

Rear fog lamp switch
(Wiper intermittent dial position 4)

●

Rear wiper ON
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

F

G

H
PKIB4956J

●

Wiper intermittent dial position 2

●

Wiper intermittent dial position 6

●

Wiper intermittent dial position 7

Approx. 1.0V

I

J
OFF
(Wiper intermittent dial position 4)

WW
PKIB4958J

Approx. 1.2V
8

L

Combination switch
output 3

Output

ON

L

Any of several conditions below
●

Lighting switch 2ND
(Wiper intermittent dial position 4)

●

Lighting switch HI beam
(Operates only HI beam switch)
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 2

●

Wiper intermittent dial position 3

WW-77

M

PKIB4959J

Approx. 1.0V

HEADLAMP WASHER
Measuring condition
Terminal
No.

Wire
color

Signal name

Signal
input/
output

Ignition
switch

Reference value [V]
Operation or condition

OFF
(Wiper intermittent dial position 4)

PKIB4958J

9

V

Combination switch
output 1

Output

Approx. 1.2V

ON
Any of several conditions below
●

Turn signal switch to right

●

Turn signal switch to left

●

Front wiper switch MIST

●

Front wiper switch LO

●

Front washer switch

PKIB4959J

Approx. 1.0V

13

14

15

GB

P

W

Combination switch
input 1

Combination switch
input 3

Combination switch
input 5

Input

Input

Input

ON

●

OFF

●

Front wiper switch HI
(Wiper intermittent dial position 4)

●

Rear wiper switch INT
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 2

●

Wiper intermittent dial position 3

●

Wiper intermittent dial position 6

●

Wiper intermittent dial position 7

●

OFF

●

Lighting switch AUTO

●

Rear fog lamp switch

●

Front wiper switch MIST

●

Front wiper switch INT

●

Front wiper switch LO

●

OFF

●

Lighting switch 1ST

●

Lighting switch 2ND

●

Lighting switch HIGH beam
(Operates only HIGH beam switch)

●

Turn signal switch to right

ON

ON

WW-80, «Reference Values for
BCM (Input)»

WW-80, «Reference Values for
BCM (Input)»

WW-80, «Reference Values for
BCM (Input)»

19

L

CAN H

Input/
output

—

—

—

24

O

Ignition power supply

Input

ON

—

Battery voltage

WW-78

HEADLAMP WASHER
Measuring condition
Terminal
No.

Wire
color

Signal name

Signal
input/
output

A

Ignition
switch

Reference value [V]
Operation or condition

B

C

OFF
(Wiper intermittent dial position 4)

PKIB4958J

D

Approx. 1.2V
27

GR

Combination switch
output 4

Output

ON

Any of several conditions below
●

Lighting switch AUTO
(Wiper intermittent dial position 4)

●

Lighting switch 1ST
(The same result with
lighting switch 2ND)
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 5

●

Wiper intermittent dial position 6

E

F

PKIB4959J

G

Approx. 1.0V

H

OFF
(Wiper intermittent dial position 4)

I

PKIB4958J

28

G

Combination switch
output 2

Output

ON
Any of several conditions below
●

Lighting switch 2ND

●

Lighting switch PASSING
(Operates only PASSING switch)

●

Front wiper switch INT

●

Front wiper switch HI

WW

L
PKIB4959J

Approx. 1.0V

33

R

Combination switch
input 2

Input

ON

J

Approx. 1.2V

●

OFF

●

Front washer switch
(Wiper intermittent dial position 4)

●

Rear wiper switch ON
(Wiper intermittent dial position 4)

●

Rear washer switch ON
(Wiper intermittent dial position 4)

●

Wiper intermittent dial position 1

●

Wiper intermittent dial position 5

●

Wiper intermittent dial position 6

WW-79

WW-80, «Reference Values for
BCM (Input)»

M

HEADLAMP WASHER
Measuring condition
Terminal
No.

34

Wire
color

Y

Signal
input/
output

Signal name

Combination switch
input 4

Ignition
switch

Input

ON

39

Y

CAN L

Input/
output

—

62

G

Headlamp washer
switch

Input

ON

70

B

Ground

74

Y

79

Y

Reference value [V]
Operation or condition
●

OFF

●

Front fog lamp switch ON

●

Lighting switch 2ND

●

Lighting switch PASSING
(Operates only PASSING switch)

●

Turn signal switch to left
—

—
Operated

Headlamp
washer switch

WW-80, «Reference Values for
BCM (Input)»

Other than above

0
Battery voltage

—

ON

—

0

Power source
(Fusible link)

Input

OFF

—

Battery voltage

Power source
(Fusible link)

Input

OFF

—

Battery voltage

Reference Values for BCM (Input)

BKS001KQ

CAUTION:
●
Check combination switch system terminal waveform under the loaded condition with lighting
switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded.
●
Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position.
Wiper dial position can be confirmed on CONSULT-II. Refer to WW-24, «DATA MONITOR» .
INPUT

Condition and reference value
OFF

Lighting switch 1ST

PKIB4956J

INPUT 5
(Wiper intermittent dial position
4)

Lighting switch 2ND

PKIB8624J

Approx. 0.9V

Approx. 1.5 — 2.0V

Lighting switch HI beam
(Operates only HI beam switch)

Turn signal switch to right

PKIB8639J

Approx. 2.5 — 3.0V

—

PKIB8625J
PKIB8644J

Approx. 1.5 — 2.0V

Approx. 1.5 — 2.0V

WW-80

HEADLAMP WASHER
INPUT

Condition and reference value
OFF

Lighting switch 2ND

Turn signal switch to left

A

B

PKIB4958J

INPUT 4
(Wiper intermittent dial position
4)

PKIB8628J

Approx. 1.0V

Approx. 1.5 — 2.0V

Front fog lamp switch
(Operates only front fog lamp
switch)

Lighting switch PASSING
(Operates only PASSING switch)

PKIB8630J

C

Approx. 2.0V

D

E

—

F
PKIB8629J
PKIB8627J

Approx. 1.5 — 2.0V
OFF

Approx. 2.0V
Lighting switch AUTO

Front wiper switch INT

G

H

PKIB4958J

INPUT 3
(Wiper intermittent dial position
4)

Approx. 1.0V

PKIB8631J

Approx. 2.0V

PKIB8632J

I

Approx. 2.0V

Any of several conditions below
● Front
● Front

wiper switch LO

J

Rear fog lamp switch

wiper switch MIST

—

PKIC1030E
PKIB8629J

WW

L

Approx. 1.5V

Approx. 2.0V

M

WW-81

HEADLAMP WASHER
INPUT

Condition and reference value
Front washer switch
(Wiper intermittent dial position 4)

OFF
(Wiper intermittent dial position 4)

PKIB4958J

Rear washer switch
(Wiper intermittent dial position 4)

PKIB8632J

PKIB8631J

Approx. 2.0V

Approx. 2.0V

Approx. 1.0V

Any of the conditions below
INPUT 2
Rear wiper switch ON
(Wiper intermittent dial position 4)

● Wiper

intermittent dial position 1

● Wiper

intermittent dial position 5

● Wiper

intermittent dial position 6
—

PKIB8634J

Approx. 1.5 — 2.0V

PKIB8633J

Approx. 2.0V
Any of the conditions below
OFF
(Wiper intermittent dial position 4)

Front wiper switch HI
(Wiper intermittent dial position 4)

● Rear wiper switch INT
(Wiper intermittent dial position 4)
● Wiper

PKIB4958J

intermittent dial position 3

PKIB8635J

Approx. 1.0V

Approx. 2.0V

PKIB8636J

Approx. 2.0V

INPUT 1
Any of the conditions below

Any of the conditions below
● Wiper

intermittent dial position 1

● Wiper

intermittent dial position 6

● Wiper

intermittent dial position 2

● Wiper

intermittent dial position 7

—

PKIB8637J

PKIB8638J

Approx. 2.5 — 3.0V

Approx. 2.0V

Terminals and Reference Values for IPDM E/R

BKS0013K

Measuring condition

Signal
Input/
output

Ignition
switch

Operation or condition

Ground

—

ON

—

0

L

CAN H

Input/
output

—

—

—

B

Ground

—

—

—

0

Terminal No.

Wire
color

3

B

52
54

Signal name

Reference value [V]

WW-82

HEADLAMP WASHER
Terminal No.

Wire
color

56

LG

58

Y

Measuring condition

Signal
Input/
output

Ignition
switch

Headlamp washer
signal

Output

ON

CAN L

Input/
output

—

Signal name

Reference value [V]

Headlamp
washer

: Operating

Battery voltage

: Other than
above

0

—

B

—

CONSULT-II Function (BCM)

C
BKS0013M

D

Refer to WW-24, «CONSULT-II Function (BCM)» .

CONSULT-II Function (IPDM E/R)

BKS0013N

Refer to WW-25, «CONSULT-II Function (IPDM E/R)» .

E

Diagnosis Chart by Symptom
Symptom

Possible causes

BKS001HF

Possible malfunctioning system and part
BCM — headlamp washer switch system

Headlamp washer
switch signal malfunction

●

40A fusible link

●

10A fuse

●

Headlamp washer switch

●

Harness and connector between headlamp
washer switch and BCM

●

Harness and connector between headlamp
washer switch and ground

●

Headlamp washer
motor output malfunction

●

30A fusible link

●

20A fuse

●

Headlamp washer motor

●

Headlamp washer relay

●

Harness and connector between IPDM E/R
and headlamp washer relay

●

Harness and connector between headlamp
washer relay and headlamp washer motor

●

Harness and connector between headlamp
washer motor and ground

●

Inspection procedure

IPDM E/R

WW-83

Reference
page

F

CONSULT-II
●

G

ACTIVE TEST
(BCM)

H
Other than CONSULT-II
●

Headlamp washer switch
output inspection

BCM

IPDM E/R — Headlamp washer motor system

Headlamp washer
does not operate

A

Operation or condition

CONSULT-II
●

ACTIVE TEST
(IPDM E/R)

I
WW-84,
«Headlamp
Washer
Does Not
Operate»

J

WW
Other than CONSULT-II
●

Headlamp washer motor
output inspection

L

M

HEADLAMP WASHER
Headlamp Washer Does Not Operate

BKS0013O

1. CHECK FUSE
Check fuse and fusible link for blown-out.

●

Unit

Power source

Fuse No.

Headlamp washer relay

Battery

L

IPDM E/R

Battery

61, 62

Battery

J

Ignition switch ON or START position

5

BCM

Refer to WW-75, «Wiring Diagram —HLC—» .
OK or NG
OK
>> GO TO 2.
NG
>> If fuse is blown, be sure to eliminate cause of problem before installing new fuse or fusible link,
Refer to PG-4, «POWER SUPPLY ROUTING CIRCUIT» .

2. CHECK BCM POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector.
Check voltage between BCM harness connector and ground.
Terminals

Ignition switch position

(+)
Connector

Terminal
(Wire color)

M59

74

M59

79

M57

24

(–)

Ground

OFF

ACC

ON

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

Battery
voltage

0V

0V

Battery
voltage

MKIB0352E

OK or NG
OK
>> GO TO 3.
NG
>> Check harness for open or short between fuse, fusible link and BCM.

3. CHECK IPDM E/R GROUND CIRCUIT
1.
2.

Disconnect IPDM E/R harness connector.
Check continuity between IPDM E/R harness connector and
ground.
Connector

Terminal
(Wire color)

E11

3

E12

54

Continuity
Ground

Yes

OK or NG
OK
>> GO TO 4.
NG
>> Harness for open ground circuit.

MKIB2004E

WW-84

HEADLAMP WASHER

4. CHECK BCM GROUND CIRCUIT

A

Check continuity between BCM harness connector and ground.
Terminals

B

Continuity

Connector

Terminal
(Wire color)

M57

2

Ground

Yes

M59

70

Ground

Yes

OK or NG
OK
>> GO TO 5.
NG
>> Check harness ground circuit.

C

D
MKIB0353E

5. ACTIVE TEST

E

1.

Select “BCM” on CONSULT-II. Select “ACTIVE TEST” on
“SELECT DIAG MODE” screen.
2. Select “HEAD LAMP WASHER” on “SELECT TEST ITEM”
screen.
3. Touch “ON” screen.
Does headlamp washer operate normally?
YES >> GO TO 12.
NO
>> GO TO 6.

F

G

H
SKIB6240E

6. CHECK POWER SUPPLY CIRCUIT TO HEADLAMP WASHER RELAY

I

1.
2.
3.

J

Turn ignition switch OFF.
Remove headlamp washer relay.
Check voltage between headlamp washer relay harness connector and ground.

WW

Terminal
(+)
Headlamp washer
relay connector
M19

(-)

Voltage

L

Terminal
1

Ground

Battery voltage

M

5

OK or NG
OK
>> GO TO 7.
NG
>> Repair harness or connector.

MKIB2304E

7. CHECK HEADLAMP WASHER RELAY
1.
2.

Apply battery voltage to between headlamp washer relay terminal 1 and 2.
Check continuity between terminal 3 and 5.
3–5

: Continuity should exist.

OK or NG
OK
>> GO TO 8.
NG
>> Replace headlamp washer relay.
MKIB2007E

WW-85

HEADLAMP WASHER

8. CHECK IPDM E/R
1.
2.
3.
4.

Turn ignition switch OFF.
Install headlamp washer relay.
Turn ignition switch ON.
Select “IPDM E/R” on CONSULT-II. Select “HEAD LAMP
WASHER” active test. Refer to WW-25, «ACTIVE TEST» . When
headlamp washer operating, check voltage between IPDM E/R
harness connector and ground.
Terminals
(+)

Headlamp washer
condition

(-)

Connector

Terminal

E12

56

Ground

Voltage [V]
(Approx.)

OFF

Battery voltage

ON

0

MKIB2008E

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 9.

9. CHECK CONTINUITY BETWEEN IPDM E/R AND HEADLAMP WASHER RELAY
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R harness connector and remove headlamp washer relay.
Check continuity between IPDM E/R harness connector and
headlamp washer relay harness connector.
IPDM E/R

Headlamp washer relay

Connector

Terminal

Connector

Terminal

E12

56

M19

2

Continuity
Yes

>> Replace IPDM E/R. Refer to PG-37, «Removal and
Installation of IPDM E/R» .
>> Repair harness or connector.

OK
NG

MKIB2009E

10. CHECK HEADLAMP WASHER MOTOR CIRCUIT
1.
2.

Disconnect headlamp washer motor connector.
Check continuity between headlamp washer relay harness connector (A) and headlamp washer motor harness connector (B).
A

B

Continuity

Connector

Terminal

Connector

Terminal

M19

3

E25

2

Yes

OK or NO
OK
>> GO TO 11.
NO
>> Repair harness or connector.
MKIB2305E

WW-86

HEADLAMP WASHER

11. CHECK HEADLAMP WASHER MOTOR GROUND CIRCUIT

A

Check continuity between headlamp washer motor harness connector and ground.
B

Headlamp washer
motor connector

Terminal

E25

1

Continuity
Ground
Yes

OK or NG
OK
>> Replace headlamp washer motor. Refer to WW-88,
«Removal and Installation for Headlamp Washer Motor»
.
NG
>> Repair harness or connector.

C

D
MKIB2011E

12. CHECK HEADLAMP WASHER SWITCH CIRCUIT

E

1.
2.

F

3.

Turn ignition switch OFF.
Disconnect BCM connector and headlamp washer switch connector.
Check continuity between BCM harness connector and
headlamp washer switch harness connector.
BCM

Headlamp washer switch

Connector

Terminal

Connector

Terminal

M58

62

M18

1

G

Continuity

H

Yes

OK or NO
OK
>> GO TO 13.
NO
>> Repair harness or connector.

MKIB2012E

I

13. CHECK HEADLAMP WASHER SWITCH

J

Check continuity between headlamp washer switch terminals 1 and
2.
Headlamp washer switch terminal
1

2

Switch condition

Continuity

OFF

No

ON

Yes

WW

L

OK or NG
OK
>> GO TO 14.
NG
>> Replace headlamp washer switch.

M
MKIB2013E

14. CHECK HEADLAMP WASHER SWITCH GROUND CIRCUIT
Check continuity between headlamp washer switch harness connector and ground.
Headlamp washer
switch connector

Terminal

M18

2

Ground

Continuity
Yes

OK or NG
OK
>> Replace BCM. Refer to BCS-17, «Removal and Installation of BCM» .
NG
>> Repair harness or connector.
MKIB2014E

WW-87

HEADLAMP WASHER
Removal and Installation for Headlamp Washer Nozzle

BKS0013P

REMOVAL
1.
2.
3.

Remove front bumper. Refer to EI-4, «FRONT BUMPER»
Remove headlamp washer tube.
Remove headlamp washer nozzle from front bumper.

INSTALLATION
Install in the reverse order of removal.

Removal and Installation for Washer Tank

BKS0013Q

Refer to WW-46, «Removal and Installation of Washer Tank» ,

Removal and Installation for Headlamp Washer Motor

BKS0013R

1.
2.
3.

Remove front bumper. Refer to EI-4, «FRONT BUMPER»
Remove headlamp washer motor (1) connector and hose.
Pull out headlamp washer motor in the direction of the arrow
( ) in the figure, and remove the washer pump from the washer
tank.
CAUTION:
When installing headlamp washer motor, there should be no
packing twist, etc.
MKIB2240E

Headlamp Washer Tube Layout

BKS0013S

MKIB2222E

1.

Headlamp cleaner RH

2.

Washer tank

WW-88

3.

Headlamp cleaner LH

HORN
HORN
Wiring Diagram —HORN—

PFP:25610

A
BKS0013T

B

C

D

E

F

G

H

I

J

WW

L

M

MKWA4291E

WW-89

HORN
Removal and Installation

BKS0013U

REMOVAL
1.
2.
3.

Remove front grille. Refer to EI-10, «Removal and Installation» .
Disconnect horn connector.
Remove horn mounting nut (A) and remove horn (1) from vehicle.

MKIB2238E

INSTALLATION
Installation is the reverse order of removal.
●
Tighten horn bolt to specified torque.
Horn mounting bolt

: 17.1 N·m (1.74 kg-m, 12.6 in-lb)

WW-90

POWER SOCKET
POWER SOCKET
Wiring Diagram —P/SCKT—

PFP:253A2

A
BKS0013V

B

C

D

E

F

G

H

I

J

WW

L

M

MKWA4292E

WW-91

POWER SOCKET
Removal and Installation

BKS0013W

REMOVAL
1.
2.
3.
4.
–

Remove center console assembly. Refer to IP-13, «CENTER
CONSOLE ASSEMBLY» .
Remove instrument panel stay cover. Refer to IP-9, «M. Instrument Pad (Driver Side)» .
Disconnect the power socket connector.
Remove inner socket (1) from the ring (2), while pressing the
hook (B) on the ring out from square hole (A).
Cut out (C)
SKIB3767J

INSTALLATION
Note the following, and install in the reverse order of the removal.
NOTE:
Install the inner socket with its cut out aligned with that on the ring.

Removal and Installation of Console Power Socket

BKS001HA

REMOVAL
1.
2.
3.

Remove center console assembly. Refer to IP-13, «CENTER
CONSOLE ASSEMBLY» .
Disconnect power socket connector.
Remove inner socket (2) from the ring (1), while pressing the
hook (B) on the ring out from square hole (A).

MKIB2301E

INSTALLATION
Note the following, and install in the reverse order of the removal.
NOTE:
Install the inner socket with its cut out aligned with that on the ring.

Removal and Installation of Luggage Room Power Socket

BKS001HB

REMOVAL
1.
2.
3.

Remove luggage side finisher lower (left). Refer to EI-32, «LUGGAGE FLOOR TRIM» .
Disconnect power socket connector.
Remove inner socket (2) from the ring (1), while pressing the
hook (B) on the ring out from square hole (A).

MKIB2302E

INSTALLATION
Note the following, and install in the reverse order of the removal.
NOTE:
Install the inner socket with its cut out aligned with that on the ring.

WW-92

ACCELERATOR CONTROL SYSTEM

B ENGINE

SECTION

ACC

ACCELERATOR CONTROL SYSTEM

A

ACC

C

D

CONTENTS
ACCELERATOR CONTROL SYSTEM …………………. 2
Removal and Installation …………………………………… 2
REMOVAL ……………………………………………………. 2
INSTALLATION …………………………………………….. 2
INSPECTION AFTER INSTALLATION …………….. 2

SERVICE DATA AND SPECIFICATIONS (SDS) …….. 3
Tightening Torque …………………………………………….. 3

E

F

G

H

I

J

K

L

M

ACC-1

ACCELERATOR CONTROL SYSTEM
ACCELERATOR CONTROL SYSTEM
Removal and Installation

PFP:18005
BBS003Z9

PBIC1506E

1.

Accelerator pedal assembly

2.

Accelerator pedal stopper
(Under floor carpet)

REMOVAL
1. Remove harness connector.
2. Remove mounting bolts, and remove accelerator assembly.
CAUTION:
●
Do not disassemble accelerator pedal assembly and remove sensors.
●
Handle them carefully without subjecting them to impacts such as dropping.
●
Be careful not to get it wet.
3. Fold the floor carpet and remove accelerator pedal stopper.
● Remove pedal stopper by turning it counterclockwise with fingers.

INSTALLATION
Install in the reverse order of removal. be careful of the following:
●
Insert locating pin into vehicle side to position accelerator pedal assembly. Install mounting bolt to accelerator pedal assembly.
●
Align the stud bolt on the floor with the thread hole to insert accelerator pedal stopper until it contacts the
face.

INSPECTION AFTER INSTALLATION
●
●
●

●

Check that the accelerator pedal moves smoothly within the whole operation range.
Check that the accelerator pedal securely returns to the original position.
For the electrical inspection of the accelerator pedal assembly, refer to EC-409, «DTC P2138 APP SENSOR» (CR WITH EURO-OBD), EC-725, «DTC P2138 APP SENSOR» (CR WITHOUT EURO-OBD) and
EC-1197, «DTC P2138 APP SENSOR» (HR WITH EURO-OBD), EC-1517, «DTC P2138 APP SENSOR»
(HR WITHOUT EURO-OBD) or “Interpretation”, “DIESEL INJECTION” in EC section(K9K).
When accelerator electrical connector is disconnected, perform EC-69, «Accelerator Pedal Released
Position Learning» (CR WITH EURO-OBD), EC-486, «Accelerator Pedal Released Position Learning»
(CR WITHOUT EURO-OBD) and EC-857, «Accelerator Pedal Released Position Learning» (HR WITH
EURO-OBD), EC-1278, «Accelerator Pedal Released Position Learning» (HR WITHOUT EURO-OBD).

ACC-2

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Tightening Torque

PFP:00030

A
BBS003ZA

Unit: N·m (kg-m, in-lb)
Accelerator pedal assembly

4.3 — 5.9 (0.44 — 0.60, 38 — 52)

ACC

C

D

E

F

G

H

I

J

K

L

M

ACC-3

SERVICE DATA AND SPECIFICATIONS (SDS)

ACC-4

ALPHABETICAL INDEX
A
A/C air flow ………………………………… ATC-24, MTC-21
A/C component layout …………………. ATC-16, MTC-16
A/C compressor mounting ………….. ATC-140, MTC-86
A/C compressor precaution ……………… ATC-8, MTC-8
A/C control operation (auto A/C) …………………. ATC-22
A/C control operation (manual A/C) ……………. MTC-20
A/C controller ………………………………………….. MTC-62
A/C diagnostic work flow (auto A/C) ……………. ATC-97
A/C HFC134a (R134a) system precaution ……. ATC-4,
MTC-4
A/C HFC134a (R134a) system service procedure …….
ATC-135, MTC-81
A/C HFC134a (R134a) system service tools .. ATC-12,
MTC-12
A/C HFC134a system service equipment precaution …
ATC-8, MTC-8
A/C lubricant (R134a) …….. ATC-5, ATC-17, ATC-151,
MTC-5, MTC-17, MTC-97
A/C operational check ………………….. ATC-55, MTC-34
A/C self-diagnoses (auto A/C) ………. ATC-46, ATC-97
A/C service data specification ……… ATC-151, MTC-97
A/C trouble diagnoses (manual A/C) ………….. MTC-23
A/C unit assembly ……………………… ATC-118, MTC-65
A/C, A — Wiring diagram …………………………….. ATC-31
A/C, M — Wiring diagram …………………………… MTC-26
A/T fluid checking ……………………………. AT-18, MA-56
A/T fluid replacement ……………………….. AT-19, MA-57
A/T fluid temperature sensor ……………………… AT-114
A/T IND — Wiring diagram ……………………………… DI-49
A/T indicator ……………………………………………….. DI-48
A/T shift control system …………………………….. AT-332
A/T shift lock system …………………………………. AT-338
A/T shift lock system — Wiring diagram ………… AT-339
A/T trouble diagnoses …………………………………. AT-40
A/T Wiring diagram AT — BA/FTS ……. AT-181, AT-236
A/T Wiring diagram AT — CAN ………… AT-103, AT-258
A/T Wiring diagram AT — ENG SS …… AT-122, AT-242
A/T Wiring diagram AT — FTS …………………….. AT-111
A/T Wiring diagram AT — LPSV ………. AT-154, AT-252
A/T Wiring diagram AT — MAIN ………. AT-194, AT-261
A/T Wiring diagram AT — NONDTC ……………… AT-296
A/T Wiring diagram AT — OVRCSV …. AT-172, AT-226
A/T Wiring diagram AT — PNP/SW ………………. AT-106
A/T Wiring diagram AT — PT/SEN …… AT-187, AT-246
A/T Wiring diagram AT — SSV/A ……… AT-160, AT-216
A/T Wiring diagram AT — SSV/B ……… AT-165, AT-221
A/T Wiring diagram AT — TCV ………… AT-143, AT-231
A/T Wiring diagram AT — VSS A/T ….. AT-117, AT-205
A/T Wiring diagram AT — VSSMTR …. AT-177, AT-210
ABS — Wiring diagram ………………………………. BRC-13
ABS sensor rotor ………………………………………. RAX-5
Accelerator pedal position (APP) sensor …….. EC-383,
EC-392, EC-409, EC-699, EC-708, EC-725, EC-1172,
EC-1181, EC-1197, EC-1492, EC-1501, EC-1517,
EC-1751, EC-1837, EC-1855
Accelerator pedal released position learning …. EC-69,
EC-486, EC-857, EC-1278

Air bag …. SRS-3, SRS-36, SRS-40, SRS-42, SRS-44
Air bag disposal ………………………………………. SRS-49
Air bleeding (hydraulic clutch) ………………………… CL-8
Air bleeding for brake system ………………………. BR-10
Air cleaner and air duct ………………… EM-118, EM-245
Air cleaner filter …………………………… EM-119, EM-246
Air cleaner filter replacement(CR) ………………… MA-34
Air cleaner filter replacement(HR) ………………… MA-44
Air cleaner filter replacement(K9K) ………………. MA-52
Air conditioner cut control EC-821, EC-1255, EC-1618
Air flow meter — See Mass air flow sensor ……. EC-935,
EC-1354
Air mix door control linkage adjustment ……… MTC-37,
MTC-71
Air mix. door motor ……………………. ATC-64, ATC-125
Alternator ………………………………………………….. SC-15
Ambient sensor …………………………. ATC-99, ATC-114
Angular tightening application ……….. EM-105, EM-227
Antenna ……………………………………………………. AV-11
AP/SEN — Wiring diagram .. EC-156, EC-339, EC-560,
EC-656
APPS — Wiring diagram . EC-1752, EC-1838, EC-1856
APPS1 — Wiring diagram .. EC-385, EC-701, EC-1174,
EC-1494
APPS2 — Wiring diagram .. EC-394, EC-710, EC-1183,
EC-1503
APPS3 — Wiring diagram .. EC-411, EC-727, EC-1199,
EC-1519
Audio ………………………………………………………….. AV-3
AUDIO — Wiring diagram ……………………………….. AV-4
Auto air conditioner — Wiring diagram …………. ATC-31
Auto amp …………………….. ATC-44, ATC-57, ATC-112
Auto wiper …………………………………………………. WW-4
Automatic amplifier ……………………… ATC-44, ATC-57
Automatic transaxle number …………………………. GI-48
Automatic transmission fluid replacement …….. MA-56
Axle …………………………………………………………. MA-60
B
Back door trim …………………………………………….. EI-22
Back door window …………………………………….. GW-10
Back window ……………………………………………. GW-10
BACK/L — Wiring diagram …………………………… LT-131
Back-up lamp …………………………………………… LT-131
Barometric pressure (BARO) sensor …………. EC-1863
Basic inspection …. EC-66, EC-483, EC-851, EC-1272
Battery ……………………………………………………….. SC-5
BCM (Body control module) ………………………… BCS-3
Blower motor ….. ATC-71, ATC-123, MTC-39, MTC-69
Blower resistor ………………………………………… MTC-73
Board computer ………………………………………….. DI-21
Board-on lift ……………………………………………….. GI-41
Brake booster ……………………………………………. BR-17
Brake fluid change ……………………………………….. BR-9
Brake fluid level ………………………………………… MA-58
Brake fluid level and line check ……………………… BR-9
Brake hydraulic line ……………………………………. BR-11
Brake inspection ……………………………………….. MA-58

IDX-2

ALPHABETICAL INDEX
Brake lines and cables inspection ………………… MA-58
Brake master cylinder …………………………………. BR-14
Brake pedal ………………………………………………… BR-6
Brake switch …. EC-377, EC-693, EC-1167, EC-1487,
EC-1820, EC-1850
BRK/SW — Wiring diagram EC-379, EC-695, EC-1168,
EC-1488, EC-1821, EC-1851
Bulb specifications …………………………………….. LT-183
Bumper, front ………………………………………………… EI-4
Bumper, rear …………………………………………………. EI-8
C
Camshaft ………………………………………………… EM-151
Camshaft inspection ……………………. EM-157, EM-325
Camshaft position sensor (CMPS) EC-1075, EC-1778
Camshaft position sensor (PHASE) . EC-257, EC-616,
EC-1049, EC-1413
CAN — Wiring diagram ……… EC-135, EC-550, EC-926,
EC-1345, EC-1706, LAN-23, LAN-38, LAN-51, LAN-65,
LAN-79, LAN-94, LAN-108, LAN-123, LAN-136,
LAN-150, LAN-164
CAN (Controller Area Network) ………. AT-39, BRC-48,
LAN-21
CAN communication ……….. EC-134, EC-137, EC-549,
EC-552, EC-822, EC-925, EC-928, EC-1256, EC-1344,
EC-1347, EC-1624, EC-1705, AT-39, AT-102, BRC-48,
LT-89, LAN-21
Canister-See EVAP canister EC-43, EC-472, EC-826,
EC-1260
CD/CHG — Wiring diagram …………………………….. AV-4
CHARGE — Wiring diagram …….. SC-16, SC-17, SC-18
Charging system ………………………………………… SC-15
Chassis and body maintenance …………………… MA-55
Circuit breaker …………………………………………… PG-17
CKPS — Wiring diagram …………………………… EC-1775
Closed loop control EC-34, EC-463, EC-818, EC-1252
Clutch cover …………………………………….. CL-11, CL-12
Clutch disc ………………………………………………… CL-11
Clutch master cylinder ………………………………….. CL-9
Clutch pedal ………………………………………………… CL-6
CMPS — Wiring diagram …………………………… EC-1779
Coil spring (front) ……………………………………….. FSU-8
Coil spring (rear) ……………………………………….. RSU-9
Collision diagnosis ……………………………………. SRS-58
Combination lamp, rear, removal and installation ……..
LT-149
Combination switch ……………………………………. WW-8
COMM — Wiring diagram ………………………………. DI-24
Component Location (auto A/C) …………………. ATC-28
Component Location (manual A/C) ……………. MTC-25
Compression pressure ……………………………… EM-173
Compressor mounting ……………….. ATC-140, MTC-86
Conformity check ……………………………………. EC-1680
Connecting rod …………………………… EM-208, EM-327
Connecting rod bearing clearance ………………. EM-211
Connecting rod bushing clearance ……………… EM-208
CONSULT for ABS ………………………………….. BRC-19
CONSULT for engine …………………… EC-102, EC-519

CONSULT general information ……………………… GI-35
CONSULT-II for engine ………………. EC-891, EC-1312
Control units (terminal arrangement) …………….. PG-90
Controller Area Network (CAN) ……… AT-39, BRC-48,
LAN-21
Converter housing installation ……….. AT-358, AT-465
COOL/F — Wiring diagram EC-349, EC-666, EC-1135,
EC-1456, EC-1866
Coolant mixture ratio ………………………………….. MA-26
Coolant replacement ………………………………….. MA-49
Cooling circuit (engine) ……………………… CO-7, CO-26
Cooling fan …………………………. CO-14, CO-33, CO-52
Cooling fan control ………………………………….. EC-1620
Cooling fan motor ……… EC-1130, EC-1451, EC-1864
Cooling fan relay ……….. EC-1130, EC-1451, EC-1864
Cowl top …………………………………………………….. EI-12
Crankcase ventilation system — See Positive crankcase
ventilation ………….. EC-45, EC-474, EC-828, EC-1262
Crankshaft ……………………. EM-189, EM-211, EM-328
Crankshaft position sensor (POS) …. EC-250, EC-609,
EC-1042, EC-1405
Crankshaft position sensor (TDC) …………….. EC-1774
Cylinder block …………………………….. EM-189, EM-329
Cylinder head ………………… EM-173, EM-177, EM-276
Cylinder head bolt tightening EM-176, EM-277, EM-321

A

B

C

D

E

F

G

H

D
Data link connector EC-448, EC-800, EC-893, EC-900,
EC-1313
Data link connector for Consult ………. EC-104, EC-521
Diagnosis sensor unit ………………………………. SRS-48
Diagnostic trouble code (DTC) for OBD system EC-22,
EC-49, EC-451, EC-477, EC-803, EC-833, EC-1239,
EC-1265, EC-1601
Diagnostic trouble code (DTC) inspection priority chart
EC-80, EC-497, EC-869, EC-1290
Dimensions ………………………………………………… GI-48
Door glass ………………………….. GW-5, GW-89, GW-93
Door mirror ……………………………………………….. GW-96
Door trim ……………………………………………………. EI-20
Drive belt ……………………………………. EM-114, EM-242
Drive belt inspection ………………………………….. MA-49
Drive computer …………………………………. DI-21, DI-24
Drive shaft (front) ……………………………………… FAX-10
Driver air bag ………………………………………….. SRS-36
Dropping resistor (A/T) …………………. AT-158, AT-256
DTC work support ………………………… EC-109, EC-898
Duct and grilles …………………………. ATC-130, MTC-76
E
ECM input/output signal ……. EC-95, EC-512, EC-883,
EC-902, EC-1304, EC-1321, EC-1673
ECM power supply EC-128, EC-282, EC-543, EC-626,
EC-918, EC-1337, EC-1816
ECM relay ……………………………………………… EC-1845
ECM/PW — Wiring diagram EC-283, EC-627, EC-1817
ECMRLY — Wiring diagram ………………………. EC-1846

IDX-3

I

J

K

L

IDX

ALPHABETICAL INDEX
ECTS — Wiring diagram …… EC-168, EC-567, EC-949,
EC-1363, EC-1728
EGR function …………………………… EC-1622, EC-1791
EGR volume control valve ……………………….. EC-1795
EGR volume control valve control position sensor …….
EC-1800, EC-1805
EGRC/V — Wiring diagram …………. EC-1792, EC-1796,
EC-1801, EC-1806
Electric throttle control actuator …….. EC-291, EC-293,
EC-305, EC-635, EC-637, EC-649, EC-1082, EC-1084,
EC-1430, EC-1433
Electrical diagnoses …………………………………….. GI-12
Electrical load signal circuit EC-419, EC-735, EC-1207,
EC-1528
Electrical unit …………………………………………….. PG-90
Electrical units location ……………………………….. PG-82
Electronic ignition (EI) system EC-36, EC-465, EC-819,
EC-1253
Engine control circuit diagram EC-93, EC-510, EC-881,
EC-1302, EC-1671
Engine control component parts location ………. EC-86,
EC-503, EC-875, EC-1296, EC-1668
Engine control module (ECM) ……….. EC-279, EC-623,
EC-928, EC-1072, EC-1347, EC-1420, EC-1423,
EC-1825, EC-1826, EC-1828
Engine control system diagram ……. EC-816, EC-1250
Engine control system diagram and chart …….. EC-33,
EC-462, EC-1609
Engine coolant ……………………… CO-8, CO-27, CO-48
Engine coolant temperature sensor (ECTS) … EC-166,
EC-565, EC-947, EC-1361, EC-1727
Engine fail-safe system …….. EC-81, EC-498, EC-870,
EC-1291
Engine oil ……………………………….. LU-6, LU-16, LU-23
Engine oil filter replacement(CR) …………………. MA-35
Engine oil filter replacement(HR) …………………. MA-46
Engine oil filter replacement(K9K) ……………….. MA-54
Engine oil precautions …………………………………… GI-7
Engine oil replacement(CR) ………………………… MA-34
Engine oil replacement(HR) ………………………… MA-45
Engine oil replacement(K9K) ………………………. MA-53
Engine removal …………………………… EM-184, EM-279
Engine room cover ………………………. EM-121, EM-241
Engine serial number …………………………………… GI-47
ETC1 — Wiring diagram …. EC-294, EC-638, EC-1085,
EC-1434
ETC2 — Wiring diagram …. EC-301, EC-645, EC-1092,
EC-1441
ETC3 — Wiring diagram …. EC-306, EC-650, EC-1097,
EC-1446
EVAP canister ……. EC-43, EC-472, EC-826, EC-1260
EVAP canister purge volume control solenoid valve ….
EC-40, EC-270, EC-469, EC-737, EC-1063, EC-1530
EVAP vapor lines inspection(CR) ………………… MA-37
EVAP vapor lines inspection(HR) ………………… MA-48
Evaporative emission (EVAP) system EC-40, EC-469,
EC-823, EC-1257
Exhaust manifold ………………………… EM-124, EM-253
Exhaust system inspection ………………… EX-3, MA-55

F
F/FOG — Wiring diagram ……………………………… LT-76
F/PUMP — Wiring diagram EC-428, EC-751, EC-1216,
EC-1544, EC-1760
Floor trim ……………………………………………………. EI-29
Flow charts ………………………………………………… GI-25
Fluid temperature sensor (A/T) …………………… AT-114
Fluids ………………………………………………………. MA-24
Fluorescent leak detector ………….. ATC-147, MTC-93
Flywheel (clutch) ………………………………………… CL-13
Flywheel runout ………………………………………. EM-214
Fog lamp, front …………………………………………… LT-73
Freeze frame data . EC-50, EC-478, EC-834, EC-893,
EC-1266, EC-1314
FRO2 — Wiring diagram …. EC-757, EC-764, EC-1550,
EC-1558
Front axle ………………………………………………….. FAX-6
Front bumper ……………………………………………….. EI-4
Front disc brake …………………………………………. BR-21
Front fog lamp ……………………………………………. LT-73
Front passenger air bag ……………………………. SRS-40
Front seat ……………………………………………………. SE-7
Front seat belt …………………………………….. SB-3, SB-4
Front seat belt pre-tensioner SB-2, SB-3, SB-4, SRS-3
Front side air bag …………………………………….. SRS-42
Front suspension ………………………………………. FSU-5
Front washer ……………………………………………… WW-4
Front wiper ………………………………………………… WW-4
FRPS — Wiring diagram ……………………………. EC-1737
FTS — Wiring diagram ………………………………. EC-1733
FUEL — Wiring diagram …. EC-220, EC-228, EC-1014,
EC-1021
Fuel check valve …………………………… EC-40, EC-469
Fuel cut control (at no load high engine speed) EC-36,
EC-465, EC-820, EC-1254
Fuel filter ……………………………………………….. EC-1625
Fuel filter replacement ………………………………… FL-26
Fuel gauge ………………………………………………… FL-29
Fuel injection control system ……………………. EC-1612
Fuel injection system ……. EC-218, EC-226, EC-1012,
EC-1019, EC-1719
Fuel injector . EC-1209, EC-1537, EC-1625, EC-1740,
EC-1745
Fuel injector and fuel tube ………………………… EM-135
Fuel line inspection …………………………….. FL-3, FL-14
Fuel line inspection(CR) …………………………….. MA-33
Fuel line inspection(HR) …………………………….. MA-44
Fuel line inspection(K9K) ……………………………. MA-52
Fuel precautions …………………………………………… GI-5
Fuel pressure check EC-71, EC-488, EC-860, EC-1281
Fuel pressure release ………. EC-71, EC-488, EC-860,
EC-1281
Fuel pump …….. EC-427, EC-750, EC-1215, EC-1543,
EC-1721, EC-1759
Fuel pump and gauge …………………………. FL-4, FL-15
Fuel rail pressure sensor …………………………. EC-1736
Fuel system …………………………….. FL-3, FL-14, FL-25
Fuel tank …………………………………. FL-8, FL-19, FL-31

IDX-4

ALPHABETICAL INDEX
Fuel tank vacuum relief valve ………. EC-826, EC-1260
Fuel temperature sensor …………………………. EC-1732
Fuse …………………………………………………………. PG-17
Fuse and fusible link box …………………………….. PG-96
Fusible link ………………………………………………… PG-17
G
Garage jack and safety stand ……………………….. GI-40
Generator …………………………………………………. SC-15
Generator — See Alternator ………………………….. SC-15
Generic scan tool (GST) ……………….. EC-111, EC-900
GLOW — Wiring diagram ……………. EC-1785, EC-1789
Glow control system …… EC-1619, EC-1784, EC-1788
Glow plug …………………………………. EM-260, EC-1620
Grease ……………………………………………………… MA-24
Grille — See Exterior ……………………………………… EI-10
Ground distribution …………………………………….. PG-38
H
H/AIM — Wiring diagram ……………………………….. LT-68
H/LAMP — Wiring diagram …………………………….. LT-11
Harness connector …………………………………….. PG-88
Harness layout …………………………………………… PG-48
Hazard warning lamp …………………………………… LT-98
Headlamp aiming control ……………………………… LT-68
Headlamp leveler — See Headlamp aiming control …….
LT-68
Headlamp washer …………………………………….. WW-73
Headlining — See Roof trim ……………………………. EI-30
Heated oxygen sensor 1 ….. EC-178, EC-185, EC-195,
EC-310, EC-316, EC-577, EC-584, EC-756, EC-959,
EC-967, EC-977, EC-1101, EC-1107, EC-1373,
EC-1381, EC-1549
Heated oxygen sensor 1 heater ……. EC-143, EC-763,
EC-985, EC-1557
Heated oxygen sensor 2 ….. EC-203, EC-210, EC-322,
EC-330, EC-591, EC-768, EC-991, EC-998, EC-1113,
EC-1121, EC-1388, EC-1563
Heated oxygen sensor 2 heater ……. EC-149, EC-774,
EC-1006, EC-1569
Heated seat ………………………………………………… SE-4
Height (Dimensions) ……………………………………. GI-48
HFC134a (R134a) system precaution .. ATC-4, MTC-4
HFC134a (R134a) system service procedure ATC-135,
MTC-81
HFC134a (R134a) system service tools ……… ATC-12,
MTC-12
HFC134a system service equipment precaution ……….
ATC-8, MTC-8
HLC — Wiring diagram ……………………………….. WW-75
HO2S1 — Wiring diaram …… EC-180, EC-188, EC-198,
EC-579, EC-586, EC-961, EC-970, EC-980, EC-1375,
EC-1383
HO2S1H — Wiring diagram …………….. EC-145, EC-987
HO2S2 — Wiring diagram …. EC-205, EC-213, EC-325,
EC-333, EC-593, EC-993, EC-1001, EC-1116,
EC-1124, EC-1390

HO2S2H — Wiring diagram …………… EC-151, EC-1008
Horn ……………………………………………………….. WW-89
HORN — Wiring diagram …………………………….. WW-89
How to erase DTC ………………………………….. EC-1628
How to erase DTC for OBD system …. EC-57, EC-478,
EC-841, EC-1267
HSEAT — Wiring diagram ………………………………. SE-5
I
IATS — Wiring diagram …… EC-163, EC-944, EC-1716
IATSEN — Wiring diagram ……………. EC-780, EC-1576
Identification plate ……………………………………….. GI-47
Idle air volume learning …….. EC-69, EC-486, EC-858,
EC-1279
Idle speed EC-66, EC-483, EC-851, EC-856, EC-1272,
EC-1277
Idle speed control (ISC) …………………………… EC-1616
Ignition coil ……… EM-132, EC-433, EC-784, EC-1221,
EC-1580
Ignition control system ….. EC-433, EC-784, EC-1221,
EC-1580
Ignition timing ……… EC-66, EC-483, EC-851, EC-856,
EC-1272, EC-1277
IGNSYS — Wiring diagram EC-434, EC-785, EC-1222,
EC-1581
In vehicle sensor ……………………… ATC-102, ATC-115
INJECT — Wiring diagram . EC-422, EC-745, EC-1210,
EC-1538, EC-1741, EC-1746
Injector ………….. EC-421, EC-744, EC-1209, EC-1537
Injector adjustment value …………………………. EC-1731
Injector adjustment value registration ………… EC-1625
Intake air system ………………………….. EC-338, EC-654
Intake air temperature sensor ……….. EC-161, EC-779,
EC-942, EC-1575, EC-1715
Intake door control linkage adjustment ……….. ATC-70,
MTC-38, MTC-70
Intake door motor ………………………. ATC-68, ATC-124
Intake manifold ……………………………………….. EM-120
Intake sensor ………………………….. ATC-108, ATC-117
Intake valve timing control . EC-139, EC-554, EC-930,
EC-1349
Intake valve timing control solenoid valve …… EC-286,
EC-630, EC-930, EC-1077, EC-1349, EC-1425
Interior lamp ……………………………………………… LT-150
IPDM (Intelligent power distribution module engine
room) ……………………………………………………….. PG-18
ISO 15031-2 Terminology …………………………….. GI-49
ISO 15031-5 Service $01 — 09 …………. EC-47, EC-830
IVC — Wiring diagram ……. EC-287, EC-631, EC-1078,
EC-1426
K
Keyless entry system — See Multi-remote control system
BL-111
Knock sensor (KS) ……….. EC-246, EC-605, EC-1038,
EC-1401, EC-1770
Knuckle spindle ………………………………………….. FAX-6

IDX-5

A

B

C

D

E

F

G

H

I

J

K

L

IDX

ALPHABETICAL INDEX
KS — Wiring diagram ……… EC-247, EC-606, EC-1039,
EC-1402, EC-1771
L
Length (Dimensions) ……………………………………. GI-48
Line pressure test (A/T) ………………………………. AT-56
Liquid gasket application ……. EM-106, EM-228, LU-3,
LU-13, CO-3, CO-22
Location of electrical units …………………………… PG-82
Lubricant (R134a) A/C ……. ATC-5, ATC-17, ATC-151,
MTC-5, MTC-17, MTC-97
Lubricants ………………………………………………… MA-24
Lubrication circuit (engine) ………………….. LU-5, LU-15
Lubrication oil A/C ……………………… ATC-151, MTC-97
Lubrication-locks, hinges and hood latches …… MA-61
Luggage compartment trim …………………………… EI-32
M
MAFS — Wiring diagram .. EC-937, EC-1356, EC-1723
Magnet clutch …………………………….. ATC-78, MTC-43
MAIN — Wiring diagram …… EC-128, EC-543, EC-918,
EC-1337, EC-1698
Malfunction indicator (MI) ……………….. EC-58, EC-479
Malfunction indicator lamp (MIL) …… EC-843, EC-1268
Manifold absolute pressure (MAP) sensor …… EC-155,
EC-559
Manual air conditioner — Wiring diagram ……… MTC-26
Mass air flow sensor (MAFS) ………. EC-935, EC-1354,
EC-1722
Master cylinder (brake) ……………………………….. BR-14
MIL data link connectors circuit ….. EC-1236, EC-1596
MIL/DL — Wiring diagram .. EC-448, EC-800, EC-1236,
EC-1596, EC-1869
Mirror, door ………………………………………………. GW-96
Mirror, out side ………………………………………….. GW-96
Misfire ……………………….. EC-240, EC-1032, EC-1768
Mode door control linkage adjustment ………… ATC-62,
MTC-36, MTC-72
Mode door motor ………………………. ATC-60, ATC-126
Model variation …………………………………………… GI-45
Molding — See Exterior ………………. EI-16, EI-17, EI-19
Multiport fuel injection (MFI) system … EC-34, EC-463,
EC-817, EC-1251
Multiport fuel injection precautions ………………….. GI-6
Multi-remote control system ……………………….. BL-111
N
NATS — Wiring diagram ……………………………… BL-219
NATS (Nissan anti-theft system) precautions ……. GI-3
NVH troubleshooting (BR) ……………………. BR-5, PB-2
NVH troubleshooting (RSU) ………………………… RSU-4
NVH troubleshooting (ST) ……………………………… PS-4
O
Oil cooler (engine) ……………………………………… LU-27

Oil filter ………………………………….. LU-9, LU-19, LU-25
Oil pan (engine) ………………………….. EM-127, EM-257
Oil pressure (engine) ………………. LU-6, LU-16, LU-23
Oil pump (engine) ……………………………. LU-10, LU-26
Oil seal replacement (engine) ……………………. EM-170
Oil vapour rebreathing …………………………….. EC-1622
On board diagnostic system EC-47, EC-476, EC-830,
EC-1264, EC-1628
Out side mirror …………………………………………. GW-96
Overdrive control switch ….. AT-197, AT-202, AT-288,
AT-293
Overheat ………. EC-345, EC-662, EC-1130, EC-1451,
EC-1864
Oversize piston ……………………………………….. EM-210
P
Park/Neutral position switch ………… EC-371, EC-688,
EC-1158, EC-1479
Park/neutral position switch (A/T) ….. AT-105, AT-197,
AT-288
Parking brake control ……………………………………. PB-3
PCV (positive crankcase ventilation) . EC-45, EC-474,
EC-828, EC-1262
PGC/V — Wiring diagram . EC-272, EC-1065, EC-1531
PHASE — Wiring diagram . EC-259, EC-618, EC-1051,
EC-1415
Piston assembly ………………………….. EM-210, EM-326
Piston pin inspection ………………………………… EM-326
Piston ring inspection …………………… EM-207, EM-327
Piston to bore clearance …………………………… EM-210
PNP/SW — Wiring diagram EC-373, EC-689, EC-1160,
EC-1480
POS — Wiring diagram …… EC-252, EC-611, EC-1044,
EC-1407
POWER — Wiring diagram …………………………….. PG-5
Power door lock …………………………………………. BL-16
Power socket …………………………………………… WW-91
Power steering gear ……………………………………… PS-9
Power supply routing …………………………………… PG-4
Power transistor …………………………………….. ATC-127
Power window …………………… GW-32, GW-89, GW-93
Precations for Leak detection dye … ATC-11, MTC-11
Precautions (General) ……………………………………. GI-4
PRGVLV — Wirng diagram ………………………….. EC-738
R
R/FOG — Wiring diagram ……………………………… LT-90
Radiator …………………………….. CO-12, CO-31, CO-51
Radiator fan — See Cooling fan ……………………. CO-52
Radio — See Audio ………………………………………… AV-3
Rain sensor ……………………………………………….. WW-4
Rear axle …………………………………………………. RAX-5
Rear bumper ………………………………………………… EI-8
Rear combination lamp removal and installation ……….
LT-149
Rear drum brake ………………………………………… BR-27
Rear seat ………………………………………………….. SE-12

IDX-6

ALPHABETICAL INDEX
Rear seat belt ……………………………………………… SB-4
Rear suspension ……………………………………….. RSU-5
Rear washer ……………………………………………. WW-49
Rear window defogger ……………………………….. GW-12
Rear wiper ………………………………………………. WW-49
Refrigerant connection precaution …….. ATC-5, MTC-5
Refrigerant discharging evacuating charging ATC-135,
MTC-81
Refrigerant general precaution …………. ATC-4, MTC-4
Refrigerant lines ……………………….. ATC-135, MTC-81
Refrigerant pressure sensor …………. EC-443, EC-794,
EC-1231, EC-1590, EC-1811, ATC-85, MTC-51
Refrigeration cycle ………………………. ATC-15, MTC-15
Removal and installation (A/T) …………………… AT-356
Road test …………………… AT-58, AT-61, AT-64, AT-65
Road wheel size …………………………………………. GI-48
Rocker cover ……………………………… EM-140, EM-270
Roof trim …………………………………………………….. EI-30
Room lamp — See Interior lamp ……………………. LT-150
ROOM/L — Wiring diagram ………………………….. LT-155
RP/SEN — Wiring diagram . EC-444, EC-795, EC-1232,
EC-1591, EC-1812
RRO2 — Wiring diagram …. EC-769, EC-775, EC-1564,
EC-1570
S
S/LOCK — Wiring diagram BL-21, BL-27, BL-65, BL-72
Seat belt inspection …………………………… SB-5, MA-61
Seat belt pre-tensioner ………………………… SB-3, SB-4
Seat belt pre-tensioner disposal …………………. SRS-49
Seat belt, front ……………………………………. SB-3, SB-4
Seat belt, rear ……………………………………………… SB-4
Seat, front …………………………………………………… SE-7
Seat, rear ………………………………………………….. SE-12
Self-diagnostic results ………………… EC-893, EC-1313
SEN/PW — Wiring diagram EC-364, EC-681, EC-1151,
EC-1472, EC-1830
Sheft warning system ………………………………… BL-214
SHIFT — Wiring diagram …………………………….. AT-339
Shift lock system ………………………………………. AT-338
Shift schedule ……………………………………………. AT-67
Shock absorber (front) ………………………………… FSU-8
Shock absorber (rear) ………………………………… RSU-7
Side air bag ……………………………….. SRS-42, SRS-44
Side air bag (satellite) sensor …………………….. SRS-46
Side curtain air bag …………………………………… SRS-44
Side trim …………………………………………………….. EI-26
SMJ (super multiple junction) ………………………. PG-92
Spare tire size …………………………………………….. GI-48
Spark plug ………………………………………………. EM-133
Spark plug replacement(CR) ……………………….. MA-36
Spark plug replacement(HR) ……………………….. MA-47
Specification value EC-117, EC-532, EC-907, EC-1326
Spiral cable ……………………………………………… SRS-38
Spot lamp ………………………………………………… LT-171
SRS — See Supplemental Restraint System …… SRS-5
SRS — Wiring diagram ………………….. SRS-11, SRS-12
SRS Trouble diagnoses ………………………………. SRS-8

Stabilizer bar (front) ………………………………….. FSU-11
Stall test (A/T) ……………………………………………. AT-53
Standardized relay ……………………………………… PG-93
START — Wiring diagram …………………… SC-46, SC-48
Starter ………………………………………………………. SC-45
Starting system ………………………………………….. SC-45
Steering gear and linkage inspection ……………. MA-60
Steering linkage …………………………………………… PS-9
Steering wheel and column ………………….. PS-5, PS-7
Steering wheel play ……………………………………… PS-5
Steering wheel turning force ………………………….. PS-5
Stop lamp …………………………………………………. LT-129
Stop lamp switch EC-377, EC-693, EC-1167, EC-1487,
EC-1820, EC-1850
STOP/L — Wiring diagram ……………………………. LT-129
Sunload sensor ……………………….. ATC-105, ATC-116
Super lock …………………………………………………. BL-59
Supplemental Restraint System ………………….. SRS-5
Supplemental restraint system — Wiring diagram ……….
SRS-11, SRS-12
Suspension ………………………………………………. MA-60
Symbols and abbreviations …………………. GI-11, GI-23
Symptom matrix chart ………. EC-82, EC-499, EC-871,
EC-1292
SYSTEM ………………………………………………….. BRC-6
System readiness test (SRT) code …… EC-51, EC-834
T
TC boost control solnoid valve ………………….. EC-1710
TC boost sensor …………………………………….. EC-1763
TCBST-Wiring diagram ……………………………. EC-1764
TCC/V — Wiring diagram …………………………… EC-1711
TCM inspection table ………………………………….. AT-80
THEFT — Wiring diagram ……………………………. BL-214
Thermo control amp …………………………………. MTC-64
Thermostat …………………………………….. CO-19, CO-38
Three way catalyst function …………. EC-264, EC-1056
Three way catalyst precautions ………………………. GI-5
Throttle control motor … EC-1084, EC-1096, EC-1433,
EC-1445
Throttle control motor relay EC-299, EC-643, EC-1084,
EC-1090, EC-1433, EC-1439
Throttle position sensor (TPS) ………. EC-171, EC-233,
EC-359, EC-361, EC-402, EC-570, EC-598, EC-676,
EC-678, EC-718, EC-953, EC-1026, EC-1146,
EC-1148, EC-1191, EC-1367, EC-1395, EC-1467,
EC-1469, EC-1511
Throttle valve closed position learning EC-69, EC-486,
EC-857, EC-1279
Tie-rod ……………………………………………………….. PS-9
Tie-rod ball joints …………………………………………. PS-9
Tightening torque of standard bolts ……………….. GI-44
Timing belt ……………………………………………… EM-272
Timing chain …………………………………………… EM-142
Tire size …………………………………………………….. GI-48
Torque converter installation …………. AT-358, AT-465
Tow truck towing …………………………………………. GI-42
TPS1 — Wiring diagram …. EC-235, EC-600, EC-1028,

IDX-7

A

B

C

D

E

F

G

H

I

J

K

L

IDX

ALPHABETICAL INDEX
EC-1397
TPS2 — Wiring diagram …… EC-173, EC-572, EC-955,
EC-1369
TPS3 — Wiring diagram …. EC-404, EC-720, EC-1193,
EC-1513
Tread-FR&RR (Dimensions) …………………………. GI-48
Trouble diagnoses ………………………………………. GI-12
Trouble diagnosis-Basic test procedure …….. EC-1660
Trouble diagnosis-Symptom …………………….. EC-1634
Turbocharger ………………………………………….. EM-253
Turbocharger precautions ………………………………. GI-6
TURN — Wiring diagram ……………………………… LT-101
Turn signal lamp …………………………………………. LT-98
Two trip detection logic …….. EC-47, EC-476, EC-830,
EC-1264

WIPER — Wiring diagram ……………………………. WW-13
Wiring Diagram (Cell code) list ……………………. PG-79
Wiring diagrams ………………………………………….. GI-16
Wrist pin — See Piston pin inspection ………….. EM-206

V
Vacuum hose (brake system) ………………………. BR-19
Vacuum hose drawing (Engine control) ………… EC-92,
EC-509, EC-880, EC-1301, EC-1611
Vacuum pump …………………………………………. EM-261
Valve clearance …………….. EM-166, EM-292, EM-324
Valve guide ………………………………… EM-179, EM-322
Valve lifter ………………………………………………. EM-160
Valve seat ………………………………….. EM-181, EM-322
Valve spring ……………………………….. EM-182, EM-324
VDC -Wiring diagram ……………………………….. BRC-54
Vehicle identification number ………………………… GI-46
Vehicle recovery (freeing a stuck vehicle) ………. GI-42
Vehicle speed sensor (VSS) …………. EC-277, EC-799,
EC-1070, EC-1595, EC-1810
Ventilation air filter …………………….. ATC-129, MTC-75
Viscosity number (SAE) ……………………………… MA-25
W
WARN — Wiring diagram …………………….. DI-34, DI-40
Warning chime ……………………………………………. DI-53
Warning lamps ……………………………………………. DI-33
Water pump ……………………….. CO-17, CO-36, CO-54
Wheel alignment (front) ………………………………. FSU-6
Wheel alignment (rear) ………………………………. RSU-6
Wheel bearing (front) ………………………………….. FAX-6
Wheel bearing (rear) ………………………………….. RAX-5
Wheel hub (front) ……………………………………….. FAX-6
Wheel hub (rear) ……………………………………….. RAX-5
Wheel sensor (VDC) ………………………………… BRC-86
Wheel sensors (ABS) ………………………………. BRC-36
Wheel size …………………………………………………. GI-48
Wheelbase (Dimensions) ……………………………… GI-48
Width (Dimensions) …………………………………….. GI-48
WINDOW — Wiring diagram …………….. GW-41, GW-45
Window antenna ………………………………………… AV-11
Window, back …………………………………………… GW-10
Window, back door ……………………………………. GW-10
Window, door ……………………………….. GW-89, GW-93
Windshield …………………………………………………. GW-5
WIP/R — Wiring diagram ………………… WW-51, WW-54

IDX-8

AUDIO, VISUAL & TELEPHONE SYSTEM

K ELECTRICAL

SECTION

AV

AUDIO, VISUAL & TELEPHONE SYSTEM

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 2
AUDIO ………………………………………………………………. 3
System Description ………………………………………….. 3
SPEED DEPENDENT VOLUME SYSTEM ……….. 3
Component parts Location ………………………………… 3
Wiring Diagram —AUDIO— ………………………………. 4
Terminals and Reference Value for Audio Unit ……… 6
Symptom Chart ……………………………………………….. 8
Steering Switch Resistance Check …………………….. 9
Removal and Installation of Audio Unit ……………….. 9
REMOVAL ……………………………………………………. 9
INSTALLATION …………………………………………….. 9

Removal and Installation of Front Door Speaker ….. 9
REMOVAL ……………………………………………………. 9
INSTALLATION …………………………………………….. 9
Removal and Installation of Rear Door Speaker ….. 9
REMOVAL ……………………………………………………. 9
INSTALLATION …………………………………………… 10
Removal and Installation of Tweeter …………………. 10
REMOVAL ………………………………………………….. 10
INSTALLATION …………………………………………… 10
AUDIO ANTENNA ……………………………………………. 11
Location of Antenna ………………………………………… 11
Removal and Installation of Roof Antenna …………. 11
REMOVAL ………………………………………………….. 11
INSTALLATION …………………………………………… 11

E

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AV

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AV-1

PRECAUTIONS
PFP:00011
PRECAUTIONS
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

BKS001AK

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

AV-2

AUDIO
AUDIO
System Description

PFP:28111

A
BKS001AL

Refer to Owner’s Manual for audio system operating instructions.
B

SPEED DEPENDENT VOLUME SYSTEM
Volume level of this system turns up and down automatically in proportion to the vehicle speed. And the control level can be selected by the customer.

C

Component parts Location

BKS001C2

D

E

F

G

H

I

J

AV
SKIB8381E

L

M

AV-3

AUDIO
Wiring Diagram —AUDIO—

BKS001AM

MKWA4265E

AV-4

AUDIO
A

B

C

D

E

F

G

H

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J

AV

L

M

MKWA4266E

AV-5

AUDIO
Terminals and Reference Value for Audio Unit
Terminal No.
(wire color)
(+)

(–)

4 (B)

Ground

Item

Ground

Signal
input/
output
—

BKS001AO

Condition
Voltage
Ignition
switch

Operation

ON

—
Press MODE switch

10 (L)

Ground

Remote control A

Input

ON

Ground

Remote control B

Input

ON

Approx. 1.7 V

Press VOL UP switch

Approx. 3.3 V

—

Remote control GND

—

ON

21 (B)

22 (O)

Audio signal rear RH

Output

ON

Approx. 5 V

Press SEEK DOWN
switch

Approx. 1.7 V

Press VOL DOWN
switch

Approx. 3.3 V

Except for above
12 (R)

Approx. 0 V

Press SEEK UP switch

Except for above

11 (W)

Approx. 0 V

—

Approx. 5 V
Approx. 0 V

Receive audio signal

SKIA0177E

23 (W)

24 (R)

Audio signal front RH

Output

ON

Receive audio signal

SKIA0177E

25 (V)

26 (P)

Audio signal front LH

Output

ON

Receive audio signal

SKIA0177E

27 (G)

28 (GR)

Audio signal rear LH

Output

ON

Receive audio signal

SKIA0177E

31 (R)

Ground

Vehicle speed signal
(2-pulse)

Input

ON

34 (LG)

Ground

Battery power supply

Input

OFF

When vehicle speed is
approx. 40 km/h (25
MPH)
ELF1080D

AV-6

—

Battery voltage

AUDIO
Terminal No.
(wire color)
(+)

36 (V)

Item

(–)

Ground

Illumination signal

37 (L)

Ground

ACC power

38 (B)

Ground

Ground

Signal
input/
output

Input

Condition

A
Voltage

Ignition
switch
ON

Operation
Lighting switch is ON
(position 1).

Approx. 12 V

Turn lighting switch OFF.

Approx. 0 V

Input

ACC

—

Battery voltage

—

ON

—

Approx. 0 V

B

C

D

E

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AV

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AV-7

AUDIO
Symptom Chart
●

●

BKS001C3

The majority of the audio malfunctions are the result of outside causes (bad CD/cassette, electromagnetic
interference, etc.). Check the symptoms below to diagnose the malfunction.
The vehicle itself can be a source of noise if noise prevention parts or electrical equipment is malfunctioning. Check if noise is caused and/or changed by engine speed, ignition switch turned to each position, and
operation of each piece of electrical equipment, and then determine the cause.
NOTE:
● CD-R is not guaranteed to play because they can contain compressed audio (MP3, WMA) or could be
incorrectly mastered by the customer on a computer.
● Check if the CDs carry the Compact Disc Logo. If not, the disc is not mastered to the “red book” Compact Disc Standard and may not play.
Symptom

Probable malfunction location
●

Audio unit power supply circuit

●

Audio unit

●

Remote control signal circuit between steering switch and combination
switch (spiral cable)

●

Remote control signal circuit between combination switch (spiral cable)
and audio unit

●

Steering wheel audio control switch

●

Combination switch (spiral cable)

●

Audio unit

●

Audio unit

●

Audio signal circuit between audio unit and speaker

●

Speaker

●

Tweeter

●

Audio unit

●

Antenna feeder

●

Roof antenna

●

Audio unit

●

Vehicle speed signal circuit between combination meter and audio unit

●

Audio unit

●

Combination meter

Audio system does not work properly.

Audio steering wheel switch does not operate properly.

No sound can be heard from all speakers.

No sound can be heard from one or several speakers.

No sound can be heard from radio or noise is caught.

Speed dependent volume system does not function.

NOTE:
Noise resulting from variations in field strength, such as fading noise and multi-path noise, or external noise
from trains and other sources, is not a malfunction.
●
Fading noise: This noise occurs because of variations in the field strength in a narrow range due to mountains or buildings blocking the signal.
●
Multi-path noise: This noise results from a time difference between the broadcast waves directly from the
station arriving at the antenna and the waves reflected by mountains or buildings.

AV-8

AUDIO
Steering Switch Resistance Check

BKS001AP

A

Check continuity between steering switch harness connector terminals 14, 15 and 16.
Resistance value
14 − 16
MODE ON
SEEK UP ON
VOL UP ON

:0−1Ω
: 164 − 166 Ω
: 646 − 658 Ω

15 − 16
SEEK DOWN ON
VOL DOWN ON

: 164 − 166 Ω
: 646 − 658 Ω

B

Removal and Installation of Audio Unit

C

D
SKIB8537E

BKS001AU

E

REMOVAL
1.
2.

Remove cluster lid C. Refer to IP-8, «K. Cluster Lid C» .
Remove screws (A) and remove audio unit (1) and bracket.

F

G

H

SKIB3963J

I

INSTALLATION
Install in the reverse order of removal.

J

Removal and Installation of Front Door Speaker

BKS001AV

REMOVAL
1.
2.

Remove front door finisher. Refer to EI-20, «DOOR FINISHER» .
Remove screws (A) and remove speaker (1).

AV

L

M

SKIB3965J

INSTALLATION
Install in the reverse order of removal.

Removal and Installation of Rear Door Speaker
REMOVAL
1.

Remove rear side finisher. Refer to EI-20, «DOOR FINISHER» .

AV-9

BKS001AW

AUDIO
2.

Remove screws (A) and remove speaker (1).

SKIB3965J

INSTALLATION
Install in the reverse order of removal.

Removal and Installation of Tweeter

BKS001AZ

REMOVAL
1.
2.

Remove corner cover inner. Refer to GW-96, «DOOR MIRROR» .
Remove screws (A) and remove tweeter.

SKIB8634E

INSTALLATION
Install in the reverse order of removal.

AV-10

AUDIO ANTENNA
AUDIO ANTENNA
Location of Antenna

PFP:28200

A
BKS001B0

B

C

D

E

F

G

H

I
SKIB8382E

Removal and Installation of Roof Antenna

BKS001B1

J

REMOVAL
1.
2.

: Vehicle front
Remove headliner. Refer to EI-30, «HEADLINER» .
Remove roof antenna mounting nut (A) and antenna feeder (1).
Then remove roof antenna.

AV

L

M

SKIB8635E

INSTALLATION
Install in the reverse order of removal.
Roof Antenna mounting nut
: 4.0 N·m (0.41 kg-m, 35 in-lb)

AV-11

AUDIO ANTENNA

AV-12

AUTOMATIC AIR CONDITIONER

J AIR CONDITIONER

SECTION

ATC

AUTOMATIC AIR CONDITIONER

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 4
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 4
PrecautionsforProcedureswithoutCowlTopCover….. 4
Precautions for Working with HFC-134a (R-134a)….. 4
General Refrigerant Precautions ………………………… 4
Lubricant Precautions ………………………………………. 5
Precautions for Refrigerant Connection ………………. 5
FEATURES OF NEW TYPE REFRIGERANT
CONNECTION ……………………………………………… 5
O-RING AND REFRIGERANT CONNECTION….. 6
Precautions for Servicing Compressor ………………… 8
Precautions for Service Equipment …………………….. 8
RECOVERY/RECYCLING EQUIPMENT ………….. 8
ELECTRONIC LEAK DETECTOR …………………… 8
VACUUM PUMP …………………………………………… 9
MANIFOLD GAUGE SET ……………………………….. 9
SERVICE HOSES …………………………………………. 9
SERVICE COUPLERS …………………………………. 10
REFRIGERANT WEIGHT SCALE …………………. 10
CALIBRATING ACR4 WEIGHT SCALE ………….. 10
CHARGING CYLINDER ……………………………….. 10
Precautions for Leak Detection Dye ……………………11
IDENTIFICATION ………………………………………….11
IDENTIFICATION LABEL FOR VEHICLE …………11
PREPARATION ………………………………………………… 12
HFC-134a (R-134a) Service Tools and Equipment… 12
Commercial Service Tools ……………………………….. 14
REFRIGERATION SYSTEM ………………………………. 15
Refrigerant Cycle …………………………………………… 15
REFRIGERANT FLOW ………………………………… 15
FREEZE PROTECTION ………………………………. 15
Refrigerant System Protection …………………………. 15
REFRIGERANT PRESSURE SENSOR …………. 15
PRESSURE RELIEF VALVE …………………………. 15
Component Layout …………………………………………. 16

LUBRICANT …………………………………………………….. 17
Maintenance of Lubricant Quantity in Compressor… 17
LUBRICANT ……………………………………………….. 17
LUBRICANT RETURN OPERATION ……………… 17
LUBRICANT ADJUSTING PROCEDURE FOR
COMPONENTS REPLACEMENT EXCEPT
COMPRESSOR ………………………………………….. 18
LUBRICANT ADJUSTING PROCEDURE FOR
COMPRESSOR REPLACEMENT ………………….. 18
AIR CONDITIONER CONTROL …………………………. 20
System Construction ………………………………………. 20
AIR MIX DOOR CONTROL (AUTOMATIC TEMPERATURE CONTROL) ………………………………. 20
FAN SPEED CONTROL ……………………………….. 20
INTAKE DOOR CONTROL …………………………… 20
OUTLET DOOR CONTROL ………………………….. 20
MAGNET CLUTCH CONTROL ……………………… 21
SELF-DIAGNOSTIC SYSTEM ………………………. 21
Description of Control System ………………………….. 22
Control Operation …………………………………………… 22
DISPLAY SCREEN ………………………………………. 23
AUTO SWITCH …………………………………………… 23
TEMPERATURE CONTROL SWITCH (POTENTIO TEMPERATURE CONTROL) ………………….. 23
RECIRCULATION (REC) SWITCH ………………… 23
FRESH (FRE) SWITCH ……………………………….. 23
DEFROSTER (DEF) SWITCH ……………………….. 23
REAR WINDOW DEFOGGER SWITCH …………. 23
OFF SWITCH ……………………………………………… 23
A/C SWITCH ………………………………………………. 23
MODE SWITCH ………………………………………….. 23
FAN SWITCH ……………………………………………… 23
Discharge Air Flow …………………………………………. 24
System Description …………………………………………. 25
SWITCHES AND THEIR CONTROL FUNCTION… 25
CAN Communication System Description ………….. 25
TROUBLE DIAGNOSIS …………………………………….. 26
CONSULT-II Function (BCM) …………………………… 26
CONSULT-II BASIC OPERATION ………………….. 26
DATA MONITOR …………………………………………. 26

ATC-1

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ATC

K

L

M

How to Perform Trouble Diagnosis for Quick and
Accurate Repair ……………………………………………… 27
WORK FLOW ……………………………………………… 27
SYMPTOM TABLE ………………………………………. 27
ComponentParts and Harness Connector Location… 28
ENGINE COMPARTMENT ……………………………. 28
PASSENGER COMPARTMENT …………………….. 29
Circuit Diagram ………………………………………………. 30
Wiring Diagram —A/C— CR Engine Models ………. 31
Wiring Diagram —A/C—HR Engine Models ……….. 35
Wiring Diagram —A/C— K9K Engine Models …….. 39
Wiring Diagram —PTC/H— K9K Engine LHD Models ………………………………………………………………… 43
Auto Amp. Terminals and Reference Value ………… 44
PIN CONNECTOR TERMINAL LAYOUT ………… 44
TERMINALS AND REFERENCE VALUE FOR
AUTO AMP. ………………………………………………… 44
Self-diagnosis Function …………………………………… 46
DESCRIPTION ……………………………………………. 46
FUNCTION CONFIRMATION PROCEDURE …… 48
AUXILIARY MECHANISM: TEMPERATURE
SETTING TRIMMER ……………………………………. 54
Operational Check ………………………………………….. 55
CHECKING MEMORY FUNCTION ………………… 55
CHECKING BLOWER ………………………………….. 55
CHECKING DISCHARGE AIR ………………………. 55
CHECKING RECIRCULATION ………………………. 56
CHECKING TEMPERATURE INCREASE ………. 56
CHECKING TEMPERATURE DECREASE ……… 56
CHECK A/C SWITCH …………………………………… 56
CHECKING AUTO MODE …………………………….. 57
Power Supply and Ground Circuit for Auto Amp. … 57
INSPECTION FLOW ……………………………………. 57
COMPONENT DESCRIPTION ………………………. 58
DIAGNOSTIC PROCEDURE FORA/C SYSTEM… 58
Mode Door Motor Circuit …………………………………. 60
INSPECTION FLOW ……………………………………. 60
SYSTEM DESCRIPTION ……………………………… 61
COMPONENT DESCRIPTION ………………………. 62
DIAGNOSTIC PROCEDURE FOR MODE
DOOR MOTOR …………………………………………… 63
Air Mix Door Motor Circuit ……………………………….. 64
INSPECTION FLOW ……………………………………. 64
SYSTEM DESCRIPTION ……………………………… 65
COMPONENT DESCRIPTION ………………………. 66
DIAGNOSTIC PROCEDURE FOR AIR MIX
DOOR MOTOR …………………………………………… 67
Intake Door Motor Circuit …………………………………. 68
INSPECTION FLOW ……………………………………. 68
SYSTEM DESCRIPTION ……………………………… 69
COMPONENT DESCRIPTION ………………………. 70
DIAGNOSTIC PROCEDURE FOR INTAKE
DOOR MOTOR …………………………………………… 70
Blower Motor Circuit ……………………………………….. 71
INSPECTION FLOW ……………………………………. 71
SYSTEM DESCRIPTION ……………………………… 72
DIAGNOSTIC PROCEDURE FOR BLOWER
MOTOR ……………………………………………………… 73
COMPONENT INSPECTION ………………………… 77

Magnet Clutch Circuit ……………………………………….78
INSPECTION FLOW ……………………………………..78
SYSTEM DESCRIPTION ……………………………….79
DIAGNOSTIC PROCEDURE FOR MAGNET
CLUTCH ……………………………………………………..79
COMPONENT INSPECTION ………………………….85
Insufficient Cooling …………………………………………..86
INSPECTION FLOW ……………………………………..86
PERFORMANCE TEST DIAGNOSIS ………………88
PERFORMANCE CHART ………………………………90
TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE ………………………………………………………….91
Insufficient Heating ………………………………………….94
INSPECTION FLOW ……………………………………..94
Noise ……………………………………………………………..96
INSPECTION FLOW ……………………………………..96
Self-diagnosis …………………………………………………97
INSPECTION FLOW ……………………………………..97
Memory Function …………………………………………….98
INSPECTION FLOW ……………………………………..98
Ambient Sensor Circuit …………………………………….99
COMPONENT DESCRIPTION ……………………….99
AMBIENT TEMPERATURE INPUT PROCESS…99
DIAGNOSTIC PROCEDURE FOR AMBIENT
SENSOR ……………………………………………………..99
COMPONENT INSPECTION ……………………….. 101
In-vehicle Sensor Circuit ………………………………… 102
COMPONENT DESCRIPTION …………………….. 102
DIAGNOSTIC PROCEDURE FOR IN-VEHICLE
SENSOR …………………………………………………… 102
COMPONENT INSPECTION ……………………….. 104
Sunload Sensor Circuit ………………………………….. 105
COMPONENT DESCRIPTION …………………….. 105
SUNLOAD INPUT PROCESS ……………………… 105
DIAGNOSTIC PROCEDURE FOR SUNLOAD
SENSOR …………………………………………………… 105
COMPONENT INSPECTION ……………………….. 107
Intake Sensor Circuit ……………………………………… 108
COMPONENT DESCRIPTION …………………….. 108
DIAGNOSTICPROCEDUREFORINTAKESENSOR …………………………………………………………. 108
COMPONENT INSPECTION ……………………….. 110
Engine Coolant Temperature Circuit ………………… 111
CONTROLLER ……………………………………………….. 112
Removal and Installation of Controller ……………… 112
REMOVAL …………………………………………………. 112
INSTALLATION ………………………………………….. 112
Disassembly and Assembly of Controller …………. 112
DISASSEMBLY ………………………………………….. 112
ASSEMBLY ……………………………………………….. 113
AMBIENT SENSOR ………………………………………… 114
Removal and Installation ………………………………… 114
REMOVAL …………………………………………………. 114
INSTALLATION ………………………………………….. 114
IN-VEHICLE SENSOR …………………………………….. 115
Removal and Installation ………………………………… 115
REMOVAL …………………………………………………. 115
INSTALLATION ………………………………………….. 115

ATC-2

SUNLOAD SENSOR ………………………………………..116
Removal and Installation …………………………………116
REMOVAL ………………………………………………….116
INSTALLATION …………………………………………..116
INTAKE SENSOR …………………………………………….117
Removal and Installation …………………………………117
REMOVAL ………………………………………………….117
INSTALLATION …………………………………………..117
A/C UNIT ASSEMBLY ………………………………………118
Removal and Installation …………………………………118
REMOVAL ………………………………………………….118
INSTALLATION …………………………………………. 120
Disassembly and Assembly …………………………… 121
BLOWER MOTOR ………………………………………….. 123
Removal and Installation ……………………………….. 123
REMOVAL ………………………………………………… 123
INSTALLATION …………………………………………. 123
INTAKE DOOR MOTOR ………………………………….. 124
Removal and Installation ……………………………….. 124
REMOVAL ………………………………………………… 124
INSTALLATION …………………………………………. 124
AIR MIX DOOR MOTOR ………………………………….. 125
Removal and Installation ……………………………….. 125
REMOVAL ………………………………………………… 125
INSTALLATION …………………………………………. 125
MODE DOOR MOTOR ……………………………………. 126
Removal and Installation ……………………………….. 126
REMOVAL ………………………………………………… 126
INSTALLATION …………………………………………. 126
POWER TRANSISTOR …………………………………… 127
Removal and Installation ……………………………….. 127
REMOVAL ………………………………………………… 127
INSTALLATION …………………………………………. 127
HEATER CORE ……………………………………………… 128
Removal and Installation ……………………………….. 128
REMOVAL ………………………………………………… 128
INSTALLATION …………………………………………. 128
AIR CONDITIONER FILTER …………………………….. 129
Removal and Installation ……………………………….. 129
FUNCTION ……………………………………………….. 129
REPLACEMENT TIMING ……………………………. 129
REPLACEMENT PROCEDURES ………………… 129
DUCTS AND GRILLES …………………………………… 130
Removal and Installation ……………………………….. 130
REMOVAL ………………………………………………… 130
INSTALLATION …………………………………………. 134
REFRIGERANT LINES ……………………………………. 135
HFC-134a (R-134a) Service Procedure …………… 135
SETTING OF SERVICE TOOLS AND EQUIPMENT ………………………………………………………. 135

Components ………………………………………………… 137
CR ENGINE MODELS ……………………………….. 137
HR ENGINE MODELS ……………………………….. 138
K9K ENGINE MODELS ………………………………. 139
Removal and Installation of Compressor ………….. 140
REMOVAL ………………………………………………… 140
INSTALLATION …………………………………………. 140
CHECK DISC TO PULLEY CLEARANCE ……… 141
Removal and Installation for Pipe and Hose …….. 141
REMOVAL ………………………………………………… 141
INSTALLATION …………………………………………. 141
Removal and Installation for Refrigerant Pressure
Sensor ………………………………………………………… 142
REMOVAL AND INSTALLATION …………………. 142
Removal and Installation for Condenser (Models
without Integrated Condenser) ……………………….. 142
REMOVAL ………………………………………………… 142
INSTALLATION …………………………………………. 143
Removal and Installation for Condenser (Models
with Integrated Condenser) ……………………………. 143
REMOVAL ………………………………………………… 143
INSTALLATION …………………………………………. 143
RemovalandInstallationforLiquidTank(HREngine
with A/T Models) …………………………………………… 144
REMOVAL ………………………………………………… 144
INSTALLATION …………………………………………. 144
RemovalandInstallationfor LiquidTank (ExceptHR
Engine with A/T Models) ………………………………… 144
REMOVAL ………………………………………………… 144
INSTALLATION …………………………………………. 145
Removal and Installation for Evaporator ………….. 145
REMOVAL ………………………………………………… 145
INSTALLATION …………………………………………. 145
Removal and Installation for Expansion Valve …… 145
REMOVAL ………………………………………………… 145
INSTALLATION …………………………………………. 146
Checking for Refrigerant Leaks ………………………. 147
Checking System for Leaks Using the Fluorescent
Leak Detector ………………………………………………. 147
Dye Injection ………………………………………………… 147
Electronic Refrigerant Leak Detector ……………….. 148
PRECAUTIONS FOR HANDLING LEAK
DETECTOR ………………………………………………. 148
CHECKING PROCEDURE …………………………. 149
SERVICE DATA AND SPECIFICATIONS (SDS) …. 151
COMPRESSOR ……………………………………………. 151
LUBRICANT ………………………………………………… 151
REFRIGERANT ……………………………………………. 151
ENGINE IDLING SPEED ……………………………….. 151
BELT TENSION ……………………………………………. 151

ATC-3

A

B

C

D

E

F

G

H

I

ATC

K

L

M

PRECAUTIONS
PFP:00001
PRECAUTIONS
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

BJS000AI

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Precautions for Procedures without Cowl Top Cover

BJS000AJ

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

PIIB3706J

Precautions for Working with HFC-134a (R-134a)

BJS000AK

WARNING:
●
Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor malfunction is likely to occur.
●
The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed:
–
When removing refrigerant components from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
–
When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just
before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system.
–
Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. Without proper sealing, lubricant will become moisture saturated and should not be used.
–
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant
manufacturers.
–
Do not allow lubricant (Nissan A/C System Oil Type R) to come in contact with styrofoam parts.
Damage may result.

General Refrigerant Precautions

BJS000AL

WARNING:
●
Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.

ATC-4

PRECAUTIONS
●

●
●

●
●
●

●

Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
Do not store or heat refrigerant containers above 52°C.
Do not heat a refrigerant container with an open flame; if container warming is required, place the
bottom of the container in a warm pail of water.
Do not intentionally drop, puncture, or incinerate refrigerant containers.
Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air conditioning systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a)
have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause
injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers.

Lubricant Precautions
●

●

–

–

–

●

●

B

C

D

E

BJS000AM

Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components.
F
If lubricant other than that specified is used, compressor malfunction is likely to occur.
The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following
handling precautions must be observed:
When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize G
the entry of moisture from the atmosphere.
When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the H
entry of moisture into system.
Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. WithI
out proper sealing, lubricant will become moisture saturated and should not be used.
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat.
Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety ATC
information may be obtained from refrigerant and lubricant manufacturers.
Do not allow lubricant (Nissan A/C System Oil Type R) to come in contact with styrofoam parts. Damage
may result.
K

Precautions for Refrigerant Connection

BJS000AN

A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
●
Expansion valve to evaporator
●
Refrigerant pressure sensor to condenser

FEATURES OF NEW TYPE REFRIGERANT CONNECTION
●

A

The O-ring has been relocated. It has also been provided with a groove for proper installation. This eliminates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of
the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing
characteristics.

ATC-5

L

M

PRECAUTIONS
●

The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections.

SHA815E

O-RING AND REFRIGERANT CONNECTION
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse Orings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or
around, the connection.

O-Ring Part Numbers and Specifications (CR Engine Models)
Connection type

New

Piping connection point

Part number

Qty.

Low-pressure flexible hose to heater & cooling unit

92473 BC700

1

High-pressure pipe to heater & cooling unit

92471 BC700

1

Condenser to high-pressure flexible hose

92472 BC700

1

Condenser to high-pressure pipe

92471 BC700

1

Compressor to low-pressure flexible hose

92474 BC700

1

Compressor to high-pressure flexible hose

92472 BC700

1

Liquid tank to condenser pipe

92471 N8210

1

—

–

Inlet

92477 AX000

1

Outlet

92477 AX005

1

Refrigerant pressure sensor
Former
Expansion valve to evaporator

Remarks

O-Ring Part Numbers and Specifications (HR Engine Models)
Connection type

New

Part number

Qty.

Low-pressure flexible hose to heater & cooling unit

Piping connection point

92473 N8210

1

High-pressure pipe to heater & cooling unit

92471 N8210

1

Condenser to high-pressure flexible hose

92472 N8210

1

Condenser to high-pressure pipe

92471 N8210

1

Compressor to low-pressure flexible hose

92474 N8210

1

Compressor to high-pressure flexible hose

92472 N8210

1

Liquid tank to condenser pipe

92471 N8210

1

—

–

Inlet

92477 AX000

1

Outlet

92477 AX005

1

Refrigerant pressure sensor
Former
Expansion valve to evaporator

ATC-6

Remarks

PRECAUTIONS
O-Ring Part Numbers and Specifications (K9K Engine Models)
Connection type

New

Piping connection point

Part number

Qty.

Low-pressure flexible hose to heater & cooling unit

92473 N8210

1

Low-pressure flexible hose to Low-pressure pipe

92473 N8210

1

High-pressure pipe to heater & cooling unit

92471 N8210

1

Condenser to high-pressure flexible hose

92472 N8210

1

Condenser to high-pressure pipe

92471 N8210

1

Compressor to low-pressure flexible hose

92474 N8210

1

Compressor to high-pressure flexible hose

92472 N8210

1

Liquid tank to condenser pipe

92471 N8210

1

—

–

Inlet

92477 AX000

1

Outlet

92477 AX005

1

Refrigerant pressure sensor
Former
Expansion valve to evaporator

Remarks

A

B

C

D

E

WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is F
less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.
CAUTION:
G
When replacing or cleaning refrigerant cycle components, observe the following.
●
When the compressor is removed, store it in the same position as it is when mounted on the car.
Malfunction to do so will cause lubricant to enter the low-pressure chamber.
H
●
When connecting tubes, always use a torque wrench and a back-up wrench.
●
After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
●
When installing an air conditioner in the vehicle, connect the pipes as the final stage of the operaI
tion. Do not remove the seal caps of pipes and other components until just before required for
connection.
●
Allow components stored in cool areas to warm to working area temperature before removing seal
ATC
caps. This prevents condensation from forming inside A/C components.
●
Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
●
Always replace used O-rings.
K
●
When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not
to apply lubricant to threaded portion.
Gasoline engine
Name
Parts number
●
●
●

Nissan A/C System Oil Type R
KLH00 — PAGR0

K9K engine
Nissan A/C System Oil Type S
KLH00 — PAGS0

O-ring must be closely attached to dented portion of tube.
When replacing the O-ring, be careful not to damage O-ring and tube.
Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that
the O-ring is installed to tube correctly.

ATC-7

L

M

PRECAUTIONS
●

After connecting line, perform leak test and make sure that there is no leakage from connections.
When the refrigerant leaking point is found, disconnect that line and replace the O-ring. Then
tighten connections of seal seat to the specified torque.

RHA861F

Precautions for Servicing Compressor
●
●
●

●

●

●

BJS000AO

Plug all openings to prevent moisture and foreign matter from entering.
When the compressor is removed, store it in the same position as it is when mounted on the car.
When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compressor” exactly. Refer to ATC-17, «Maintenance of Lubricant Quantity in Compressor» .
Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubricant, wipe it off by using a clean waste cloth moistened with thinner.
After compressor service operation, turn the compressor shaft by hand more than five turns in
both directions. This will equally distribute lubricant inside the compressor. After the compressor
is installed, let the engine idle and operate the compressor for one hour.
After replacing the compressor magnet clutch, apply voltage to the new one and check for usual
operation.

Precautions for Service Equipment

BJS000AP

RECOVERY/RECYCLING EQUIPMENT
Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never
introduce any refrigerant other than that specified into the machine.

ELECTRONIC LEAK DETECTOR
Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance.

ATC-8

PRECAUTIONS
VACUUM PUMP
A

The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric pressure. So the vacuum pump lubricant may migrate out of the pump
into the service hose. This is possible when the pump is switched off
after evacuation (vacuuming) and hose is connected to it.
To prevent this migration, use a manual valve placed near the hoseto-pump connection, as follows.
●
Usually vacuum pumps have a manual isolator valve as part of
the pump. Close this valve to isolate the service hose from the
pump.
●
For pumps without an isolator, use a hose equipped with a manual shut-off valve near the pump end. Close the valve to isolate
the hose from the pump.
●
If the hose has an automatic shut-off valve, disconnect the hose
from the pump. As long as the hose is connected, the valve is
open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.

B

C

D

E

F

G
RHA270DA

H

MANIFOLD GAUGE SET
Be certain that the gauge face indicates HFC-134a or R-134a. Be
sure the gauge set has 1/2″-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) and specified lubricants.

I

ATC

K
SHA533D

SERVICE HOSES

L

Be certain that the service hoses display the markings described
(colored hose with black stripe). All hoses must include positive shutoff devices (either manual or automatic) near the end of the hoses
opposite the manifold gauge.

M

RHA272D

ATC-9

PRECAUTIONS
SERVICE COUPLERS
Never attempt to connect HFC-134a (R-134a) service couplers to a
CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will
not properly connect to the CFC-12 (R-12) system. However, if an
improper connection is attempted, discharging and contamination
may occur.
Shut-off valve rotation

A/C service valve

Clockwise

Open

Counterclockwise

Close
RHA273D

REFRIGERANT WEIGHT SCALE
Verify that no refrigerant other than HFC-134a (R-134a) and specified lubricants have been used with the scale. If the scale controls
refrigerant flow electronically, the hose fitting must be 1/2″-16
ACME.

RHA274D

CALIBRATING ACR4 WEIGHT SCALE
Calibrate the scale every three months.
To calibrate the weight scale on the ACR4:
1. Press “Shift/Reset” and “Enter” at the same time.
2. Press “8787” . “A1” will be displayed.
3. Remove all weight from the scale.
4. Press “0” , then press “Enter” . “0.00” will be displayed and change to “A2” .
5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb) on the center of
the weight scale.
6. Enter the known weight using four digits. (Example 10 lb = 10.00, 10.5 lb = 10.50)
7. Press “Enter” — the display returns to the vacuum mode.
8. Press “Shift/Reset” and “Enter” at the same time.
9. Press “6” — the known weight on the scale is displayed.
10. Remove the known weight from the scale. “0.00” will be displayed.
11. Press “Shift/Reset” to return the ACR4 to the program mode.

CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder’s top valve
when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an
electronic scale or of quality recycle/recharge equipment.

ATC-10

PRECAUTIONS
Precautions for Leak Detection Dye
●

●

●

●

●

●

●

●
●
●

●

BJS000AQ

The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet
(UV) lamp is required to illuminate the dye when inspecting for leaks.
Always wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of
the fluorescent dye.
The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluorescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector to pinpoint refrigerant leaks.
For your safety and your customer’s satisfaction, read and follow all manufacture’s operating instructions
and precautions prior to performing the work.
A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal
should only be repaired after confirming the leak with an electronic refrigerant leak detector.
Always remove any remaining dye from the leak area after repairs are complete to avoid a misdiagnosis
during a future service.
Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled,
clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period
of time cannot be removed.
Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).
Do not use more than one refrigerant dye bottle (1/4 ounce /7.4 cc) per A/C system.
Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use
HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system or CFC-12 (R-12) leak detector dye
in HFC-134a (R-134a) A/C system or A/C system damage may result.
The fluorescent properties of the dye will remain for over three (3) years unless a compressor malfunction
occurs.

A

B

C

D

E

F

G

H

IDENTIFICATION
I

NOTE:
Vehicles with factory installed fluorescent dye have a green label.
Vehicles without factory installed fluorescent dye have a blue label.

ATC

IDENTIFICATION LABEL FOR VEHICLE
Vehicles with factory installed fluorescent dye have this identification
label on the front side of hood.

K

L

M
MJIB0432E

ATC-11

PREPARATION
PREPARATION
HFC-134a (R-134a) Service Tools and Equipment

PFP:00002
BJS000AS

Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or
its lubricant.
Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubricant.
Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles
refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid
mixed use of the refrigerants/lubricant.
Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will
occur and compressor malfunction will result.
Tool number
Tool name

Description

Container color: Light blue
Container marking: HFC-134a (R134a)
Fitting size: Thread size

HFC-134a (R-134a) refrigerant

●

Large container 1/2″ -16 ACME

S-NT196

Type: Polyalkylene glycol oil (PAG),
type R (DH-PR)
Application: HFC-134a (R-134a) vane
rotary compressors (Nissan only)
Lubricity: 40 m
(1.4 Imp fl oz.)

KLH00-PAGR0
Nissan A/C System Oil Type R
(DH-PR)
S-NT197

Recovery/Recycling/
Recharging equipment (ACR4)

Function: Refrigerant recovery and
recycling and recharging

RJIA0195E

Power supply:
DC 12V (Cigarette lighter)

Electrical leak detector

SHA705EB

ATC-12

PREPARATION
Tool number
Tool name

Description

(J-43926)
Refrigerant dye leak detection kit
Kit includes:
(J-42220)
UV lamp and UV safety goggles
(J-41459)
HFC-134a (R-134a) dye injector
Use with J-41447, 1/4 ounce
bottle
(J-41447)
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
(J-43872)
Refrigerant dye cleaner

A

B

C
Power supply:
DC 12V (Battery terminal)

D

ZHA200H

E
Power supply:
DC 12V (Battery terminal)
For checking refrigerant leak when
fluorescent dye is installed in A/C
system
Includes:
UV lamp and UV safety goggles

(J-42220)
UV lamp and UV safety goggles

SHA438F

Application:
For HFC-134a (R-134a) PAG oil
Container:
1/4 ounce (7.4 cc) bottle
(Includes self-adhesive dye
identification labels for affixing to
vehicle after charging system with
dye.)

(J-41447)
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
SHA439F

F

G

H

I

ATC

(J-41459)
HFC-134a (R-134a) dye injector
Use with J-41447, 1/4 ounce
bottle

For injecting 1/4 ounce of fluorescent
leak detection dye into A/C system

K

L

SHA440F

M
(J-43872)
Refrigerant dye cleaner

For cleaning dye spills

SHA441F

Identification:
●

Manifold gauge set (with hoses
and couplers)

The gauge face indicates HFC-134a
(R-134a).

Fitting size: Thread size
●

RJIA0196E

ATC-13

1/2″ -16 ACME

PREPARATION
Tool number
Tool name

Description
Hose color:

Service hoses
●

High-pressure side hose

●

Low-pressure side hose

●

Utility hose

Service couplers
High-pressure side coupler

●

Low-pressure side coupler

Low hose: Blue with black stripe

●

High hose: Red with black stripe

●

Utility hose: Yellow with black stripe
or green with black stripe

Hose fitting to gauge:
S-NT201

●

●

●

1/2″ -16 ACME

Hose fitting to service hose:
●

M14 x 1.5 fitting is optional or
permanently attached.

S-NT202

For measuring of refrigerant
Fitting size: Thread size

Refrigerant weight scale

●

1/2″ -16 ACME

S-NT200

Capacity:

Vacuum pump
(Including the isolator valve)

●

Air displacement: 4 CFM

●

Micron rating: 20 microns

●

Oil capacity: 482 g (17 oz.)

Fitting size: Thread size
S-NT203

●

1/2″ -16 ACME

Commercial Service Tools

BJS000AT

Tool name

Description

Power tool

For loosening bolts and nuts

PBIC0190E

ATC-14

REFRIGERATION SYSTEM
REFRIGERATION SYSTEM
Refrigerant Cycle

PFP:KA990

A
BJS000AU

REFRIGERANT FLOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank,
through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator is
controlled by an externally equalized expansion valve, located inside the evaporator case.

FREEZE PROTECTION

B

C

Under usual operating conditions, when the A/C is switched ON, the compressor runs continuously, and the
evaporator pressure, and therefore, temperature is controlled by the compressor to prevent freeze up.

Refrigerant System Protection

BJS000AV

D

REFRIGERANT PRESSURE SENSOR
The refrigerant system is protected against excessively high- or low-pressures by the refrigerant pressure sensor, located on the condenser. If the system pressure rises above, or falls below the specifications, the refrigerant pressure sensor detects the pressure inside the refrigerant line and sends the voltage signal to the ECM.
ECM makes the A/C relay go OFF and stops the compressor when pressure on the high-pressure side
detected by refrigerant pressure sensor is over about 2,746 kPa (27.46 bar, 28.0 kg/cm2 , 398 psi), or below
about 134 kPa (1.34 bar, 1.4 kg/cm2 , 20 psi).

PRESSURE RELIEF VALVE
The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor.
When the pressure of refrigerant in the system increases to an unusual level [more than 3.8MPa (38 bar,
38.76 kg/cm2 , 551 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere.

E

F

G

H

I

ATC

K

L

M

MJIB0355E

ATC-15

REFRIGERATION SYSTEM
Component Layout

BJS000AW

MJIB0368E

1.

Defroster nozzle

2.

Side defroster duct

3.

Side ventilator duct

4.

A/C unit

5.

Center ventilator duct

6.

Front floor duct

7.

Rear floor duct

ATC-16

LUBRICANT
LUBRICANT
Maintenance of Lubricant Quantity in Compressor

PFP:KLG00

A
BJS000AX

The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compressor when replacing any component or after a large refrigerant leakage occurred. It is important to maintain the
specified amount.
If lubricant quantity is not maintained properly, the following malfunctions may result:
●
Lack of lubricant: May lead to a seized compressor.
●
Excessive lubricant: Inadequate cooling (thermal exchange interference)

B

C

LUBRICANT
D

Gasoline engine
Name

Nissan A/C System Oil Type R

Parts number

K9K engine
Nissan A/C System Oil Type S

KLH00 — PAGR0

KLH00 — PAGS0

E

LUBRICANT RETURN OPERATION
Adjust the lubricant quantity according to the test group shown below.

F

1. CHECK LUBRICANT RETURN OPERATION
Can lubricant return operation be performed?
●
A/C system works properly.
●
There is no evidence of a large amount of lubricant leakage.
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant return operation.
OK or NG
OK
>> GO TO 2.
NG
>> GO TO 3.

2. PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS
1.
–
–
–
–
–

2.
3.

Start engine, and set the following conditions:
Engine speed: Idling to 1,200 rpm
A/C switch: ON
Blower speed: Max. position
Temp. control: Optional (Set so that intake air temperature is 25 to 30°C.)
Intake position: Recirculation (REC)
Perform lubricant return operation for about 10 minutes.
Stop engine.
>> GO TO 3.

3. CHECK REPLACEMENT PART
Should the compressor be replaced?
YES >> GO TO ATC-18, «LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT» .
NO
>> GO TO ATC-18, «LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR» .

ATC-17

G

H

I

ATC

K

L

M

LUBRICANT
LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR
After replacing any of the following major components, add the correct amount of lubricant to the system.
Amount of lubricant to be added
Lubricant to be added to system
Part replaced

Amount of lubricant
m
(Imp fl oz.)

Remarks

Evaporator

35 (1.2)

—

Condenser

15 (0.5)

—

Liquid tank

5 (0.2)

—

30 (1.1)

Large leak

—

Small leak *1

In case of refrigerant leak
*1: If refrigerant leak is small, no addition of lubricant is needed.

LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT
1.
2.
3.
4.
5.
6.
7.

Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If
NG, recover refrigerant from equipment lines.
Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into
the recovery/recycling equipment.
Drain the lubricant from the old (removed) compressor into a graduated container and recover the amount
of lubricant drained.
Drain the lubricant from the new compressor into a separate, clean container.
Measure an amount of new lubricant installed equal to amount drained from old compressor. Add this
lubricant to new compressor through the suction port opening.
Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant
to new compressor through the suction port opening.
If the liquid tank also needs to be replaced, add another 5 m (0.2 Imp fl oz.) of lubricant at this time.
Do not add this 5 m (0.2 Imp fl oz.) of lubricant only when replaces the compressor.

ATC-18

LUBRICANT
A

B

C

D

E

F

G

H

I

SJIA0596E

ATC

K

L

M

ATC-19

AIR CONDITIONER CONTROL
AIR CONDITIONER CONTROL
System Construction

PFP:27500
BJS000AY

AIR MIX DOOR CONTROL (AUTOMATIC TEMPERATURE CONTROL)
The air mix door is automatically controlled so that in-vehicle temperature is maintained at a predetermined
value by the temperature setting, ambient temperature, in-vehicle temperature and amount of sunload.

FAN SPEED CONTROL
Blower speed is automatically controlled by the temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and air mix door position.
With fan control dial set to AUTO switch is pressed, the blower motor starts to gradually increase air flow volume.
When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flowing.

INTAKE DOOR CONTROL
The intake doors are automatically controlled by the temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and ON-OFF operation of the compressor.

OUTLET DOOR CONTROL
The outlet door is automatically controlled by the temperature setting, ambient temperature, in-vehicle temperature, intake temperature and amount of sunload.

ATC-20

AIR CONDITIONER CONTROL
MAGNET CLUTCH CONTROL
A

B

C

D

E

F
SJIA0703E

When A/C switch, AUTO switch or DEF switch is pressed, auto amp. inputs compressor ON signal to BCM.
BCM sends compressor ON signal to ECM, via CAN communication line.
ECM judges whether compressor can be turned ON, based on each sensor status (refrigerant-pressure sensor signal, throttle angle, etc.). If it judges compressor can be turned ON, it sends compressor ON signal to
IPDM E/R, via CAN communication line.
Upon receipt of compressor ON signal from ECM, IPDM E/R turns air conditioner relay ON to operate compressor.

G

H

I

SELF-DIAGNOSTIC SYSTEM
The self-diagnostic system is built into the auto amp. to quickly locate the cause of symptoms.

ATC

K

L

M

ATC-21

AIR CONDITIONER CONTROL
Description of Control System

BJS000AZ

The control system consists of input sensors, switches, the auto amp. (microcomputer) and outputs.
The relationship of these components is shown in the figure below:

SJIA0712E

Control Operation

BJS000B0

MJIB0369E

1.

Fan SW

2.

MODE SW

3.

Fresh (FRE) SW

4.

Reciculation (REC) SW

5.

AUTO SW

6.

Temperature control SW

ATC-22

AIR CONDITIONER CONTROL
7.

Defroster (DEF) SW

10. A/C SW

8.

Rear window defogger SW

9.

Display screen

A

11. OFF SW

DISPLAY SCREEN
Displays the operational status of the system.

B

AUTO SWITCH
●

●

The compressor, intake doors, air mix doors, outlet doors and blower speed are automatically controlled
so that the in-vehicle temperature will reach, and be maintained at the set temperature selected by the
operator.
When pressing AUTO switch, air inlet, air outlet, fan speed, and discharge air temperature are automatically controlled. (Inlet is automatically controlled only when FRE or REC switch is OFF.)

C

D

TEMPERATURE CONTROL SWITCH (POTENTIO TEMPERATURE CONTROL)
Increases or decreases the set temperature.

E

RECIRCULATION (REC) SWITCH
●

●

When REC switch is ON, REC switch indicator turns ON, air inlet is fixed to REC, and compressor will turn
ON.
When FRE switch is turned ON, air outlet switches to D/F or DEF position, or when compressor is turned
from ON to OFF, REC switch is automatically turned OFF (fixed to FRE mode).

FRESH (FRE) SWITCH
●
●

F

G

When FRE switch is ON, FRE switch indicator turns ON, and air inlet is fixed to FRE.
When REC switch is turned ON, FRE switch is automatically turned OFF (fixed to REC mode). FRE mode
can be re-entered by pressing FRE switch again.

H

DEFROSTER (DEF) SWITCH
Positions the air outlet doors to the defrost position. Also positions the intake doors to the outside air position,
and compressor will turn ON.

I

REAR WINDOW DEFOGGER SWITCH
When illumination is ON, rear window is defogged.

ATC

OFF SWITCH
The compressor and blower are OFF, the intake doors are set to the outside air position, and the air outlet
doors are set to the foot position.

K

A/C SWITCH
The compressor is ON or OFF.
(Pressing the A/C switch when the A/C switch is ON will turn off the A/C switch and compressor.)

L

MODE SWITCH
Controls the air discharge outlets.
When air outlet switches to D/F position, compressor will turn ON and fixed to REC mode.

FAN SWITCH
Manually control the blower speed. Four speeds are available for manual control (as shown on the display
screen).

ATC-23

M

AIR CONDITIONER CONTROL
Discharge Air Flow

BJS000JB

MJIB0511E

ATC-24

AIR CONDITIONER CONTROL
System Description

BJS000B4

A

SWITCHES AND THEIR CONTROL FUNCTION

B

C

D

E

F

G

H

I
MJIB0507E

ATC

K

L

M

SJIA0717E

CAN Communication System Description

BJS000B5

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only. For details, refer to LAN-27,
«CAN Communication Unit» .

ATC-25

TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
CONSULT-II Function (BCM)

PFP:00004
BJS000B6

CONSULT-II can display diagnostic item using the diagnostic test modes shown following.
System part

Check item, diagnosis mode

BCM

Data monitor

Description
Displays BCM input data in real time.

CONSULT-II BASIC OPERATION
Refer to GI-36, «CONSULT-II Start Procedure» .

DATA MONITOR
Operation Procedure
1.

Touch “AIR CONDITIONER” on “SELECT TEST ITEM” screen.

MJIB0465E

2.

Touch “DATA MONITOR” on “SELECT DIAG MODE” screen.

MJIB0466E

3.

Touch either “ALL SIGNALS” or “SELECTION FROM MENU” on
“DATA MONITOR” screen.

All signals

Monitors all the items.

Selection from menu

Selects and monitors the individual item selected.

4.

5.
6.

When “SELECTION FROM MENU” is selected, touch items to
be monitored. When “ALL SIGNALS” is selected, all the items
will be monitored.
Touch “START”.
Touch “RECORD” while monitoring, then the status of the monitored item can be recorded. To stop recording, touch “STOP”.

RJIA1111E

Display Item List
Monitor item name
“operation or unit”

Contents

IGN ON SW

“ON/OFF”

Displays “IGN Position (ON)/OFF, ACC Position (OFF)” status as judged from ignition switch signal.

FAN ON SIG

“ON/OFF”

Displays “FAN (ON)/FAN (OFF)” status as judged from blower fan motor switch signal.

AIR COND SW

“ON/OFF”

Displays “COMP (ON)/COMP (OFF)” status as judged from air conditioner switch signal.

ATC-26

TROUBLE DIAGNOSIS
How to Perform Trouble Diagnosis for Quick and Accurate Repair

BJS000B7

A

WORK FLOW

B

C

D
SHA900E

*1

ATC-55, «Operational Check»

E

SYMPTOM TABLE
Symptom

A/C system does not come on.

Reference Page

Go to Trouble Diagnosis Procedure for A/C System.

Air outlet does not change.

ATC-57, «Power
Supply and
Ground Circuit for
Auto Amp.»

Go to Trouble Diagnosis Procedure for Mode Door Motor.

ATC-60, «Mode
Door Motor Circuit»

Go to Trouble Diagnosis Procedure for Air Mix Door Motor.

ATC-64, «Air Mix
Door Motor Circuit»

Go to Trouble Diagnosis Procedure for Intake Door Motor.

ATC-68, «Intake
Door Motor Circuit»

Blower motor operation is malfunctioning
under out of starting fan speed control.

Go to Trouble Diagnosis Procedure for Blower Motor.

ATC-71, «Blower
Motor Circuit»

Magnet clutch does not engage.

Go to Trouble Diagnosis Procedure for Magnet Clutch.

ATC-78, «Magnet
Clutch Circuit»

Insufficient cooling

Go to Trouble Diagnosis Procedure for Insufficient Cooling.

ATC-86, «Insufficient Cooling»

Insufficient heating

Go to Trouble Diagnosis Procedure for Insufficient Heating.

ATC-94, «Insufficient Heating»

Noise

Go to Trouble Diagnosis Procedure for Noise.

ATC-96, «Noise»

Self-diagnosis cannot be performed.

Go to Trouble Diagnosis Procedure for Self-diagnosis.

Memory function does not operate.

Go to Trouble Diagnosis Procedure for Memory Function.

Mode door motor does not operate normally.

Intake door does not change.
Intake door motor does not operate normally.

G

H

Discharge air temperature does not change.
Air mix door motor does not operate normally.

F

I

ATC

Blower motor operation is malfunctioning.

ATC-27

ATC-97, «Selfdiagnosis»
ATC-98, «Memory
Function»

K

L

M

TROUBLE DIAGNOSIS
Component Parts and Harness Connector Location

BJS000B8

ENGINE COMPARTMENT

MJIB0478E

1.

Compressor
(CR & HR engine F28)
(K9K engine F129)

2.

Ambient sensor E17

4.

Condenser

5.

Liquid tank

ATC-28

3.

Refrigerant pressure sensor
(CR & HR engine E21)
(K9K engine E65)

TROUBLE DIAGNOSIS
PASSENGER COMPARTMENT
A

B

C

D

E

F

G

H

I

ATC

K

L

M

MJIB0479E

1.

Power transistor M30, M31

2.

Intake door motor M28

3.

Controller (Auto amp.) M64, M65

4.

Blower motor M56

5.

Sunload sensor M43

6.

In-vehicle sensor M43

7.

Air mix door motor M51

8.

Intake sensor M44

9.

Mode door motor M50

ATC-29

TROUBLE DIAGNOSIS
Circuit Diagram

BJS000B9

MJWA0273E

ATC-30

TROUBLE DIAGNOSIS
Wiring Diagram —A/C— CR Engine Models

BJS000BA

A

B

C

D

E

F

G

H

I

ATC

K

L

M

MJWA0274E

ATC-31

TROUBLE DIAGNOSIS

MJWA0275E

ATC-32

TROUBLE DIAGNOSIS
A

B

C

D

E

F

G

H

I

ATC

K

L

M

MJWA0276E

ATC-33

TROUBLE DIAGNOSIS

MJWA0277E

ATC-34

TROUBLE DIAGNOSIS
Wiring Diagram —A/C—HR Engine Models

BJS000JD

A

B

C

D

E

F

G

H

I

ATC

K

L

M

MJWA0278E

ATC-35

TROUBLE DIAGNOSIS

MJWA0279E

ATC-36

TROUBLE DIAGNOSIS
A

B

C

D

E

F

G

H

I

ATC

K

L

M

MJWA0280E

ATC-37

TROUBLE DIAGNOSIS

MJWA0281E

ATC-38

TROUBLE DIAGNOSIS
Wiring Diagram —A/C— K9K Engine Models

BJS000EZ

A

B

C

D

E

F

G

H

I

ATC

K

L

M

MJWA0282E

ATC-39

TROUBLE DIAGNOSIS

MJWA0283E

ATC-40

TROUBLE DIAGNOSIS
A

B

C

D

E

F

G

H

I

ATC

K

L

M

MJWA0284E

ATC-41

TROUBLE DIAGNOSIS

MJWA0285E

ATC-42

TROUBLE DIAGNOSIS
Wiring Diagram —PTC/H— K9K Engine LHD Models

BJS000F0

A

B

C

D

E

F

G

H

I

ATC

K

L

M

MJWA0286E

PTC heater function is intended to improve the heating performance with CTP electrical system for air heating
system which is broken down into several stages controlled by relays.

ATC-43

TROUBLE DIAGNOSIS
Auto Amp. Terminals and Reference Value

BJS000BB

Measure voltage between each terminal and ground by following terminals and reference value for auto amp.

MJIB0370E

PIN CONNECTOR TERMINAL LAYOUT

MJIB0371E

TERMINALS AND REFERENCE VALUE FOR AUTO AMP.
Terminal
No.

Wire
color

1

LG

Item
Power supply for BAT

Ignition
switch

Voltage
(V)

Condition
—

OFF

Battery voltage

At idle (after warming up,
approx. 80°C)
4

BR

Engine coolant temperature
sensor signal

ON

CAUTION:
The wave forms vary
depending on coolant temperature.
SKIB3651J

5

B

Illumination ground

ON

—

Approx. 0

7

G

Power supply for IGN 2

OFF

—

Battery voltage

10

B

Ground

ON

—

Approx. 0

12

SB

FAN ON signal

ON

FAN speed: 1st step (manual)

ZJIA0583J

13

P

Compressor ON signal

ON

A/C switch: ON
(Blower motor operates.)

ZJIA0584J

ATC-44

TROUBLE DIAGNOSIS
Terminal
No.

14

Wire
color

W

Item

Rear window defogger ON
signal

Ignition
switch

ON

Voltage
(V)

Condition
When rear window defogger
switch is depressed.

Approx. 0

When rear window defogger
switch is released.

Approx. 5

A

B

C
15

GR

Blower PWM

ON

FAN speed: 1st step (manual)

D
ZJIA0863J

16

V

17

O

19

BR

20

SB

21

LG

22

Y

Illumination signal
Power supply for IGN 1

ON

Light switch: ON

Approx. 12

Light switch: OFF

Approx. 0

ON

—

E

Battery voltage

F

Air mix door motor drive signal

ON

Immediately after temperature
adjustment switch operation

G

HAK0627D

23

GR

24

W

25

P

26

V

Mode door motor drive signal

ON

H

I

Immediately after mode switch
operation

ATC
HAK0627D

Approx. 0

FRE→REC

Approx. 12

G

Intake door motor drive signal

28

LG

In-vehicle sensor

—

—

—

29

O

Intake sensor

—

—

—

30

SB

Ambient sensor

—

—

—

31

P

Sunload sensor

—

—

—

32

R

Rear window defogger feedback signal

ON

33

R

Sensor ground

ON

36

B

Intake door motor drive signal

ON

ON

REC or
FRE switch

REC→FRE

27

Rear window defogger: ON

Approx. 12

Rear window defogger: OFF

Approx. 0

REC or
FRE switch

ATC-45

Approx. 0

REC→FRE

Approx. 12

FRE→REC

Approx. 0

K

L

M

TROUBLE DIAGNOSIS
Self-diagnosis Function

BJS000BC

DESCRIPTION
The self-diagnostic system diagnoses sensors, door motors, blower motor, etc. by system line. Refer to applicable sections (items) for details. Shifting from usual control to the self-diagnostic system is accomplished by
starting the engine (turning the ignition switch ON) and pressing OFF switch for at least 5 seconds. The OFF
switch must be pressed within 10 seconds after starting the engine (ignition switch is turned ON). This system
will be canceled by either pressing AUTO switch or turning the ignition switch OFF. Shifting from one step to
another is accomplished by means of pushing temperature control switch, as required.

ATC-46

TROUBLE DIAGNOSIS
Additionally shifting from STEP-5 to AUXILIARY MECHANISM is accomplished by means of pushing fan
switch (UP: ).

A

B

C

D

E

F

G

H

I

ATC

K

L

M

MJIB0372E

ATC-47

TROUBLE DIAGNOSIS
FUNCTION CONFIRMATION PROCEDURE

1. SET IN SELF-DIAGNOSTIC MODE
1.
2.

Turn ignition switch ON.
Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned
ON.), press OFF switch for at least 5 seconds.
CAUTION:
If battery voltage drops below 12V during diagnosis STEP-3, door motor speed becomes slower and
as a result, the system may generate an error even when operation is usual. To avoid this, start engine
before performing this diagnosis.
>> GO TO 2.

2. STEP-1: LED AND DISPLAY ARE CHECKED
Check display screen (1) and LED illumination (2).
OK or NG
OK
>> GO TO 3.
NG
>> Malfunction OFF switch or AUTO amp. Refer to ATC97, «Self-diagnosis» .

MJIB0373E

3. CHECK TO ADVANCE SELF-DIAGNOSIS STEP-2
Press temperature control switch (UP: ).
Advance to self-diagnosis STEP-2?
YES >> GO TO 4.
NO
>> Replace auto amp. (Temperature control switch is malfunctioning.)

4. CHECK TO RETURN SELF-DIAGNOSIS STEP-1
Press temperature control switch (DOWN: ).
Return to self-diagnosis STEP-1?
YES >> GO TO 5.
NO
>> Replace auto amp. (Temperature control switch is malfunctioning.)

5. STEP-2: SENSOR CIRCUITS ARE CHECKED FOR OPEN OR SHORT CIRCUIT
Press temperature control switch (UP: ).
Does code No. 20 appear on the display?
YES >> GO TO 6.
NO
>> GO TO 13.

SJIA0737E

ATC-48

TROUBLE DIAGNOSIS

6. STEP-3: AIR MIX DOOR AND MODE DOOR POSITIONS ARE CHECKED

A

Press temperature control switch (UP: ).
Does code No. 30 appear on the display?
YES >> GO TO 7.
NO
>> GO TO 14.

B

C

D
SJIA0738E

7. STEP-4: OPERATION OF EACH DOOR MOTOR IS CHECKED

E

1.
2.

F

Press temperature control switch (UP: ).
Press
(DEF) switch. Code No. of each door motor test is
indicated on the display.
>> GO TO 8.

G

H
RHA495A

8. CHECK ACTUATORS

I

Refer to the following chart and confirm discharge air flow, air temperature, blower motor voltage, compressor, ionizer and indicator
(ION mode) operation.

ATC

K

L
MJIB0374E

M
41

42

43

44

45

46

Mode door position

Code No.

VENT

B/L 1

B/L 2

FOOT

D/F

DEF

Intake door position

REC

REC

FRE

FRE

FRE

FRE

Air mix door position

FULL COLD

FULL COLD

50%

50%

FULL HOT

FULL HOT

Blower motor voltage

5V

10.5V

8.5V

8.5V

8.5V

Battery voltage

Compressor

ON

ON

ON

OFF

OFF

ON

Fan ON signal

12V

12V

12V

1V

1V

12V

ATC-49

TROUBLE DIAGNOSIS
Checks must be made visually, by listening to any noise, or by touching air outlets with your hand, etc. for
improper operation.
OK or NG
OK
>> GO TO 9.
NG
>> ● Air outlet does not change.
Go to Mode Door Motor Circuit. Refer to ATC-60, «Mode Door Motor Circuit» .
● Intake door does not change.
Go to Intake Door Motor Circuit. Refer to ATC-68, «Intake Door Motor Circuit» .
● Blower motor operation is malfunctioning.
Go to Blower Motor Circuit. Refer to ATC-71, «Blower Motor Circuit» .
● Magnet clutch does not engage.
Go to Magnet Clutch Circuit. Refer to ATC-78, «Magnet Clutch Circuit» .
● Discharge air temperature does not change.
Go to Air Mix Door Motor Circuit. Refer to ATC-64, «Air Mix Door Motor Circuit» .

9. STEP-5: TEMPERATURE OF EACH SENSOR IS CHECKED
1.
2.

Press temperature control switch (UP:
Code No. 5 appears on the display.

).

>> GO TO 10.

10. CHECK AMBIENT SENSOR
Press
(DEF) switch one time. Temperature detected by ambient
sensor is indicated on the display.
NOTE:
If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor.
OK or NG
OK
>> GO TO 11.
NG
>> Go to Ambient Sensor Circuit. Refer to ATC-99, «Ambient Sensor Circuit» .
SJIA0744E

11. CHECK IN-VEHICLE SENSOR
Press
(DEF) switch second time. Temperature detected by invehicle sensor is indicated on the display.
NOTE:
If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor.
OK or NG
OK
>> GO TO 12.
NG
>> Go to In-vehicle Sensor Circuit. Refer to ATC-102, «Invehicle Sensor Circuit» .
SJIA0746E

ATC-50

TROUBLE DIAGNOSIS

12. CHECK INTAKE SENSOR

A

Press
(DEF) switch third time. Temperature detected by intake
sensor is indicated on the display.
NOTE:
If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor.
OK or NG
OK
>> 1. Turn ignition switch OFF or AUTO switch ON.
2. INSPECTION END
NG
>> Go to Intake Sensor Circuit. Refer to ATC-108, «Intake
Sensor Circuit» .

B

C

D
SJIA0748E

13. CHECK MALFUNCTIONING SENSOR

E

Refer to the following chart for malfunctioning code No.
(If two or more sensors malfunction, corresponding code No. blink respectively twice.)
*1: Perform self-diagnosis STEP-2 under sunshine.
When performing indoors, aim a light (more than 60W) at sunload sensor, otherwise code No.25 will indicate
despite that sunload sensor is functioning properly.

F

Code No.

Malfunctioning sensor (Including circuits)

21 / AUTO 21

Ambient sensor

*2

22 / AUTO 22

In-vehicle sensor

*3

24 / AUTO 24

Intake sensor

*4

25 / AUTO 25

Sunload sensor *1

*5

Intake door motor PBR

*6

26 /

AUTO

26

G

Reference page

H

I

*2: ATC-99, «DIAGNOSTIC PROCEDURE FOR AMBIENT SENSOR» .
*3: ATC-102, «DIAGNOSTIC PROCEDURE FOR IN-VEHICLE SENSOR» .
*4: ATC-108, «DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR» .
*5: ATC-105, «DIAGNOSTIC PROCEDURE FOR SUNLOAD SENSOR» .
*6: ATC-70, «DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR» .

ATC

K

L

M

SJIA0752E

>> INSPECTION END

ATC-51

TROUBLE DIAGNOSIS

14. CHECK MALFUNCTIONING DOOR MOTOR POSITION SWITCH
Air mix and/or mode door motor is/are malfunctioning.
Door motor corresponding to the DTC
Code No.*1 *2

31, 32, 33, 34

35, 36, 37, 38

Corresponding door motor

Air mix door

Mode door

DTC for an inoperative harness
Corresponding door motor

Air mix door motor

Mode door motor

Corresponding terminal
(Door motor side)

3

4

1

6

3

4

1

6

Corresponding terminal
(Auto amp. side)

19

22

21

20

23

26

25

24

Code number for short circuit

AUTO31

AUTO32

AUTO33

AUTO34

AUTO35

AUTO36

AUTO37

AUTO38

Code number for open circuit

31

32

33

34

35

36

37

38

Reference Page

*3

*4

(If two or more air mix or mode doors are out of order, corresponding code numbers blink respectively twice.)
*1: If air mix door motor harness connector is disconnected, the following display pattern will appear.
31→32→33→34→Return to 31
*2: If mode door motor harness connector is disconnected, the following display pattern will appear.
35→36→37→38→Return to 35
*3: ATC-64, «Air Mix Door Motor Circuit» .
*4: ATC-60, «Mode Door Motor Circuit» .
NOTE:
●
If all four terminals of each door motor show an open circuit,
there is probably a disconnected connector or an open circuit in
actuator drive power supply harness.
●
If a short circuit occurs in the harness between terminal for each
door motor and drive signal, although it cannot be detected by
self-diagnosis, the door motor will vibrate when it operate.

SJIA0951E

Door Motor Starting Position Reset
●
Pressing the DEF switch during STEP-3 will send a reset signal
to air mix door and mode door motor to reset them to the starting
position.
During reset: The 30 and DEF switch LED will blinks. (For
approx. 9 seconds)

SJIA0952E

ATC-52

TROUBLE DIAGNOSIS
A

B

C
SJIA0757E

D

>> INSPECTION END
E

F

G

H

I

ATC

K

L

M

ATC-53

TROUBLE DIAGNOSIS
AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER
The trimmer compensates for differences in range of ±3°C between temperature setting (displayed digitally)
and temperature felt by driver.
Operating procedures for this trimmer are as follows:
1. Begin self-diagnosis STEP-5 mode. Refer to ATC-46, «Self-diagnosis Function» .
2.
3.
4.

Press fan switch (UP: ) to set system in auxiliary mode.
Display shows 0°C in auxiliary mechanism.
Press temperature control switch as desired. Temperature will change at a rate of 1°C each time a switch
is pressed.

SJIA0761E

When battery cable is disconnected or battery voltage is 9.0V or less, trimmer operation is canceled. Set
temperature returns to the initial condition, i.e. 0°C.

ATC-54

TROUBLE DIAGNOSIS
Operational Check

BJS000BD

A

The purpose of the operational check is to confirm that the system operates properly.
Conditions

: Engine running at usual operating temperature
B

CHECKING MEMORY FUNCTION
1.

Press temperature control switch (UP: ) until 32°C is displayed.
2. Press OFF switch.
3. Turn the ignition switch OFF.
4. Turn the ignition switch ON.
5. Press the AUTO switch.
6. Confirm that the set temperature remains at previous temperature.
7. Press OFF switch.
If NG, go to trouble diagnosis procedure for ATC-98, «Memory Function» .
If OK, continue the check.

C

D

E
MJIB0375E

F

CHECKING BLOWER
1.

Press fan switch (UP: ). Blower should operate on low speed.
The fan symbol should have one blade lit.

G

2.

Press fan switch (UP: ), and continue checking blower speed
and fan symbol until all speeds are checked.
3. Leave blower on max. speed.
If NG, go to trouble diagnosis procedure for ATC-71, «Blower Motor
Circuit» .
If OK, continue the check.

H

I

MJIB0376E

ATC

CHECKING DISCHARGE AIR
1.
2.

Press MODE switch and DEF switch.
Each position indicator should change shape.

K

L

M

MJIB0377E

3.

Confirm that discharge air comes out according to the air distribution table. Refer to ATC-24, «Discharge Air Flow» .
Intake door position is checked in the next step.
If NG, go to trouble diagnosis procedure for ATC-60, «Mode Door
Motor Circuit» .
If OK, continue the check.
NOTE:
Confirm that the compressor clutch is engaged (sound or visual
inspection) and intake door position is at FRESH when the DEF is
selected.
MJIB0374E

ATC-55

TROUBLE DIAGNOSIS
CHECKING RECIRCULATION
1.

Press recirculation (REC) switch one time. Recirculation LED
should illuminate.
2. Press fresh (FRE) switch one time. Fresh LED should illuminate.
3. Listen for intake door position change (you should hear blower
sound change slightly).
If NG, go to trouble diagnosis procedure for ATC-68, «Intake Door
Motor Circuit» .
If OK, continue the check.
MJIB0378E

CHECKING TEMPERATURE INCREASE
1.

Press temperature control switch (UP: ) until 32°C is displayed.
2. Check for hot air at discharge air outlets.
If NG, go to trouble diagnosis procedure for ATC-94, «Insufficient
Heating» .
If OK, continue the check.

MJIB0379E

CHECKING TEMPERATURE DECREASE
1.

Press temperature control switch (DOWN: ) until 18°C is displayed.
2. Check for cold air at discharge air outlets.
If NG, go to trouble diagnosis procedure for ATC-86, «Insufficient
Cooling» .
If OK, continue the check.

MJIB0380E

CHECK A/C SWITCH
1.
2.

Press AUTO and A/C switches.
A/C switch LED will turn ON.
● Confirm that the compressor clutch engages (sound or visual
inspection).
If NG, go to trouble diagnosis procedure for ATC-78, «Magnet Clutch
Circuit» .
If OK, continue the check.

MJIB0381E

ATC-56

TROUBLE DIAGNOSIS
CHECKING AUTO MODE
1.
2.

●

●

●

Press AUTO switch.
Display should indicate AUTO.
● Confirm that discharge air and blower speed will depend on
ambient, in-vehicle, and set temperatures.
If NG, go to trouble diagnosis procedure for ATC-57, «Power
Supply and Ground Circuit for Auto Amp.» , then if necessary,
trouble diagnosis procedure for ATC-78, «Magnet Clutch Circuit»
.
If all operational checks are OK (symptom cannot be duplicated), go to Incident Simulation Tests in GI-25, «How to Perform
MJIB0382E
Efficient Diagnosis for an Electrical Incident» and perform tests
as outlined to simulate driving conditions environment.
If symptom appears, refer to ATC-27, «SYMPTOM TABLE» and perform applicable trouble diagnosis procedures.

Power Supply and Ground Circuit for Auto Amp.

A

B

C

D

E

BJS000BE

F

SYMPTOM: A/C system does not come on.

INSPECTION FLOW
G

H

I

ATC

K

L

M

MJIB0383E

*1

ATC-58, «DIAGNOSTIC PROCEDURE FOR A/C SYSTEM»

*2

ATC-55, «Operational Check»

ATC-57

TROUBLE DIAGNOSIS
COMPONENT DESCRIPTION
Auto Amp. (Automatic Amplifier)
The auto amp. has a built-in microcomputer which processes information sent from various sensors needed for air conditioner operation. The air mix door motor, mode door motor, intake door motor,
blower motor and compressor are then controlled.
The auto amp. is unitized with control mechanisms. Signal from various switches and Potentio Temperature Control (PTC) are directly
entered into auto amp.
Self-diagnostic functions are also built into auto amp. to provide
quick check of malfunctions in the auto air conditioner system.
MJIB0370E

Potentio Temperature Control (PTC)
The PTC is built into the auto amp. It can be set at an interval of 1°C
in the 18°C to 32°C temperature range by pressing temperature control switch. The set temperature is displayed.

MJIB0384E

DIAGNOSTIC PROCEDURE FOR A/C SYSTEM
SYMPTOM: A/C system does not come on.

SJIA0785E

ATC-58

TROUBLE DIAGNOSIS

1. CHECK POWER SUPPLY CIRCUIT FOR AUTO AMP.
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect auto amp. connector.
Check voltage between auto amp. harness connector and
ground.
Terminals

B

Ignition switch position

C

(+)
Connector

Auto amp.: M64

OFF

ACC

ON

1

Battery
voltage

Battery
voltage

Battery
voltage

7

Approx.
0V

Approx.
0V

Battery
voltage

Approx.
0V

Approx.
0V

Battery
voltage

Terminal

(-)

Ground

17

D
MJIB0433E

E

OK or NG
OK
>> GO TO 2.
NG
>> Check 10A fuses (Nos. 5, 7 and 19, located in the fuse block). Refer to PG-95, «FUSE BLOCK» .
● If fuses are OK, check harness for open circuit. Repair or replace if necessary.
● If fuses are NG, replace fuse and check harness for short circuit. Repair or replace if necessary.

F

G

2. CHECK GROUND CIRCUIT FOR AUTO AMP.

H

1.
2.

I

Turn ignition switch OFF.
Check continuity between auto amp. harness connector and
ground.
Connector
Auto amp.: M64

Terminal
10

Continuity
Ground

ATC

Yes

OK or NG
OK
>> Replace auto amp.
NG
>> Repair or replace harness.

K
MJIB0434E

L

M

ATC-59

TROUBLE DIAGNOSIS
Mode Door Motor Circuit

BJS000BF

SYMPTOM:
●
Air outlet does not change.
●
Mode door motor does not operate normally.

INSPECTION FLOW

MJIB0385E

*1

ATC-24, «Discharge Air Flow»

*4
*7

*2

ATC-55, «Operational Check»

*3

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 1.

ATC-48, «FUNCTION CONFIRMA*5
TION PROCEDURE», see No. 5 to 7.

ATC-99, «Ambient Sensor Circuit»

*6

ATC-102, «In-vehicle Sensor Circuit»

ATC-105, «Sunload Sensor Circuit»

ATC-125, «AIR MIX DOOR
MOTOR»

*9

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 13.

*8

ATC-60

TROUBLE DIAGNOSIS
*10 ATC-48, «FUNCTION CONFIRMATION PROCEDURE» see No. 14.

*11 ATC-126, «MODE DOOR MOTOR»

*12 ATC-27, «SYMPTOM TABLE»

A

*13 ATC-108, «Intake Sensor Circuit»

SYSTEM DESCRIPTION
Component Parts

B

Mode door control system components are:
●
Auto amp.
●
Mode door motor
●
In-vehicle sensor
●
Ambient sensor
●
Sunload sensor

C

D

System Operation
The auto amp. receives data from each of the sensors. When a drive signal is input from auto amp. to door
motor, a step motor built into the door motor rotates according to the drive signal, and then stops at the position of target door.
Mode door changes to manual select mode by pressing MODE/DEF switch of the controller. That allows mode
door to be fixed.
Pressing AUTO switch allows automatic control by auto amp., and mode door is fixed in the FOOT position by
pressing OFF switch.
During automatic operation of mode door, mode door position (VENT, B/L, FOOT) is selected according to the
temperature of discharge air calculated by auto amp. based on the target opening angle of air mix door and
the amount of sunload. And only when ambient temperature is extremely low with the mode door in the FOOT
position, D/F is selected and prevents windshield fogging.

E

F

G

H

I

ATC

K

L

M
SJIA0788E

ATC-61

TROUBLE DIAGNOSIS
Drive System of Step Motor Type Door Motor

SJIA0971E

●
●

Motor is actuated in sequence by energizing four drive coils.
Rotation direction can be changed by changing pattern of excitation.

Mode Door Control Specification

RHA384HA

COMPONENT DESCRIPTION
Mode Door Motor
The mode door motor is attached to the A/C unit assembly. It rotates
so that air is discharged from the outlet set by the auto amp. Motor
rotation is conveyed to a link which activates the mode door.

MJIB0463E

ATC-62

TROUBLE DIAGNOSIS
DIAGNOSTIC PROCEDURE FOR MODE DOOR MOTOR
A

1. CHECK MODE DOOR MOTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect mode door motor connector.
Check continuity between mode door motor connector terminal.
Connector

Terminals

B

Continuity

C

Yes

D

1
3
Mode door motor: M50

2

4
6

SJIA0948E

OK or NG
OK
>> GO TO 2.
NG
>> Replace mode door motor.

E

2. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND MODE DOOR MOTOR

F

1.
2.

G

Disconnect auto amp. connector.
Check continuity between auto amp. harness connector (A) and
mode door motor harness connector (B).
A
Connector

B
Terminal

Connector

23
Auto amp.:
M65

Terminal

H

Continuity

3

24

Mode door
motor: M50

25
26

I

6
Yes

1

MJIB0386E

4

ATC

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

K

3. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND GROUND
L

Check continuity between auto amp. harness connector and ground.
Connector

Terminal

Continuity

23
Auto amp.: M65

24

M
Ground

No

25
26

OK or NG
OK
>> Replace auto amp.
NG
>> Repair harness or connector.

MJIB0387E

ATC-63

TROUBLE DIAGNOSIS
Air Mix Door Motor Circuit

BJS000BG

SYMPTOM:
●
Discharge air temperature does not change.
●
Air mix door motor does not operate.

INSPECTION FLOW

MJIB0388E

*1

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 1.

*2

ATC-99, «Ambient Sensor Circuit»

*4

ATC-105, «Sunload Sensor Circuit»

*5

ATC-64, «Air Mix Door Motor Circuit» *6

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 13.

*7

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 14.

*8

ATC-64, «Air Mix Door Motor Circuit» *9

ATC-55, «Operational Check»

*10 ATC-27, «SYMPTOM TABLE»

*11 ATC-108, «Intake Sensor Circuit»

ATC-64

*3

ATC-102, «In-vehicle Sensor Circuit»

*12 ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 5 to 7.

TROUBLE DIAGNOSIS
SYSTEM DESCRIPTION
Component Parts

A

Air mix door control system components are:
●
Auto amp.
●
Air mix door motor
●
In-vehicle sensor
●
Intake sensor
●
Ambient sensor
●
Sunload sensor

B

C

D

System Operation
The auto amp. receives data from each of the sensors. When setting a target temperature by using temperature button, auto amp. corrects preset temperature, performs an arithmetical operation based on signals from
sensors and determines opening angle of target air mix door.
Air mix door is constantly controlled so as to keep optimum opening angle of air mix door based on target and
present opening angles of air mix door. Air mix door is fixed in the full cold position when preset temperature is
set to 18°C, and full hot position when set to 32°C.

E

F

G

H

I

ATC

SJIA0789E

Drive System of Step Motor Type Door Motor

K

L

M

SJIA0970E

●
●

Motor is actuated in sequence by energizing four drive coils.
Rotation direction can be changed by changing pattern of excitation.

ATC-65

TROUBLE DIAGNOSIS
Air Mix Door Control Specification

RHA457H

COMPONENT DESCRIPTION
Air Mix Door Motor
The air mix door motor is attached to the A/C unit assembly. It
rotates so that the air mix door is opened or closed to a position set
by the auto amp. Motor rotation is conveyed through a shaft and the
air mix door position is then feedback to the auto amp. by PBR builtin air mix door motor.

MJIB0464E

ATC-66

TROUBLE DIAGNOSIS
DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR
A

1. CHECK AIR MIX DOOR MOTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect air mix door motor connector.
Check continuity between air mix door motor connector terminals.

B

C
Connector

Terminals

Continuity
1

Air mix motor: M51

D

3

2

Yes

4
6

SJIA0948E

E

OK or NG
OK
>> GO TO 2.
NG
>> Replace air mix door motor.

F

2. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND AIR MIX DOOR MOTOR
1.
2.

Disconnect auto amp. connector.
Check continuity between auto amp. harness connector (A) and
air mix door motor harness connector (B).
A
Connector

H

B
Terminal

Connector

19

Terminal

Continuity

3

20
Auto amp.: M65

G

Air mix door
motor: M51

21
22

I

6
Yes

1

MJIB0389E

4

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

ATC

K

3. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND GROUND

L

Check continuity between auto amp. harness connector and ground.
Connector

Terminal

Continuity

M

19
Auto amp.: M65

20

Ground

No

21
22

OK or NG
OK
>> Replace auto amp.
NG
>> Repair harness or connector.

MJIB0390E

ATC-67

TROUBLE DIAGNOSIS
Intake Door Motor Circuit

BJS000BH

SYMPTOM:
●
Intake door does not change.
●
Intake door motor does not operate normally.

INSPECTION FLOW

MJIB0391E

*1

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 1.

*2

ATC-99, «Ambient Sensor Circuit»

*3

ATC-102, «In-vehicle Sensor Circuit»

*4

ATC-105, «Sunload Sensor Circuit»

*5

ATC-64, «Air Mix Door Motor Circuit»

*6

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 13.

*7

ATC-124, «INTAKE DOOR MOTOR»

*8

ATC-55, «Operational Check»

*9

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 5 to
7.

*10 ATC-27, «SYMPTOM TABLE»

*11 ATC-108, «Intake Sensor Circuit»

ATC-68

TROUBLE DIAGNOSIS
SYSTEM DESCRIPTION
Component Parts

A

Intake door control system components are:
●
Auto amp.
●
Intake door motor
●
In-vehicle sensor
●
Ambient sensor
●
Sunload sensor
●
Intake sensor
●
ECM

B

C

D

System Operation
Suction opening is basically fixed in the position FRESH when DEF switch, FRE switch, or OFF switch (only at
the time of REC switch OFF) is pressed or when A/C switch is OFF. It is fixed in the position RECIRCULATION
when REC switch is pressed. It is automatically controlled at all other times.
During automatic control of suction opening, any of FRESH, 20% FRESH and RECIRCULATION is selected
according to the target opening angle of air mix door calculated by auto amp. based on the in-vehicle temperature, ambient temperature and the amount of solar radiation.

E

F

G

H

I

ATC

K

L
SJIA0790E

Intake Door Control Specification
M

RHA383H

ATC-69

TROUBLE DIAGNOSIS
COMPONENT DESCRIPTION
Intake Door Motor
The intake door motor is attached to the A/C unit assembly. It rotates
so that air is drawn from inlets set by the auto amp. Motor rotation is
conveyed to a lever which activates the intake door.

SJIA0814E

DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR

1. CHECK POWER SUPPLY FOR INTAKE DOOR MOTOR
1.
2.

Turn ignition switch ON.
Check voltage between intake door motor harness connector.
Terminals
Terminal

Connector

Intake door motor: M28

Condition

(+)

(−)

1

2

FRE → REC

2

1

REC → FRE

Voltage
(Approx.)

12 V

OK or NG
OK
>> Replace intake door motor.
NG
>> GO TO 2.

MJIB0392E

2. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND INTAKE DOOR MOTOR
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect auto amp. connector.
Disconnect intake door motor connector.
Check continuity between auto amp. harness connector (A) and
intake door motor harness connector (B).
A
Connector
Auto amp.: M65

B
Terminal

Connector

Terminal

27

Intake door motor:
M28

1

36

Continuity

2

Yes

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

3. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND GROUND
OK or NG
OK
>> Replace auto amp.
NG
>> Repair harness or connector.

ATC-70

MJIB0393E

TROUBLE DIAGNOSIS
Blower Motor Circuit

BJS000BI

A

SYMPTOM: Blower motor operation is malfunctioning.

INSPECTION FLOW
B

C

D

E

F

G

H

I

ATC

K

L

M

MJIB0394E

*1

ATC-55, «Operational Check»

*2

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No.
1.

*3

ATC-48, «FUNCTION CONFIRMATION
PROCEDURE», see No. 5.

*4

ATC-48, «FUNCTION CONFIRMA- *5
TION PROCEDURE», see No. 7.

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No.
13.

*6

ATC-73, «DIAGNOSTIC PROCEDURE
FOR BLOWER MOTOR»

ATC-71

TROUBLE DIAGNOSIS
*7

ATC-27, «SYMPTOM TABLE»

*8

ATC-99, «Ambient Sensor Circuit» *9

*10 ATC-105, «Sunload Sensor Circuit» *11 ATC-108, «Intake Sensor Circuit»

ATC-102, «In-vehicle Sensor Circuit»

*12 CR(WITH EURO–OBD): EC-166
CR(WITHOUT EURO–OBD): EC-565
HR(WITH EURO–OBD): EC-947
HR(WITHOUT EURO–OBD): EC-1361
K9K: EC-1727

*For further information refer to EC-21, «APPLICATION NOTICE» .

SYSTEM DESCRIPTION
Component Parts
Fan speed control system components are:
●
Auto amp.
●
In-vehicle sensor
●
Ambient sensor
●
Sunload sensor
●
Intake sensor

System Operation

MJIB0395E

Automatic Mode
In the automatic mode, the blower motor speed is calculated by the auto amp. based on input from in-vehicle
sensor, sunload sensor, intake sensor and ambient sensor.
The blower motor is applied voltage ranges from approximately 3.0 volts (lowest speed) to 12 volts (highest
speed).
The control blower speed (in the range of 3.0 to 12V), auto amp. supplies a gate voltage to the power transistor. Based on this voltage, auto amp. controls voltage supplied to the blower motor.

Starting Fan Speed Control
Start up from COLD SOAK Condition (Automatic mode)
In a cold start up condition where the engine coolant temperature is below 56°C, the blower will not operate for
a short period of time (up to 150 seconds). The exact start delay time varies depending on the ambient and
engine coolant temperature.
In the most extreme case (very low ambient) the blower starting delay will be 150 seconds as described
above. After this delay, the blower will operate at low speed until the engine coolant temperature rises above
56°C, at which time the blower speed will increase to the objective speed.
Start up from usual or HOT SOAK Condition (Automatic mode)

ATC-72

TROUBLE DIAGNOSIS
The blower will begin operation momentarily after the A/C switch is pushed. The blower speed will gradually
rise to the objective speed over a time period of 3 seconds or less (actual time depends on the objective
blower speed).

A

Blower Speed Compensation
Sunload
When the in-vehicle temperature and the set temperature are very close, the blower will be operating at low
speed. The low speed will vary depending on the sunload. During conditions of low or no sunload, the blower
low speed is usual low speed (approx. 4.0V). During high sunload conditions, auto amp. causes the blower
speed to increase (approx. 6.5V).

B

C

Fan Speed Control Specification
D

E

F
SJIA0792E

G

DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR
SYMPTOM: Blower motor operation is malfunctioning.

H

I

ATC

MJIB0396E

K

1. CHECK POWER SUPPLY FOR BLOWER MOTOR
1.
2.
3.

Disconnect blower motor connector.
Turn ignition switch ON.
Check voltage between blower motor harness connector and
ground.
Terminals
(+)

(−)

Connector

Terminal

Blower motor: M56

1

Ground

Voltage
(Approx.)
Battery voltage

MJIB0516E
OK or NG
OK
>> GO TO 2.
NG
>> Check power supply circuit and 15A fuses (Nos. 18 and 20, located in the fuse block). Refer to
PG-95, «FUSE BLOCK» .
● If fuses are OK, check harness for open circuit. Repair or replace if necessary.
● If fuses are OK, check blower relay. Replace if necessary.
● If fuses are NG, replace fuse and check harness for short circuit. Repair or replace if necessary.

ATC-73

L

M

TROUBLE DIAGNOSIS

2. CHECK CIRCUIT POWER SUPPLY FOR POWER TRANSISTOR
1.
2.
3.
4.
5.

Turn ignition switch OFF.
Connect blower motor connector.
Disconnect power transistor connector.
Turn ignition switch ON.
Check voltage between power transistor harness connector (A),
(B) and ground.
Terminals
(−)

Voltage
(Approx.)

Ground

Battery voltage

(+)
Connector

Terminal

A

Power transistor: M30

1

B

Power transistor: M31

4

MJIB0397E

OK or NG
OK
>> GO TO 3.
NG
>> ● Terminal 1 — Ground: Repair harness or connector.
● Terminal 4 — Ground: GO TO 5.

3. CHECK GROUND CIRCUIT FOR POWER TRANSISTOR
1.
2.

Turn ignition switch OFF.
Check continuity between power transistor harness connector
and ground.
Connector
Power transistor: M30

Terminal
2

Continuity
Ground

Yes

OK or NG
OK
>> GO TO 4.
NG
>> Repair harness or connector.
MJIB0398E

ATC-74

TROUBLE DIAGNOSIS

4. CHECK FOR AUTO AMP. OUTPUT
1.
2.

A

Reconnect power transistor connector.
Turn ignition switch ON.
B

C

D
MJIB0399E

3.

Change the fan speed from Lo to Hi, and confirm the duty ratios between power transistor harness connector and ground using an oscilloscope. Usual terminal 6 drive signal duty ratios are shown in the table
below.

E

F

G

H

I

ATC

K
SJIA0944E

OK or NG
OK
>> GO TO 5.
NG
>> ● Fan speed is stuck at speed 4: GO TO 7.
● Fan speed is stuck at speed 1: GO TO 8.

L

M

5. CHECK BLOWER MOTOR
1.
2.
3.

Turn ignition switch OFF.
Remove blower motor connector.
Check continuity between blower motor connector terminals.
Connector
Blower motor: M56

Terminal
1

Continuity
2

Yes

OK or NG
OK
>> GO TO 6.
NG
>> Replace blower motor.
MJIB0517E

ATC-75

TROUBLE DIAGNOSIS

6. CHECK CIRCUIT CONTINUITY BETWEEN BLOWER MOTOR AND POWER TRANSISTOR
Check continuity between blower motor harness connector (A) and
power transistor harness connector (B).
A

B

Continuity

Connector

Terminal

Connector

Terminal

Blower motor:
M56

2

Power transistor:
M31

4

Yes

OK or NG
OK
>> GO TO 7.
NG
>> Repair harness or connector.

MJIB0518E

7. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND POWER TRANSISTOR
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect power transistor connector.
Disconnect auto amp. connector.
Check continuity between auto amp. harness connector (A) and
power transistor harness connector (B).
A

B

Connector

Terminal

Connector

Terminal

Auto amp.: M64

15

Power transistor:
M31

6

Continuity
Yes
MJIB0401E

OK or NG
OK
>> Replace power transistor.
NG
>> Repair harness or connector.

8. CHECK FOR AUTO AMP. OUT PUT 2
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect auto amp. connector.
Turn ignition switch ON.
Check output signal between auto amp. harness connector and
ground.
Terminals
(+)

Connector

(−)

Condition

Voltage
(Approx.)

Terminal
MJIB0402E

Auto
amp.:
M64

15

Ground

Fan speed:
1st

ZJIA0863J

OK or NG
OK
>> Replace auto amp.
NG
>> Replace power transistor.

ATC-76

TROUBLE DIAGNOSIS
COMPONENT INSPECTION
Blower Motor

A

Confirm smooth rotation of the blower motor (1).
●
Ensure that there are no foreign particles inside the A/C unit
assembly.

B

C

D
SJIA0735E

E

F

G

H

I

ATC

K

L

M

ATC-77

TROUBLE DIAGNOSIS
Magnet Clutch Circuit

BJS000BJ

SYMPTOM: Magnet clutch does not engage.

INSPECTION FLOW

MJIB0403E

*1

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 1.

*2

ATC-99, «Ambient Sensor Circuit»

*3

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 13.

*4

ATC-79, «DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH»

*5

ATC-91, «TROUBLE DIAGNOSIS
FOR UNUSUAL PRESSURE»

*6

ATC-55, «Operational Check»

*7

ATC-48, «FUNCTION CONFIRMA*8
TION PROCEDURE», see No. 5 to 7.

ATC-27, «SYMPTOM TABLE»

*9

ATC-108, «Intake Sensor Circuit»

ATC-78

TROUBLE DIAGNOSIS
SYSTEM DESCRIPTION
A

Auto amp. controls compressor operation by intake air temperature and signal from ECM.

Low Temperature Protection Control
Auto amp. will turn compressor ON or OFF as determined by a signal detected by intake sensor.
When intake air temperatures are higher than 3.5°C (38°F), the compressor turns ON. The compressor turns OFF when intake air temperatures are lower than 2°C (36°F).

B

C

D

E
SJIA0802E

DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH
F

SYMPTOM: Magnet clutch does not engage when A/C switch is ON.

G

H

I

ATC

K

MJIB0404E

L

1. CHECK INTAKE SENSOR CIRCUIT
Check intake sensor. Refer to ATC-48, «FUNCTION CONFIRMATION PROCEDURE» , see No. 12.
OK or NG
OK
>> GO TO 2.
NG
>> Malfunctioning intake sensor: Refer to ATC-108, «Intake Sensor Circuit» .

2. PERFORM AUTO ACTIVE TEST
Refer to PG-22, «Auto Active Test» .
Does the magnet clutch operate?
YES >> ●
WITH CONSULT-II
GO TO 6.
●
WITHOUT CONSULT-II
GO TO 7.
NO
>> GO TO 3.

ATC-79

M

TROUBLE DIAGNOSIS

3. CHECK POWER SUPPLY COMPRESSOR
1.
2.
3.
4.
5.

Turn ignition switch OFF.
Disconnect compressor connector.
Start the engine.
Press AUTO switch and A/C switch ON.
Check voltage between compressor harness connector and
ground.
Terminals
(+)
Engine

CR and HR
K9K

Voltage
(Approx.)

(−)

Connector

MJIB0405E

Terminal

Compressor: F28

Ground
1

Compressor: F129

12V

OK or NG
OK
>> GO TO 5.
NG
>> Check power supply circuit and 10A fuse (No. 51, located in the fuse block), and GO TO 4. Refer
to PG-32, «IPDM E/R Terminal Arrangement» .
● If fuse is OK, GO TO 4.
● If fuse is NG, replace fuse and GO TO 4.

4. CHECK CIRCUIT CONTINUITY BETWEEN IPDM E/R AND COMPRESSOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect IPDM E/R connector.
Check continuity between compressor harness connector (A)
and IPDM E/R harness connector (B).
A
Engine

Connector

CR and HR

Compressor:
F28

K9K

4.

Continuity

Terminal

Connector

Terminal

1

IPDM E/R:
E7

41

Compressor:
F129

Yes
MJIB0406E

Check continuity between compressor harness connection (A) and ground.
Engine

CR and HR
K9K

5.

B

Connector
Compressor:
F28

Terminal

Continuity
Ground

1

No

Compressor:
F129

Check continuity between compressor harness connector and
ground.
Engine

K9K

Connector

Terminal

Compressor:
F129

2

Ground

Continuity
Yes

OK or NG
OK
>> GO TO 5.
NG
>> Repair harness or connector.
MJIA0205E

ATC-80

TROUBLE DIAGNOSIS

5. CHECK MAGNET CLUTCH

A

Check for operation sound when applying battery voltage direct current to terminal.
OK or NG
OK
>> 1. Replace IPDM E/R.
2. Go to self-diagnosis procedure ATC-48, «FUNCTION
CONFIRMATION PROCEDURE» and perform selfdiagnosis STEP-4. Confirm that magnet clutch operation usual.
NG
>> 1. Replace compressor.
2. Go to self-diagnosis procedure ATC-48, «FUNCTION
CONFIRMATION PROCEDURE» and perform selfdiagnosis STEP-4. Confirm that magnet clutch operation usual.

B

C

D
MJIB0407E

E

6. CHECK BCM INPUT (COMPRESSOR ON) SIGNAL
F

Check compressor ON/OFF signal. Refer to ATC-26, «CONSULT-II
Function (BCM)» .
A/C SW ON
A/C SW OFF

: AIR COND SW ON
: AIR COND SW OFF

G

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 7.

H

RJIA1111E

I

7. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND BCM.
1.
2.
3.

A

4.

ATC

Turn ignition switch OFF.
Disconnect auto amp. harness connector.
Check continuity between auto amp. harness connector (A) and
BCM harness connector.

K

B

Connector

Terminal

Connector

Terminal

Auto amp.: M64

13

BCM: M58

61

Continuity
Yes

Check continuity between auto amp.harness connector (A) and
ground.
A
Connector

Terminal

Auto amp.: M64

13

Ground

L

Continuity
No

OK or NG
OK
>> GO TO 8.
NG
>> Repair harness or connector.

ATC-81

M
MJIB0408E

TROUBLE DIAGNOSIS

8. CHECK VOLTAGE FOR AUTO AMP. (COMPRESSOR ON SIGNAL)
1.
2.
3.

Reconnect auto amp. harness connector and BCM harness connector.
Turn ignition switch ON.
Confirm compressor ON signal between auto amp. harness connector and ground.
Terminals
(+)

Connector

(-)

Condition

Voltage
(Approx.)

Terminal
MJIB0409E

Auto
amp.: M64

Ground
13

A/C switch:
ON
(Blower
motor operates.)
ZJIA0584J

OK or NG
OK
>> GO TO 9.
NG
>> Replace auto amp.

ATC-82

TROUBLE DIAGNOSIS

9. CHECK REFRIGERANT PRESSURE SENSOR

A

WITH CONSULT-II
Start the engine.
Check the voltage of refrigerant pressure sensor.
CR(WITH EURO–OBD): Refer to EC-112, «CONSULT-II Reference Value in Data Monitor Mode» .
CR(WITHOUT EURO–OBD): Refer to EC-527, «CONSULT-II Reference Value in Data Monitor Mode» .
HR(WITH EURO–OBD): Refer to EC-902, «CONSULT-II Reference Value in Data Monitor» .
HR(WITHOUT EURO–OBD): Refer to EC-1321, «CONSULT-II Reference Value in Data Monitor» .
K9K: Refer to EC-1694, «CONSULT-II Reference Value in Data Monitor Mode» .
*For further information refer to EC-21, «APPLICATION NOTICE» .
WITHOUT CONSULT-II
1. Start the engine.
2. Check voltage between ECM harness connector and ground.
1.
2.

B

C

D

E

Terminals
Engine

(+)
Connector
ECM: F2

69

HR

ECM: F51

41

K9K

ECM: F134

89

●

NG

>> ●
●
●
●
●

Condition

Voltage
(Approx.)

F

Ground

A/C switch: ON
(Blower motor
operates.)

1-4V

G

Terminal

CR

OK or NG
OK
>> ●

(-)

H

WITH CONSULT-II
GO TO 10.
WITHOUT CONSULT-II
GO TO 11.
CR (WITH EURO–OBD): Refer to EC-443 .
CR (WITHOUT EURO–OBD): Refer to EC-794 .
HR (WITH EURO–OBD): Refer to EC-1231 .
HR (WITHOUT EURO–OBD): Refer to EC-1590 .
K9K: Refer to EC-1811 .

I

ATC

K
MJIB0410E

10. CHECK BCM INPUT (FAN ON) SIGNAL

L

Check FAN ON/OFF signal. Refer to ATC-26, «CONSULT-II Function
(BCM)» .
FAN SW ON
FAN SW OFF

M

: FAN ON SIG ON
: FAN ON SIG OFF

OK or NG
OK
>> GO TO 13.
NG
>> GO TO 11.

RJIA1111E

ATC-83

TROUBLE DIAGNOSIS

11. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND BCM
1.
2.
3.

Turn ignition switch OFF.
Disconnect auto amp. connector and BCM connector.
Check continuity between auto amp. harness connector (A) and
BCM harness connector (B).
A

B

Connector

Terminal

Connector

Terminal

Auto amp.: M64

12

BCM: M58

50

4.

Continuity
Yes

Check continuity between auto amp.harness connector (A) and
ground.

MJIB0411E

A
Connector

Terminal

Auto amp.: M64

12

Ground

Continuity
No

OK or NG
OK
>> GO TO 12.
NG
>> Repair harness or connector.

12. CHECK VOLTAGE FOR AUTO AMP. (FAN ON SIGNAL)
1.
2.
3.

Reconnect auto amp. connector and BCM connector.
Turn ignition switch ON.
Confirm fan ON signal between auto amp. harness connector
and ground using oscilloscope.
Terminals
(+)

Connector

(−)

Condition

Voltage
(Approx.)

Terminal
MJIB0412E

Auto
amp.:
M64

Ground
12

Fan speed:
1st

ZJIA0583J

OK or NG
OK
>> Replace auto amp.
NG
>> Replace BCM.

13. CHECK CAN COMMUNICATION
Check CAN communication. Refer to BCS-17, «CAN Communication Inspection With CONSULT-II (Self-Diagnosis)» .
●
BCM – ECM
●
ECM – IPDM E/R
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace malfunction part(s).

ATC-84

TROUBLE DIAGNOSIS
COMPONENT INSPECTION
Refrigerant Pressure Sensor

A

The refrigerant pressure sensor (1) is attached to the condenser.
B

C

D

MJIB0457E

Make sure that the A/C refrigerant pressure and the sensor output
voltage are within the specified range as shown in the A/C operating
condition figure.
CR(WITH EURO–OBD): Refer to EC-443 .
CR(WITHOUT EURO–OBD): Refer to EC-794 .
HR(WITH EURO–OBD): Refer to EC-1231 .
HR(WITHOUT EURO–OBD): Refer to EC-1590 .
K9K: Refer to EC-1811 .
*For further information refer to EC-21, «APPLICATION NOTICE» .

E

F

G

H
RJIA2954E

I

ATC

K

L

M

ATC-85

TROUBLE DIAGNOSIS
Insufficient Cooling

BJS000BK

SYMPTOM: Insufficient cooling

INSPECTION FLOW

MJIB0413E

*1

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 1.

*2

ATC-64, «Air Mix Door Motor Circuit» *3

*4

ATC-54, «AUXILIARY MECHANISM: TEMPERATURE SETTING
TRIMMER»

*5

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 13.

ATC-86

*6

ATC-90, «Test Reading»
ATC-71, «Blower Motor Circuit»

TROUBLE DIAGNOSIS
*7

ATC-78, «Magnet Clutch Circuit»

*8

ATC-88, «PERFORMANCE TEST
DIAGNOSIS»

*11 CR: EM-14, «Checking drive Belts»
*10 ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 5 to 7.
HR: EM-114, «Checking Drive Belts»
K9K: EM-242, «Checking Drive
Belts»

*For further information refer to EC-21, «APPLICATION NOTICE» .

*9

ATC-55, «Operational Check»

A
*12 CR(WITH EURO–OBD): EC-345
CR(WITHOUT EURO–OBD): EC-662
HR(WITH EURO–OBD): EC-1130
HR(WITHOUT EURO–OBD): EC-1451
K9K: EC-1864

B

C

D

E

F

G

H

I

ATC

K

L

M

ATC-87

TROUBLE DIAGNOSIS
PERFORMANCE TEST DIAGNOSIS

RJIA1601E

*1

ATC-90, «PERFORMANCE CHART» *2

*4

ATC-64, «Air Mix Door Motor Circuit»

ATC-90, «PERFORMANCE CHART» *3

ATC-88

ATC-91, «TROUBLE DIAGNOSIS
FOR UNUSUAL PRESSURE»

TROUBLE DIAGNOSIS
A

B

C

D

E

F

G

H

I

ATC

K

L

M

RJIA3107E

*1

ATC-141, «CHECK DISC TO PULLEY CLEARANCE»

*2

ATC-71, «Blower Motor Circuit»

ATC-89

*3

CR: EM-14, «Checking drive Belts»
HR: EM-114, «Checking Drive Belts»
K9K: EM-242, «Checking Drive
Belts»

TROUBLE DIAGNOSIS
PERFORMANCE CHART
Test Condition
Testing must be performed as follows:
Vehicle condition

Indoors or in the shade (in a well-ventilated place)

Doors

Closed

Door window

Open

Hood

Open

TEMP.

Max. COLD

Mode switch

(Ventilation) set

Recirculation (REC) switch

(Recirculation) set
Max. speed set

Fan (blower) speed
Engine speed

Idle speed

Operate the air conditioning system for 10 minutes before taking measurements.

Test Reading
Recirculating-to-discharge Air Temperature Table
Inside air (Recirculating air) at blower assembly inlet
Relative humidity
%

Discharge air temperature at center ventilator
°C (°F)

Air temperature
°C (°F)

50 — 60

60 — 70

20 (68)

7.2 — 9.1 (45 — 48)

25 (77)

11.4 — 13.8 (53 — 57)

30 (86)

15.5 — 18.4 (60 — 65)

35 (95)

20.3 — 23.7 (69 — 75)

20 (68)

9.1 — 10.9 (48 — 52)

25 (77)

13.8 — 16.2 (57 — 61)

30 (86)

18.4 — 21.3 (65 — 70)

35 (95)

23.7 — 27.1 (75 — 81)

Ambient Air Temperature-to-operating Pressure Table
Ambient air
Relative humidity
%

50 — 70

High-pressure (Discharge side)

Low-pressure (Suction side)

Air temperature
°C (°F)

kPa (bar, kg/cm2 , psi)

kPa (bar, kg/cm2 , psi)

20 (68)

843 — 1,036 *1
(11.08 — 13.63, 8.6 — 10.6, 122 — 150)

159.0 — 194.0
(1.59 — 1.94, 1.62 — 1.98, 23.1 — 28.1)

25 (77)

1,094 — 1,338 *1
(10.94 — 13.38, 11.2 — 13.6, 159 — 194)

196.3 — 240.0
(1.96 — 2.40, 2.00 — 2.45, 28.5 — 34.8)

30 (86)

1,298 — 1,590 *1
(12.98 — 15.90, 13.2 — 16.2, 188 — 231)

248.0 — 302.7
(2.48 — 3.03, 2.53 — 3.09, 36.0 — 43.9)

35 (95)

1,383 — 1,688 *2
(13.83 — 16.88, 14.1 — 17.2, 201 — 245)

308.8 — 377.4
(3.09 — 3.77, 3.15 — 3.85, 44.8 — 54.7)

40 (104)

1,628 — 1,988 *2
(16.28 — 19.88, 16.6 — 20.3, 236 — 288)

377.4 — 461.2
(3.77 — 4.61, 3.85 — 4.70, 54.7 — 66.8)

*1: In the motor fan low-speed control
*2: In the motor fan high-speed control

ATC-90

TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE
Whenever system’s high and/or low side pressure(s) is/are unusual, diagnose using a manifold gauge. The
marker above the gauge scale in the following tables indicates the standard (usual) pressure range. Since the
standard (usual) pressure, however, differs from vehicle, refer to above table (Ambient air temperature-tooperating pressure table).

A

B

Both High- and Low-pressure Sides are Too High
Gauge indication

Refrigerant cycle

Probable cause

Pressure is reduced soon
after water is splashed on
condenser.

Air suction by cooling fan is
insufficient.

Excessive refrigerant charge in
refrigeration cycle.
Insufficient condenser cooling performance.
↓
1. Condenser fins are clogged.

Corrective action
Reduce refrigerant until
specified pressure is
obtained.

D
●

Clean condenser.

●

Check and repair cooling
fan if necessary.

2. Improper fan rotation of cooling
fan.
Both high- and low-pressure
sides are too high.

●

Low-pressure pipe is not
cold.

●

When compressor is
stopped high-pressure
value quickly drops by
approximately 196 kPa
(1.96 bar, 2 kg/cm2 , 28
psi). It then decreases
gradually thereafter.

AC359A

Engine tends to overheat.

●

●

An area of the low-pressure pipe is colder than
areas near the evaporator
outlet.
Plates are sometimes covered with frost.

C

E

F
Poor heat exchange in condenser
(After compressor operation stops,
high-pressure decreases too
slowly.).
↓
Air in refrigeration cycle.

Evacuate repeatedly and
recharge system.

Engine cooling systems malfunction.

Check and repair each
engine cooling system.

●

Excessive liquid refrigerant on lowpressure side.

●

Excessive refrigerant discharge
flow.

●

Expansion valve is open a little
compared with the specification.

G

H

I

ATC
Replace expansion valve.

K

↓
Improper expansion valve adjustment.

L

High-pressure Side is Too High and Low-pressure Side is Too Low
Gauge indication

Refrigerant cycle

Probable cause

Corrective action

M

High-pressure side is too high
and low-pressure side is too low.
Upper side of condenser and
high-pressure side are hot,
however, liquid tank is not so
hot.

High-pressure tube or parts located
between compressor and condenser
are clogged or crushed.

AC360A

ATC-91

●

Check and repair or
replace malfunctioning
parts.

●

Check lubricant for
contamination.

TROUBLE DIAGNOSIS
High-pressure Side is Too Low and Low-pressure Side is Too High
Gauge indication
High-pressure side is too low
and low-pressure side is too
high.

Refrigerant cycle

Probable cause

Corrective action

High- and low-pressure sides
become equal soon after compressor operation stops.

Compressor pressure operation
is improper.
↓
Damaged inside compressor
packings.

Replace compressor.

No temperature difference
between high- and low-pressure sides.

Compressor pressure operation
is improper.
↓
Damaged inside compressor
packings.

Replace compressor.

AC356A

Both High- and Low-pressure Sides are Too Low
Gauge indication

Refrigerant cycle
●

Liquid tank inlet and expansion valve are frosted.

●

Temperature of expansion
valve inlet is extremely low as
compared with areas near liquid tank.

●

AC353A

There is a big temperature
difference between liquid tank
outlet and inlet. Outlet temperature is extremely low.

●

●

Both high- and low-pressure
sides are too low.

Probable cause

Expansion valve inlet may be
frosted.

Liquid tank inside is slightly
clogged.

High-pressure pipe located
between liquid tank and expansion valve is clogged.

Corrective action

●

Replace liquid tank.

●

Check lubricant for contamination.

●

Check and repair malfunctioning parts.

●

Check lubricant for contamination.

Temperature difference
occurs somewhere in highpressure side.

Expansion valve and liquid tank
are warm or only cool when
touched.

There is a big temperature difference between expansion
valve inlet and outlet while the
valve itself is frosted.

Low refrigerant charge.
↓
Leaking fittings or components
Expansion valve closes a little
compared with the specification.
↓
1. Improper expansion valve
adjustment.
2. Malfunctioning expansion
valve.

Check refrigerant for leaks.
Refer to ATC-147, «Checking
for Refrigerant Leaks» .

●

Remove foreign particles by
using compressed air.

●

Replace expansion valve.

●

Check lubricant for contamination.

●

Check and repair malfunctioning parts.

●

Check lubricant for contamination.

●

Check intake sensor circuit.
Refer to ATC-108, «Intake
Sensor Circuit» .

●

Replace compressor.

●

Repair evaporator fins.

●

Replace evaporator.

●

Refer to ATC-71, «Blower
Motor Circuit» .

3. Outlet and inlet may be
clogged.
An area of the low-pressure
pipe is colder than areas near
the evaporator outlet.

Air flow volume is not enough or
is too low.

Low-pressure pipe is clogged or
crushed.

Evaporator is frozen.

ATC-92

TROUBLE DIAGNOSIS
Low-pressure Side Sometimes Becomes Negative
Gauge indication
Low-pressure side sometimes
becomes negative.

Refrigerant cycle
●

●

AC354A

Air conditioning system
does not function and does
not cyclically cool the compartment air.
The system constantly functions for a certain period of
time after compressor is
stopped and restarted.

Probable cause
Refrigerant does not discharge cyclically.
↓
Moisture is frozen at expansion valve outlet and inlet.
↓
Water is mixed with refrigerant.

Corrective action

A

B
●

Drain water from refrigerant
or replace refrigerant.

●

Replace liquid tank.

C

D

Low-pressure Side Becomes Negative
Gauge indication

Refrigerant cycle

Probable cause

Corrective action
Leave the system at rest until
no frost is present. Start it
again to check whether or not
the malfunction is caused by
water or foreign particles.
●

Low-pressure side becomes negative.
Liquid tank or front/rear side of
expansion valve’s pipe is
frosted or dewed.

High-pressure side is closed
and refrigerant does not flow.
↓
Expansion valve or liquid tank
is frosted.

●

AC362A

●

If water is the cause, initially
cooling is okay. Then the
water freezes causing a
blockage. Drain water from
refrigerant or replace refrigerant.
If due to foreign particles,
remove expansion valve
and remove the particles
with dry and compressed air
(not shop air).
If either of the above methods cannot correct the malfunction, replace expansion
valve.

●

Replace liquid tank.

●

Check lubricant for contamination.

E

F

G

H

I

ATC

K

L

M

ATC-93

TROUBLE DIAGNOSIS
Insufficient Heating

BJS000BL

SYMPTOM: Insufficient heating

INSPECTION FLOW

MJIB0414E

*1

ATC-55, «Operational Check»

*2

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 1.

*3

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 5 to 7.

*4

ATC-64, «Air Mix Door Motor Circuit» *5

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 13.

*6

ATC-71, «Blower Motor Circuit»

ATC-94

TROUBLE DIAGNOSIS
*7

ATC-64, «Air Mix Door Motor Circuit» *8

CR(WITH EURO–OBD): EC-166
*9
CR’WITHOUT EURO–OBD): EC-565
HR(WITH EURO–OBD): EC-947
HR(WITHOUT EURO–OBD): EC-1361
K9K: EC-1727

*10 CR: CO-15 or CO-16
HR: CO-34 or CO-35
K9K: CO-53

*For further information refer to EC-21, «APPLICATION NOTICE» .

CR: CO-9
HR: CO-28
K9K: CO-49

A

B

C

D

E

F

G

H

I

ATC

K

L

M

ATC-95

TROUBLE DIAGNOSIS
Noise

BJS000BM

SYMPTOM: Noise

INSPECTION FLOW

SJIA0843E

ATC-96

TROUBLE DIAGNOSIS
*1

ATC-55, «Operational Check»

*4

CR: EM-14, «Checking drive Belts»
HR: EM-114, «Checking Drive Belts»
K9K: EM-242, «Checking Drive
Belts»

*2

ATC-141, «CHECK DISC TO PULLEY CLEARANCE»

*3

ATC-17, «Maintenance of Lubricant
Quantity in Compressor»

A

B

Self-diagnosis

BJS000BN

C

SYMPTOM: Self-diagnosis cannot be performed.

INSPECTION FLOW
D

E

F

G

H

I

ATC

K

L

M
MJIB0415E

*1

ATC-57, «Power Supply and Ground
Circuit for Auto Amp.»

*2

ATC-99, «Ambient Sensor Circuit»

*3

ATC-102, «In-vehicle Sensor Circuit»

*4

ATC-105, «Sunload Sensor Circuit»

*5

ATC-108, «Intake Sensor Circuit»

*6

ATC-64, «Air Mix Door Motor Circuit»

*7

ATC-55, «Operational Check»

*8

ATC-27, «SYMPTOM TABLE»

ATC-97

TROUBLE DIAGNOSIS
Memory Function

BJS000BO

SYMPTOM: Memory function does not operate.

INSPECTION FLOW

MJIB0416E

*1

ATC-57, «Power Supply and Ground
Circuit for Auto Amp.»

*2

ATC-55, «Operational Check»

ATC-98

*3

ATC-48, «FUNCTION CONFIRMATION PROCEDURE», see No. 5.

TROUBLE DIAGNOSIS
Ambient Sensor Circuit

BJS000BP

A

COMPONENT DESCRIPTION
Ambient Sensor
The ambient sensor (1) is attached on the radiator core support
upper. It detects ambient temperature and converts it into a resistance value which is then input into the auto amp.

B

C

D

MJIB0467E

AMBIENT TEMPERATURE INPUT PROCESS
The auto amp. includes a processing circuit for the ambient sensor input. However, when the temperature
detected by the ambient sensor increases quickly, the processing circuit retards the auto amp. function. It only
allows the auto amp. to recognize an ambient temperature increase of 0.33°C (0.6°F) per 100 seconds.
As an example, consider stopping for a few minutes after high speed driving. Although the actual ambient temperature has not changed, the temperature detected by the ambient sensor will increase. This is because the
heat from the engine compartment can radiate to the front grille area, location of the ambient sensor.

E

F

G

DIAGNOSTIC PROCEDURE FOR AMBIENT SENSOR
SYMPTOM: Ambient sensor circuit is open or shorted. (21 or AUTO
21 is indicated on auto amp. As a result of performing self-diagnosis
STEP-2.)

H

I

ATC

SJIA0807E

1. CHECK VOLTAGE BETWEEN AMBIENT SENSOR AND GROUND
1.
2.
3.
4.

L

Turn ignition switch OFF.
Disconnect ambient sensor connector.
Turn ignition switch ON.
Check voltage between ambient sensor harness connector and
ground.

M

Terminals
(+)

(−)

Connector

Terminal

Ambient sensor:
E17

4

Voltage
(Approx.)

Ground
5V

OK or NG
OK
>> GO TO 2.
NG
>> GO TO 4.

ATC-99

K

MJIB0417E

TROUBLE DIAGNOSIS

2. CHECK CIRCUIT CONTINUITY BETWEEN AMBIENT SENSOR AND AUTO AMP.
1.
2.
3.

Turn ignition switch OFF.
Disconnect auto amp. connector.
Check continuity between ambient sensor harness connector
(A) and auto amp. harness connector (B).
A

B

Connector

Terminal

Connector

Terminal

Ambient sensor:
E17

3

Auto amp.: M65

33

Continuity
Yes

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

MJIB0418E

3. CHECK AMBIENT SENSOR
Refer to ATC-114, «AMBIENT SENSOR» .
OK or NG
OK
>> 1. Replace auto amp.
2. Go to self-diagnosis ATC-48, «FUNCTION CONFIRMATION PROCEDURE» and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed.
NG
>> 1. Replace ambient sensor.
2. Go to self-diagnosis ATC-48, «FUNCTION CONFIRMATION PROCEDURE» and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed.

4. CHECK CIRCUIT CONTINUITY BETWEEN AMBIENT SENSOR AND AUTO AMP.
1.
2.
3.

Turn ignition switch OFF.
Disconnect auto amp. connector.
Check continuity between ambient sensor harness connector
(A) and auto amp. harness connector (B).
A

4.

B

Connector

Terminal

Connector

Terminal

Ambient sensor:
E17

4

Auto amp.: M65

30

Continuity
Yes

Check continuity between ambient sensor harness connector
(A) and ground.
A

MJIB0419E

Continuity

Connector

Terminal

Ambient sensor:
E17

4

Ground
No

OK or NG
OK
>> 1. Replace auto amp.
2. Go to self-diagnosis ATC-48, «FUNCTION CONFIRMATION PROCEDURE»
diagnosis STEP-2. Confirm that code No. 20 is displayed.
NG
>> Repair harness or connector.

ATC-100

and perform self-

TROUBLE DIAGNOSIS
COMPONENT INSPECTION
Ambient Sensor

A

After disconnecting ambient sensor connector E32, measure resistance between terminals 1 and 2 at sensor side, using the table
below.

B

Temperature °C (°F)

Resistance kΩ

−15 (5)

12.73

−10 (14)

9.92

−5 (23)

7.80

0 (32)

6.19

5 (41)

4.95

10 (50)

3.99

15 (59)

3.24

20 (68)

2.65

25 (77)

2.19

30 (86)

1.81

35 (95)

1.51

40 (104)

1.27

45 (113)

1.07

C

D

E

F

G

MJIB0468E

If NG, replace ambient sensor.

H

I

ATC

K

L

M

ATC-101

TROUBLE DIAGNOSIS
In-vehicle Sensor Circuit

BJS000BQ

COMPONENT DESCRIPTION
In-vehicle Sensor
The in-vehicle sensor (1) is located on instrument lower finisher. It
converts variations in temperature of compartment air drawn from
the aspirator into a resistance value. It is then input into the auto
amp.

MJIB0420E

Aspirator
The aspirator (1) is located on passenger’s side of A/C unit assembly. It produces vacuum pressure due to air discharged from the A/C
unit, continuously taking compartment air in the aspirator.

MJIB0421E

RJIA1402E

DIAGNOSTIC PROCEDURE FOR IN-VEHICLE SENSOR
SYMPTOM: In-vehicle sensor circuit is open or shorted. (22 or AUTO
22 is indicated on auto amp. as a result of performing self-diagnosis
STEP-2.)

SJIA0815E

ATC-102

TROUBLE DIAGNOSIS

1. CHECK VOLTAGE BETWEEN IN-VEHICLE SENSOR AND GROUND
1.
2.
3.
4.

A

Turn ignition switch OFF.
Disconnect in-vehicle sensor connector.
Turn ignition switch ON.
Check voltage between in-vehicle sensor harness connector
and ground.

B

C
Terminals
(+)

Voltage
(Approx.)

(−)

Connector

D

Terminal
Ground

In-vehicle sensor:
M43

1

SJIA0816E

5V

E

OK or NG
OK
>> GO TO 2.
NG
>> GO TO 4.

F

2. CHECK CIRCUIT CONTINUITY BETWEEN IN-VEHICLE SENSOR AND AUTO AMP.
1.
2.
3.

Turn ignition switch OFF.
Disconnect auto amp. connector.
Check continuity between in-vehicle sensor harness connector
(A) and auto amp. harness connector (B).
A

B

G

H

Continuity

Connector

Terminal

Connector

Terminal

In-vehicle sensor:
M43

2

Auto amp.: M65

33

I
Yes

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

MJIB0422E

3. CHECK IN-VEHICLE SENSOR

ATC

K

Refer to ATC-115, «IN-VEHICLE SENSOR» .
OK or NG
OK
>> 1. Replace auto amp.
2. Go to self-diagnosis ATC-48, «FUNCTION CONFIRMATION PROCEDURE» and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed.
NG
>> 1. Replace in-vehicle sensor.
2. Go to self-diagnosis ATC-48, «FUNCTION CONFIRMATION PROCEDURE» and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed.

ATC-103

L

M

TROUBLE DIAGNOSIS

4. CHECK CIRCUIT CONTINUITY BETWEEN IN-VEHICLE SENSOR AND AUTO AMP.
1.
2.
3.

Turn ignition switch OFF.
Disconnect auto amp. connector.
Check continuity between in-vehicle sensor harness connector
(A) and auto amp. harness connector (B).
A

4.

B

Connector

Terminal

Connector

Terminal

In-vehicle sensor:
M43

1

Auto amp.: M65

28

Continuity
Yes

Check continuity between in-vehicle sensor harness connector
(A) and ground.
A

MJIB0423E

Continuity

Connector

Terminal

In-vehicle sensor:
M43

1

Ground
No

OK or NG
OK
>> 1. Replace auto amp.
2. Go to self-diagnosis ATC-48, «FUNCTION CONFIRMATION PROCEDURE» and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed.
NG
>> Repair harness or connector.

COMPONENT INSPECTION
In-vehicle Sensor
After disconnecting in-vehicle sensor connector M41, measure resistance between terminals 1 and 2 at sensor side, using the table
below.
Temperature °C (°F)

Resistance kΩ

−15 (5)

12.73

−10 (14)

9.92

−5 (23)

7.80

0 (32)

6.19

5 (41)

4.95

10 (50)

3.99

15 (59)

3.24

20 (68)

2.65

25 (77)

2.19

30 (86)

1.81

35 (95)

1.51

40 (104)

1.27

45 (113)

1.07
MJIB0424E

If NG, replace in-vehicle sensor.

ATC-104

TROUBLE DIAGNOSIS
Sunload Sensor Circuit

BJS000BR

A

COMPONENT DESCRIPTION
Sunload Sensor
The sunload sensor (1) is located on the instrument upper mask. It
detects sunload entering through windshield by means of a photo
diode. The sensor converts the sunload into a current value which is
then input into the auto amp.

B

C

D

MJIB0431E

SUNLOAD INPUT PROCESS
The auto amp. also includes a processing circuit which averages the variations in detected sunload over a
period of time. This prevents drastic swings in the ATC system operation due to small or quick variations in
detected sunload.
For example, consider driving along a road bordered by an occasional group of large trees. The sunload
detected by the sunload sensor will vary whenever the trees obstruct the sunlight. The processing circuit averages the detected sunload over a period of time, so that the (insignificant) effect of the trees momentarily
obstructing the sunlight does not cause any change in the ATC system operation. On the other hand, shortly
after entering a long tunnel, the system will recognize the change in sunload, and the system will react accordingly.

E

F

G

H

DIAGNOSTIC PROCEDURE FOR SUNLOAD SENSOR
SYMPTOM: Sunload sensor circuit is open or shorted. (25 or AUTO
25 is indicated on auto amp. as a result of performing self-diagnosis
STEP-2.)

I

ATC

K

SJIA0820E

L

1. CHECK VOLTAGE BETWEEN SUNLOAD SENSOR AND GROUND
1.
2.
3.
4.

M

Turn ignition switch OFF.
Disconnect sunload sensor connector.
Turn ignition switch ON.
Check voltage between sunload sensor harness connector and
ground.
Terminals
(+)

(−)

Connector

Terminal

Sunload sensor: M23

1

Voltage
(Approx.)

Ground
5V

OK or NG
OK
>> GO TO 2.
NG
>> GO TO 4.

ATC-105

SJIA0821E

TROUBLE DIAGNOSIS

2. CHECK CIRCUIT CONTINUITY BETWEEN SUNLOAD SENSOR AND AUTO AMP.
1.
2.
3.

Turn ignition switch OFF.
Disconnect auto amp. connector.
Check continuity between sunload sensor harness connector
(A) and auto amp. harness connector (B).
A

B

Connector

Terminal

Connector

Terminal

Sunload sensor: M23

2

Auto amp.: M65

33

Continuity
Yes

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

MJIB0422E

3. CHECK SUNLOAD SENSOR
1. Reconnect sunload sensor connector and auto amp. connector.
2. Refer to ATC-116, «SUNLOAD SENSOR» .
OK or NG
OK
>> 1. Replace auto amp.
2. Go to self-diagnosis ATC-48, «FUNCTION CONFIRMATION PROCEDURE» and perform self-diagnosis
STEP-2. Confirm that code No. 20 is displayed.
NG
>> 1. Replace sunload sensor.
2. Go to self-diagnosis ATC-48, «FUNCTION CONFIRMATION PROCEDURE» and perform self-diagnosis
STEP-2. Confirm that code No. 20 is displayed.

MJIA0089E

4. CHECK CIRCUIT CONTINUITY BETWEEN SUNLOAD SENSOR AND AUTO AMP.
1.
2.
3.

Turn ignition switch OFF.
Disconnect auto amp. connector.
Check continuity between sunload sensor harness connector
(B) and auto amp. harness connector (B).
A

4.

B

Connector

Terminal

Connector

Terminal

Sunload sensor: M23

1

Auto amp.: M65

31

Continuity
Yes

Check continuity between sunload sensor harness connector
(A) and ground.

MJIB0425E

A
Connector

Terminal

Sunload sensor: M23

1

Ground

Continuity
No

OK or NG
OK
>> 1. Replace auto amp.
2. Go to self-diagnosis ATC-48, «FUNCTION CONFIRMATION PROCEDURE» and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed.
NG
>> Repair harness or connector.

ATC-106

TROUBLE DIAGNOSIS
COMPONENT INSPECTION
Sunload Sensor

A

Measure voltage between auto amp. harness connector M65 terminal 31 and ground.
If NG, replace sunload sensor (1).

B

C

D

E

F

G

MJIB0469E

●

H

When checking sunload sensor, select a place where sun shines directly on it.
I

ATC

K

L

M

SHA930E

ATC-107

TROUBLE DIAGNOSIS
Intake Sensor Circuit

BJS000BS

COMPONENT DESCRIPTION
Intake Sensor
The intake sensor (1) is located on the A/C unit. It converts temperature of air that through the evaporator (2) into a resistance value
which is then input to the auto amp.

MJIB0459E

DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR
SYMPTOM: Intake sensor circuit is open or shorted. (24 or AUTO 24
is indicated on auto amp. as a result of performing self-diagnosis
STEP-2.)

SJIA0824E

1. CHECK VOLTAGE BETWEEN INTAKE SENSOR AND GROUND
1.
2.
3.
4.

Turn ignition switch OFF.
Disconnect intake sensor connector.
Turn ignition switch ON.
Check voltage between intake sensor harness connector and
ground.
Terminals
(+)

(−)

Connector

Terminal

Intake sensor: M44

1

Ground

Voltage
(Approx.)
5V

OK or NG
OK
>> GO TO 2.
NG
>> GO TO 4.

ATC-108

SJIA0825E

TROUBLE DIAGNOSIS

2. CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND AUTO AMP.
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect auto amp. connector.
Check continuity between intake sensor harness connector (A)
and auto amp. harness connector (B).
A

B

B

Connector

Terminal

Connector

Terminal

Intake sensor: M44

2

Auto amp.: M65

33

C

Continuity
Yes

D

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness or connector.

MJIB0426E

E

3. CHECK INTAKE SENSOR
Refer to ATC-117, «INTAKE SENSOR» .
OK or NG
OK
>> 1. Replace auto amp.
2. Go to self-diagnosis ATC-48, «FUNCTION CONFIRMATION PROCEDURE» and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed.
NG
>> 1. Replace intake sensor.
2. Go to self-diagnosis ATC-48, «FUNCTION CONFIRMATION PROCEDURE» and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed.

4. CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND AUTO AMP.
1.
2.
3.

B

Connector

Terminal

Intake sensor: M44

1

4.

Connector
Auto amp.: M65

ATC

K

Continuity
29

Yes

L
MJIB0427E

Continuity

Connector

Terminal

Intake sensor: M44

1

H

Terminal

Check continuity between intake sensor harness connector (A)
and ground.
A

G

I

Turn ignition switch OFF.
Disconnect auto amp. connector.
Check continuity between intake sensor harness connector (A)
and auto amp. harness connector (B).
A

F

Ground
No

OK or NG
OK
>> 1. Replace auto amp.
2. Go to self-diagnosis ATC-48, «FUNCTION CONFIRMATION PROCEDURE» and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed.
NG
>> Repair harness or connector.

ATC-109

M

TROUBLE DIAGNOSIS
COMPONENT INSPECTION
Intake Sensor
After disconnecting intake sensor connector (1) M44, measure resistance between terminals 1 and 2 at sensor side, using the table
below.
Temperature °C (°F)

Resistance kΩ

−15 (5)

12.34

−10 (14)

9.62

−5 (23)

7.56

0 (32)

6.00

5 (41)

4.80

10 (50)

3.87

15 (59)

3.15

20 (68)

2.57

25 (77)

2.12

30 (86)

1.76

35 (95)

1.47

40 (104)

1.23

45 (113)

1.04
MJIB0470E

If NG, replace intake sensor.

ATC-110

TROUBLE DIAGNOSIS
Engine Coolant Temperature Circuit

BJS000BT

Symptom: Low engine coolant temperature startup airflow control cannot be cancelled, or the mode cannot be
switched to low engine coolant temperature startup airflow control.

Inspection Procedure

A

B

1. COMBINATION METER FUNCTION INSPECTION
Is engine coolant temperature gauge operating normally?
OK or NG
OK
>> GO TO 2.
NG
>> GO TO DI-19, «Check Water Temperature Warning/indicator Lamp» of Combination Meter.

C

D

2. HARNESS INSPECTION
1.
2.
3.

E

Turn ignition switch OFF.
Disconnect auto amp. connector and combination meter connector.
Check continuity between auto amp. harness connector (A) and
combination meter harness connector (B).
A

B

F

G

Continuity

Connector

Terminal

Connector

Terminal

Auto amp.: M64

4

Combination
meter: M27

35

Yes
MJIB0428E

4.

H

Check continuity between auto amp. harness connector (A) and
ground.
I

A
Connector

Terminal

Auto amp.: M64

4

Ground

Continuity
No

ATC

OK or NG
OK
>> GO TO 3.
NG
>> Repair harness and connector.

K

3. ENGINE COOLANT TEMPERATURE SIGNAL INSPECTION
L

After warming up engine, check voltage waveform between combination meter harness connector and ground.
Terminals
(+)
Connector

Combination
meter: M27

M
(−)

Condition

Voltage (approx.)

Terminal

35

Ground

After
warming
up,
approx.
80°C.

MJIB0429E

SKIB3651J

OK or NG
OK
>> Replace auto amp.
NG
>> Replace combination meter.

ATC-111

CONTROLLER
CONTROLLER
Removal and Installation of Controller

PFP:28074
BJS000BU

REMOVAL
1.
2.
3.

Remove controller mounting clips (A) using remover tool.
Disconnect controller harness connector and front passenger air
bag OFF indicator harness connector.
Remove controller (1).

ZJIA0790J

INSTALLATION
Installation is basically the reverse order of removal.

Disassembly and Assembly of Controller

BJS000BV

ZJIA0791J

1.

Controller assembly

4.

TEMP ring

5.

A/C finisher

6.

A/C button

7.

TEMP button

8.

REC button

9.

LCD ring

10. Rear DEF button

2.

FRE button

11. AUTO button

3.

MODE ring

12. FAN button

13. MODE button

DISASSEMBLY
1.

Remove rear DEF button (1) using screwdriver (A).

ZJIA0792J

ATC-112

CONTROLLER
2.

Remove A/C button (1) using screwdriver (A).
A

B

C
ZJIA0793J

D

3.

Remove FRE button (1) and REC button (2) using screwdriver.
E

F

G
ZJIA0794J

ASSEMBLY
Assembly is basically the reverse order of disassembly.

H

I

ATC

K

L

M

ATC-113

AMBIENT SENSOR
AMBIENT SENSOR
Removal and Installation

PFP:27722
BJS000BY

REMOVAL
1.
2.

Remove front grille (left side). Refer to EI-10, «Removal and Installation» .
Disconnect ambient sensor connector, and then remove ambient sensor (1).

MJIB0467E

INSTALLATION
Installation is basically the reverse order of removal.

ATC-114

IN-VEHICLE SENSOR
IN-VEHICLE SENSOR
Removal and Installation

PFP:27720

A
BJS000BZ

REMOVAL
1.
2.

Remove instrument lower finisher. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove mounting screw (A), and then remove in-vehicle sensor
(1) from instrument lower finisher (2).

B

C

D

E
MJIB0430E

INSTALLATION
Installation is basically the reverse order of removal.

F

G

H

I

ATC

K

L

M

ATC-115

SUNLOAD SENSOR
SUNLOAD SENSOR
Removal and Installation

PFP:27721
BJS000C0

REMOVAL
1.
2.

Remove instrument upper mask. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Disconnect sunload sensor connector, and then remove sunload
sensor (1).

MJIB0431E

INSTALLATION
Installation is basically the reverse order of removal.

ATC-116

INTAKE SENSOR
INTAKE SENSOR
Removal and Installation

PFP:27723

A
BJS000C1

REMOVAL
1.

2.

Remove evaporator. Refer to ATC-145, «Removal and Installation for Evaporator» .
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
Remove intake sensor (1) from evaporator (2).

B

C

D

E

MJIB0459E

F

INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
●
Replace O-rings for A/C piping with new ones, and then apply compressor oil to it when installing
it.
●
Mark the mounting position of intake sensor.
●
When recharging refrigerant, check for leaks.

G

H

I

ATC

K

L

M

ATC-117

A/C UNIT ASSEMBLY
A/C UNIT ASSEMBLY
Removal and Installation

PFP:27110
BJS000C2

REMOVAL
1.
2.

3.
4.
5.

Use a refrigerant collecting equipment (for HFC-134a) to discharge refrigerant.
Drain coolant from cooling system.
CR: Refer to CO-28, «Changing Engine coolant» .
HR: Refer to CO-28, «Changing Engine coolant» .
K9K: Refer to CO-49, «Changing Engine Coolant» .
Remove cowl top cover. Refer to EI-12, «Removal and Installation» .
Remove lower dash insulator.
Remove mounting bolt (A), and then disconnect low-pressure
flexible hose (1) and high-pressure pipe (2) from evaporator.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.

MJIB0471E

6.

Remove clamps (A), and then disconnect heater hoses (1) from
heater core.

MJIB0472E

7.
8.

Remove console box assembly. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove mounting nuts (A) and harness clamps (B), and then
remove instrument stay (1).

MJIB0473E

ATC-118

A/C UNIT ASSEMBLY
9.

Disconnect intake sensor connector (1).
A

B

C
MJIB0474E

D

10.
11.
12.
13.

Remove instrument panel & pad. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove side ventilator ducts. Refer to ATC-132, «Removal of Side Ventilator Ducts» .
Remove center ventilator ducts. Refer to ATC-132, «Removal of Center Ventilator Ducts» .
Remove A/C unit assembly mounting bolts (A), steering member mounting bolts (B), steering column
mounting nuts (C) and harness clips.

E

F

G

H

I

ATC

K
MJIB0435E

14. Remove steering member, and then remove A/C unit assembly.

L

M

ATC-119

A/C UNIT ASSEMBLY
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
●
Replace O-rings for A/C piping with new ones, and then apply compressor oil to it when installing
it.
●
When recharging refrigerant, check for leaks.
NOTE:
●
When filling radiator with coolant.
CR: Refer to CO-9, «Changing Engine coolant» .
HR: Refer to CO-28, «Changing Engine coolant» .
K9K: Refer to CO-49, «Changing Engine Coolant» .
●
Recharge the refrigerant.
A/C unit assembly mounting bolt
Tightening torque
: 6.9 N·m (0.7 kg-m, 61 in-lb)
Steering member mounting bolt
Tightening torque
: 12 N·m (1.25 kg-m, 9 ft-lb)
Steering column mounting nut
Tightening torque
: 12 N·m (1.25 kg-m, 9 ft-lb)

ATC-120

A/C UNIT ASSEMBLY
Disassembly and Assembly

BJS000C3

A

B

C

D

E

F

G

H

I

ATC

K

L

M

MJIB0480E

1.

Center defroster duct

2.

Seal

3.

Intake case

4.

Insulator

5.

Nut

6.

Blower motor

7.

Air conditioner filter

Ventilator-defroster door lever

8.

Evaporator assembly

9.

10. Foot door lever

11.

Air mix door link

12. Main link

13. Foot door link

14.

Rod

15. Rod holder

16. Rod

17.

Mode door motor

18. Foot duct assembly (RH)

ATC-121

A/C UNIT ASSEMBLY
19. Aspirator

20.

Heater cover

21. Lower blower case

22. Heater core assembly

23.

Power transistor

24. Foot duct assembly (LH)

25. Intake door lever

26.

Rod holder

27. Rod

28. Intake door motor

29.

Air mix door motor

30. Rod

31. Rod holder

32.

Air mix door lever

33. Heater pipe packing

34. Heater hose cover

35.

Cover

36. Expansion valve assembly

37. O-ring

38.

Evaporator valve block

39. Expansion valve cover

40. Intake sensor

41.

Drain hose

42. Blower case (RH)

43. Blower case (LH)

44.

Ventilator-defroster door

45. Air mix door 1

46. Air mix door 2

47.

Foot door

48. Foot door link

ATC-122

BLOWER MOTOR
BLOWER MOTOR
Removal and Installation

PFP:27226

A
BJS000C4

REMOVAL
1.
2.
3.
4.

Remove instrument panel & pad. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove side ventilator duct (right). Refer to ATC-132, «Removal of Side Ventilator Ducts» .
Disconnect blower motor connector (1).
Push flange holding hook (A), and then remove blower motor (2)
from A/C unit assembly (3).
CAUTION:
When blower fan and blower motor are assembled, the balance is adjusted, so do not replace the individual parts.

B

C

D

E
MJIB0440E

INSTALLATION

F

Installation is basically the reverse order of removal.
CAUTION:
Correctly install blower motor flange holding hook in A/C unit assembly.

G

H

I

ATC

K

L

M

ATC-123

INTAKE DOOR MOTOR
INTAKE DOOR MOTOR
Removal and Installation

PFP:27730
BJS000C5

REMOVAL
1.
2.
3.

Remove instrument lower finisher and instrument lower cover (LH). Refer to IP-4, «INSTRUMENT PANEL
ASSEMBLY» .
Disconnect connector (A).
Remove mounting screws (B), and then remove intake door
motor (1).

MJIB0441E

INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
After installing door motor, perform door motor starting position reset by following self-diagnosis
STEP-3. Refer to ATC-46, «Self-diagnosis Function» .

ATC-124

AIR MIX DOOR MOTOR
AIR MIX DOOR MOTOR
Removal and Installation

PFP:27732

A
BJS000C6

REMOVAL
1.
2.
3.

Remove instrument lower finisher. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove console box assembly. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove mounting nuts (A) and harness clamps (B), and then
remove instrument stay (1).

B

C

D

E
MJIB0442E

4.
5.

F

Remove mounting screws (A), and then remove air mix door
motor (1).
Disconnect air mix door motor connector.

G

H

I
MJIB0443E

INSTALLATION
ATC
Installation is basically the reverse order of removal.
CAUTION:
After installing door motor, perform door motor starting position reset by following self-diagnosis
STEP-3. Refer to ATC-46, «Self-diagnosis Function» .
K

L

M

ATC-125

MODE DOOR MOTOR
MODE DOOR MOTOR
Removal and Installation

PFP:27731
BJS000C7

REMOVAL
1.
2.
3.

Remove glove box assembly and instrument lower cover (RH). Refer to IP-4, «INSTRUMENT PANEL
ASSEMBLY» .
Remove mounting screws (A), and then remove mode door
motor (1).
Disconnect mode door motor connector.

MJIB0444E

INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
After installing door motor, perform door motor starting position reset by following self-diagnosis
STEP-3. Refer to ATC-46, «Self-diagnosis Function» .

ATC-126

POWER TRANSISTOR
POWER TRANSISTOR
Removal and Installation

PFP:27761

A
BJS000C8

REMOVAL
1.
2.

Remove A/C unit assembly. Refer to ATC-118, «A/C UNIT ASSEMBLY» .
Remove mounting screws (A), and then remove power transistor (1).

B

C

D

E
MJIB0445E

INSTALLATION
Installation is basically the reverse order of removal.

F

G

H

I

ATC

K

L

M

ATC-127

HEATER CORE
HEATER CORE
Removal and Installation

PFP:27140
BJS000C9

REMOVAL
1.
2.
3.
4.

Remove A/C unit assembly. Refer to ATC-118, «A/C UNIT ASSEMBLY» .
Remove foot duct (left). Refer to ATC-132, «Removal of Foot Ducts» .
Remove mounting screws (A).
Slide heater core (1) to leftward.

MJIB0439E

INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
After installing door motor, perform door motor starting position reset by following self-diagnosis
STEP-3. Refer to ATC-46, «Self-diagnosis Function» .

ATC-128

AIR CONDITIONER FILTER
AIR CONDITIONER FILTER
Removal and Installation

PFP:27277

A
BJS000CA

FUNCTION
Air inside passenger compartment is kept clean at either recirculation or fresh mode by installing air conditioner filter into A/C unit
assembly.

B

C

D

SJIA0651E

E

REPLACEMENT TIMING
Replace air conditioner filter.
Refer to MA-55, «CHASSIS AND BODY MAINTENANCE» .
Caution label is fixed inside glove box.

F

REPLACEMENT PROCEDURES
1.
2.
3.
4.
5.

G

Remove glove box assembly. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Compress air conditioner filter downward while sliding it to the
right side of the vehicle.
Turn the bottom of air conditioner filter upward, and then remove
it.
Replace with new one and reinstall on A/C unit assembly.
Reinstall glove box assembly.

H

I

ATC
MJIB0446E

K

L

M

ATC-129

DUCTS AND GRILLES
DUCTS AND GRILLES
Removal and Installation

PFP:27860
BJS000CB

REMOVAL

MJIB0447E

1.

Side defroster duct (right)

2.

Defroster nozzle

3.

Side defroster duct (left)

4.

Side defroster grille (left)

5.

Instrument side panel (left)

6.

Instrument panel & pad

7.

Side ventilator assembly (left)

8.

Cluster lid C

9.

Side ventilator assembly (right)

10. Instrument finisher E

11. Instrument side panel (right)

Removal of Center Ventilator Grilles
1.
2.

Remove cluster lid C. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove center ventilator grilles (1) mounting screws (A) using a
screwdriver (B), and then remove center ventilator grilles (1).

MJIB0448E

ATC-130

DUCTS AND GRILLES
Removal of Side Ventilator Grilles
1.

Remove instrument pad assembly (left). Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .

2.

Side ventilator grille (left) (1) mounting pawl (
side ventilator grille (left)(1) is pulled out.

A

) is pushed, and
B

C

D
MJIB0449E

3.

Remove instrument pad assembly (right). Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .

4.

Side ventilator grille (right) (1) mounting pawl (
and side ventilator grille (right)(1) is pulled out.

E

) is pushed,
F

G

H
MJIB0450E

Removal of Defroster Nozzle and Ducts
1.
2.

Remove instrument upper finisher. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove mounting screws (A) and then remove side defroster duct (right) (1) and side defroster duct (left)
(2).

I

ATC

K

L

M

MJIB0451E

3.

Remove mounting screws (B), and then remove defroster nozzle (3).

ATC-131

DUCTS AND GRILLES
Removal of Side Ventilator Ducts
1.
2.

Remove instrument panel & pad. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove mounting screws (A) and clip (B), and then remove
side ventilator duct (left) (1).

MJIB0475E

3.

Remove mounting screw (A) and clip (B), and then remove side
ventilator duct (right) (1).

MJIB0476E

Removal of Center Ventilator Ducts
1.
2.

Remove instrument panel & pad. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove mounting screws (A), and then remove center ventilator ducts (1).

MJIB0477E

Removal of Foot Ducts
1.
2.
3.

Remove A/C unit assembly. Refer to ATC-118, «A/C UNIT ASSEMBLY» .
Remove intake door motor (2). Refer to ATC-124, «INTAKE DOOR MOTOR» .
Remove mounting screws (A), and then remove foot duct (left)
(1).

MJIB0452E

ATC-132

DUCTS AND GRILLES
4.

Remove mounting screws (A), and then remove foot duct (right)
(1).

A

B

C
MJIB0453E

D

Removal of Floor Ducts

E

F

G

H

I

MJIB0454E

1.
2.

1.

Front floor duct

4.

Rear floor duct (right)

2.

Rear floor duct (left)

3.

ATC

Clip

K

Remove front seats and center console assembly. Refer to SE-8, «Removal and Installation»
«INSTRUMENT PANEL ASSEMBLY» .
Disengage claws (A), and then remove front floor duct (1).

and IP-4,
L

M

MJIB0455E

3.

Peel back floor trim to a point where floor duct is visible.

ATC-133

DUCTS AND GRILLES
4.

Remove mounting clips (A), and then remove rear floor duct
(left) (1) and rear floor duct (right) (2).

MJIB0456E

INSTALLATION
Installation is basically the reverse order of removal.

ATC-134

REFRIGERANT LINES
REFRIGERANT LINES
HFC-134a (R-134a) Service Procedure

PFP:92600

A
BJS000CC

SETTING OF SERVICE TOOLS AND EQUIPMENT
Discharging Refrigerant

B

WARNING:
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If
accidental system discharge occurs, ventilate work area before resuming service. Additional health
and safety information may be obtained from refrigerant and lubricant manufacturers.

C

D

E

F

G

H

I
SHA539DE

Evacuating System and Charging Refrigerant

ATC

K

L

M

SHA540DC

ATC-135

REFRIGERANT LINES

RJIA2143E

*1

ATC-17, «LUBRICANT RETURN
OPERATION»

*4

ATC-88, «PERFORMANCE TEST
DIAGNOSIS»

*2

ATC-147, «Checking for Refrigerant
Leaks»

ATC-136

*3

ATC-149, «CHECKING PROCEDURE»

REFRIGERANT LINES
Components

BJS000CD

A

CR ENGINE MODELS

B

C

D

E

F

G

H

I
MJIB0436E

1.

High-pressure flexible hose

2.

Radiator (Condenser)

3.

Liquid tank

4.

Compressor

5.

High-pressure pipe

6.

Low-pressure flexible hose

ATC

K

L

M

ATC-137

REFRIGERANT LINES
HR ENGINE MODELS

MJIB0437E

1.

High-pressure flexible hose

2.

Radiator (Condenser)

3.

Liquid tank

4.

Compressor

5.

High-pressure pipe

6.

Low-pressure flexible hose

7.

Service valve (High pressure)

8.

Service valve (Low pressure)

9.

Refrigerant pressure sensor

10. Condenser

ATC-138

REFRIGERANT LINES
K9K ENGINE MODELS
A

B

C

D

E

F

G

H

I

ATC

K

L
MJIB0438E

1.

High-pressure flexible hose

2.

Refrigerant pressure sensor

3.

Liquid tank

4.

Radiator (Condenser)

5.

Condenser

6.

Compressor

7.

Service valve (Low pressure)

8.

Low-pressure flexible hose

9.

High-pressure pipe

10. Service valve (High pressure)

ATC-139

M

REFRIGERANT LINES
Removal and Installation of Compressor

BJS000CE

REMOVAL
1.
2.
3.

Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
Remove engine undercover, using power tools.
Remove low-pressure flexible hose mounting nut and high-pressure flexible hose mounting bolt from
compressor.

MJIB0273E

4.

5.
6.

CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
Remove A/C compressor belt.
CR: Refer to EM-14, «DRIVE BELTS» .
HR: Refer to EM-114, «DRIVE BELTS» .
K9K: Refer to EM-242, «DRIVE BELTS» .
Disconnect compressor connector.
Remove mounting bolts from compressor, using power tools.

MJIB0134E

7.

Remove compressor downward of the vehicle.

INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
●
Replace O-rings of low-pressure flexible hose and high-pressure flexible hose with a new ones,
and then apply compressor oil to it when installing it.
●
When recharging refrigerant, check for leaks.
Compressor mounting bolt
Tightening torque

: 20.0 N·m (2.05 kg-m, 14.8 ft-lb)

ATC-140

REFRIGERANT LINES
CHECK DISC TO PULLEY CLEARANCE
A

Check clearance around entire periphery of clutch disc.
Disc to pulley
clearance

: 0.3 — 0.6 mm (0.012 — 0.024 in)
B

If specified clearance is not obtained, replace compressor.

C

RHA087E

Removal and Installation for Pipe and Hose

D

BJS000I9

REMOVAL
1.
2.
3.

4.

5.
6.

7.

E
Use recovery/recycling recharging equipment [for HFC-134a (R-134a)] to discharge refrigerant.
Remove the low-pressure flexible hose bracket mounting bolt and nut.
Remove the high-pressure pipe and low-pressure flexible hose mounting bolts (air conditioner unit side).
F
CAUTION:
Seal the connecting points of the pipe and hose with caps and vinyl tape, etc. to prevent them from
being exposed to the atmosphere.
G
Remove the low-pressure flexible hose mounting bolt or nut (compressor side) and then remove the lowpressure flexible hose.
CAUTION:
H
Seal the connecting points of the hose with caps and vinyl tape, etc. to prevent them from being
exposed to the atmosphere.
Remove the front bumper and air guide (RH). Refer to EI-4, «Removal and Installation» and BL-13,
I
«Removal and Installation» .
Remove the high-pressure pipe mounting bolt (liquid tank side) and then remove the high-pressure pipe.
CAUTION:
ATC
Seal the connecting points of the pipe with caps and vinyl tape, etc. to prevent them from being
exposed to the atmosphere.
Remove the high-pressure flexible hose mounting bolts and then remove the high-pressure flexible hose.
K
CAUTION:
Seal the connecting points of the hoses with caps and vinyl tape, etc. to prevent them from being
exposed to the atmosphere.
L

INSTALLATION

CAUTION:
●
Replace the O-rings on the high-pressure pipe, low-pressure flexible hose, and high-pressure flexible hose with new ones, and apply compressor lubricant to O-rings before installing.
●
When charging refrigerant, check for refrigerant leaks.
High-pressure pipe mounting bolt
Tightening torque
: 4.4 N·m (0.45 kg-m, 39.0 in-lb)
Low-pressure flexible hose and high-pressure pipe mounting bolts (evaporator side)
Tightening torque
: 4.4 N·m (0.45 kg-m, 39.0 in-lb)
Low-pressure flexible hose mounting bolt (compressor side)
Tightening torque
: 13.7 N·m (1.4 kg-m, 10.1 ft-lb)
Low-pressure flexible hose bracket mounting bolt/nut
Tightening torque
: 4.2 N·m (0.43 kg-m, 37.2 in-lb)
High-pressure flexible hose mounting bolt
Tightening torque
: 13.7 N·m (1.4 kg-m, 10.1 ft-lb)

ATC-141

M

REFRIGERANT LINES
Removal and Installation for Refrigerant Pressure Sensor

BJS000IA

MJIB0457E

1.

Refrigerant pressure sensor

4.

Air guide

2.

Condenser

3.

Liquid tank

REMOVAL AND INSTALLATION
1.
2.
3.

Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant.
Remove the front bumper and air guide (RH) (4). Refer to EI-4, «Removal and Installation» and BL-13,
«Removal and Installation» .
Use a adjustable wrench A or other tool to hold the refrigerant pressure sensor mounting block, and then
remove the refrigerant pressure sensor from the condenser (CR and HR engine models) or the high-pressure flexible hose (K9K engine models).
CAUTION:
● Be careful when working so as not to damage the condenser core.
● When installing refrigerant pressure sensor, apply compressor lubricant to the O-rings.
Refrigerant pressure sensor
Tightening torque
: 10.8 N·m (1.1 kg-m, 8.0 ft-lb)

Removal and Installation for Condenser (Models without Integrated Condenser)
BJS000IB

REMOVAL
1.
2.
3.

4.

Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant.
Remove the front bumper and air guide (RH). Refer to EI-4, «Removal and Installation» and BL-13,
«Removal and Installation» .
Disconnect the high-pressure flexible hose and high-pressure
pipe from the condenser.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmosphere.
Disconnect the refrigerant pressure sensor connector, and then
remove the harness clip (CR engine models).

MJIA0059E

ATC-142

REFRIGERANT LINES
5.

6.
7.

Use cord, etc., to hold the condenser and radiator to each radiator core support upper.
NOTE:
To prevent the condenser and radiator from being dropped when
the radiator core lower support is removed.
Remove the mounting bolts, and then remove the radiator core
lower support.
Remove the condenser from underneath the vehicle.
CAUTION:
Do not damage the condenser core.

A

B

C
MJIA0060E

D

INSTALLATION
CAUTION:
●
Replace O-rings on the high-pressure pipe and high-pressure flexible hose with new ones. Apply
compressor lubricant to O-rings when installing them.
●
When charging refrigerant, check for refrigerant leaks.
High-pressure flexible hose bolt
Tightening torque : 13.7 N·m (1.4 kg-m, 10.1 ft-lb)
High-pressure pipe mounting bolt
Tightening torque : 4.4 N·m (0.45 kg-m, 39.0 in-lb)
Radiator core lower support mounting bolts.
Tightening torque : 51.1 N·m (5.3 kg-m, 37.7 ft-lb)

E

F

G

H

Removal and Installation for Condenser (Models with Integrated Condenser)
BJS000IC

REMOVAL
1.
2.
3.

4.

I
Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant.
Remove the front bumper and air guide (RH). Refer to EI-4, «Removal and Installation» and BL-13,
«Removal and Installation» .
ATC
Disconnect the high-pressure flexible hose from the condenser.
Disconnect the high-pressure pipe from the liquid tank.
CAUTION:
K
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmosphere.
L
Remove the radiator assembly.
CR: Refer to CO-12, «Removal and Installation» .
HR: Refer to CO-31, «Removal and Installation» .
M
CAUTION:
MJIA0214E
Do not damage the radiator and condenser core.

INSTALLATION
CAUTION:
●
Replace O-rings on the high-pressure pipe and high-pressure flexible hose with new ones. Apply
compressor lubricant to O-rings when installing them.
●
When charging refrigerant, check for refrigerant leaks.

ATC-143

REFRIGERANT LINES
Removal and Installation for Liquid Tank (HR Engine with A/T Models)

BJS000ID

REMOVAL
1.
2.
3.
4.

Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
Remove condenser. Refer to ATC-142, «Removal and Installation for Condenser (Models without Integrated Condenser)» .
Clean around the liquid tank to remove foreign material and corrosion.
Remove the liquid tank bracket (upper/lower) mounting bolts.

MJIA0061E

5.
6.

Lift up the liquid tank bracket, and remove it from the condenser
protruding area.
Lift up the liquid tank and remove it.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmosphere.

MJIA0062E

INSTALLATION
Install the liquid tank, and then install liquid tank bracket to the condenser.
CAUTION:
●
Make sure the liquid tank bracket is correctly inserted into
the condenser’s protruding area (the liquid tank bracket
does not move below the center of the liquid tank).
●
Replace the condenser pipe O-rings with new ones. Apply a
coat of compressor lubricant to the O-rings prior to installation.
MJIA0063E

Liquid tank bracket (upper) mounting bolt
Tightening torque : 3.38 N·m (0.35 kg-m, 30.0 in-lb)
Liquid tank bracket (lower) mounting bolt
Tightening torque : 5.74 N·m (0.58 kg-m, 50.8 in-lb)

Removal and Installation for Liquid Tank (Except HR Engine with A/T Models)
BJS000IE

REMOVAL
1.
2.
3.
4.
5.

Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
Clean around the liquid tank to remove foreign material and corrosion.
Remove the high-pressure pipe from the liquid tank.
Remove the condenser pipe mounting bolt from the liquid tank,
and remove pipe from the condenser protruding area.
Remove the liquid tank bracket bolts and then remove the liquid
tank.
MJIA0215E

ATC-144

REFRIGERANT LINES
CAUTION:
Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being
exposed to the atmosphere.

A

INSTALLATION
Install the liquid tank, and then install liquid tank bracket to the condenser.
CAUTION:
Replace the condenser pipe O-rings with new ones. Apply a coat of compressor lubricant to the Orings prior to installation.

Removal and Installation for Evaporator

B

C

BJS000IF

REMOVAL
1. Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant.
2. Remove the A/C unit. Refer to ATC-118, «A/C UNIT ASSEMBLY» .
CAUTION:
Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being
exposed to the atmosphere.
3. Remove the air conditioner filter, mode door motor, and foot duct (RH). Refer to ATC-129, «AIR CONDITIONER FILTER» , ATC-126, «MODE DOOR MOTOR» and ATC-132, «Removal of Foot Ducts» .
4. Remove the lower blower case and expansion valve cover.
5. Slide the evaporator (1) and lower blower case (2) downward,
and remove the intake sensor (3).
6. Remove the evaporator from the lower blower case.

D

E

F

G

H

I

MJIB0462E

ATC

INSTALLATION
CAUTION:
●
Replace low-pressure flexible hose and high-pressure pipe O-rings with new ones. Apply a coat of
compressor lubricant prior to installation.
●
When installing a new evaporator, install the thermistor of intake air temperature in the same position as the removed intake sensor.
●
When removing and installing the intake sensor, do not rotate the thermistor insertion part.
Mounting bolts for the low-pressure flexible hoses and high-pressure pipes.
Tightening torque
: 4.4 N·m (0.45 kg-m, 39.0 in-lb)

Removal and Installation for Expansion Valve

L

M
BJS000IG

REMOVAL
1.

Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
2. Disconnect the low-pressure flexible hose and high-pressure
pipe from the evaporator.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmosphere.
3. Remove the two bolts from the expansion valve, and then
remove the expansion valve.
MJIB0460E

ATC-145

K

REFRIGERANT LINES
INSTALLATION
CAUTION:
Replace the removed O-rings with new ones. Apply a coat of compressor lubricant to the O-rings prior
to installation.
Expansion valve mounting bolts
Tightening torque : 4.0 N·m (0.41 kg-m, 35.4 in-lb)
Mounting bolts for the low-pressure flexible hoses and high-pressure pipes.
Tightening torque : 4.4 N·m (0.45 kg-m, 39.0 in-lb)

ATC-146

REFRIGERANT LINES
Checking for Refrigerant Leaks

BJS000CN

Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent
dye leak detector.
If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was
repaired and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electronic leak detector probe slower and closer to the suspected leak area will improve
the chances of finding a leak.

Checking System for Leaks Using the Fluorescent Leak Detector

A

B

C

D

E
BJS000CO

1.

Check A/C system for leaks using the UV lamp and safety goggles [SST: J-42220] in a low sunlight area
(area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a F
bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indicates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
G
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner [SST: J-43872] to prevent future misdiagnosis.
H
4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant
leak detector.
NOTE:
I
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Clean with a dry cloth or blow off with shop air.
ATC
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.

Dye Injection

BJS000CP

(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1.
2.
3.
4.
5.

6.

7.

Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm2 , 50
psi).
Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool [SST: J-41459].
Connect the injector tool to the A/C low-pressure side service fitting.
Start engine and switch A/C ON.
When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture’s operating instructions).
With the engine still running, disconnect the injector tool from the service fitting.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system
connection and proceed with the service procedures.
Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.

ATC-147

K

L

M

REFRIGERANT LINES
Electronic Refrigerant Leak Detector

BJS000CQ

PRECAUTIONS FOR HANDLING LEAK DETECTOR
When performing a refrigerant leak check, use an A/C electrical leak
detector (SST) or equivalent. Ensure that the instrument is calibrated
and set properly per the operating instructions.
The leak detector is a delicate device. In order to use the leak detector properly, read the operating instructions and perform any specified maintenance.

SHA705EB

1.

Position probe approximately 5 mm (3/16 in) away from point to
be checked.

SHA707EA

2.

When testing, circle each fitting completely with probe.

SHA706E

3.

Move probe along component approximately 25 to 50 mm (1 to
2 in)/sec.

SHA708EA

ATC-148

REFRIGERANT LINES
CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette
smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Turn engine OFF.
2. Connect a suitable A/C manifold gauge set to the A/C service ports.
3.

4.

Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm2 , 50 psi) above 16°C. If
less than specification, recover/evacuate and recharge the system with the specified amount of refrigerant.
NOTE:
At temperatures below 16°C, leaks may not be detected since the system may not reach 345 kPa (3.45
bar, 3.52 kg/cm2 , 50 psi).
Perform the leak test from the high-pressure side (compressor discharge a to evaporator inlet f) to the
low-pressure side (evaporator drain hose g to shaft seal k). Refer to ATC-137, «Components» . Perform a
leak check for the following areas carefully. Clean the component to be checked and move the leak
detected probe completely around the connection/component.
Compressor
Check the fitting of high- and low-pressure flexible hoses, relief valve and shaft seal.

A

B

C

D

E

F

Condenser
Check the fitting of high-pressure flexible hose and pipe, refrigerant pressure sensor.

G

Liquid tank
Check the refrigerant connection.

H

Service valves
I
Check all around the service valves. Ensure service valve caps are secured on the service valves (to prevent leaks).
NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any ATC
false readings by leak detector.

5.
6.
7.
8.
a.
b.
c.
d.
e.
9.

Cooling unit (Evaporator)
With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the
cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended
procedure for actual wait time) before inserting the leak detector probe into the drain hose.
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water
or dirt that may be in the drain hose.
If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected
leak, then repeat check as outlined above.
Do not stop when one leak is found. Continue to check for additional leaks at all system components.
If no leaks are found, perform steps 7-10.
Start engine.
Set the heater A/C control as follows;
A/C switch: ON
MODE door position: VENT (Ventilation)
Intake door position: Recirculation
Temperature control dial: Max. cold
Fan speed: High
Run engine at 1,500 rpm for at least 2 minutes.

ATC-149

K

L

M

REFRIGERANT LINES
10. Turn engine off and perform leak check again following steps 4
through 6 above.
Refrigerant leaks should be checked immediately after stopping
the engine. Begin with the leak detector at the compressor. The
pressure on the high-pressure side will gradually drop after
refrigerant circulation stops and pressure on the low-pressure
side will gradually rise, as shown in the graph. Some leaks are
more easily detected when pressure is high.
11. Before connecting ACR4 to vehicle, check ACR4 gauges. No
refrigerant pressure should be displayed. If pressure is displayed, recover refrigerant from equipment lines.
12. Discharge A/C system using approved refrigerant recovery
equipment. Repair the leaking fitting or component if necessary.
13. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks.
14. Perform A/C performance test to ensure system works properly.

ATC-150

SHA839E

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
COMPRESSOR
Model

PFP:00030

A
BJS000IH

CR engine models

HR engine models

K9K engine models

ZEXEL VALEO CLIMATE
CONTROL make KC59G

CR-10

SANDEN make SD6V12

Type

Vane rotary

Displacement

Max.

cm3 (cu
in)/rev

Min.

Cylinder bore × stroke mm (in)

Variable volume piston

80 (4.88)
Theoretical displacement

96 (5.86)
Theoretical displacement

125.1 (7.63)
6.2 (0.38)

5 vanes, φ51.0 × 7.28

5 vanes, φ50.2 × 8.5

—

Direction of rotation
Poly V (4grooves)

V-Ribbed (7 grooves)

E
Poly V (6 grooves)

LUBRICANT

BJS000J9

F
CR engine models

HR engine models

K9K engine models

ZEXEL VALEO CLIMATE CONTROL make KC59G

CR-10

SANDEN make SD6V12

Name
Part number
Capacity
m (lmp fl
oz)

Nissan A/C System Oil Type R

Nissan A/C System Oil Type S

KLH00-PAGR0

KLH00-PAGS0

Total in system

—

—

135 (4.75)

Compressor
(Service part)
charging
amount

—

—

135 (4.75)

REFRIGERANT
Model

G

H

I

BJS000JA

ATC

CR engine models

HR engine models

K9K engine models

ZEXEL VALEO CLIMATE CONTROL make KC59G

CR-10

SANDEN make SD6V12

K

0.55 ± 0.05 (1.21 ± 0.11)

L

Type
Capacity
kg (lb)

C

D

Clockwise (viewed from drive end)

Drive belt

Model

B

HFC-134a (R-134a)
0.475 ± 0.025 (1.04 ± 0.055)

0.475 ± 0.025 (1.04 ± 0.055)

ENGINE IDLING SPEED

BJS000IK

M

Refer to EC-449, «SERVICE DATA AND SPECIFICATIONS (SDS)» . CR (with EURO−OBD).
Refer to EC-801, «SERVICE DATA AND SPECIFICATIONS (SDS)» . CR (without EURO−OBD).
Refer to EC-1237, «SERVICE DATA AND SPECIFICATIONS (SDS)» . HR (with EURO−OBD).
Refer to EC-1597, «SERVICE DATA AND SPECIFICATIONS (SDS)» . HR (without EURO−OBD).
Refer to EC-1870, «SERVICE DATA AND SPECIFICATIONS (SDS)» .K9K.

BELT TENSION

BJS000IL

Refer to EM-14, «Tension Adjustment» . (CR engine models).
Refer to EM-114, «Tension Adjustment» . (HR engine models).
Refer to EM-242, «Tension Adjustment» . (K9K engine models).

ATC-151

SERVICE DATA AND SPECIFICATIONS (SDS)

ATC-152

AUTOMATIC TRANSAXLE

C TRANSMISSION/TRANSAXLE

SECTION

AT

AUTOMATIC TRANSAXLE

A

B

AT

D

E

CONTENTS
APPLICATION NOTICE ………………………………………. 6
How to Check Vehicle Type ………………………………. 6
INDEX FOR DTC ……………………………………………….. 7
Alphabetical Index ……………………………………………. 7
DTC No. Index (For EURO-OBD models Only) ……. 9
PRECAUTIONS ……………………………………………….. 10
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………. 10
PrecautionsNecessaryforSteeringWheelRotation
After Battery Disconnect …………………………………. 10
PrecautionsforOnBoardDiagnostic(OBD)System
of A/T and Engine (For EURO-OBD models Only)….11
Precautions …………………………………………………….11
Service Notice or Precautions ………………………….. 12
PREPARATION ………………………………………………… 14
Special Service Tools ……………………………………… 14
Commercial Service Tools ……………………………….. 16
A/T FLUID ……………………………………………………….. 18
Checking A/T Fluid …………………………………………. 18
Changing A/T Fluid ………………………………………… 19
A/T CONTROL SYSTEM …………………………………… 20
Cross-Sectional View ……………………………………… 20
Shift Mechanism …………………………………………….. 21
TCM Function ………………………………………………… 30
Input/Output Signal of TCM ……………………………… 31
Line Pressure Control …………………………………….. 32
Shift Control ………………………………………………….. 33
Lock-up Control ……………………………………………… 34
Engine Brake Control (Overrun Clutch Control) ….. 35
Control Valve …………………………………………………. 37
Centrifugal Cancel Mechanism ………………………… 38
CAN COMMUNICATION …………………………………… 39
System Description ………………………………………… 39
CAN Communication Unit ……………………………….. 39
TROUBLE DIAGNOSIS …………………………………….. 40
DTC Inspection Priority Chart ………………………….. 40
Fail-safe ……………………………………………………….. 40
How to Perform Trouble Diagnoses for Quick and
Accurate Repair …………………………………………….. 42

A/T Electrical Parts Location ……………………………. 50
Circuit Diagram ………………………………………………. 52
Inspections Before Trouble Diagnosis ……………….. 53
Road Test ……………………………………………………… 58
Check Before Engine is Started ………………………… 58
Check at Idle ………………………………………………….. 59
Cruise Test — Part 1 ………………………………………. 61
Cruise Test — Part 2 ………………………………………. 64
Cruise Test — Part 3 ………………………………………. 65
Vehicle Speed at Which Gear Shifting Occurs ……. 67
Vehicle Speed at Which Lock-up Occurs/Releases… 67
Symptom Chart ………………………………………………. 68
TCM Terminals and Reference Value ………………… 80
CONSULT-II Function (A/T) ……………………………… 83
Diagnostic Procedure Without CONSULT-II ……….. 94

EURO-OBD
ON BOARD DIAGNOSTIC (OBD) SYSTEM ………… 98
Introduction ……………………………………………………. 98
OBD Function for A/T System ………………………….. 98
One or Two Trip Detection Logic of OBD …………… 98
OBD Diagnostic Trouble Code (DTC) ……………….. 98
Malfunction Indicator Lamp (MIL) ……………………. 101
DTC U1000 CAN COMMUNICATION LINE ………… 102
Description …………………………………………………… 102
On Board Diagnosis Logic ……………………………… 102
Possible Cause …………………………………………….. 102
DTC Confirmation Procedure …………………………. 102
Wiring Diagram — AT — CAN ………………………… 103
Diagnostic Procedure ……………………………………. 104
DTC P0705 PARK/NEUTRAL POSITION (PNP)
SWITCH ………………………………………………………… 105
Description …………………………………………………… 105
CONSULT-II Reference Value ………………………… 105
On Board Diagnosis Logic ……………………………… 105
Possible Cause …………………………………………….. 105
DTC Confirmation Procedure …………………………. 105
Wiring Diagram — AT — PNP/SW ………………….. 106

AT-1

F

G

H

I

J

K

L

M

Diagnostic Procedure ……………………………………. 107
Component Inspection …………………………………… 109
DTC P0710 A/T FLUID TEMPERATURE SENSOR
CIRCUIT ………………………………………………………… 110
Description …………………………………………………… 110
CONSULT-II Reference Value ………………………… 110
On Board Diagnosis Logic ……………………………… 110
Possible Cause …………………………………………….. 110
DTC Confirmation Procedure …………………………. 110
Wiring Diagram — AT — FTS …………………………..111
Diagnostic Procedure ……………………………………. 112
Component Inspection …………………………………… 114
DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) ……………………………………….. 115
Description …………………………………………………… 115
CONSULT-II Reference Value ………………………… 115
On Board Diagnosis Logic ……………………………… 115
Possible Cause …………………………………………….. 115
DTC Confirmation Procedure …………………………. 115
Wiring Diagram — AT — VSSA/T ……………………. 117
Diagnostic Procedure ……………………………………. 118
DTC P0725 ENGINE SPEED SIGNAL ………………. 121
Description …………………………………………………… 121
CONSULT-II Reference Value ………………………… 121
On Board Diagnosis Logic ……………………………… 121
Possible Cause …………………………………………….. 121
DTC Confirmation Procedure …………………………. 121
Wiring Diagram — AT — ENGSS ……………………. 122
Diagnostic Procedure ……………………………………. 123
DTC P0731 A/T 1ST GEAR FUNCTION …………….. 125
Description …………………………………………………… 125
On Board Diagnosis Logic ……………………………… 125
Possible Cause …………………………………………….. 125
DTC Confirmation Procedure …………………………. 126
Diagnostic Procedure ……………………………………. 127
DTC P0732 A/T 2ND GEAR FUNCTION ……………. 129
Description …………………………………………………… 129
On Board Diagnosis Logic ……………………………… 129
Possible Cause …………………………………………….. 129
DTC Confirmation Procedure …………………………. 130
Diagnostic Procedure ……………………………………. 131
DTC P0733 A/T 3RD GEAR FUNCTION ……………. 132
Description …………………………………………………… 132
On Board Diagnosis Logic ……………………………… 132
Possible Cause …………………………………………….. 132
DTC Confirmation Procedure …………………………. 133
Diagnostic Procedure ……………………………………. 134
DTC P0734 A/T 4TH GEAR FUNCTION ……………. 136
Description …………………………………………………… 136
CONSULT-II Reference Value ………………………… 136
On Board Diagnosis Logic ……………………………… 136
Possible Cause …………………………………………….. 136
DTC Confirmation Procedure …………………………. 137
Diagnostic Procedure ……………………………………. 138
DTC P0740 TORQUE CONVERTER CLUTCH
SOLENOID VALVE …………………………………………. 142
Description …………………………………………………… 142
CONSULT-II Reference Value ………………………… 142
On Board Diagnosis Logic ……………………………… 142

Possible Cause …………………………………………….. 142
DTC Confirmation Procedure ………………………….. 142
Wiring Diagram — AT — TCV ………………………… 143
Diagnostic Procedure …………………………………….. 144
Component Inspection ……………………………………146
DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP) .147
Description …………………………………………………… 147
CONSULT-II Reference Value …………………………. 147
On Board Diagnosis Logic ……………………………… 147
Possible Cause …………………………………………….. 147
DTC Confirmation Procedure ………………………….. 148
Diagnostic Procedure …………………………………….. 149
DTC P0745 LINE PRESSURE SOLENOID VALVE.153
Description …………………………………………………… 153
CONSULT-II Reference Value …………………………. 153
On Board Diagnosis Logic ……………………………… 153
Possible Cause …………………………………………….. 153
DTC Confirmation Procedure ………………………….. 153
Wiring Diagram — AT — LPSV ………………………. 154
Diagnostic Procedure …………………………………….. 155
Component Inspection ……………………………………158
DTC P0750 SHIFT SOLENOID VALVE A …………… 159
Description …………………………………………………… 159
CONSULT-II Reference Value …………………………. 159
On Board Diagnosis Logic ……………………………… 159
Possible Cause …………………………………………….. 159
DTC Confirmation Procedure ………………………….. 159
Wiring Diagram — AT — SSV/A ……………………… 160
Diagnostic Procedure …………………………………….. 161
Component Inspection ……………………………………163
DTC P0755 SHIFT SOLENOID VALVE B …………… 164
Description …………………………………………………… 164
CONSULT-II Reference Value …………………………. 164
On Board Diagnosis Logic ……………………………… 164
Possible Cause …………………………………………….. 164
DTC Confirmation Procedure ………………………….. 164
Wiring Diagram — AT — SSV/B ……………………… 165
Diagnostic Procedure …………………………………….. 166
Component Inspection ……………………………………168
DTC P1705 ACCELERATOR PEDAL POSITION
(APP) SENSOR ………………………………………………. 169
Description …………………………………………………… 169
CONSULT-II Reference Value …………………………. 169
On Board Diagnosis Logic ……………………………… 169
Possible Cause …………………………………………….. 169
DTC Confirmation Procedure ………………………….. 169
Diagnostic Procedure …………………………………….. 170
DTC P1760 OVERRUN CLUTCH SOLENOID
VALVE ……………………………………………………………. 171
Description …………………………………………………… 171
CONSULT-II Reference Value …………………………. 171
On Board Diagnosis Logic ……………………………… 171
Possible Cause …………………………………………….. 171
DTC Confirmation Procedure ………………………….. 171
Wiring Diagram — AT — OVRCSV …………………. 172
Diagnostic Procedure …………………………………….. 173
Component Inspection ……………………………………175
DTC VEHICLE SPEED SENSOR MTR ………………. 176
Description …………………………………………………… 176

AT-2

CONSULT-II Reference Value ………………………… 176
On Board Diagnosis Logic …………………………….. 176
Possible Cause ……………………………………………. 176
DTC Confirmation Procedure …………………………. 176
Wiring Diagram — AT — VSSMTR …………………. 177
Diagnostic Procedure ……………………………………. 178
DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP
SENSOR CIRCUIT AND TCM POWER SOURCE). 180
Description ………………………………………………….. 180
CONSULT-II Reference Value ………………………… 180
On Board Diagnosis Logic …………………………….. 180
Possible Cause ……………………………………………. 180
DTC Confirmation Procedure …………………………. 180
Wiring Diagram — AT — BA/FTS …………………… 181
Diagnostic Procedure ……………………………………. 182
Component Inspection ………………………………….. 185
DTC TURBINE REVOLUTION SENSOR …………… 186
Description ………………………………………………….. 186
CONSULT-II Reference Value ………………………… 186
On Board Diagnosis Logic …………………………….. 186
Possible Cause ……………………………………………. 186
DTC Confirmation Procedure …………………………. 186
Wiring Diagram — AT — PT/SEN …………………… 187
Diagnostic Procedure ……………………………………. 188
CONTROL UNIT (RAM), CONTROL UNIT (ROM). 192
Description ………………………………………………….. 192
On Board Diagnosis Logic …………………………….. 192
Possible Cause ……………………………………………. 192
DTC Confirmation Procedure …………………………. 192
Diagnostic Procedure ……………………………………. 192
MAIN POWER SUPPLY AND GROUND CIRCUIT. 193
Description ………………………………………………….. 193
On Board Diagnosis Logic …………………………….. 193
Possible Cause ……………………………………………. 193
DTC Confirmation Procedure …………………………. 193
Wiring Diagram — AT — MAIN ………………………. 194
Diagnostic Procedure ……………………………………. 195
PNP, OD SWITCH AND CLOSED THROTTLE,
WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT ……………………………………………………………… 197
CONSULT-II Reference Value ………………………… 197
TCM Terminals and Reference Value ………………. 197
Diagnostic Procedure ……………………………………. 198
Component Inspection ………………………………….. 202

EXC.F/EURO-OBD
VEHICLE SPEED SENSOR·A/T (REVOLUTION
SENSOR) ………………………………………………………. 203
Description ………………………………………………….. 203
CONSULT-II Reference Value ………………………… 203
On Board Diagnosis Logic …………………………….. 203
Possible Cause ……………………………………………. 203
DTC Confirmation Procedure …………………………. 203
Wiring Diagram — AT — VSSAT ……………………. 205
Diagnostic Procedure ……………………………………. 206
VEHICLE SPEED SENSOR MTR …………………….. 209
Description ………………………………………………….. 209
CONSULT-II Reference Value ………………………… 209

On Board Diagnosis Logic ……………………………… 209
Possible Cause …………………………………………….. 209
DTC Confirmation Procedure …………………………. 209
Wiring Diagram — AT — VSSMTR …………………. 210
Diagnostic Procedure ……………………………………. 211
ACCELERATOR PEDAL POSITION (APP) SENSOR ………………………………………………………………. 213
Description …………………………………………………… 213
CONSULT-II Reference Value ………………………… 213
On Board Diagnosis Logic ……………………………… 213
Possible Cause …………………………………………….. 213
DTC Confirmation Procedure …………………………. 213
Diagnostic Procedure ……………………………………. 214
SHIFT SOLENOID VALVE A ……………………………. 215
Description …………………………………………………… 215
CONSULT-II Reference Value ………………………… 215
On Board Diagnosis Logic ……………………………… 215
Possible Cause …………………………………………….. 215
DTC Confirmation Procedure …………………………. 215
Wiring Diagram — AT — SSV/A ……………………… 216
Diagnostic Procedure ……………………………………. 217
Component Inspection …………………………………… 219
SHIFT SOLENOID VALVE B ……………………………. 220
Description …………………………………………………… 220
CONSULT-II Reference Value ………………………… 220
On Board Diagnosis Logic ……………………………… 220
Possible Cause …………………………………………….. 220
DTC Confirmation Procedure …………………………. 220
Wiring Diagram — AT — SSV/B ……………………… 221
Diagnostic Procedure ……………………………………. 222
Component Inspection …………………………………… 224
OVERRUN CLUTCH SOLENOID VALVE …………… 225
Description …………………………………………………… 225
CONSULT-II Reference Value ………………………… 225
On Board Diagnosis Logic ……………………………… 225
Possible Cause …………………………………………….. 225
DTC Confirmation Procedure …………………………. 225
Wiring Diagram — AT — OVRCSV …………………. 226
Diagnostic Procedure ……………………………………. 227
Component Inspection …………………………………… 229
TORQUE CONVERTER CLUTCH SOLENOID
VALVE …………………………………………………………… 230
Description …………………………………………………… 230
CONSULT-II Reference Value ………………………… 230
On Board Diagnosis Logic ……………………………… 230
Possible Cause …………………………………………….. 230
DTC Confirmation Procedure …………………………. 230
Wiring Diagram — AT — TCV ………………………… 231
Diagnostic Procedure ……………………………………. 232
Component Inspection …………………………………… 234
BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) ……. 235
Description …………………………………………………… 235
CONSULT-II Reference Value ………………………… 235
On Board Diagnosis Logic ……………………………… 235
Possible Cause …………………………………………….. 235
DTC Confirmation Procedure …………………………. 235
Wiring Diagram — AT — BA/FTS ……………………. 236

AT-3

A

B

AT

D

E

F

G

H

I

J

K

L

M

Diagnostic Procedure ……………………………………. 237
Component Inspection …………………………………… 240
ENGINE SPEED SIGNAL ………………………………… 241
Description …………………………………………………… 241
CONSULT-II Reference Value ………………………… 241
On Board Diagnosis Logic ……………………………… 241
Possible Cause …………………………………………….. 241
DTC Confirmation Procedure …………………………. 241
Wiring Diagram — AT — ENGSS ……………………. 242
Diagnostic Procedure ……………………………………. 243
TURBINE REVOLUTION SENSOR …………………… 245
Description …………………………………………………… 245
CONSULT-II Reference Value ………………………… 245
On Board Diagnosis Logic ……………………………… 245
Possible Cause …………………………………………….. 245
DTC Confirmation Procedure …………………………. 245
Wiring Diagram — AT — PT/SEN …………………… 246
Diagnostic Procedure ……………………………………. 247
LINE PRESSURE SOLENOID VALVE ………………. 251
Description …………………………………………………… 251
CONSULT-II Reference Value ………………………… 251
On Board Diagnosis Logic ……………………………… 251
Possible Cause …………………………………………….. 251
DTC Confirmation Procedure …………………………. 251
Wiring Diagram — AT — LPSV ………………………. 252
Diagnostic Procedure ……………………………………. 253
Component Inspection …………………………………… 256
CAN COMMUNICATION LINE ………………………….. 257
Description …………………………………………………… 257
On Board Diagnosis Logic ……………………………… 257
Possible Cause …………………………………………….. 257
DTC Confirmation Procedure …………………………. 257
Wiring Diagram — AT — CAN ………………………… 258
Diagnostic Procedure ……………………………………. 259
MAIN POWER SUPPLY AND GROUND CIRCUIT. 260
Description …………………………………………………… 260
On Board Diagnosis Logic ……………………………… 260
Possible Cause …………………………………………….. 260
DTC Confirmation Procedure …………………………. 260
Wiring Diagram — AT — MAIN ………………………. 261
Diagnostic Procedure ……………………………………. 262
A/T 1ST GEAR FUNCTION ……………………………… 264
Description …………………………………………………… 264
On Board Diagnosis Logic ……………………………… 264
Possible Cause …………………………………………….. 264
DTC Confirmation Procedure …………………………. 265
Diagnostic Procedure ……………………………………. 266
A/T 2ND GEAR FUNCTION ……………………………… 268
Description …………………………………………………… 268
On Board Diagnosis Logic ……………………………… 268
Possible Cause …………………………………………….. 268
DTC Confirmation Procedure …………………………. 269
Diagnostic Procedure ……………………………………. 270
A/T 3RD GEAR FUNCTION ……………………………… 271
Description …………………………………………………… 271
On Board Diagnosis Logic ……………………………… 271
Possible Cause …………………………………………….. 271
DTC Confirmation Procedure …………………………. 272
Diagnostic Procedure ……………………………………. 273

A/T 4TH GEAR FUNCTION ………………………………275
Description …………………………………………………… 275
On Board Diagnosis Logic ……………………………… 275
Possible Cause …………………………………………….. 275
DTC Confirmation Procedure ………………………….. 276
Diagnostic Procedure …………………………………….. 277
A/T TCC S/V FUNCTION (LOCK-UP) ………………… 281
Description …………………………………………………… 281
CONSULT-II Reference Value …………………………. 281
On Board Diagnosis Logic ……………………………… 281
Possible Cause …………………………………………….. 281
DTC Confirmation Procedure ………………………….. 282
Diagnostic Procedure …………………………………….. 283
CONTROL UNIT (RAM), CONTROL UNIT (ROM) .287
Description …………………………………………………… 287
On Board Diagnosis Logic ……………………………… 287
Possible Cause …………………………………………….. 287
DTC Confirmation Procedure ………………………….. 287
Diagnostic Procedure …………………………………….. 287
PNP, OD SWITCH AND CLOSED THROTTLE,
WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT ………………………………………………………………. 288
CONSULT-II Reference Value …………………………. 288
TCM Terminals and Reference Value ………………. 288
Diagnostic Procedure …………………………………….. 289
Component Inspection ……………………………………293

ALL
TROUBLE DIAGNOSIS FOR SYMPTOMS ………… 294
Wiring Diagram — AT — NONDTC …………………. 294
EXC.F/EURO-OBD ……………………………………….. 296
OD OFF Indicator Lamp Does Not Come On ……. 299
Engine Cannot Be Started in “P” and “N” Position.301
In“P” Position,VehicleMoves Forwardor Backward
When Pushed ………………………………………………. 302
In “N” Position, Vehicle Moves ………………………… 302
Large Shock “N” → “R” Position ……………………… 303
Vehicle Does Not Creep Backward in “R” Position.304
Vehicle Does Not Creep Forward in “D”, “2” or “1”
Position ……………………………………………………….. 306
Vehicle Cannot Be Started from D1 ………………….. 307
A/T Does Not Shift: D1 → D2 or Does Not Kickdown:
D4 → D2 ………………………………………………………. 309
A/T Does Not Shift: D2 → D3 ………………………….. 311
A/T Does Not Shift: D3 → D4 ………………………….. 314
A/T Does Not Perform Lock-up ……………………….. 316
A/T Does Not Hold Lock-up Condition ……………… 317
Lock-up Is Not Released ………………………………… 318
Engine Speed Does Not Return to Idle (Light Braking D4 → D3 ) ……………………………………………….. 318
A/T Does Not Shift: D4 → D3 , When OD OFF ….. 320
A/T Does Not Shift: D3 → 22 , When Selector Lever
“D” → “2” Position …………………………………………. 321
A/T Does Not Shift: 22 → 11 , When Selector Lever
“2” → “1” Position ………………………………………….. 323
Vehicle Does Not Decelerate by Engine Brake ….. 325
TCM Self-diagnosis Does Not Activate …………….. 329

AT-4

TRANSMISSION CONTROL MODULE …………….. 330
Removal and Installation (LHD) ……………………… 330
Removal and Installation (RHD) ……………………… 331
SHIFT CONTROL SYSTEM …………………………….. 332
Control Device Removal and Installation …………. 332
Control Device Disassembly and Assembly ……… 335
Selector Lever Knob Removal and Installation …. 336
Adjustment of A/T Position …………………………….. 336
Checking of A/T Position ……………………………….. 337
A/T SHIFT LOCK SYSTEM ……………………………… 338
Description ………………………………………………….. 338
Shift Lock System Parts Location …………………… 338
Wiring Diagram — AT — SHIFT ……………………… 339
Diagnostic Procedure ……………………………………. 340
KEY INTERLOCK CABLE ………………………………. 342
Removal and Installation ……………………………….. 342
ON-VEHICLE SERVICE ………………………………….. 345
Control Valve Assembly and Accumulators ………. 345
Park/Neutral Position (PNP) Switch ………………… 349
Revolution Sensor ………………………………………… 350
TurbineRevolutionSensor(PowerTrainRevolution
Sensor) ……………………………………………………….. 351
Differential Side Oil Seal ……………………………….. 353
AIR BREATHER HOSE …………………………………… 355
Removal and Installation ……………………………….. 355
TRANSAXLE ASSEMBLY ……………………………….. 356
Removal and Installation ……………………………….. 356
OVERHAUL …………………………………………………… 360
Components ………………………………………………… 360
Oil Channel …………………………………………………. 366
Locations of Adjusting Shims, Needle Bearings and
Thrust Washers ……………………………………………. 367
Locations of Snap Rings ……………………………….. 368
DISASSEMBLY ………………………………………………. 369
Disassembly ………………………………………………… 369
REPAIR FOR COMPONENT PARTS ………………… 384
Manual Shaft ……………………………………………….. 384
Oil Pump …………………………………………………….. 388
Control Valve Assembly ………………………………… 392
Control Valve Upper Body ……………………………… 401
Control Valve Lower Body ……………………………… 405
Reverse Clutch …………………………………………….. 408
High Clutch ………………………………………………….. 413

Forward and Overrun Clutches ………………………. 419
Low & Reverse Brake ……………………………………. 426
Rear Internal Gear and Forward Clutch Hub …….. 431
Output Shaft, Output Gear, Idler Gear, Reduction
Pinion Gear and Bearing Retainer …………………… 435
Band Servo Piston Assembly …………………………. 441
Final Drive …………………………………………………… 447
ASSEMBLY ……………………………………………………. 452
Assembly (1) ………………………………………………… 452
Adjustment (1) ……………………………………………… 453
Assembly (2) ………………………………………………… 457
Adjustment (2) ……………………………………………… 462
Assembly (3) ………………………………………………… 465
SERVICE DATA AND SPECIFICATIONS (SDS) …. 474
General Specifications …………………………………… 474
Vehicle Speed at Which Gear Shifting Occurs ….. 474
Vehicle Speed at When Lock-up Occurs/Releases. 474
Stall Speed ………………………………………………….. 474
Line Pressure ………………………………………………. 474
Adjusting shims, Needle Bearings, Thrust Washers
and Snap Rings ……………………………………………. 475
Control Valves ……………………………………………… 476
Accumulator …………………………………………………. 476
Clutches and Brakes …………………………………….. 476
Final Drive …………………………………………………… 478
Planetary Carrier ………………………………………….. 478
Oil Pump ……………………………………………………… 478
Input Shaft …………………………………………………… 478
Reduction Pinion Gear ………………………………….. 478
Band Servo ………………………………………………….. 478
Output Shaft ………………………………………………… 478
Bearing Retainer …………………………………………… 479
Total End Play ………………………………………………. 479
Reverse Clutch End Play ……………………………….. 479
Removal and Installation ……………………………….. 479
Shift Solenoid Valves …………………………………….. 479
Solenoid Valves ……………………………………………. 479
A/T Fluid Temperature Sensor ………………………… 479
Revolution Sensor ………………………………………… 479
Dropping Resistor …………………………………………. 479
TurbineRevolutionSensor(PowerTrainRevolution
Sensor) ……………………………………………………….. 479

AT-5

A

B

AT

D

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APPLICATION NOTICE
APPLICATION NOTICE
How to Check Vehicle Type

PFP:00000
BCS000N5

Check the Euro-OBD (E-OBD) discrimination of the vehicle (refer to GI-45, «IDENTIFICATION INFORMATION» ) to confirm the service information in AT section.

AT-6

INDEX FOR DTC
INDEX FOR DTC
Alphabetical Index

PFP:00024

A
BCS000N6

NOTE:
If DTC “CAN COMM CIRCUIT” is displayed with other DTCs, first perform the trouble diagnosis for
DTC “CAN COMM CIRCUIT”. Refer to AT-102 (EURO-OBD models) or AT-257 (Except EURO-OBD
models).

EURO-OBD MODELS

B

AT
DTC

Items
(CONSULT-II screen terms)

CONSULT-II or GST*1

Reference page

D

A/T 1ST GR FNCTN

P0731

AT-125

A/T 2ND GR FNCTN

P0732

AT-129

A/T 3RD GR FNCTN

P0733

AT-132

A/T 4TH GR FNCTN

P0734

AT-136

A/T TCC S/V FNCTN

P0744

AT-147

ATF TEMP SEN/CIRC

P0710

AT-110

—

AT-180

U1000

AT-102

CONTROL UNIT (RAM)

—

AT-192

CONTROL UNIT (ROM)

—

AT-192

ENGINE SPEED SIG

P0725

AT-121

LINE PRESSURE S/V

P0745

AT-153

OVERRUN CLUTCH S/V

P1760

AT-171

PNP SW/CIRC

P0705

AT-105

SHIFT SOLENOID/V A*2

P0750

AT-159

SHIFT SOLENOID/V B*2

P0755

AT-164

T/C CLUTCH SOL/V

P0740

AT-142

THROTTLE POSI SEN*2

P1705

AT-169

—

AT-186

VHCL SPEED SEN-A/T*3

P0720

AT-115

VHCL SPEED SEN-MTR

—

AT-176

BATT/FLUID TEMP SEN
CAN COMM CIRCUIT

TURBINE SENSOR

*1: This number is prescribed by ISO 15031-5.
*2: When the fail-safe operation occurs, the MIL illuminates.
*3: The MIL illuminates when both the “Revolution sensor signal” and the “Vehicle speed sensor signal” meet the fail-safe condition at
the same time.

AT-7

E

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INDEX FOR DTC
EXCEPT EURO-OBD MODELS
X: Applicable, —: Not applicable
TCM self-diagnosis
Items (CONSULT-II screen terms)

Reference
page

OD OFF indicator lamp

“A/T” with
CONSULT-II

A/T 1ST GR FNCTN

—

X

AT-264

A/T 2ND GR FNCTN

—

X

AT-268

A/T 3RD GR FNCTN

—

X

AT-271

A/T 4TH GR FNCTN

—

X

AT-275

A/T TCC S/V FNCTN

—

X

AT-281

BATT/FLUID TEMP SEN

X

X

AT-235

CAN COMM CIRCUIT

X

X

AT-257

CONTROL UNIT (RAM)

—

X

AT-287

CONTROL UNIT (ROM)

—

X

AT-287

ENGINE SPEED SIG

X

X

AT-241

LINE PRESSURE S/V

X

X

AT-251

OVERRUN CLUTCH S/V

X

X

AT-225

SHIFT SOLENOID/V A

X

X

AT-215

SHIFT SOLENOID/V B

X

X

AT-220

T/C CLUTCH SOL/V

X

X

AT-230

THROTTLE POSI SEN

X

X

AT-213

TURBINE SENSOR

X

X

AT-245

VHCL SPEED SEN-A/T

X

X

AT-203

VHCL SPEED SEN-MTR

X

X

AT-209

AT-8

INDEX FOR DTC
DTC No. Index (For EURO-OBD models Only)

BCS000N7

NOTE:
If DTC “CAN COMM CIRCUIT” is displayed with other DTCs, first perform the trouble diagnosis for
DTC “CAN COMM CIRCUIT”. Refer to AT-102 (EURO-OBD models) or AT-257 (Except EURO-OBD
models).
DTC
CONSULT-II or

Items
(CONSULT-II screen terms)

GST*1

A

B

Reference page

AT

P0705

PNP SW/CIRC

AT-105

P0710

ATF TEMP SEN/CIRC

AT-110

P0720

VHCL SPEED SEN-A/T*3

AT-115

P0725

ENGINE SPEED SIG

AT-121

P0731

A/T 1ST GR FNCTN

AT-125

P0732

A/T 2ND GR FNCTN

AT-129

P0733

A/T 3RD GR FNCTN

AT-132

P0734

A/T 4TH GR FNCTN

AT-136

P0740

T/C CLUTCH SOL/V

AT-142

P0744

A/T TCC S/V FNCTN

AT-147

P0745

LINE PRESSURE S/V

AT-153

P0750

SHIFT SOLENOID/V A*2

AT-159

P0755

SHIFT SOLENOID/V B*2

AT-164

P1705

THROTTLE POSI SEN*2

AT-169

P1760

OVERRUN CLUTCH S/V

AT-171

U1000

CAN COMM CIRCUIT

AT-102

—

BATT/FLUID TEMP SEN

AT-180

—

CONTROL UNIT (RAM)

AT-192

—

CONTROL UNIT (ROM)

AT-192

—

TURBINE SENSOR

AT-186

—

VHCL SPEED SEN-MTR

AT-176

*1: This number is prescribed by ISO 15031-5.
*2: When the fail-safe operation occurs, the MIL illuminates.
*3: The MIL illuminates when both the “Revolution sensor signal” and the “Vehicle speed sensor signal” meet the fail-safe condition at
the same time.

D

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AT-9

PRECAUTIONS
PFP:00001
PRECAUTIONS
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

BCS000N8

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Precautions Necessary for Steering Wheel Rotation After Battery Disconnect
BCS000N9

NOTE:
●
This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT
SYSTEM).
●
Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.
●
Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing
work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mechanism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.

OPERATION PROCEDURE
1.

2.
3.
4.
5.
6.

Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
Perform the necessary repair operation.
When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
Perform a self-diagnosis check of all control units using CONSULT-II.

AT-10

PRECAUTIONS
Precautions for On Board Diagnostic (OBD) System of A/T and Engine (For
EURO-OBD models Only)

BCS000NA

A

The ECM has an on board diagnostic system. It will light up the malfunction indicator lamp (MIL) to warn the
driver of a malfunction causing emission deterioration.
B
CAUTION:
●
Be sure to turn the ignition switch OFF and disconnect battery negative cable from battery negative terminal before any repair or inspection work. The open/short circuit of related switches, senAT
sors, solenoid valves, etc. will cause the MIL to light up.
●
Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MIL to light up due to an open circuit. (Be sure the connectors are free from water,
grease, dirt, bent terminals, etc.)
D
●
Be sure to route and secure the harnesses properly after work. Interference of the harness with a
bracket, etc. may cause the MIL to light up due to a short circuit.
●
Be sure to erase the unnecessary malfunction information (repairs completed) from the TCM and E
ECM before returning the vehicle to the customer.

Precautions
●

BCS000NB

F

Before connecting or disconnecting the TCM harness connector, turn ignition switch OFF and disconnect the battery
cable from the negative terminal. Failure to do so may damage the TCM. Because battery voltage is applied to TCM
even if ignition switch is turned off.

G

H

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SEF289H

●

When connecting or disconnecting pin connectors into or
from TCM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on TCM
pin terminal, when connecting pin connectors.

J

K

L

AAT470A

●

●

●

●
●

●

Before replacing TCM, perform TCM input/output signal
inspection and make sure whether TCM functions properly
or not. (See page AT-80, «TCM Terminals and Reference
Value».)
After performing each TROUBLE DIAGNOSIS, perform
“DTC (Diagnostic Trouble Code) Confirmation Procedure”.
The DTC should not be displayed in the “DTC Confirmation
Procedure” if the repair is completed.
Before proceeding with disassembly, thoroughly clean the outside of the transaxle. It is important to prevent the internal parts
MEF040DA
from becoming contaminated by dirt or other foreign matter.
Disassembly should be done in a clean work area.
Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere
with the operation of the A/T.
Place disassembled parts in order for easier and proper assembly.

AT-11

M

PRECAUTIONS
●

●
●
●

●
●

●
●
●

All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
Gaskets, seals and O-rings should be replaced any time the A/T is disassembled.
It is very important to perform functional tests whenever they are indicated.
The valve body contains precision parts and requires extreme care when parts are removed and serviced.
Place disassembled valve body parts in order for easier and proper assembly. Care will also prevent
springs and small parts from becoming scattered or lost.
Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.
Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings
and seals, or hold bearings and washers in place during assembly. Do not use grease.
Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.
After overhaul, refill the A/T with new ATF.
When the A/T drain plug is removed, only some of the fluid is drained. Old A/T fluid will remain in torque
converter and ATF cooling system.
Always follow the procedures under “Changing A/T Fluid” in the AT section when changing A/T fluid. Refer
to AT-19, «Changing A/T Fluid» , AT-18, «Checking A/T Fluid» .

Service Notice or Precautions

BCS000NC

TORQUE CONVERTER SERVICE
The torque converter should be replaced under any of the following conditions:
●
External leaks in the hub weld area.
●
Converter hub is scored or damaged.
●
Converter pilot is broken, damaged or fits poorly into crankshaft.
●
Steel particles are found after flushing the cooler and cooler lines.
●
Pump is damaged or steel particles are found in the converter.
●
Vehicle has TCC shudder and/or no TCC apply. Replace only after all hydraulic and electrical diagnoses
have been made. (Converter clutch material may be glazed.)
●
Converter is contaminated with engine coolant containing antifreeze.
●
Internal malfunction of stator roller clutch.
●
Heavy clutch debris due to overheating (blue converter).
●
Steel particles or clutch lining material found in fluid filter or on magnet when no internal parts in unit are
worn or damaged — indicates that lining material came from converter.
The torque converter should not be replaced if:
●
The fluid has an odor, is discolored, and there is no evidence of metal or clutch facing particles.
●
The threads in one or more of the converter bolt holes are damaged.
●
A/T malfunction did not display evidence of damaged or worn internal parts, steel particles or clutch plate
lining material in unit and inside the fluid filter.
●
Vehicle has been exposed to high mileage (only). The exception may be where the torque converter
clutch dampener plate lining has seen excess wear by vehicles operated in heavy and/or constant traffic,
such as taxi, delivery or police use.

AT-12

PRECAUTIONS
OBD SELF-DIAGNOSIS (FOR EURO-OBD MODELS ONLY)
A/T self-diagnosis is performed by the TCM in combination with the ECM. The results can be read through A
the blinking pattern of the OD OFF indicator lamp or the malfunction indicator lamp (MIL). Refer to the
table on AT-95, «Judgement of Self-diagnosis Code» for the indicator used to display each self-diagnostic
result.
B
●
The self-diagnostic results indicated by the MIL are automatically stored in both the ECM and TCM memories.
Always perform the procedure “HOW TO ERASE DTC” on AT-99, «HOW TO ERASE DTC» to com- AT
plete the repair and avoid unnecessary blinking of the MIL.
●
The following self-diagnostic items can be detected using ECM self-diagnostic results mode* only when
the OD OFF indicator lamp does not indicate any malfunctions.
D
–
PNP switch
–
A/T 1st, 2nd, 3rd, or 4th gear function
*: For details of OBD, refer to AT-98, «ON BOARD DIAGNOSTIC (OBD) SYSTEM» .
E
●

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AT-13

PREPARATION
PREPARATION
Special Service Tools

PFP:00100
BCS000NE

Tool number
Tool name

Description

ST2505S001
Oil pressure gauge set

Measuring line pressure

1. ST25051001
Oil pressure gauge
2. ST25052000
Hose
3. ST25053000
Joint pipe
4. ST25054000
Adapter

NT097

5. ST25055000
Adapter
ST35325000
Drift
a: 215 mm (8.46 in)
b: 25 mm (0.98 in) dia.
c: M12 X 1.5P

Installing LH differential side oil seal
(Use with KV31103000)

SCIA7102E

KV31103000
Drift
a: 59 mm (2.32 in) dia.
b: 49 mm (1.93 in) dia.

Installing LH differential side oil seal
(Use with ST35325000)

SCIA7103E

ST27180001
Puller
a: 100 mm (3.94 in)
b: 110 mm (4.33 in)
c: M8 X 1.25P

●

Removing idler gear

●

Removing output gear

●

Removing and installing clutch spring retainer
assembly

●

Removing and installing cancel cover

●

Removing and installing retaining pin of manual
plate

●

Installing retaining pin of manual shaft

●

Installing retaining pin of parking rod plate

NT424

KV31103200
Clutch spring compressor
a: 179 mm (7.05 in)
b: 76 mm (2.99 in) dia.
c: 174 mm (6.85 in)

SCIA7104E

ST23540000
Pin punch
a: 2.3 mm (0.091 in) dia.
b: 4 mm (0.16 in) dia.

NT442

AT-14

PREPARATION
Tool number
Tool name

Description

KV32101000
Pin punch
a: 4 mm (0.16 in) dia.

A

Removing and installing lock pin of pinion mate shaft

B

AT
NT410

ST33400001
Drift
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.

●

Installing oil pump housing oil seal

●

Installing output gear bearing outer race

D

E
NT086

KV381054S0
Puller
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)

●

Removing output shaft bearing outer race

●

Removing output gear bearing outer race

●

Removing idler gear bearing outer race

F

G

NT414

ST30031000
Puller
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.

Removing reduction pinion gear bearing inner race

H

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NT411

ST35272000
Drift
a: 72 mm (2.83 in) dia.
b: 40 mm (1.57 in) dia.
c: 35.5 mm (1.398 in) dia.

●

Installing reduction pinion gear bearing inner race

●

Installing idler gear bearing inner race

●

Installing output gear bearing inner race

K

L
NT107

ST37830000
Drift
a: 61.9 mm (2.437 in) dia.
b: 39 mm (1.54 in) dia.

Installing idler gear bearing outer race

M

NT084

KV40104840
Drift
a: 49 mm (1.93 in) dia.
b: 42 mm (1.65 in) dia.

Installing output shaft bearing outer race

NT108

AT-15

PREPARATION
Tool number
Tool name

Description

ST33200000
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.

Installing differential side bearings

NT091

ST35271000
Drift
a: 72 mm (2.83 in) dia.
b: 63 mm (2.48 in) dia.

●

Installing idler gear

●

Installing output gear

●

Measuring turning torque of reduction pinion gear

●

Measuring turning torque of output shaft

NT115

ST3127S000
Preload gauge
1. GG9103000
Torque wrench
2. HT62940000
Socket adapter
3. HT62900000
Socket adapter

NT124

Commercial Service Tools

BCS000NF

Tool name

Description

Drift
a: 22 mm (0.87 in) dia.

Installing manual shaft oil seal

SCIA7105E

Drift
a: 54 mm (2.13 in) dia.
b: 47 mm (1.85 in) dia.

Installing RH differential side oil seal

NT115

Drift
a: 70 mm (2.76 in) dia.
b: 40 mm (1.57 in) dia.
c: 31 mm (1.22 in) dia.

Removing and installing output shaft bearing inner
race

NT107

Puller

NT077

AT-16

●

Removing output gear bearing inner race

●

Removing idler gear bearing inner race

●

Removing and installing band servo piston snap
ring

●

Removing differential side bearings

PREPARATION
Tool name

Description

Drift
a: 33 mm (1.30 in) dia.

Removing output gear bearing inner race

A

B

AT

SCIA7105E

Drift
a: 34 mm (1.34 in) dia.

Removing idler gear bearing inner race

D

E
SCIA7105E

Drift
a: 38 mm (1.50 in) dia.

Removing differential side bearings

F

G
SCIA7105E

Puller

Removing differential side bearing

H

I
SCIA7106E

Pin punch
a: 2 mm (0.08 in) dia.

Aligning groove of manual shaft and hole of
transaxle case

J

K

NT410

L

M

AT-17

A/T FLUID
A/T FLUID
Checking A/T Fluid
1.
2.
3.

a.
b.
c.

PFP:KLE40
BCS000NG

Warm up engine.
Check for A/T fluid leakage.
Before driving, A/T fluid level can be checked at A/T fluid temperatures of 30 to 50°C (86 to 122°F) using “COLD” range on A/
T fluid level gauge.
Park vehicle on level surface and set parking brake.
Start engine and move selector lever through each gear position. Leave selector lever in “P” position.
Check A/T fluid level with engine idling.

SCIA3451E

d.

e.

f.

4.
5.

6.

7.

Remove A/T fluid level gauge and wipe clean with lint-free cloth.
CAUTION:
When wiping away the A/T fluid level gauge, always use
lint-free cloth, not a cloth one.
Re-insert A/T fluid level gauge into A/T fluid charging pipe as far
as it will go.
CAUTION:
Firmly fix the A/T fluid level gauge to the A/T fluid charging
pipe using a stopper attached.
Remove A/T fluid level gauge and note reading. If reading is at
SMA051D
low side of range, add ATF to the A/T fluid charging pipe.
CAUTION:
Do not overfill.
Drive vehicle for approximately 5 minutes in urban areas.
Re-check A/T fluid level at A/T fluid temperatures of 50 to 80°C (122 to 176°F) using “HOT” range on A/T
fluid level gauge.
CAUTION:
● When wiping away the A/T fluid level gauge, always use lint-free cloth, not cloth one.
● Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using a stopper attached.
Check A/T fluid condition:
● If ATF is very dark or smells burned, check operation of A/T and repair if necessary. Flush cooling system after repair of A/T.
● If ATF contains frictional material (clutches, bands, etc.), replace radiator and flush cooler line using
cleaning solvent and compressed air after repair of A/T. Refer to CO-12, «RADIATOR» .
Install the removed A/T fluid level gauge into the A/T fluid charging pipe.
CAUTION:
Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using a stopper attached.

AT-18

A/T FLUID
Changing A/T Fluid
1.
2.
3.

4.
5.

BCS000NH

Warm up ATF.
Stop engine.
Drain ATF from drain hole and refill with new ATF. Always refill same volume with drained fluid.
CAUTION:
Do not reuse drain plug gasket.
Fluid grade:

Nissan Genuine ATF Matic D or equivalent
Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS» .

Fluid capacity:

Approx. 7.7

Drain plug:

Refer to AT-360, «Components» .

(6-3/4 Imp qt)

Run engine at idle speed for 5 minutes.
Check A/T fluid level and condition. Refer to AT-18, «Checking A/T Fluid» . If ATF is still dirty, repeat steps
2 through 5.

A

B

AT

D

E

F

G

H

I

J

K

L

M

AT-19

A/T CONTROL SYSTEM
A/T CONTROL SYSTEM
Cross-Sectional View

PFP:31036
BCS000NI

SCIA6171J

1.

Converter housing

2.

Oil pump

3.

4.

Reverse clutch

5.

High clutch

6.

Brake band
Front planetary gear

7.

Low one-way clutch

8.

Rear planetary gear

9.

Forward clutch

10. Overrun clutch

11. Low & reverse brake

12. Output gear

13. Band servo piston

14. Reverse clutch drum

15. Side cover

16. Idler gear

17. Forward one-way clutch

18. Transaxle case

19. Reduction pinion gear

20. Final gear

21. Differential case

22. Input shaft

23. Torque converter

AT-20

A/T CONTROL SYSTEM
Shift Mechanism

BCS000NJ

A

CONSTRUCTION

B

AT

D

E

F

SAT998I

1.

Torque converter

2.

Oil pump

3.

4.

Brake band

5.

Reverse clutch

6.

High clutch

7.

Front sun gear

8.

Front pinion gear

9.

Front internal gear

10. Front planetary carrier

11. Rear sun gear

12. Rear pinion gear

13. Rear internal gear

14. Rear planetary carrier

15. Forward clutch

16. Forward one-way clutch

17. Overrun clutch

18. Low one-way clutch

19. Low & reverse brake

20. Parking pawl

21. Parking gear

22. Output shaft

23. Idle gear

24. Output gear

Abbr.

I

Function

5

Reverse clutch

R/C

To transmit input power to front sun gear 7 .

6

High clutch

H/C

To transmit input power to front planetary carrier 10 .

15

Forward clutch

F/C

To connect front planetary carrier 10 with forward one-way clutch 16 .

17

Overrun clutch

O/C

To connect front planetary carrier 10 with rear internal gear 13 .

Brake band

B/B

To lock front sun gear 7 .

16

Forward one-way clutch

F/O.C

When forward clutch 15 is engaged, to stop rear internal gear 13 from rotating
in opposite direction against engine revolution.

18

Low one-way clutch

L/O.C

To stop front planetary carrier 10 from rotating in opposite direction against
engine revolution.

19

Low & reverse brake

L & R/B

To lock front planetary carrier 10 .

4

H

J

FUNCTION OF CLUTCH AND BRAKE
Clutch and brake components

G

Input shaft

AT-21

K

L

M

A/T CONTROL SYSTEM
CLUTCH AND BAND CHART
Band servo
Shift position

R/C
5

H/C
6

F/C
15

O/C
17

2nd
apply

3rd
release

4th
apply

F/O.C
16

L/O.C
18

L&R/B
19

Lockup

P

PARK
POSITION

R

REVERSE
POSITION

N

NEUTRAL
POSITION
1st

*1D

B

2nd

*1A

B

3rd

*1A

B
Automatic
shift

D*4

4th

2

C

*2C

C

*3C

C

B

1st

B

2nd

B

3rd

1

Remarks

*2C

C

B

2nd

B
*2C

C

1⇔2⇔3
⇔4

B
Automatic
shift
1⇔2⇐3

B

1st

3rd

*1

B

B

Locks (held
stationary)
in 1st speed
1⇐2⇐3

●

*1: Operates when OD OFF. (OD OFF indicator lamp is on.)

●

*2: Oil pressure is applied to both 2nd “apply” side and 3rd “release” side of band servo piston. However, brake band does not contract because oil pressure area on the “release” side is greater than that on the “apply” side.

●

*3: Oil pressure is applied to 4th “apply” side on condition *2 above, and brake band contracts.

●

*4: A/T will not shift to 4th when OD OFF. (OD OFF indicator lamp is on.)

●

: Operates.

●

A: Operates when throttle opening is less than specification**, activating engine brake.

●

B: Operates during “progressive” acceleration.

●

C: Operates but does not affect power transmission.

●

D: Operates when throttle opening is less than specification**, but does not affect engine brake.

–

**: Overrun clutch remains in engaged condition when throttle opening is less than 1/16.

AT-22

A/T CONTROL SYSTEM
POWER TRANSMISSION
“N” and “P” Positions
●

●

A

“N” position
Power from the input shaft is not transmitted to the output shaft because the clutches do not operate.
“P” position
Similar to the “N” position, the clutches do not operate. The parking pawl engages with the parking gear to
mechanically hold the output shaft so that the power train is locked.

B

AT

D

E

F

G

H
SAT991I

I

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AT-23

A/T CONTROL SYSTEM
“11 ” Position
●

Forward clutch

●

Forward one-way clutch

●

Overrun clutch

●

Low & reverse brake

Engine brake

As overrun clutch engages, rear internal gear is locked by the operation of low and
reverse brake.
This is different from that of D1 and 21 .

Overrun clutch always engages, therefore engine brake can be obtained when decelerating.

SCIA1816E

AT-24

A/T CONTROL SYSTEM
“D1 ” and “21 ” Positions
●

Forward one-way clutch

●

Forward clutch

●

Low one-way clutch

Overrun clutch
engagement conditions
(Engine brake)
*:

Rear internal gear is locked to rotate counterclockwise because of the functioning of these three
clutches.

A

B
D1 : OD OFF (OD OFF indicator lamp is on) and throttle opening is less than specification*
21 : Always engaged
At D1 and 21 positions, engine brake is not activated due to free turning of low one- way clutch.

AT

Overrun clutch remains in engaged condition when throttle opening is less than 1/16.

D

E

F

G

H

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K

L
SAT377J

M

AT-25

A/T CONTROL SYSTEM
“D2 ”, “22 ” and “12 ” Positions
●

Forward clutch

●

Forward one-way
clutch

●

Brake band

Overrun clutch
engagement conditions
*:

Rear sun gear drives rear planetary carrier and combined front internal gear. Front internal gear now
rotates around front sun gear accompanying front planetary carrier.
As front planetary carrier transfers the power to rear internal gear through forward clutch and forward oneway clutch, this rotation of rear internal gear increases the speed of rear planetary carrier compared with
that of the 1st speed.
D2 : OD OFF (OD OFF indicator lamp is on) and throttle opening is less than specification*
22 and 12 : Always engaged

Overrun clutch remains in engaged condition when throttle opening is less than 1/16.

SAT378J

AT-26

A/T CONTROL SYSTEM
“D3 ”, “23 ” and “13 ” Positions
●

High clutch

●

Forward clutch

●

Forward one-way
clutch

Overrun clutch
engagement conditions
*:

Input power is transmitted to front planetary carrier through high clutch. And front planetary carrier is connected to rear internal gear by operation of forward clutch and forward one-way clutch.
This rear internal gear rotation and another input (the rear sun gear) accompany rear planetary carrier to
turn at the same speed.

A

B

D3 : OD OFF (OD OFF indicator lamp is on) and throttle opening is less than specification*
23 and 13 : Always engaged

AT

Overrun clutch remains in engaged condition when throttle opening is less than 1/16.

D

E

F

G

H

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K

L
SAT379J

M

AT-27

A/T CONTROL SYSTEM
“D4 ” (OD) Position
●

High clutch

●

Brake band

●

Forward clutch (Does not affect power
transmission)

Engine brake

Input power is transmitted to front carrier through high clutch.
This front carrier turns around the sun gear which is fixed by brake band and makes
front internal gear (output) turn faster.

At D4 position, there is no one-way clutch in the power transaxle line and engine
brake can be obtained when decelerating.

SAT380J

AT-28

A/T CONTROL SYSTEM
“R” Position
●

Reverse clutch

●

Low & reverse brake

Engine brake

Front planetary carrier is stationary because of the operation of low and reverse brake.
Input power is transmitted to front sun gear through reverse clutch, which drives front
internal gear in the opposite direction.
As there is no one-way clutch in the power transaxle line, engine brake can be
obtained when decelerating.

A

B

AT

D

E

F

G

H

I

J

K

SAT381J

L

M

AT-29

A/T CONTROL SYSTEM
TCM Function

BCS000NK

The function of the TCM is to:
●
Receive input signals sent from various switches and sensors.
●
Determine required line pressure, shifting point, lock-up operation, and engine brake operation.
●
Send required output signals to the respective solenoids.

CONTROL SYSTEM OUTLINE
The automatic transaxle senses vehicle operating conditions through various sensors or signals. It always
controls the optimum shift position and reduces shifting and lock-up shocks.
SWITCHES & SENSORS

TCM

ACTUATORS

PNP switch
Accelerator pedal position signal
Closed throttle position signal
Wide open throttle position signal
Engine speed signal
A/T fluid temperature sensor
Revolution sensor
Turbine revolution sensor (Power
train revolution sensor)
Vehicle speed sensor
Overdrive control switch signal
Stop lamp switch signal

Shift control
Line pressure control
Lock-up control
Overrun clutch control
Fail-safe control
Self-diagnosis
CONSULT-II communication line
control

Shift solenoid valve A
Shift solenoid valve B
Overrun clutch solenoid valve
Torque converter clutch solenoid
valve
Line pressure solenoid valve
OD OFF indicator lamp

Þ

Þ

CONTROL SYSTEM DIAGRAM

SCIA7112E

AT-30

A/T CONTROL SYSTEM
Input/Output Signal of TCM

BCS000NL

A
Line
pressure
control

Vehicle
speed
control

Shift
control

Lock-up
control

Engine
brake
control

Fail-safe
function

Self-diagnostics
function

Accelerator pedal position signal(*5)

X

X

X

X

X

(*3) X

X

Vehicle speed sensor·A/T
(Revolution sensor)

X

X

X

X

(*3) X

X

Vehicle speed sensor·MTR

(*1) X

(*1) X

(*1) X

(*1) X

X

Closed throttle position signal(*5)

(*2) X

(*2) X

X

(*4) X

Wide open throttle position signal(*5)

(*2) X

(*2) X

X

X

Control item

Input

Turbine revolution sensor (Power
train revolution sensor)

AT

(*4) X
X

Engine speed signal
PNP switch

X

X

Overdrive control switch signal(*5)
TCM power supply voltage signal

Output

X

X

X

X

X

X

X

X

X

X

X

X

(*3) X

D

X

E

(*4) X
(*4) X

F

X
X

(*4) X

X

Shift solenoid valve A/B
Line pressure solenoid

X

X

Stop lamp switch signal(*5)
A/T fluid temperature sensors

B

G

X
X

X

Torque converter clutch solenoid
valve

X

Overrun clutch solenoid valve

X

OD OFF indicator lamp(*6)

X

X

(*3) X

X

(*3) X

X

(*3) X

X

(*3) X

X

*1: Spare for vehicle speed sensor·A/T (revolution sensor)
*2: Spare for accelerator pedal position signal
*3: If these input and output signals are different, the TCM triggers the fail-safe function.
*4: Used as a condition for starting self-diagnostics; if self-diagnosis are not started, it is judged that there is some kind of error.
*5: Input by CAN communications.
*6: Output by CAN communications.

H

I

X

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AT-31

A/T CONTROL SYSTEM
Line Pressure Control
●
●
●

BCS000NM

TCM has various line pressure control characteristics to match the driving conditions.
An ON-OFF duty signal is sent to the line pressure solenoid valve based on TCM characteristics.
Hydraulic pressure on the clutch and brake is electronically controlled through the line pressure solenoid
valve to accommodate engine torque. This results in smooth shift operation.

NORMAL CONTROL
The characteristic of the line pressure to the throttle opening is set
for suitable clutch operation.

SAT003J

BACK-UP CONTROL (ENGINE BRAKE)
If the selector lever is shifted to “2” position while driving in D4 or D3,
great driving force is applied to the clutch inside the transaxle. Clutch
operating pressure (line pressure) must be increased to deal with
this driving force.

SAT004J

DURING SHIFT CHANGE
The line pressure is temporarily reduced corresponding to a change
in engine torque when shifting gears (that is, when the shift solenoid
valve is switched for clutch operation) to reduce shifting shock.

SCIA4828E

AT-32

A/T CONTROL SYSTEM
AT LOW FLUID TEMPERATURE
●

●

A/T fluid viscosity and frictional characteristics of the clutch facing change with A/T fluid temperature.
Clutch engaging or band-contacting pressure is compensated for, according to A/T fluid temperature, to
stabilize shifting quality.
The line pressure is reduced below 60°C (140°F) to prevent
shifting shock due to high viscosity of A/T fluid when temperature is low.

A

B

AT

D

SCIA4829E

●

Line pressure is increased to a maximum irrespective of the
throttle opening when A/T fluid temperature drops to −10°C
(14°F). This pressure rise is adopted to prevent a delay in clutch
and brake operation due to extreme drop of A/T fluid viscosity at
low temperature.

E

F

G

H
SCIA4830E

Shift Control

BCS000NN

The shift is regulated entirely by electronic control to accommodate vehicle speed and varying engine operations. This is accomplished by electrical signals transmitted by the revolution sensor and the ECM (accelerator
pedal position sensor). This results in improved acceleration performance and fuel economy.

I

J

CONTROL OF SHIFT SOLENOID VALVES A AND B
The TCM activates shift solenoid valves A and B according to signals from the accelerator pedal position sensor and revolution sensor to select the optimum gear position on the basis of the shift
schedule memorized in the TCM.
The shift solenoid valve performs simple ON-OFF operation. When
set to “ON”, the drain circuit closes and pilot pressure is applied to
the shift valve.

K

L

M

SAT008J

RELATION BETWEEN SHIFT SOLENOID VALVES A AND B AND GEAR POSITIONS
Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

AT-33

A/T CONTROL SYSTEM
CONTROL OF SHIFT VALVES A AND B

SAT009J

Pilot pressure generated by the operation of shift solenoid valves A and B is applied to the end face of shift
valves A and B.
The figure above shows the operation of shift valve B. When the shift solenoid valve is “ON”, pilot pressure
applied to the end face of the shift valve overcomes spring force, moving the valve upward.

Lock-up Control

BCS000NO

The torque converter clutch piston in the torque converter is locked to eliminate torque converter slip and to
increase power transmission efficiency. The solenoid valve is controlled by an ON-OFF duty signal sent from
the TCM. The signal is converted to an oil pressure signal which controls the torque converter clutch piston.

CONDITIONS FOR LOCK-UP OPERATION
When vehicle is driven in 3rd and 4th gear positions, vehicle speed and throttle opening are detected. If the
detected values fall within the lock-up zone memorized in the TCM, lock-up is performed.
OD

ON

Selector lever
Gear position

OFF
“D” position
D3

D4

Vehicle speed sensor

More than set value

Throttle position sensor

Less than set opening

Closed throttle position switch

OFF

A/T fluid temperature sensor

More than 40°C (104°F)

TORQUE CONVERTER CLUTCH SOLENOID VALVE CONTROL
Lock-up Control System Diagram

SCIA5623E

AT-34

A/T CONTROL SYSTEM
Lock-up Released
In the lock-up released state, the torque converter clutch control valve is set into the unlocked state by draining the torque converter clutch piston applying pressure and the torque converter clutch piston release pressure is generated.
In this way, the torque converter clutch piston is not coupled.

A

B

Lock-up Applied
In the lock-up applied state, the torque converter clutch control valve is set into the locked state by generating
the torque converter clutch piston applying pressure and the torque converter clutch piston release pressure is AT
drained.
In this way, the torque converter clutch piston is pressed and coupled.
D
SMOOTH LOCK-UP CONTROL
When shifting from the lock-up released state to the lock-up applied state, the current output to the torque converter clutch solenoid is controlled with the TCM. In this way, when shifting to the lock-up applied state, the
torque converter clutch is temporarily set to the half-clutched state to reduce the shock.

E

Half-clutched State
The current output from the TCM to the torque converter clutch solenoid is varied to steadily increase the
torque converter clutch solenoid pressure.
In this way, the lock-up applying pressure gradually rises and while the torque converter clutch piston is put
into half-clutched status, the torque converter clutch piston applying pressure is increased and the coupling is
completed smoothly.

Engine Brake Control (Overrun Clutch Control)

F

G

BCS000NP

Forward one-way clutch is used to reduce shifting shocks in downshifting operations. This clutch transmits
engine torque to the wheels. However, drive force from the wheels is not transmitted to the engine because
the one-way clutch rotates idle. This means the engine brake is not effective.
The overrun clutch operates when the engine brake is needed.

H

I

OVERRUN CLUTCH OPERATING CONDITIONS
J

K

L

M

SCIA7186E

AT-35

A/T CONTROL SYSTEM
OVERRUN CLUTCH SOLENOID VALVE CONTROL
The overrun clutch solenoid valve is operated by an ON-OFF signal
transmitted by the TCM to provide overrun clutch control (engine
brake control).
When this solenoid valve is “ON”, the pilot pressure drain port
closes. When it is “OFF”, the drain port opens.
During the solenoid valve “ON” pilot pressure is applied to the end
face of the overrun clutch control valve.

SAT015J

OVERRUN CLUTCH CONTROL VALVE OPERATION
When the solenoid valve is “ON”, pilot pressure is applied to the
overrun clutch control valve. This pushes up the overrun clutch control valve. The line pressure is then shut off so that the clutch does
not engage. Only in “1” position, however, 1 range pressure is
applied to overrun clutch control valve, resulting in valve moving
downward and clutch engaged.
When the solenoid valve is “OFF”, pilot pressure is not generated. At
this point, the overrun clutch control valve moves downward by
spring force. As a result, overrun clutch operation pressure is provided by the overrun clutch reducing valve. At overrun clutch reducing valve in “D” position, the hydraulic pressure is reduced to a level
that balances the spring force. This is sent to overrun clutch control
valve and becomes the operating pressure of overrun clutch which is
engaged at all times. In “2” position and “1” position, overrun clutch
reducing valve is pushed down by 2 range pressure. Line pressure is
directly sent to overrun clutch control valve and becomes the operating pressure of overrun clutch which is engaged at all times.

SCIA7172E

AT-36

A/T CONTROL SYSTEM
Control Valve

BCS000NQ

A

FUNCTION OF CONTROL VALVES
Valve name

Function

Pressure regulator valve, plug and sleeve
plug

Regulates oil discharged from the oil pump to provide optimum line pressure for all driving conditions.

Pressure modifier valve and sleeve

Used as a signal supplementary valve to the pressure regulator valve. Regulates pressure-modifier pressure (signal pressure) which controls optimum line pressure for all
driving conditions.

B

AT

Pilot valve

Regulates line pressure to maintain a constant pilot pressure level which controls lock-up
mechanism, overrun clutch, shift timing.

Accumulator control valve

Regulates accumulator back-pressure to pressure suited to driving conditions.

Manual valve

Directs line pressure to oil circuits corresponding to select positions.
Hydraulic pressure drains when the shift lever is in Neutral.

Shift valve A

Simultaneously switches three oil circuits using output pressure of shift solenoid valve A
to meet driving conditions (vehicle speed, throttle opening, etc.).
Provides automatic downshifting and upshifting (1st → 2nd → 3rd → 4th gears/4th →
3rd → 2nd → 1st gears) in combination with shift valve B.

Shift valve B

Simultaneously switches two oil circuits using output pressure of shift solenoid valve B in
relation to driving conditions (vehicle speed, throttle opening, etc.).
Provides automatic downshifting and upshifting (1st → 2nd → 3rd → 4th gears/4th →
3rd → 2nd → 1st gears) in combination with shift valve A.

G

Switches hydraulic circuits to prevent engagement of the overrun clutch simultaneously
with application of the brake band in D4 . (Interlocking occurs if the overrun clutch
engages during D4 .)

H

Overrun clutch control valve

D

E

F

1st reducing valve

Reduces low & reverse brake pressure to dampen engine-brake shock when downshifting from the 1st position 12 to 11 .

Overrun clutch reducing valve

Reduces oil pressure directed to the overrun clutch and prevents engine-brake shock.
In the 1st and 2nd positions, line pressure acts on the overrun clutch reducing valve to
increase the pressure-regulating point, with resultant engine brake capability.

I

Torque converter relief valve

Prevents an excessive rise in torque converter pressure.

J

Torque converter clutch control valve, plug
and sleeve

Activates or inactivates the lock-up function.
Also provides smooth lock-up through transient application and release of the lock-up
system.

1-2 accumulator valve and piston

Lessens the shock find when the 2nd gear band servo contracts, and provides smooth
shifting.

3-2 timing valve

Switches the pace that oil pressure is released depending on vehicle speed; maximizes
the high clutch release timing, and allows for soft downshifting.

Shuttle valve

Determines if the overrun clutch solenoid valve should control the 3-2 timing valve or the
overrun clutch control valve and switches between the two.

Cooler check valve

At low speeds and with a small load when a little heat is generated, saves the volume of
cooler flow, and stores the oil pressure for lock-up.

AT-37

K

L

M

A/T CONTROL SYSTEM
Centrifugal Cancel Mechanism

BCS000NR

FUNCTION
The centrifugal cancel mechanism is a mechanism to cancel the centrifugal hydraulic pressure instead of the
conventional check balls. It cancels the centrifugal hydraulic pressure which is generated as high clutch drum
rotates, and it allows for preventing high clutch from dragging and for providing stable high clutch piston pressing force in all revolution speeds.

STRUCTURE/OPERATION
A centrifugal cancel housing is provided to cancel the clutch housing pressure. The centrifugal cancel housing
is always filled with ATF from the dedicated fluid passage of oil pump.

SCIA6832E

When Clutch Pressure Is Not Applied
As high clutch drum rotates, a centrifugal force applies to the remaining ATF in clutch housing to push high
clutch piston. However, on the other hand, the centrifugal force also applies to ATF filled in centrifugal cancel
housing, resulting in a force that pushes high clutch piston back. Consequently the high clutch piston does not
move because both forces cancel each other, and thus high clutch is prevented from dragging.

When Clutch Pressure Is Applied
Clutch pressure that applies to clutch housing overcomes the fluid pressure and spring force of the opposing
centrifugal housing to push high clutch piston, and high clutch is engaged. At this time, the centrifugal force
caused by the revolution speed of high clutch drum has no impact any more since the centrifugal force that
applies to the clutch pressure of clutch housing is canceled by the centrifugal force that applies to centrifugal
cancel housing. As a result, high clutch piston pressing force is always stable in all revolution speeds, and
thus smooth shifting characteristics are achieved.

SCIA6833E

AT-38

CAN COMMUNICATION
CAN COMMUNICATION
System Description

PFP:23710

A
BCS000NS

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- B
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
AT
Each control unit transmits/receives data but selectively reads required data only.

CAN Communication Unit

BCS000NT

D

Refer to LAN-27, «CAN Communication Unit» .

E

F

G

H

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M

AT-39

TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
DTC Inspection Priority Chart

PFP:00004
BCS000NU

If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
chart.
NOTE:
If DTC “CAN COMM CIRCUIT” is displayed with other DTCs, first perform the trouble diagnosis for
DTC “CAN COMM CIRCUIT”. Refer to AT-102 (EURO-OBD models) or AT-257 (Except EURO-OBD
models).
Priority

Detected items

1

CAN communication line

2

Except above

Fail-safe

BCS000NV

The TCM has an electronic Fail-safe mode. This allows the vehicle to be driven even if a major electrical input/
output device circuit is damaged.
Under Fail-Safe, the vehicle always runs in third gear, even with a shift lever position of “1”, “2” or “D”. The customer may complain of sluggish or poor acceleration.
Always follow the “AT-43, «WORK FLOW» ”.
The SELF-DIAGNOSIS results will be as follows:
●
The first SELF-DIAGNOSIS will indicate damage to the vehicle speed sensor or the revolution sensor.
●
During the next SELF-DIAGNOSIS, performed after checking the sensor, no damages will be indicated.

FAIL-SAFE FUNCTION
The following fail-safe functions allow vehicles to be driven even when sensor, switch or solenoid malfunction
occurs.

Vehicle Speed Sensor·A/T (Revolution Sensor)
Vehicle speed sensor·MTR signal is input from combination meter.

Accelerator Pedal Position Sensor Signal and Throttle Position Sensor Signal
TCM controls the throttle opening angle to a predetermined fixed position to enable driving if a malfunctioning
signal is input to TCM.

PNP Switch
When the multiple PNP switch signals are input to TCM, the priority of selector lever position becomes “D”,
“N”, “R”, “2” and “1” in order by internal TCM determination.
The use of 4th gear is inhibited until normal operation resumes. Because the hydraulic circuit of the control
valve is switched by manual valve according to the selector lever position, however, actual operating condition
of vehicle becomes as follows.
Actual lever position

PNP switch input signal

Running status

“P”

“P” position and other position signals

P

“R”

“R” position and other position signals

R

“N”

“N” position and other position signals

N

“D”

“D” position and other position signals

D1 ⇔D2 ⇔D3 ⇔D4

“2” position and other position signals (Except “1” position)

21 ⇔22 ⇔23

“2” position and “1” position signals

21 ⇔22

“1” position and other position signals (Except “2” position)

11 ⇔12 ⇔13

“1” position and “2” position signals

11 ⇔12

“2”

“1”

AT-40

TROUBLE DIAGNOSIS
Shift Solenoid Valve A and B
If non-standard solenoid signal is sent to TCM, use of certain gears is limited. Refer to chart shown below.
Malfunction in solenoid
valve A

Normal
Shift position

“D” position

“2” position

“1” position

A

B

Gear

A

B

●

●

1st

–

×

●

2nd

×

×

●
●

A

B

●→×

●→×

–

●→×

3rd

–

×

4th

●

B

–

–

–

×

–

–

–

x

×

–

–

–

–

x

●→×

–

–

–

1st

–

●→×

●→×

–

–

–

●

2nd

–

●→×

×

×

3rd

–

●

●

1st

×

●

×

×

3rd

Gear

Malfunction in solenoid
valves A and B
A

×

Gear

Malfunction in solenoid
valve B

3rd

A

×

–

–

–

x

×

–

–

–

–

●→×

●→×

–

–

–

2nd

–

●→×

×

–

–

–

3rd

–

x

×

–

–

–

Gear

B

AT

D
3rd

●: Solenoid ON
×: Solenoid OFF
–: Non-standard condition

E

F

G

Line Pressure Solenoid Valve
If non-standard solenoid signal is sent to TCM, line pressure solenoid valve is turned OFF to achieve maximum oil pressure.

H

Torque Converter Clutch Solenoid Valve
If non-standard solenoid signal is sent to TCM, torque converter clutch solenoid valve is turned OFF to release
lock-up.

I

Overrun Clutch Solenoid Valve
If non-standard solenoid signal is sent to TCM, overrun clutch solenoid valve is turned OFF to engage overrun
clutch. This will result in more effective engine brake during deceleration.

J

K

L

M

AT-41

TROUBLE DIAGNOSIS
How to Perform Trouble Diagnoses for Quick and Accurate Repair

BCS000NW

INTRODUCTION
The TCM receives a signal from the vehicle speed sensor, accelerator pedal position sensor or PNP switch and provides shift control or
lock-up control via A/T solenoid valves.
Input and output signals must always be correct and stable in the
operation of the A/T system. The A/T system must be in good operating condition and be free of valve seizure, solenoid valve malfunction, etc.
It is much more difficult to diagnose a malfunction that occurs intermittently rather than continuously. Most intermittent malfunctions are
caused by poor electric connections or improper wiring. In this case,
careful checking of suspected circuits may help prevent the replacement of good parts.
A visual check only, may not find the cause of the malfunctions. A
road test with CONSULT-II or a circuit tester connected should be
performed. Follow the AT-43, «WORK FLOW» .
Before undertaking actual checks, take a few minutes to talk with a
customer who approaches with a driveability complaint. The customer can supply good information about such malfunctions, especially intermittent ones. Find out what symptoms are present and
under what conditions they occur. A “DIAGNOSTIC WORKSHEET”
like the example (AT-45, «DIAGNOSTIC WORKSHEET» ) should be
used.
Start your diagnosis by looking for “conventional” malfunctions first.
This will help troubleshoot driveability malfunctions on an electronically controlled engine vehicle.
Also check related Service bulletins for information.

SAT631IA

SAT632I

SEF234G

AT-42

TROUBLE DIAGNOSIS
WORK FLOW
A good understanding of the malfunction conditions can make troubleshooting faster and more accurate. In
general, each customer feels differently about a malfunction. It is important to fully understand the symptoms
or conditions for a customer complaint.
Make good use of the two sheets provided, AT-45, «Information from Customer» and AT-46, «Diagnostic Worksheet Chart» , to perform the best troubleshooting possible.

A

B

Work Flow Chart
AT

For EURO-OBD models

D

E

F

G

H

I

J

K

L

M

SCIA7146E

*1

AT-45

*2

AT-46

*3

AT-40

*4

AT-53

*5

AT-53, AT-56

*6

AT-58

*7

AT-85

*8

AT-98

*9

AT-40

*10

AT-115

*11

AT-192

*12

AT-294

AT-43

TROUBLE DIAGNOSIS
*13

AT-68

*14

AT-87

*16

AT-193

*17

EC-48

*15

AT-115

For Except EURO-OBD models

SCIA7147E

*1

AT-45

*2

AT-46

*3

AT-40

*4

AT-53

*5

AT-53, AT-56

*6

AT-58

*7

AT-85

*8

AT-94

*9

AT-203

*10

AT-287

*11

AT-294

*12

AT-68

*13

AT-87

*14

AT-97

*15

AT-203

*16

AT-287

AT-44

TROUBLE DIAGNOSIS
DIAGNOSTIC WORKSHEET
Information from Customer

A

KEY POINTS
●
WHAT….. Vehicle & A/T model
●
WHEN….. Date, Frequencies
●
WHERE….. Road conditions
●
HOW….. Operating conditions, Symptoms
Customer name

MR./MS

B

AT

Model & Year

VIN

Trans. model

Engine

Mileage

Incident Date

Manuf. Date

In Service Date

Frequency

❏ Continuous

Symptoms

❏ Vehicle does not move.
❏ No up-shift

❏ Intermittent (

❏ No down-shift

times a day)

(❏ Any position

(❏ 1st → 2nd

D

❏ 2nd → 3rd

(❏ 4th → 3rd

❏ Particular position)

E

❏ 3rd → 4th)

❏ 3rd → 2nd

❏ 2nd → 1st)

F

❏ Lock-up malfunction
❏ Shift point too high or too low.
❏ Shift shock or slip

(❏ N → D

❏ Lock-up

❏ Any drive position)

G

❏ Noise or vibration
❏ No kick down

H

❏ No pattern select
❏ Others
(

)

I

J

K

L

M

AT-45

TROUBLE DIAGNOSIS
Diagnostic Worksheet Chart
EURO-OBD models
1.

❏ Read the Fail-safe and listen to customer complaints.

AT-40,
AT-45

2.

❏ Check A/T fluid

AT-18

❏ Leakage (Follow specified procedure)
❏ Fluid condition
❏ Fluid level
3.

❏ Perform “STALL TEST” and “LINE PRESSURE TEST”.
❏ “STALL TEST” — Mark possible damaged components/others.
❏ Torque converter one-way clutch
❏ Reverse clutch
❏ Forward clutch
❏ Overrun clutch
❏ Forward one-way clutch

AT-53,
AT-56

❏ Low & reverse brake
❏ Low one-way clutch
❏ Engine
❏ Line pressure is low
❏ Clutches and brakes except high clutch and
brake band are OK

❏ “LINE PRESSURE TEST” — Suspected parts:
4.

❏ Perform “Road Test”.

AT-58

4-1.

AT-58

“Check Before Engine is Started”
❏ AT-299, «OD OFF Indicator Lamp Does Not Come On»
❏ Perform self-diagnosis. Enter checks for detected items. AT-85 , AT-94 .
❏ AT-102, «DTC U1000 CAN COMMUNICATION LINE» .
❏ AT-105, «DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH» .
❏ AT-110, «DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT» .
❏ AT-115, «DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)» .
❏ AT-121, «DTC P0725 ENGINE SPEED SIGNAL» .
❏ AT-125, «DTC P0731 A/T 1ST GEAR FUNCTION»
❏ AT-129, «DTC P0732 A/T 2ND GEAR FUNCTION» .
❏ AT-132, «DTC P0733 A/T 3RD GEAR FUNCTION» .
❏ AT-136, «DTC P0734 A/T 4TH GEAR FUNCTION» .
❏ AT-142, «DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE» .
❏ AT-147, «DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP)» .
❏ AT-153, «DTC P0745 LINE PRESSURE SOLENOID VALVE» .
❏ AT-159, «DTC P0750 SHIFT SOLENOID VALVE A» .
❏ AT-164, «DTC P0755 SHIFT SOLENOID VALVE B» .
❏ AT-169, «DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR» .
❏ AT-171, «DTC P1760 OVERRUN CLUTCH SOLENOID VALVE» .
❏ AT-176, «DTC VEHICLE SPEED SENSOR MTR» .
❏ AT-180, «DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM
POWER SOURCE)» .
❏ AT-186, «DTC TURBINE REVOLUTION SENSOR» .
❏ AT-192, «CONTROL UNIT (RAM), CONTROL UNIT (ROM)» .
❏ AT-193, «MAIN POWER SUPPLY AND GROUND CIRCUIT» .

AT-46

TROUBLE DIAGNOSIS
4.

4-2.

“Check at Idle”

AT-59

A

❏ AT-301, «Engine Cannot Be Started in “P” and “N” Position» .
❏ AT-302, «In “P” Position, Vehicle Moves Forward or Backward When Pushed» .
❏ AT-302, «In “N” Position, Vehicle Moves» .
❏ AT-303, «Large Shock “N” → “R” Position» .
❏ AT-304, «Vehicle Does Not Creep Backward in “R” Position» .
❏ AT-306, «Vehicle Does Not Creep Forward in “D”, “2” or “1” Position» .
4-3.

“Cruise Test”

B

AT-61

AT

Part 1
❏ AT-307, «Vehicle Cannot Be Started from D1» .
❏ AT-309, «A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2» .
❏ AT-311, «A/T Does Not Shift: D2 → D3» .
❏ AT-314, «A/T Does Not Shift: D3 → D4» .
❏ AT-316, «A/T Does Not Perform Lock-up» .
❏ AT-317, «A/T Does Not Hold Lock-up Condition» .
❏ AT-318, «Lock-up Is Not Released» .
❏ AT-318, «Engine Speed Does Not Return to Idle (Light Braking D4 → D3 )» .
Part 2

D

E

AT-64

❏ AT-307, «Vehicle Cannot Be Started from D1» .
❏ AT-309, «A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2» .
❏ AT-311, «A/T Does Not Shift: D2 → D3» .
❏ AT-314, «A/T Does Not Shift: D3 → D4» .
Part 3

F

G
AT-65

❏ AT-320, «A/T Does Not Shift: D4 → D3 , When OD OFF» .
❏ AT-321, «A/T Does Not Shift: D3 → 22 , When Selector Lever “D” → “2” Position» .
❏ AT-323, «A/T Does Not Shift: 22 → 11 , When Selector Lever “2” → “1” Position» .
❏ AT-325, «Vehicle Does Not Decelerate by Engine Brake» .
❏ Perform self-diagnosis. Enter checks for detected items. AT-85 , AT-94 .

H

I

❏ AT-102, «DTC U1000 CAN COMMUNICATION LINE» .
❏ AT-105, «DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH» .
❏ AT-110, «DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT» .
❏ AT-115, «DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)» .
❏ AT-121, «DTC P0725 ENGINE SPEED SIGNAL» .
❏ AT-125, «DTC P0731 A/T 1ST GEAR FUNCTION»
❏ AT-129, «DTC P0732 A/T 2ND GEAR FUNCTION» .
❏ AT-132, «DTC P0733 A/T 3RD GEAR FUNCTION» .
❏ AT-136, «DTC P0734 A/T 4TH GEAR FUNCTION» .
❏ AT-142, «DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE» .
❏ AT-147, «DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP)» .
❏ AT-153, «DTC P0745 LINE PRESSURE SOLENOID VALVE» .
❏ AT-159, «DTC P0750 SHIFT SOLENOID VALVE A» .
❏ AT-164, «DTC P0755 SHIFT SOLENOID VALVE B» .
❏ AT-169, «DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR» .
❏ AT-171, «DTC P1760 OVERRUN CLUTCH SOLENOID VALVE» .
❏ AT-176, «DTC VEHICLE SPEED SENSOR MTR» .
❏ AT-180, «DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM
POWER SOURCE)» .
❏ AT-186, «DTC TURBINE REVOLUTION SENSOR» .
❏ AT-192, «CONTROL UNIT (RAM), CONTROL UNIT (ROM)» .
❏ AT-193, «MAIN POWER SUPPLY AND GROUND CIRCUIT» .

J

K

L

M

5.

❏ For self-diagnosis NG items, inspect each component. Repair or replace the damaged parts.

AT-85,
AT-95

6.

❏ Perform “Road Test”.

AT-58

7.

❏ Perform the Diagnostic Procedures for all remaining items marked NG. Repair or replace the damaged parts.
Refer to the Symptom Chart when you perform the procedures. (The chart also shows some other possible
symptoms and the component inspection orders.)

AT-68

8.

❏ Erase DTC from TCM and ECM memories.

AT-87,
AT-97

AT-47

TROUBLE DIAGNOSIS
Except EURO-OBD models
1.

❏ Read the Fail-safe and listen to customer complaints.

AT-40,
AT-45

2.

❏ Check A/T fluid

AT-18

❏ Leakage (Follow specified procedure)
❏ Fluid condition
❏ Fluid level
3.

❏ Perform “STALL TEST” and “LINE PRESSURE TEST”.
❏ “STALL TEST” — Mark possible damaged components/others.

AT-53,
AT-56

❏ Low & reverse brake
❏ Low one-way clutch
❏ Engine
❏ Line pressure is low
❏ Clutches and brakes except high clutch and
brake band are OK

❏ Torque converter one-way clutch
❏ Reverse clutch
❏ Forward clutch
❏ Overrun clutch
❏ Forward one-way clutch
❏ “LINE PRESSURE TEST” — Suspected parts:
4.

❏ Perform “Road Test”.

AT-58

4-1.

AT-58

“Check Before Engine is Started”
❏ AT-299, «OD OFF Indicator Lamp Does Not Come On»
❏ Perform self-diagnosis. Enter checks for detected items. AT-85 , AT-94 .
❏ AT-257, «CAN COMMUNICATION LINE» .
❏ AT-203, «VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)» .
❏ AT-209, «VEHICLE SPEED SENSOR MTR» .
❏ AT-245, «TURBINE REVOLUTION SENSOR» .
❏ AT-213, «ACCELERATOR PEDAL POSITION (APP) SENSOR» .
❏ AT-215, «SHIFT SOLENOID VALVE A» .
❏ AT-220, «SHIFT SOLENOID VALVE B» .
❏ AT-225, «OVERRUN CLUTCH SOLENOID VALVE» .
❏ AT-230, «TORQUE CONVERTER CLUTCH SOLENOID VALVE» .
❏ AT-235, «BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER
SOURCE)» .
❏ AT-241, «ENGINE SPEED SIGNAL» .
❏ AT-264, «A/T 1ST GEAR FUNCTION» .
❏ AT-268, «A/T 2ND GEAR FUNCTION» .
❏ AT-271, «A/T 3RD GEAR FUNCTION» .
❏ AT-275, «A/T 4TH GEAR FUNCTION» .
❏ AT-281, «A/T TCC S/V FUNCTION (LOCK-UP)» .
❏ AT-251, «LINE PRESSURE SOLENOID VALVE» .
❏ AT-287, «CONTROL UNIT (RAM), CONTROL UNIT (ROM)» .

AT-48

TROUBLE DIAGNOSIS
4.

4-2.

“Check at Idle”

AT-59

A

❏ AT-301, «Engine Cannot Be Started in “P” and “N” Position» .
❏ AT-302, «In “P” Position, Vehicle Moves Forward or Backward When Pushed» .
❏ AT-302, «In “N” Position, Vehicle Moves» .
❏ AT-303, «Large Shock “N” → “R” Position» .
❏ AT-304, «Vehicle Does Not Creep Backward in “R” Position» .
❏ AT-306, «Vehicle Does Not Creep Forward in “D”, “2” or “1” Position» .
4-3.

“Cruise Test”

B

AT-61

AT

Part 1
❏ AT-307, «Vehicle Cannot Be Started from D1» .
❏ AT-309, «A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2» .
❏ AT-311, «A/T Does Not Shift: D2 → D3» .
❏ AT-314, «A/T Does Not Shift: D3 → D4» .
❏ AT-316, «A/T Does Not Perform Lock-up» .
❏ AT-317, «A/T Does Not Hold Lock-up Condition» .
❏ AT-318, «Lock-up Is Not Released» .
❏ AT-318, «Engine Speed Does Not Return to Idle (Light Braking D4 → D3 )» .
Part 2

D

E

AT-64

❏ AT-307, «Vehicle Cannot Be Started from D1» .
❏ AT-309, «A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2» .
❏ AT-311, «A/T Does Not Shift: D2 → D3» .
❏ AT-314, «A/T Does Not Shift: D3 → D4» .
Part 3

F

G
AT-65

❏ AT-320, «A/T Does Not Shift: D4 → D3 , When OD OFF» .
❏ AT-321, «A/T Does Not Shift: D3 → 22 , When Selector Lever “D” → “2” Position» .
❏ AT-323, «A/T Does Not Shift: 22 → 11 , When Selector Lever “2” → “1” Position» .
❏ AT-325, «Vehicle Does Not Decelerate by Engine Brake» .
❏ Perform self-diagnosis. Enter checks for detected items. AT-85 , AT-94 .

H

I

❏ AT-257, «CAN COMMUNICATION LINE» .
❏ AT-203, «VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)» .
❏ AT-209, «VEHICLE SPEED SENSOR MTR» .
❏ AT-245, «TURBINE REVOLUTION SENSOR» .
❏ AT-213, «ACCELERATOR PEDAL POSITION (APP) SENSOR» .
❏ AT-215, «SHIFT SOLENOID VALVE A» .
❏ AT-220, «SHIFT SOLENOID VALVE B» .
❏ AT-225, «OVERRUN CLUTCH SOLENOID VALVE» .
❏ AT-230, «TORQUE CONVERTER CLUTCH SOLENOID VALVE» .
❏ AT-235, «BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER
SOURCE)» .
❏ AT-241, «ENGINE SPEED SIGNAL» .
❏ AT-264, «A/T 1ST GEAR FUNCTION» .
❏ AT-268, «A/T 2ND GEAR FUNCTION» .
❏ AT-271, «A/T 3RD GEAR FUNCTION» .
❏ AT-275, «A/T 4TH GEAR FUNCTION» .
❏ AT-281, «A/T TCC S/V FUNCTION (LOCK-UP)» .
❏ AT-251, «LINE PRESSURE SOLENOID VALVE» .
❏ AT-287, «CONTROL UNIT (RAM), CONTROL UNIT (ROM)» .

J

K

L

M

5.

❏ For self-diagnosis NG items, inspect each component. Repair or replace the damaged parts.

AT-85,
AT-95

6.

❏ Perform “Road Test”.

AT-58

7.

❏ Perform the Diagnostic Procedures for all remaining items marked NG. Repair or replace the damaged parts.
Refer to the Symptom Chart when you perform the procedures. (The chart also shows some other possible
symptoms and the component inspection orders.)

AT-68

8.

❏ Erase DTC from TCM and ECM memories.

AT-87,
AT-97

AT-49

TROUBLE DIAGNOSIS
A/T Electrical Parts Location

BCS000NX

MCIB0179E

AT-50

TROUBLE DIAGNOSIS
1. O/D OFF indicator lamp

2. A/T position indicator

3. Over drive control switch

4. Accelerator pedal position (APP)
sensor

5. Turbine revolution sensor (Power
train revolution sensor)

6. PNP switch

7. Terminal body (Terminal cord
assembly connector)

8. Revolution sensor

9. TCM

A

B

10. Dropping resistor

AT

D

E

F

G

H

I

J

K

L

M

AT-51

TROUBLE DIAGNOSIS
Circuit Diagram

BCS000NY

MCWA0240E

AT-52

TROUBLE DIAGNOSIS
Inspections Before Trouble Diagnosis

BCS000NZ

A

A/T FLUID CHECK
Fluid Leakage and Fluid Level Check
Check fluid leakage and check the fluid level. Refer to AT-18, «Checking A/T Fluid» .

B

Fluid Condition Check
Check the A/T fluid condition.
Fluid status

Conceivable Cause

AT

Required Operation

Varnished (viscous
varnish state)

Clutch, brake
scorched

Replace the ATF and check the A/T
main unit and the vehicle for malfunctions (wire harnesses, cooler
pipes, etc.)

Milky white or
cloudy

Water in the ATF

Replace the ATF and check for
places where water is getting in.

Large amount of
metal powder mixed
in

Unusual wear of
sliding parts within
A/T

Replace the ATF and check for
improper operation of the A/T.

D

E

SAT638A

F

STALL TEST
Stall Test Procedure
1.
2.

G

Check ATF and engine oil levels. If necessary, add ATF and
engine oil.
Drive vehicle for approximately 10 minutes or until ATF and
engine oil reach operating temperature.
ATF operating temperature:

H

50 — 80°C (122 — 176°F)
I

SAT647B

3.
4.

Set parking brake and block wheels.
Install a tachometer where it can be seen by driver during test.
● It is good practice to mark the point of specified engine
rpm on indicator.

J

K

L

M
SAT513G

5.

Start engine, apply foot brake, and place selector lever in “D”
position.

SAT775B

AT-53

TROUBLE DIAGNOSIS
6.
7.

Accelerate to wide open throttle gradually while applying foot
brake.
Quickly note the engine stall revolution and immediately release
throttle.
CAUTION:
Do not hold down the accelerator pedal for more than 5 seconds during this test.
Stall revolution
: 2,250 — 2,700 rpm
SAT514G

8.
9.

Move selector lever to “N” position.
Cool off ATF.
CAUTION:
Run the engine at idle for at least 1 minute.
10. Repeat steps 6 through 9 with selector lever in “2”, “1” and “R”
positions.

SAT771B

Judgement of Stall Test
The test result and possible damaged components relating to each result are shown in the illustrations on next
page.
In order to pinpoint the possible damaged components, refer to AT-43, «Work Flow Chart» .
NOTE:
Stall revolution is too high in “D”, “2”, or “1” position:
●
Slippage occurs in 1st gear but not in 2nd and 3rd gears. ….. Low one-way clutch slippage
●
Slippage occurs in the following gears:
1st through 3rd gears in “D” position and engine brake functions with OD OFF. (OD OFF indicator lamp is
on.)
1st and 2nd gears in “2” position and engine brake functions with accelerator pedal released (fully closed
throttle)…… Forward clutch or forward one-way clutch slippage
Stall revolution is too high in “R” position:
●
Engine brake does not function in “1” position. ….. Low & reverse brake slippage
●
Engine brake functions in “1” position. ….. Reverse clutch slippage
Stall revolution within specifications:
●
Vehicle does not achieve speed of more than 80 km/h (50 MPH). ….. One-way clutch seizure in torque
converter housing
CAUTION:
Be careful because automatic fluid temperature increases abnormally:
●
Slippage occurs in 3rd and 4th gears in “D” position. ….. High clutch slippage
●
Slippage occurs in 2nd and 4th gears in “D” position. ….. Brake band slippage
●
Engine brake does not function in 2nd and 3rd gears in “D” position, 2nd gear in “2” position, and 1st gear
in “1” position with OD OFF. (OD OFF indicator lamp is on.) ….. Overrun clutch slippage
Stall revolution less than specifications:
●
Poor acceleration during starts. ….. One-way clutch seizure in torque converter

AT-54

TROUBLE DIAGNOSIS
A

B

AT

D

E

F

G

H

I

J

K

L

M

SCIA7113E

AT-55

TROUBLE DIAGNOSIS
LINE PRESSURE TEST
Line Pressure Test Ports
Location of line pressure test ports are shown in the figure.
●
Always replace pressure plugs as they are self-sealing
bolts.

SCIA7187E

Line Pressure Test Procedure
1.
2.

Check ATF and engine oil levels. If necessary, add ATF or
engine oil.
Drive vehicle for approx. 10 minutes or until engine oil and ATF
reach operating temperature.
ATF operating temperature:

50 — 80°C (122 -176°F)

SAT647B

3.

Install oil pressure gauge to corresponding line pressure test
port.

SCIA6528J

4.

Set parking brake and block wheels.

SAT513G

AT-56

TROUBLE DIAGNOSIS
5.

Start engine and measure line pressure at idle and stall speed.
CAUTION:
● Keep the brake pedal pressed all the way down during
measurement.
● When measuring the line pressure at the stall speed,
refer to AT-53, «STALL TEST» .

A

B

AT
SAT493G

D

Line Pressure
Line pressure [kPa (bar, kg/cm2 , psi)]

Engine speed

D, 2nd and 1st positions

R position

Idle speed

500 (5.0, 5.1, 73)

778 (7.8, 7.9, 113)

Stall speed

1,159 (11.6, 11.8, 168)

1,803 (18.0, 18.4, 262)

E

F

Judgement of Line Pressure Test
Judgement
Line pressure is low in all positions.

Line pressure is low in particular position.

Suspected parts
●

Oil pump wear

●

Control piston damage

●

Pressure regulator valve or plug sticking

●

Spring for pressure regulator valve damaged

●

Fluid pressure leakage between oil strainer and pressure regulator valve

●

Clogged strainer

●

Fluid pressure leakage between manual valve and particular clutch

●

For example, line pressure is:
− Low in “R” and “1” positions, but
− Normal in “D”, and “2” positions.
Therefore, fluid leakage exists at or around low and reverse brake circuit.
Refer to AT-22, «CLUTCH AND BAND CHART» .

At idle

Line pressure is high.

Line pressure is low.

At stall
speed

●

Accelerator pedal position signal malfunction

●

A/T fluid temperature sensor damaged

●

Line pressure solenoid valve sticking

●

Short circuit of line pressure solenoid valve circuit

●

Pressure modifier valve sticking

●

Pressure regulator valve or plug sticking

●

Open in dropping resistor circuit

●

Accelerator pedal position signal malfunction

●

Line pressure solenoid valve sticking

●

Short circuit of line pressure solenoid valve circuit

●

Pressure regulator valve or plug sticking

●

Pressure modifier valve sticking

●

Pilot valve sticking

AT-57

G

H

I

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K

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TROUBLE DIAGNOSIS
Road Test

BCS000O0

DESCRIPTION
●

●

1.
2.
3.

The purpose of the test is to determine overall performance of A/
T and analyze causes of malfunctions.
The road test consists of the following three parts:
Check before engine is started. Refer to AT-58 .
Check at idle. Refer to AT-59 .
Cruise test
● Inspection all the item from Part 1 to Part 3. Refer to AT-61 ,
AT-64 and AT-65 .
SAT786A

●

●

Before road test, familiarize yourself with all test procedures and
items to check.
Perform tests on all items until specified symptom is found.
Troubleshoot the items which are checked out to be no good
after road test. Refer to AT-83, «CONSULT-II Function (A/T)» ,
AT-94, «Diagnostic Procedure Without CONSULT-II» and AT294, «TROUBLE DIAGNOSIS FOR SYMPTOMS» .

SAT496G

Check Before Engine is Started

BCS000O1

1. CHECK OD OFF INDICATOR LAMP
1.
2.
3.

Park vehicle on flat surface.
Move selector lever to “P” position.
Turn ignition switch OFF. Wait at least 5 seconds.

SAT772B

4. Turn ignition switch ON. (Do not start engine.)
Does OD OFF indicator lamp (1) come on for about 2 seconds?
YES >> 1. Turn ignition switch OFF.
2. Perform self-diagnosis and note NG items.
Refer to AT-85, «SELF-DIAGNOSTIC RESULT
MODE» , AT-94, «Diagnostic Procedure Without CONSULT-II» .
3. Go to AT-59, «Check at Idle» .
NO
>> Stop “Road Test”. Go to AT-299, «OD OFF Indicator
Lamp Does Not Come On» .

AT-58

MCIB0175E

TROUBLE DIAGNOSIS
Check at Idle

BCS000O2

1. CHECK ENGINE START

A

1. Park vehicle on flat surface.
2. Turn ignition switch ON. (Do not start engine.)
3. Move selector lever to “P” or “N” position.
4. Turn ignition switch to “START” position.
Is engine started?
YES >> GO TO 2.
NO
>> ● Stop “Road Test”. Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-301, «Engine Cannot Be Started in “P” and
“N” Position» .

B

AT

D

E
SAT769B

2. CHECK ENGINE START

F

1. Turn ignition switch ON. (Do not start engine.)
2. Move selector lever to “R”, “D”, “2” or “1” position.
3. Turn ignition switch to “START” position.
Is engine started?
YES >> ● Stop “Road Test”. Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-301, «Engine Cannot Be Started in “P” and
“N” Position» .
● Continue “Road Test”.
NO
>> GO TO 3.

G

H

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SAT770B

J

3. CHECK VEHICLE MOVE
1.
2.
3.

K

Move selector lever to “P” position.
Turn ignition switch OFF.
Release parking brake.

L

M

SAT768B

4. Push vehicle forward or backward.
Does vehicle move when it is pushed forward or backyard?
YES >> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-302, «In “P” Position, Vehicle Moves Forward or Backward When Pushed» .
● Continue “Road Test”.
NO
>> GO TO 4.
SAT796A

AT-59

TROUBLE DIAGNOSIS

4. CHECK VEHICLE MOVE
1. Apply parking brake.
2. Start engine.
3. Move selector lever to “N” position.
4. Release parking brake.
Does vehicle move forward or backward?
YES >> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-302, «In “N” Position, Vehicle Moves» .
● Continue “Road Test”.
NO
>> GO TO 5.
SAT771B

5. CHECK SHIFT SHOCK
1.

Apply foot brake.

SAT797A

2. Move selector lever to “R” position.
Is there large shock when changing from “N” to “R” position?
YES >> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-303, «Large Shock “N” → “R” Position» .
● Continue “Road Test”.
NO
>> GO TO 6.

SAT772B

6. CHECK VEHICLE MOVE
Release foot brake for several seconds.
Does vehicle creep backward when foot brake is released?
YES >> GO TO 7.
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-304, «Vehicle Does Not Creep Backward
in “R” Position» .
● Continue “Road Test”.
SAT799A

AT-60

TROUBLE DIAGNOSIS

7. CHECK VEHICLE MOVE

A

Move selector lever to “D”, “2” and “1” positions and check if vehicle
creeps forward.
Does vehicle creep forward in all three positions?
YES >> GO TO AT-61, «Cruise Test — Part 1» .
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-306, «Vehicle Does Not Creep Forward in
“D”, “2” or “1” Position» .
● Continue “Road Test”.

B

AT

D
SAT773B

Cruise Test — Part 1

BCS000O3

1. CHECK STARTING GEAR (D1 ) POSITION
1.

Drive vehicle for approximately 10 minutes to warm engine oil and ATF up to operating temperature.
ATF operating temperature:

2.
3.
4.
5.

E

F

50 — 80°C (122 — 176°F)

Park vehicle on flat surface.
Push overdrive control switch. (OD OFF indicator lamp is off.)
Move selector lever to “P” position.
Start engine.

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H

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SCIA5472E

6.

Move selector lever to “D” position.
K

L

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SAT775B

7.

Accelerate vehicle by constantly depressing accelerator pedal
half-way.
Read gear position. Refer to AT-88, «DATA MONITOR
MODE» .
Does vehicle start from D1 ?
YES >> GO TO 2.
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-307, «Vehicle Cannot Be Started from D1» .
● Continue “Road Test”.

AT-61

SAT495G

TROUBLE DIAGNOSIS

2. CHECK SHIFT-UP (D1

TO D2 )

Check shift-up (D1 to D2 ).
Specified speed when shifting from D1 to D2. Refer to AT-67, «Vehicle Speed at Which Gear Shifting Occurs» .
Read gear position, throttle opening and vehicle speed.
Refer to AT-88, «DATA MONITOR MODE» .
Does A/T shift from D1 to D2 at the specified speed?
YES >> GO TO 3.
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-309, «A/T Does Not Shift: D1 → D2 or
Does Not Kickdown: D4 → D2» .
● Continue “Road Test”.
SCIA7188E

3. CHECK SHIFT-UP (D2

TO D3 )

Check shift-up (D2 to D3 ).
Specified speed when shifting from D2 to D3. Refer to AT-67, «Vehicle Speed at Which Gear Shifting Occurs» .
Read gear position, throttle opening and vehicle speed.
Refer to AT-88, «DATA MONITOR MODE» .
Does A/T shift from D2 to D3 at the specified speed?
YES >> GO TO 4.
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-311, «A/T Does Not Shift: D2 → D3» .
● Continue “Road Test”.
SCIA7189E

4. CHECK SHIFT-UP (D3

TO D4 )

Check shift-up (D3 to D4 ).
Specified speed when shifting from D3 to D4. Refer to AT-67, «Vehicle Speed at Which Gear Shifting Occurs» .
Read gear position, throttle opening and vehicle speed.
Refer to AT-88, «DATA MONITOR MODE» .
Does A/T shift from D3 to D4 at the specified speed?
YES >> GO TO 5.
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-314, «A/T Does Not Shift: D3 → D4» .
● Continue “Road Test”.
SCIA7190E

AT-62

TROUBLE DIAGNOSIS

5. CHECK LOCK-UP (D4

TO D4 L/U)

A

Check lock-up (D4 to D4 L/U).
Specified speed when lock-up occurs. Refer to AT-67, «Vehicle Speed at Which Lock-up Occurs/Releases» .
Read vehicle speed, throttle opening when lock-up duty
becomes 94%. Refer to AT-88, «DATA MONITOR MODE» .
Does A/T perform lock-up at the specified speed?
YES >> GO TO 6.
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-316, «A/T Does Not Perform Lock-up» .
● Continue “Road Test”.
SCIA7191E

B

AT

D

E

6. CHECK LOCK-UP HOLD
F

Check lock-up hold.
When lock-up duty becomes 94%. Refer to AT-88, «DATA MONITOR MODE» .
Does A/T hold lock-up condition for more than 30 seconds?
YES >> GO TO 7.
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-317, «A/T Does Not Hold Lock-up Condition» .
● Continue “Road Test”.

G

H

7. CHECK SHIFT-DOWN (D4 L/U TO D4 )

I

Release accelerator pedal.
When lock-up duty becomes 4%. Refer to AT-88, «DATA MONITOR MODE» .
Is lock-up released when accelerator pedal is released?
YES >> GO TO 8.
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-318, «Lock-up Is Not Released» .
● Continue “Road Test”.

8. CHECK SHIFT-DOWN (D4

J

K

L

TO D3 )

Decelerate vehicle by applying foot brake lightly.
Read gear position and engine speed. Refer to AT-88, «DATA
MONITOR MODE» .
Does engine speed return to idle smoothly when A/T is shifted from
D4 to D3 ?
YES >> 1. Stop vehicle.
2. Go to AT-64, «Cruise Test — Part 2» .
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-318, «Engine Speed Does Not Return to
Idle (Light Braking D4 → D3 )» .
● Continue “Road Test”.

AT-63

M

SAT959I

TROUBLE DIAGNOSIS
Cruise Test — Part 2

BCS000O4

1. CHECK STARTING GEAR (D1 ) POSITION
1.
2.
3.

Push overdrive control switch. (OD OFF indicator lamp is off.)
Move selector lever to “D” position.
Accelerate vehicle by half throttle again.

Read gear position. Refer to AT-88, «DATA MONITOR
MODE» .
Does vehicle start from D1 ?
YES >> GO TO 2.
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-307, «Vehicle Cannot Be Started from D1» .
● Continue “Road Test”.
SAT495G

2. CHECK SHIFT-UP AND SHIFT-DOWN (D3
1.
2.

TO D4 TO D2 )

Accelerate vehicle to 80 km/h (50 MPH) as shown in the figure.
Release accelerator pedal and then quickly depress it fully.

Read gear position and throttle opening. Refer to AT-88,
«DATA MONITOR MODE» .
Does A/T shift from D4 to D2 as soon as accelerator pedal is
depressed fully?
YES >> GO TO 3.
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-309, «A/T Does Not Shift: D1 → D2 or
Does Not Kickdown: D4 → D2» .
● Continue “Road Test”.

3. CHECK SHIFT-UP (D2

SCIA7192E

TO D3 )

Check shift-up (D2 to D3 )
Specified speed when shifting from D2 to D3 . Refer to AT-67, «Vehicle Speed at Which Gear Shifting Occurs»
.
Read gear position, throttle opening and vehicle speed.
Refer to AT-88, «DATA MONITOR MODE» .
Does A/T shift from D2 to D3 at the specified speed?
YES >> GO TO 4.
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-311, «A/T Does Not Shift: D2 → D3» .
● Continue “Road Test”.
SAT960I

AT-64

TROUBLE DIAGNOSIS

4. CHECK SHIFT-UP (D3

TO D4 ) AND ENGINE BRAKE

Release accelerator pedal after shifting from D2 to D3 .
Read gear position, throttle opening and vehicle speed.
Refer to AT-88, «DATA MONITOR MODE» .
Does A/T shift from D3 to D4 and does vehicle decelerate by engine
brake?
YES >> 1. Stop vehicle.
2. Go to AT-65, «Cruise Test — Part 3» .
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-314, «A/T Does Not Shift: D3 → D4» .
● Continue “Road Test”.

Cruise Test — Part 3

A

B

AT

D
SAT405H

E
BCS000O5

1. CHECK SHIFT-DOWN (D4 TO D3 ) (WITH OVERDRIVE CONTROL SWITCH)
F

1.
2.
3.

Push overdrive control switch. (OD OFF indicator lamp is off.)
Move selector lever to “D” position.
Accelerate vehicle using half throttle to D4 .

G

H

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SAT812A

4.

J

Release accelerator pedal.
K

L

M
SAT813A

5.

Push overdrive control switch. (OD OFF indicator lamp is on.)

Read gear position and vehicle speed. Refer to AT-88,
«DATA MONITOR MODE» .
Does A/T shift from D4 to D3 (OD OFF)?
YES >> GO TO 2.
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-320, «A/T Does Not Shift: D4 → D3 , When
OD OFF» .
● Continue “Road Test”.

AT-65

SCIA5469E

TROUBLE DIAGNOSIS

2. CHECK ENGINE BRAKE
Check engine brake.
Does vehicle decelerate by engine brake?
YES >> GO TO 3.
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-325, «Vehicle Does Not Decelerate by
Engine Brake» .
● Continue “Road Test”.
SCIA5469E

3. CHECK SHIFT-DOWN (D3

TO 22 )

Move selector lever from “D” to “2” position while driving in D3 (OD
OFF).
Read gear position. Refer to AT-88, «DATA MONITOR MODE»
.
Does A/T shift from D3 (OD OFF) to 22 ?
YES >> GO TO 4.
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-321, «A/T Does Not Shift: D3 → 22 , When
Selector Lever “D” → “2” Position» .
● Continue “Road Test”.

SAT791GA

4. CHECK ENGINE BRAKE
Check engine brake.
Does vehicle decelerate by engine brake?
YES >> GO TO 5.
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-325, «Vehicle Does Not Decelerate by
Engine Brake» .
● Continue “Road Test”.
SAT791GA

5. CHECK SHIFT-DOWN (22

TO 11 )

Move selector lever from “2” to “1” position while driving in 22 .
Read gear position. Refer to AT-88, «DATA MONITOR MODE»
.
Does A/T shift from 22 to 11 position?
YES >> GO TO 6.
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-323, «A/T Does Not Shift: 22 → 11 , When
Selector Lever “2” → “1” Position» .
● Continue “Road Test”.

AT-66

SAT778B

TROUBLE DIAGNOSIS

6. CHECK ENGINE BRAKE

A

Check engine brake.
Does vehicle decelerate by engine brake?
YES >> 1. Stop vehicle.
2. Perform self-diagnosis. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» , AT-94, «Diagnostic Procedure Without CONSULT-II» .
NO
>> ● Mark the box on the AT-45, «DIAGNOSTIC WORKSHEET» .
● GO TO AT-325, «Vehicle Does Not Decelerate by
Engine Brake» .
● Stop “Road Test”.

B

AT

D
SAT778B

E

Vehicle Speed at Which Gear Shifting Occurs

BCS000O6

Vehicle speed [km/h (MPH)]
Throttle position

●

D1 → D2

D2 → D3

D3 → D4

D4 → D3

D3 → D2

D2 → D1

Full throttle

51 — 59
(32 — 37)

97 — 105
(60 — 65)

154 — 162
(96 — 101)

150 — 158
(93 — 98)

87 — 95
(54 — 59)

41 — 49
(25 — 30)

Half throttle

31 — 39
(19 — 24)

60 — 68
(37 — 42)

122 — 130
(76 — 81)

63 — 71
(39 — 44)

36 — 44
(22 — 27)

5 — 13
(3 —

At half throttle, the accelerator opening is 4/8 of the full opening.

2.0 / 8

BCS000O7

Vehicle speed [km/h (MPH)]

Selector lever position

G

H

Vehicle Speed at Which Lock-up Occurs/Releases
Throttle position

F

Lock-up “ON”

Lock-up “OFF”

D position

76 — 84 (47 — 52)

56 — 64 (35 — 40)

D position (OD OFF)

86 — 94 (53 — 58)

83 — 91 (52 — 57)

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AT-67

TROUBLE DIAGNOSIS
Symptom Chart

BCS000O8

Numbers are arranged in order of inspection.
Perform inspections starting with number one and work up.
Items
Symptom
Condition

Torque converter is
not locked up.

ON vehicle

OFF vehicle
No Lock-up Engagement/TCC Inoperative
Torque converter
clutch piston slip.

ON vehicle

OFF vehicle

Lock-up point is
extremely high or low.

ON vehicle

Diagnostic item

Reference page

1. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

2. Vehicle speed sensor·A/T (Revolution sensor)
and vehicle speed sensor·MTR

AT-115 and
AT-176 (*1),
AT-203 and
AT-209 (*2)

3. Engine speed signal

AT-121 (*1),
AT-241 (*2)

4. A/T fluid temperature sensor

AT-110 (*1),
AT-235 (*2)

5. Line pressure test

AT-56

6. Torque converter clutch solenoid valve

AT-142 (*1),
AT-230 (*2)

7. Control valve assembly

AT-345

8. Torque converter

AT-369

1. A/T fluid level

AT-18

2. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

3. Line pressure test

AT-56

4. Torque converter clutch solenoid valve

AT-142 (*1),
AT-230 (*2)

5. Line pressure solenoid valve

AT-153 (*1),
AT-251 (*2)

6. Control valve assembly

AT-345

7. Torque converter

AT-369

1. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

2. Vehicle speed sensor·A/T (Revolution sensor)
and vehicle speed sensor·MTR

AT-115 and
AT-176 (*1),
AT-203 and
AT-209 (*2)

3. Torque converter clutch solenoid valve

AT-142 (*1),
AT-230 (*2)

4. Control valve assembly

AT-345

AT-68

TROUBLE DIAGNOSIS
Items

Symptom

Sharp shock in shifting from “N” to “D”
position.

Condition

ON vehicle

OFF vehicle

Too sharp a shock in
changing from D1 to
D2 .

Diagnostic item
1. Engine idling speed

EC-69 (*1),
EC-486 (*2)

2. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

3. Line pressure test

AT-56

4. A/T fluid temperature sensor

AT-110 (*1),
AT-235 (*2)

5. Engine speed signal

AT-121 (*1),
AT-241 (*2)

6. Line pressure solenoid valve

AT-153 (*1),
AT-251 (*2)

7. Control valve assembly

AT-345

8. Accumulator N-D

AT-345

9. Forward clutch

AT-419

1. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

2. Line pressure test

AT-56

3. Accumulator servo release

AT-345

4. Control valve assembly

AT-345

5. A/T fluid temperature sensor

AT-110 (*1),
AT-235 (*2)

6. Brake band

AT-441

1. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

2. Line pressure test

AT-56

3. Control valve assembly

AT-345

4. High clutch

AT-413

5. Brake band

AT-441

1. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

2. Line pressure test

AT-56

3. Control valve assembly

AT-345

4. Brake band

AT-441

5. Overrun clutch

AT-419

6. Forward one-way clutch

AT-431

1. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

2. Line pressure test

AT-56

3. Overrun clutch solenoid valve

AT-171 (*1),
AT-225 (*2)

4. Control valve assembly

AT-345

ON vehicle

1. Control valve assembly

AT-345

OFF vehicle

2. Low & reverse brake

AT-426

ON vehicle

OFF vehicle
Shift Shock

Too sharp a shock in
changing from D2 to
D3 .

ON vehicle

OFF vehicle

ON vehicle
Too sharp a shock in
changing from D3 to
D4 .
OFF vehicle

Gear change shock
during deceleration
by releasing accelerator pedal.

Large shock in
changing from 12 to
11 in “1” position.

Reference page

ON vehicle

AT-69

A

B

AT

D

E

F

G

H

I

J

K

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M

TROUBLE DIAGNOSIS
Items

Symptom

Too high a gear
change point from D1
to D2 , from D2 to D3 ,
from D3 to D4 .

Gear change directly
from D1 to D3
occurs.

Too high a change
point from D4 to D3 ,
from D3 to D 2 , from
D2 to D1 .

Improper Shift Timing

Kickdown does not
operate when
depressing accelerator pedal in D4 within
kickdown vehicle
speed.

Kickdown operates or
engine overruns
when depressing
accelerator pedal in
D4 beyond kickdown
vehicle speed limit.

Gear change from 22
to 23 in “2” position.
Gear change from 11
to 12 in “1” position.

Condition

Diagnostic item
1. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

2. Vehicle speed sensor·A/T (Revolution sensor)
and vehicle speed sensor·MTR

AT-115 and
AT-176 (*1),
AT-203 and
AT-209 (*2)

3. Shift solenoid valve A

AT-159 (*1),
AT-215 (*2)

4. Shift solenoid valve B

AT-164 (*1),
AT-220 (*2)

1. A/T fluid level

AT-18

2. Accumulator servo release

AT-345

3. Brake band

AT-441

1. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

2. Vehicle speed sensor·A/T (Revolution sensor)
and vehicle speed sensor·MTR

AT-115 and
AT-176 (*1),
AT-203 and
AT-209 (*2)

1. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

2. Vehicle speed sensor·A/T (Revolution sensor)
and vehicle speed sensor·MTR

AT-115 and
AT-176 (*1),
AT-203 and
AT-209 (*2)

3. Shift solenoid valve A

AT-159 (*1),
AT-215 (*2)

4. Shift solenoid valve B

AT-164 (*1),
AT-220 (*2)

1. Vehicle speed sensor·A/T (Revolution sensor)
and vehicle speed sensor·MTR

AT-115 and
AT-176 (*1),
AT-203 and
AT-209 (*2)

2. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

3. Shift solenoid valve A

AT-159 (*1),
AT-215 (*2)

4. Shift solenoid valve B

AT-164 (*1),
AT-220 (*2)

1. PNP switch adjustment

AT-350

2. Control cable adjustment

AT-336

1. PNP switch adjustment

AT-350

2. Control cable adjustment

AT-336

ON vehicle

ON vehicle
OFF vehicle

ON vehicle

ON vehicle

ON vehicle

ON vehicle

ON vehicle

Reference page

AT-70

TROUBLE DIAGNOSIS
Items

Symptom

Condition

Diagnostic item
1. A/T fluid level

AT-18

2. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

3. Overrun clutch solenoid valve

AT-171 (*1),
AT-225 (*2)

4. Shift solenoid valve A

AT-159 (*1),
AT-215 (*2)

5. Line pressure solenoid valve

AT-153 (*1),
AT-251 (*2)

6. Control valve assembly

AT-345

7. Brake band

AT-441

8. Overrun clutch

AT-419

1. A/T fluid level

AT-18

2. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

3. Shift solenoid valve A

AT-159 (*1),
AT-215 (*2)

4. Shift solenoid valve B

AT-164 (*1),
AT-220 (*2)

5. Control valve assembly

AT-345

6. High clutch

AT-413

7. Brake band

AT-441

1. A/T fluid level

AT-18

2. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

3. Shift solenoid valve A

AT-159 (*1),
AT-215 (*2)

4. Shift solenoid valve B

AT-164 (*1),
AT-220 (*2)

5. Control valve assembly

AT-345

6. Low one-way clutch

AT-369

7. High clutch

AT-413

ON vehicle
Failure to change
gear from D4 to D3 .

OFF vehicle

Failure to change
gear from D3 to D2
or from D4 to D2 .

ON vehicle

No Down Shift
OFF vehicle

ON vehicle
Failure to change
gear from D2 to D1
or from D3 to D1 .

OFF vehicle

Failure to change
from D3 to 22 when
shifting selector lever
into “2” position.
AT-321

ON vehicle

OFF vehicle

Reference page

8. Brake band

AT-441

1. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

2. Shift solenoid valve B

AT-164 (*1),
AT-220 (*2)

3. Control valve assembly

AT-345

4. Control cable adjustment

AT-336

5. Brake band

AT-441

AT-71

A

B

AT

D

E

F

G

H

I

J

K

L

M

TROUBLE DIAGNOSIS
Items

No Down Shift

Symptom

Does not change
from 12 to 11 in 1st
position.

Condition

AT-350

2. Vehicle speed sensor·A/T (Revolution sensor)
and vehicle speed sensor·MTR

AT-115 and
AT-176 (*1),
AT-203 and
AT-209 (*2)

3. Shift solenoid valve A

AT-159 (*1),
AT-215 (*2)

4. Control valve assembly

AT-345

5. Overrun clutch solenoid valve

AT-171 (*1),
AT-225 (*2)

6. Overrun clutch

AT-419

7. Low & reverse brake

AT-426

1. Control cable adjustment

AT-336

2. Shift solenoid valve A

AT-159 (*1),
AT-215 (*2)

3. Control valve assembly

AT-345

4. Vehicle speed sensor·A/T (Revolution sensor)
and vehicle speed sensor·MTR

AT-115 and
AT-176 (*1),
AT-203 and
AT-209 (*2)

5. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

6. Brake band

AT-441

1. Control cable adjustment

AT-336

2. Shift solenoid valve B

AT-164 (*1),
AT-220 (*2)

3. Control valve assembly

AT-345

4. Vehicle speed sensor·A/T (Revolution sensor)
and vehicle speed sensor·MTR

AT-115 and
AT-176 (*1),
AT-203 and
AT-209 (*2)

5. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

6. High clutch

AT-413

7. Brake band

AT-441

1. PNP switch adjustment

AT-350

2. Overdrive control switch

AT-197 (*1),
AT-288 (*2)

3. Control cable adjustment

AT-336

4. Shift solenoid valve A

AT-159 (*1),
AT-215 (*2)

5. Vehicle speed sensor·A/T (Revolution sensor)
and vehicle speed sensor·MTR

AT-115 and
AT-176 (*1),
AT-203 and
AT-209 (*2)

6. A/T fluid temperature sensor

AT-110 (*1),
AT-235 (*2)

7. Brake band

AT-441

ON vehicle

OFF vehicle

ON vehicle
No Up Shift

Failure to change
gear from D2 to D3 .

OFF vehicle

Failure to change
gear from D3 to D4 .

ON vehicle

OFF vehicle

Reference page

1. PNP switch adjustment

ON vehicle

OFF vehicle

Failure to change
gear from D1 to D2 .

Diagnostic item

AT-72

TROUBLE DIAGNOSIS
Items

No Up Shift

Symptom

A/T does not shift to
D4 when driving with
OD ON. (OD OFF
indicator lamp is off.)

Condition

Slips/Will Not Engage

AT-169 (*1),
AT-213 (*2)

2. PNP switch adjustment

AT-350

3. Overdrive control switch

AT-197 (*1),
AT-288 (*2)

4. Vehicle speed sensor·A/T (Revolution sensor)
and vehicle speed sensor·MTR

AT-115 and
AT-176 (*1),
AT-203 and
AT-209 (*2)

5. Shift solenoid valve A

AT-159 (*1),
AT-215 (*2)

6. Overrun clutch solenoid valve

AT-171 (*1),
AT-225 (*2)

7. Control valve assembly

AT-345

8. A/T fluid temperature sensor

AT-110 (*1),
AT-235 (*2)

9. Line pressure solenoid valve

AT-153 (*1),
AT-251 (*2)

10. Brake band

AT-441

11. Overrun clutch

AT-419

1. Control cable adjustment

AT-336

2. Stall test

AT-53

3. Line pressure test

AT-56

4. Line pressure solenoid valve

AT-153 (*1),
AT-251 (*2)

5. Control valve assembly

AT-345

6. Reverse clutch

AT-408

7. High clutch

AT-413

8. Forward clutch

AT-419

9. Overrun clutch

AT-419

10. Low & reverse brake

AT-426

ON vehicle

1. Control cable adjustment

AT-336

OFF vehicle

2. Low one-way clutch

AT-369

ON vehicle

ON vehicle

OFF vehicle

Vehicle will not run in
“D” and “2” positions
(but runs in “1” and
“R” positions).

Reference page

1. Accelerator pedal position sensor

OFF vehicle

Vehicle will not run in
“R” position (but runs
in “D”, “2” and “1”
positions). Clutch
slips.
Very poor acceleration.

Diagnostic item

A

B

AT

D

E

F

G

H

I

J

K

L

M

AT-73

TROUBLE DIAGNOSIS
Items

Symptom

Condition

Diagnostic item
1. A/T fluid level

AT-18

2. Stall test

AT-53

3. Line pressure test

AT-56

4. Line pressure solenoid valve

AT-153 (*1),
AT-251 (*2)

5. Control valve assembly

AT-345

6. Accumulator N-D

AT-345

7. Reverse clutch

AT-408

8. High clutch

AT-413

9. Forward clutch

AT-419

10. Forward one-way clutch

AT-431

ON vehicle
Vehicle will not run in
“D”, “1”, “2” positions
(but runs in R position). Clutch slips.
Very poor acceleration.
OFF vehicle

ON vehicle

Slips/Will Not Engage

Clutches or brakes
slip somewhat in
starting.

OFF vehicle

ON vehicle
No creep at all.
AT-304, AT-306
OFF vehicle

Almost no shock or
clutches slipping in
change from D1 to D2
.

ON vehicle

OFF vehicle

Reference page

11. Low one-way clutch

AT-369

1. A/T fluid level

AT-18

2. Control cable adjustment

AT-336

3. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

4. Line pressure test

AT-56

5. Line pressure solenoid valve

AT-153 (*1),
AT-251 (*2)

6. Control valve assembly

AT-345

7. Accumulator N-D

AT-345

8. Forward clutch

AT-419

9. Reverse clutch

AT-408

10. Low & reverse brake

AT-426

11. Oil pump

AT-388

12. Torque converter

AT-369

1. A/T fluid level

AT-18

2. Line pressure test

AT-56

3. Control valve assembly

AT-345

4. Forward clutch

AT-419

5. Oil pump

AT-388

6. Torque converter

AT-369

1. A/T fluid level

AT-18

2. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

3. Line pressure test

AT-56

4. Accumulator servo release

AT-345

5. Control valve assembly

AT-345

6. Brake band

AT-441

AT-74

TROUBLE DIAGNOSIS
Items

Symptom

Almost no shock or
slipping in changing
from D2 to D3 .

Condition

ON vehicle

OFF vehicle

Almost no shock or
slipping in changing
from D3 to D4 .

Slips/Will Not Engage

ON vehicle

OFF vehicle

Races extremely fast
or slips in changing
from D4 to D2 when
depressing accelerator pedal.

ON vehicle

OFF vehicle

Reference page

1. A/T fluid level

AT-18

2. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

3. Line pressure test

AT-56

4. Control valve assembly

AT-345

5. High clutch

AT-413

6. Forward clutch

AT-419

1. A/T fluid level

AT-18

2. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

3. Line pressure test

AT-56

4. Control valve assembly

AT-345

5. Brake band

AT-441

1. A/T fluid level

AT-18

2. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

3. Line pressure test

AT-56

4. Line pressure solenoid valve

AT-153 (*1),
AT-251 (*2)

5. Shift solenoid valve A

AT-159 (*1),
AT-215 (*2)

6. Control valve assembly

AT-345

7. Brake band

AT-441

8. Forward clutch

AT-419

1. A/T fluid level

AT-18

2. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

3. Line pressure test

AT-56

4. Line pressure solenoid valve

AT-153 (*1),
AT-251 (*2)

5. Shift solenoid valve A

AT-159 (*1),
AT-215 (*2)

6. Shift solenoid valve B

AT-164 (*1),
AT-220 (*2)

7. Control valve assembly

AT-345

8. Brake band

AT-441

9. Forward clutch

AT-419

ON vehicle

OFF vehicle

Races extremely fast
or slips in changing
from D4 to D3 when
depressing accelerator pedal.

Diagnostic item

AT-75

A

B

AT

D

E

F

G

H

I

J

K

L

M

TROUBLE DIAGNOSIS
Items

Symptom

Races extremely fast
or slips in changing
from D3 to D2 when
depressing accelerator pedal.

Condition

ON vehicle

OFF vehicle

Slips/Will Not Engage

Races extremely fast
or slips in changing
from D4 or D3 to D 1
when depressing
accelerator pedal.

ON vehicle

OFF vehicle

ON vehicle

Vehicle will not run in
any position.

OFF vehicle

Others

Engine cannot be
started in “P” and “N”
positions.
AT-301

ON vehicle

Engine starts in positions other than “P”
and “N”.

ON vehicle

Diagnostic item

Reference page

1. A/T fluid level

AT-18

2. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

3. Line pressure test

AT-56

4. Line pressure solenoid valve

AT-153 (*1),
AT-251 (*2)

5. Shift solenoid valve B

AT-164 (*1),
AT-220 (*2)

6. Control valve assembly

AT-345

7. Brake band

AT-441

8. High clutch

AT-413

1. A/T fluid level

AT-18

2. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

3. Line pressure test

AT-56

4. Line pressure solenoid valve

AT-153 (*1),
AT-251 (*2)

5. Shift solenoid valve A

AT-159 (*1),
AT-215 (*2)

6. Shift solenoid valve B

AT-164 (*1),
AT-220 (*2)

7. Control valve assembly

AT-345

8. Forward clutch

AT-419

9. Forward one-way clutch

AT-431

10. Low one-way clutch

AT-369

1. A/T fluid level

AT-18

2. Control cable adjustment

AT-336

3. Line pressure test

AT-56

4. Line pressure solenoid valve

AT-153 (*1),
AT-251 (*2)

5. Oil pump

AT-388

6. High clutch

AT-413

7. Brake band

AT-441

8. Low & reverse brake

AT-426

9. Torque converter

AT-369

10. Parking components

AT-360

1. Ignition switch and starter

PG-4, SC-45

2. Control cable adjustment

AT-336

3. PNP switch adjustment

AT-350

1. Control cable adjustment

AT-336

2. PNP switch adjustment

AT-350

AT-76

TROUBLE DIAGNOSIS
Items

Symptom

Condition

Diagnostic item

OFF vehicle
Vehicle moves when
changing into “P”
position or parking
gear does not disengage when shifted out
of “P” position.
Vehicle runs in “N”
position.
AT-302

ON vehicle

AT-18

2. Line pressure test

AT-56

3. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

B

4. Vehicle speed sensor·A/T (Revolution sensor)
and vehicle speed sensor·MTR

AT-115 and
AT-176 (*1),
AT-203 and
AT-209 (*2)

AT

5. Oil pump

AT-388

6. Torque converter

AT-369

1. Control cable adjustment

AT-336

OFF vehicle

2. Parking components

AT-360

ON vehicle

1. Control cable adjustment

AT-336

2. Forward clutch

AT-419

3. Reverse clutch

AT-408

4. Overrun clutch

AT-419

1. A/T fluid level

AT-18

2. Control cable adjustment

AT-336

3. Line pressure test

AT-56

4. Line pressure solenoid valve

AT-153 (*1),
AT-251 (*2)

5. Control valve assembly

AT-345

6. High clutch

AT-413

7. Brake band

AT-441

8. Forward clutch

AT-419

9. Overrun clutch

AT-419

1. Engine idling speed

EC-69 (*1),
EC-486 (*2)

1. Engine idling speed

EC-69 (*1),
EC-486 (*2)

2. A/T fluid level

AT-18

3. Torque converter clutch solenoid valve

AT-142 (*1),
AT-230 (*2)

4. Control valve assembly

AT-345

OFF vehicle

5. Torque converter

AT-369

ON vehicle

1. A/T fluid level

AT-18

2. Reverse clutch

AT-408

3. Low & reverse brake

AT-426

4. High clutch

AT-413

5. Low one-way clutch

AT-369

ON vehicle

1. A/T fluid level

AT-18

OFF vehicle

2. Brake band

AT-441

F

OFF vehicle

Vehicle braked when
shifting into “R” position.

OFF vehicle

Excessive creep.

Engine stops when
shifting lever into “R”,
“D”, “2” and “1” positions.

Vehicle braked by
gear change from D1
to D2 .

Vehicle braked by
gear change from D2
to D3 .

D

E

ON vehicle
Others

A

1. A/T fluid level

ON vehicle
Transaxle noise in“ P”
and “N” positions.

Reference page

ON vehicle

ON vehicle

OFF vehicle

AT-77

G

H

I

J

K

L

M

TROUBLE DIAGNOSIS
Items

Symptom

Condition
ON vehicle

Vehicle braked by
gear change from D3
to D4 .

AT-18

2. Overrun clutch

AT-419

3. Forward one-way clutch

AT-431

4. Reverse clutch

AT-408

1. A/T fluid level

AT-18

2. PNP switch adjustment

AT-349

3. Overdrive control switch

AT-197 (*1),
AT-288 (*2)

4. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

5. Vehicle speed sensor·A/T (Revolution sensor)
and vehicle speed sensor·MTR

AT-115 and
AT-176 (*1),
AT-203 and
AT-209 (*2)

6. Shift solenoid valve A

AT-159 (*1),
AT-215 (*2)

7. Shift solenoid valve B

AT-164 (*1),
AT-220 (*2)

8. Control valve assembly

AT-345

9. Reverse clutch

AT-408

10. High clutch

AT-413

11. Brake band

AT-441

12. Low & reverse brake

AT-426

13. Oil pump

AT-388

14. Torque converter

AT-369

ON vehicle

1. A/T fluid level

AT-18

OFF vehicle

2. Torque converter

AT-369

1. PNP switch adjustment

AT-349

2. Control cable adjustment

AT-336

3. Vehicle speed sensor·A/T (Revolution sensor)
and vehicle speed sensor·MTR

AT-115 and
AT-176 (*1),
AT-203 and
AT-209 (*2)

4. Control valve assembly

AT-345

5. Overrun clutch solenoid valve

AT-171 (*1),
AT-225 (*2)

6. Overrun clutch

AT-419

7. Low & reverse brake

AT-426

OFF vehicle

Maximum speed not
attained. Poor acceleration.

Others

OFF vehicle

Engine brake does
not operate in “1”
position.

Reference page

1. A/T fluid level

ON vehicle

Transaxle noise in
“D”, “2”, “1” and “R”
positions.

Diagnostic item

ON vehicle

OFF vehicle

AT-78

TROUBLE DIAGNOSIS
Items

Symptom

Condition

Diagnostic item
1. A/T fluid level

AT-18

2. Engine idling speed

EC-69 (*1),
EC-486 (*2)

3. Accelerator pedal position sensor

AT-169 (*1),
AT-213 (*2)

4. Line pressure test

AT-56

5. Line pressure solenoid valve

AT-153 (*1),
AT-251 (*2)

6. Control valve assembly

AT-345

7. Oil pump

AT-388

8. Reverse clutch

AT-408

9. High clutch

AT-413

10. Brake band

AT-441

11. Forward clutch

AT-419

12. Overrun clutch

AT-419

13. Low & reverse brake

AT-426

14. Torque converter

AT-369

1. A/T fluid level

AT-18

2. Reverse clutch

AT-408

3. High clutch

AT-413

4. Brake band

AT-441

5. Forward clutch

AT-419

6. Overrun clutch

AT-419

7. Low & reverse brake

AT-426

1. A/T fluid level

AT-18

2. Torque converter

AT-369

3. Oil pump

AT-388

4. Reverse clutch

AT-408

5. High clutch

AT-413

6. Brake band

AT-441

7. Forward clutch

AT-419

8. Overrun clutch

AT-419

9. Low & reverse brake

AT-426

ON vehicle

Transaxle overheats.

OFF vehicle

Others
ON vehicle
ATF shoots out during
operation.
White smoke emitted
from exhaust pipe
during operation.

OFF vehicle

ON vehicle

Unusual smell at A/T
fluid charging pipe.

OFF vehicle

Reference page

*1: For EURO-OBD models
*2: Except for EURO-OBD models

AT-79

A

B

AT

D

E

F

G

H

I

J

K

L

M

TROUBLE DIAGNOSIS
TCM Terminals and Reference Value

BCS000O9

TCM CONNECTOR TERMINAL LAYOUT

SCIA0495E

TCM INSPECTION TABLE
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

Item

Condition
When releasing accelerator pedal
after warming up engine.

1

2

3

P

V

O

Line pressure solenoid
valve

When depressing accelerator
pedal fully after warming up
engine.
When releasing accelerator pedal
after warming up engine.

Line pressure solenoid
valve (with dropping
resistor)

Torque converter clutch
solenoid valve

Judgement standard (Approx.)
1.5 — 3.0V

0V

4 — 14V

When depressing accelerator
pedal fully after warming up
engine.

0V

When A/T performs lock-up.

8 — 15V

When A/T does not perform lockup.

0V

5

L

CAN H

—

—

6

Y

CAN L

—

—

10

R

11

12

19

R

SB

R

Power supply

When turning ignition switch to “ON”.

Battery voltage

When turning ignition switch to “OFF”.

0V

Shift solenoid valve A

Shift solenoid valve B

Power supply

When shift solenoid valve A operates.
(When driving in “D1 ” or “D4 ”.)

Battery voltage

When shift solenoid valve A does
not operate.
(When driving in “D2 ” or “D3 ”.)

0V

When shift solenoid valve B operates.
(When driving in “D1 ” or “D2 ”.)

Battery voltage

When shift solenoid valve B does
not operate.
(When driving in “D3 ” or “D4 ”.)

0V

When turning ignition switch to “ON”.

Battery voltage

When turning ignition switch to “OFF”.

0V

AT-80

TROUBLE DIAGNOSIS
Terminal

20

25

26

Wire color

LG

B

Y

Item

Condition

Overrun clutch solenoid
valve

Ground

When overrun clutch solenoid
valve operates. (When overrun
clutch disengaged. Refer to AT-22
.)

Battery voltage

When overrun clutch solenoid
valve does not operate. (When
overrun clutch engaged. Refer to
AT-22 .)

0V

Always

0V

When setting selector lever to “1”
position.

PNP switch “1” position

When setting selector lever to
other positions.
and
27

L

PNP switch “2” position

Judgement standard (Approx.)

When setting selector lever to “2”
position.
When setting selector lever to
other positions.

28

LG

Power supply
(memory back-up)

Always

29

V

Revolution sensor

When driving at 20 km/h (12 MPH)

A

B

AT

D
Battery voltage
0V

E

Battery voltage

F
0V
Battery voltage

G

150 Hz

H
30*1

L

CONSULT- II (RX)

—

—

31*1

BR

CONSULT- II (TX)

—

—

When setting selector lever to “D”
position.
34

35

LG

L

PNP switch “D” position

When setting selector lever to
other positions.
When setting selector lever to “R”
position.

PNP switch “R” position
and

36

R

38

LG

39*2

L

When setting selector lever to
other positions.
When setting selector lever to “N”
or “P” position.

PNP switch “N” or “P”
position

When setting selector lever to
other positions.

Turbine revolution sensor (power train revolution sensor)

When driving at 20 km/h (12 MPH)

Engine speed signal

Refer to EC-95 *3 or EC-512 *4 .

Battery voltage
0V
Battery voltage

40

R

Vehicle speed sensor

42

B

Sensor ground

Always

47

48

BR

B

A/T fluid temperature
sensor

and

Ground

Battery voltage

*1 : These terminals are connected to the data link connector.

AT-81

K

L

0V

M
360 Hz

Voltage varies
between less
than 0V and
more than 4.5V
0V

When A/T fluid temperature is
20°C (68°F).

1.5V

When A/T fluid temperature is
80°C (176°F).

0.5V

Always

J

0V

and
When driving vehicle at 2 to 3 km/h
(1 to 2 MPH) for 1 m (3 ft) or more.

I

0V

TROUBLE DIAGNOSIS
*2 : This terminal is connected to the ECM.
*3 : For EURO-OBD models
*4 : Except for EURO-OBD models

AT-82

TROUBLE DIAGNOSIS
CONSULT-II Function (A/T)

BCS000OA

A

CONSULT-II can display each diagnostic item using the diagnostic test models shown following.

FUNCTION
Diagnostic test mode

Function

Reference page

Work support

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

—

Self-diagnostic results

Self-diagnostic results can be read and erased quickly.

AT-85

Data monitor

Input/Output data in the TCM can be read.

AT-88

CAN diagnostic support
monitor

The results of transmit/receive diagnosis of CAN communication can be read.

AT-90

Function test

Performed by CONSULT-II instead of a technician to determine whether each system
is “OK” or “NG”.

DTC work support

Select the operating condition to confirm Diagnostic Trouble Codes.

TCM part number

TCM part number can be read.

AT-90

Condition

Released accelerator pedal.

0.0/8

Fully depressed accelerator pedal.

8.0/8

When A/T fluid temperature is 20°C (68°F).

1.5V

When A/T fluid temperature is 80°C (176°F).

0.5V

BATTERY VOLT

When turning ignition switch to “ON”.

Battery voltage

ENGINE SPEED

Engine running

Approximately matches the tachometer
reading.

TURBINE REV

During driving (lock-up ON)

Approximately matches the engine speed.

When overdrive control switch is depressed.

ON

When overdrive control switch is released.

OFF

When setting selector lever to “N” or “P” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “R” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “D” position.

ON

When setting selector lever to other positions.

OFF

PN POSI SW

R POSITION SW

D POSITION SW

H

I

J

K
During driving

OVERDRIVE SW

G

Display value (Approx.)
Approximately matches the speedometer
reading.

FLUID TEMP SE

E

F

VHCL/S SE-A/T

THROTTLE POSI

D

—

NOTICE:
1. The CONSULT-II electrically displays shift timing and lock-up timing (that is, operation timing of each solenoid).
Check for time difference between actual shift timing and the CONSULT-II display. If the difference is
noticeable, mechanical parts (except solenoids, sensors, etc.) may be malfunctioning. Check mechanical
parts using applicable diagnostic procedures.
2. Shift schedule (which implies gear position) displayed on CONSULT-II and that indicated in Service Manual may differ slightly. This occurs because of the following reasons:
–
Actual shift schedule has more or less tolerance or allowance,
–
Shift schedule indicated in Service Manual refers to the point where shifts start, and
–
Gear position displayed on CONSULT-II indicates the point where shifts are completed.
3. Shift solenoid valve “A” or “B” is displayed on CONSULT-II at the start of shifting. Gear position is displayed upon completion of shifting (which is computed by TCM).

VHCL/S SE-MTR

AT

—

CONSULT-II REFERENCE VALUE

Item name

B

AT-83

L

M

TROUBLE DIAGNOSIS
Item name
2 POSITION SW

1 POSITION SW

CLOSED THL/SW

Condition

Display value (Approx.)

When setting selector lever to “2” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “1” position.

ON

When setting selector lever to other positions.

OFF

Released accelerator pedal.

ON

Depressed accelerator pedal.

OFF

Fully depressed accelerator pedal.

ON

Released accelerator pedal.

OFF

When shift solenoid valve A operates.
(When driving in “D1 ” or “D4 ”.)

ON

When shift solenoid valve A does not operate.
(When driving in “D2 ” or “D3 ”.)

OFF

When shift solenoid valve B operates.
(When driving in “D1 ” or “D2 ”.)

ON

When shift solenoid valve B does not operate.
(When driving in “D3 ” or “D4 ”.)

OFF

When overrun clutch solenoid valve operates.
(When overrun clutch disengaged. Refer to AT22 .)

ON

When overrun clutch solenoid valve does not
operate. (When overrun clutch engaged. Refer
to AT-22 .)

OFF

Depressed brake pedal.

ON

Released brake pedal.

OFF

During driving

1, 2, 3, 4

When setting selector lever to “N” or “P” positions.

N·P

When setting selector lever to “R” position.

R

When setting selector lever to “D” position.

D

When setting selector lever to “2” position.

2

When setting selector lever to “1” position.

1

VEHICLE SPEED

During driving

Approximately matches the speedometer
reading.

LINE PRES DTY

Line pressure low ⇔ Line pressure high

0% ⇔ 94%

TCC S/V DUTY

Lock-up OFF ⇔ Lock-up ON

4% ⇔ 94%

W/O THRL/P-SW

SHIFT S/V A

SHIFT S/V B

OVERRUN/C S/V

BRAKE SW
GEAR

SLCT LVR POSI

AT-84

TROUBLE DIAGNOSIS
CONSULT-II START PROCEDURE
A

Refer to GI-36, «CONSULT-II Start Procedure» .

SELF-DIAGNOSTIC RESULT MODE
After performing AT-94, «Diagnostic Procedure Without CONSULT-II» , place check marks for results on the
AT-45, «DIAGNOSTIC WORKSHEET» . Reference pages are provided following the items.

B

Operation Procedure
1.
2.

Perform «CONSULT-II start procedure». Refer to GI-36, «CONSULT-II Start Procedure»GI-36 .
Touch “SELF-DIAG RESULTS”.
Display shows malfunction experienced since the last erasing
operation.

AT

D

E

BCIA0031E

F

Display Items List (For EURO-OBD models)
OBD (DTC)
Items (CONSULT-II
screen terms)

CAN COMM CIRCUIT

Malfunction is detected when…

MIL indicator
lamp*1,
“ENGINE” with
CONSULT-II or
GST

G
Reference
page

H

●

When malfunction is detected in CAN communication line.

U1000

AT-102

●

TCM does not receive the correct voltage signal (based on the gear
position) from the switch.

P0705

AT-105

ATF TEMP SEN/CIRC

●

TCM receives an excessively low or high voltage from the sensor.

P0710

AT-110

VHCL SPEED SEN-A/T

●

TCM does not receive the proper voltage signal from the sensor.

P0720

AT-115

ENGINE SPEED SIG

●

TCM does not receive the proper voltage signal from the ECM.

P0725

AT-121

●

A/T cannot be shifted to the 1st gear position even if electrical circuit
is good.

P0731*2

AT-125

●

A/T cannot be shifted to the 2nd gear position even if electrical circuit
is good.

P0732*2

AT-129

●

A/T cannot be shifted to the 3rd gear position even if electrical circuit
is good.

P0733*2

AT-132

●

A/T cannot be shifted to the 4th gear position even if electrical circuit
is good.

P0734*2

AT-136

●

TCM detects an improper voltage drop when it tries to operate the
solenoid valve.

P0740

AT-142

●

A/T cannot perform lock-up even if electrical circuit is good.

P0744*2

AT-147

●

TCM detects an improper voltage drop when it tries to operate the
solenoid valve.

P0745

AT-153

●

TCM detects an improper voltage drop when it tries to operate the
solenoid valve.

P0750

AT-159

●

TCM detects an improper voltage drop when it tries to operate the
solenoid valve.

P0755

AT-164

THROTTLE POSI SEN

●

TCM receives an excessively low or high voltage from this sensor.

P1705

AT-169

OVERRUN CLUTCH S/
V

●

TCM detects an improper voltage drop when it tries to operate the
solenoid valve.

P1760

AT-171

●

TCM does not receive the proper voltage signal from the sensor.

—

AT-176

PNP SW/CIRC

A/T 1ST GR FNCTN
A/T 2ND GR FNCTN
A/T 3RD GR FNCTN
A/T 4TH GR FNCTN
T/C CLUTCH SOL/V
A/T TCC S/V FNCTN
LINE PRESSURE S/V
SHIFT SOLENOID/V A
SHIFT SOLENOID/V B

VHCL SPEED SENMTR

AT-85

I

J

K

L

M

TROUBLE DIAGNOSIS
OBD (DTC)
Items (CONSULT-II
screen terms)

Malfunction is detected when…

MIL indicator
lamp*1,
“ENGINE” with
CONSULT-II or
GST

Reference
page

BATT/FLUID TEMP
SEN

●

TCM receives an excessively low or high voltage from the sensor.

—

AT-180

TURBINE SENSOR

●

TCM does not receive proper voltage signal from sensor.

—

AT-186

CONTROL UNIT (RAM)

●

TCM memory (RAM) is malfunctioning.

—

AT-192

CONTROL UNIT (ROM)

●

TCM memory (ROM) is malfunctioning.

—

AT-192

●

This is not a malfunction message (Whenever shutting off a power
supply to the TCM, this message appears on the screen). Refer to
AT-193, «MAIN POWER SUPPLY AND GROUND CIRCUIT» .

—

AT-193

No failure has been detected.

—

—

INITIAL START
No failure
(NO SELF DIAGNOSTIC FAILURE INDICATED FURTHER
TESTING MAY BE
REQUIRED)

●

*1: Refer to AT-101, «Malfunction Indicator Lamp (MIL)» .
*2: These malfunctions cannot be displayed MIL if another malfunction is assigned to MIL.

Display Items List (Except for EURO-OBD models)
Items (CONSULT-II screen terms)

Malfunction is detected when…

Reference page

VHCL SPEED SEN-A/T

●

TCM does not receive the proper voltage signal from the sensor.

AT-203

VHCL SPEED SEN-MTR

●

TCM does not receive the proper voltage signal from the sensor.

AT-209

THROTTLE POSI SEN

●

TCM receives an excessively low or high voltage from this sensor.

AT-213

●

TCM detects an improper voltage drop when it tries to operate the solenoid valve.

AT-215

●

TCM detects an improper voltage drop when it tries to operate the solenoid valve.

AT-220

●

TCM detects an improper voltage drop when it tries to operate the solenoid valve.

AT-225

●

TCM detects an improper voltage drop when it tries to operate the solenoid valve.

AT-230

BATT/FLUID TEMP SEN

●

TCM receives an excessively low or high voltage from the sensor.

AT-235

ENGINE SPEED SIG

●

TCM does not receive the proper voltage signal from the ECM.

AT-241

TURBINE SENSOR

●

TCM does not receive proper voltage signal from sensor.

AT-245

●

TCM detects an improper voltage drop when it tries to operate the solenoid valve.

AT-251

●

When malfunction is detected in CAN communication line.

AT-257

●

A/T cannot be shifted to the 1st gear position even if electrical circuit is
good.

AT-264

●

A/T cannot be shifted to the 2nd gear position even if electrical circuit is
good.

AT-268

●

A/T cannot be shifted to the 3rd gear position even if electrical circuit is
good.

AT-271

●

A/T cannot be shifted to the 4th gear position even if electrical circuit is
good.

AT-275

A/T TCC S/V FNCTN

●

A/T cannot perform lock-up even if electrical circuit is good.

AT-281

CONTROL UNIT (RAM)

●

TCM memory (RAM) is malfunctioning.

AT-287

CONTROL UNIT (ROM)

●

TCM memory (ROM) is malfunctioning.

AT-287

SHIFT SOLENOID/V A
SHIFT SOLENOID/V B
OVERRUN CLUTCH S/V
T/C CLUTCH SOL/V

LINE PRESSURE S/V
CAN COMM CIRCUIT
A/T 1ST GR FNCTN
A/T 2ND GR FNCTN
A/T 3RD GR FNCTN
A/T 4TH GR FNCTN

AT-86

TROUBLE DIAGNOSIS
Items (CONSULT-II screen terms)

Malfunction is detected when…
●

INITIAL START
No failure
(NO SELF DIAGNOSTIC FAILURE
INDICATED FURTHER TESTING
MAY BE REQUIRED)

This is not a malfunction message (Whenever shutting off a power supply to the TCM, this message appears on the screen). Refer to AT-260,
«MAIN POWER SUPPLY AND GROUND CIRCUIT» .

Reference page

A
AT-260

B
●

No failure has been detected.

—

AT

How to Erase Self-diagnostic Results
1.
2.

Perform «CONSULT-II start procedure». Refer to GI-36, «CONSULT-II Start Procedure» .
Touch “SELF-DIAG RESULTS”.

D

E

F

BCIA0031E

3.

G

Touch “ERASE”. (The self-diagnostic results will be erased.)
H

I

J
SCIA4849E

K

L

M

AT-87

TROUBLE DIAGNOSIS
DATA MONITOR MODE
Operation Procedure
1.
2.

Perform «CONSULT-II start procedure». Refer to GI-36, «CONSULT-II Start Procedure» .
Touch “DATA MONITOR”.
NOTE:
When malfunction is detected, CONSULT-II performs
“REAL-TIME DIAGNOSIS”. Also, any malfunction detected
while in this mode will be displayed in real time.

BCIA0031E

Display Items List
X: Standard, —: Not applicable,

: Option

Monitor Item Selection
Monitored item (Unit)

VHCL/S SE-A/T (km/h)

SELECTION FROM
MENU

Remarks

TCM INPUT
SIGNALS

MAIN SIGNALS

X

—

Revolution sensor
Vehicle speed display may not be accurate under approx. 10 km/h (6 mph). It
may not indicate 0 km/h (0 mph) when
vehicle is stationary.

VHCL/S SE-MTR (km/h)

X

—

THRTL POS SEN (V)

X

—

FLUID TEMP SE (V)

X

—

BATTERY VOLT (V)

X

—

ENGINE SPEED (rpm)

X

X

TURBINE REV (rpm)

X

—

OVERDRIVE SW (ON/OFF)

X

—

PN POSI SW (ON/OFF)

X

—

R POSITION SW (ON/OFF)

X

—

D POSITION SW (ON/OFF)

X

—

2 POSITION SW (ON/OFF)

X

—

1 POSITION SW (ON/OFF)

X

—

ASCD-CRUISE (ON/OFF)

X

—

ASCD-OD CUT (ON/OFF)

X

—

KICKDOWN SW (ON/OFF)

X

—

POWERSHIFT SW (ON/OFF)

X

—

CLOSED THL/SW (ON/OFF)

X

—

W/O THRL/P-SW (ON/OFF)

X

—

*SHIFT S/V A (ON/OFF)

—

—

*SHIFT S/V B (ON/OFF)

—

—

*OVRRUN/C S/V (ON/OFF)

—

—

Signal input with CAN communication.

Not mounted but displayed.

Signal input with CAN communication.

AT-88

Displays status of check signal (reinput
signal) for TCM control signal output.
Remains unchanged when solenoid
valves are open or shorted.

TROUBLE DIAGNOSIS
Monitor Item Selection
Monitored item (Unit)

SELECTION FROM
MENU

A
Remarks

TCM INPUT
SIGNALS

MAIN SIGNALS

HOLD SW (ON/OFF)

X

—

Not mounted but displayed.

BRAKE SW (ON/OFF)

X

—

Stop lamp switch

GEAR

—

X

Gear position recognized by the TCM
updated after gear-shifting

SLCT LVR POSI

—

X

Selector lever position is recognized by
the TCM.
For fail-safe operation, the specific value
used for control is displayed.

VEHICLE SPEED (km/h)

—

X

Vehicle speed recognized by the TCM.

X

Degree of opening for accelerator recognized by the TCM
For fail-safe operation, the specific value
used for control is displayed.

THROTTLE POSI (0.0/8)

—

LINE PRES DTY (%)

—

X

TCC S/V DUTY (%)

—

X

SHIFT S/V A (ON/OFF)

—

X

SHIFT S/V B (ON/OFF)

—

X

OVERRUN/C S/V (ON/OFF)

—

X

SELF-D DP LMP (ON/OFF)

—

X

TC SLIP RATIO (0.000)

—

—

TC SLIP SPEED (rpm)

—

—

Difference between engine speed and
torque converter input shaft speed

Voltage (V)

—

—

Displays the value measured by the voltage probe.

Frequency (Hz)

—

—

DUTY-HI (high) (%)

—

—

DUTY-LOW (low) (%)

—

—

PLS WIDTH-HI (ms)

—

—

PLS WIDTH-LOW (ms)

—

—

AT-89

B

AT

D

E

F

G

H

I

J

K
The value measured by the pulse probe
is displayed.

L

M

TROUBLE DIAGNOSIS
CAN DIAGNOSTIC SUPPORT MONITOR MODE
Operation Procedure
1.
2.

Perform «CONSULT-II start procedure». Refer to GI-36, «CONSULT-II Start Procedure» .
Touch “CAN DAIG SUPPORT MNTR”.

BCIA0031E

DTC WORK SUPPORT MODE WITH CONSULT-II
Operation Procedure
1.
2.

Perform «CONSULT-II start procedure». Refer to GI-36, «CONSULT-II Start Procedure» .
Touch “DTC WORK SUPPORT”.

BCIA0031E

3.

Touch select item menu (1ST, 2ND, etc.).

SAT018K

4.

Touch “START”.

SAT589J

AT-90

TROUBLE DIAGNOSIS
5.

Perform driving test according to “DTC CONFIRMATION PROCEDURE” in “TROUBLE DIAGNOSIS FOR DTC”.

A

B

AT
SAT019K

D
●

When testing conditions are satisfied, CONSULT-II screen
changes from “OUT OF CONDITION” to “TESTING”.
E

F

G
SAT591J

6.

Stop vehicle.

H

I

J

SAT592J

●

If “NG” appears on the screen, malfunction may exist. Go
to “Diagnostic Procedure”.

K

L

M

SAT593J

AT-91

TROUBLE DIAGNOSIS
7.

Perform test drive to check gear shift feeling in accordance with
the instructions displayed.

SAT594J

8.

Touch “YES” or “NO”.

SAT595J

9.

CONSULT-II procedure ended.

SAT596J

●

If “NG” appears on the screen, malfunction may exist. Go
to “Diagnostic Procedure”.

SAT593J

AT-92

TROUBLE DIAGNOSIS
Display Items List
DTC work support item

Description
Following items for “A/T 1st gear function (P0731)” can be confirmed.

1ST GR FNCTN P0731

●

●

Self-diagnosis status (whether the diagnosis is being performed
or not)
Self-diagnostic results (OK or NG)

Following items for “A/T 2nd gear function (P0732)” can be confirmed.
2ND GR FNCTN P0732

Shift solenoid valve B

●

Each clutch

●

Hydraulic control circuit

B

AT
Shift solenoid valve B
Each clutch

●

Hydraulic control circuit

D

●

Shift solenoid valve A

E

●

Each clutch

●

Hydraulic control circuit

●

Shift solenoid valve A

●

Shift solenoid valve B

●

Overrun clutch solenoid valve

●

Line pressure solenoid valve

●

Each clutch

●

Hydraulic control circuit

Following items for “A/T TCC S/V function (lock-up) (P0744)” can
be confirmed.

●

Torque converter clutch solenoid valve

Self-diagnosis status (whether the diagnosis is being performed
or not)

●

Each clutch

●

Hydraulic control circuit

●

Self-diagnostic results (OK or NG)

●

Self-diagnosis status (whether the diagnosis is being performed
or not)

●

Self-diagnostic results (OK or NG)

●

●

TCC S/V FNCTN P0744

Shift solenoid valve A

●

●

Self-diagnosis status (whether the diagnosis is being performed
or not)

Following items for “A/T 4th gear function (P0734)” can be confirmed.
4TH GR FNCTN P0734

●

A

●

●

Following items for “A/T 3rd gear function (P0733)” can be confirmed.
3RD GR FNCTN P0733

Check item

●

●

Self-diagnosis status (whether the diagnosis is being performed
or not)
Self-diagnostic results (OK or NG)

Self-diagnostic results (OK or NG)

F

G

H

I

J

K

L

M

AT-93

TROUBLE DIAGNOSIS
Diagnostic Procedure Without CONSULT-II

BCS000OB

TCM SELF-DIAGNOSTIC PROCEDURE
Description
If a malfunction occurs in electrical system, turning ignition switch ON will illuminate OD OFF indicator lamp for
2 seconds. To detect a malfunction, entering a self-diagnosis start signal retrieves information on malfunctions
from memory and indicates malfunction by blinking OD OFF indicator lamp.

Diagnostic Procedure

1. CHECK OD OFF INDICATOR LAMP
1.
2.
3.

Park vehicle on flat surface.
Move selector lever to “P” position.
Turn ignition switch OFF. Wait at least 5 seconds.

SCIA5472E

4. Turn ignition switch ON. (Do not start engine.)
Does OD OFF indicator lamp (1) come on about 2 seconds?
YES >> GO TO 2.
NO
>> Stop procedure. Perform AT-299, «OD OFF Indicator
Lamp Does Not Come On» before proceeding.

MCIB0175E

2. JUDGEMENT PROCEDURE STEP 1
1.
2.
3.
4.
5.

Turn ignition switch OFF.
Keep pressing shift lock release button.
Move selector lever from “P” to “D” position.
Turn ignition switch ON. (Do not start engine.)
Keep pressing overdrive control switch while OD OFF indicator lamp is lighting up for 2 seconds. (OD
OFF indicator lamp is on.)
6. Keep pressing overdrive control switch and shift selector lever to the “2” position. (OD OFF indicator lamp
is on.)
7. Stop pressing overdrive control switch. (OD OFF indicator lamp is on.)
8. Shift selector lever to the “1” position. (OD OFF indicator lamp is on.)
9. Keep pressing overdrive control switch. (OD OFF indicator lamp is off.)
10. Depress accelerator pedal fully while pressing overdrive control switch.
>> GO TO 3.

AT-94

TROUBLE DIAGNOSIS

3. CHECK SELF-DIAGNOSIS CODE

A

Check OD OFF indicator lamp. Refer to AT-95, «Judgement of Self-diagnosis Code» .
B

>> DIAGNOSIS END

Judgement of Self-diagnosis Code
OD OFF indicator lamp
All judgement flickers are the same.

AT

1st judgement flicker is longer than others.

D

E

F
SCIA7161E

SCIA5591E

All circuits that can be confirmed by self-diagnosis are OK.

Revolution sensor circuit is short-circuited or disconnected.
Þ Go to AT-115, «DTC P0720 VEHICLE SPEED SENSOR·A/T
(REVOLUTION SENSOR)» (*1), AT-203, «VEHICLE SPEED
SENSOR·A/T (REVOLUTION SENSOR)» (*2).

2nd judgement flicker is longer than others.

3rd judgement flicker is longer than others.

G

H

I

J

K
SCIA5592E

SCIA5593E

Vehicle speed sensor circuit is short-circuited or disconnected.
Þ Go to AT-176, «DTC VEHICLE SPEED SENSOR MTR» (*1),
AT-209, «VEHICLE SPEED SENSOR MTR» (*2).

Accelerator pedal position (APP) sensor circuit is short-circuited
or disconnected.
Þ Go to AT-169, «DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR» (*1), AT-213, «ACCELERATOR PEDAL
POSITION (APP) SENSOR» (*2).

4th judgement flicker is longer than others.

5th judgement flicker is longer than others.

SCIA5594E

M

SCIA5595E

Shift solenoid valve A circuit is short-circuited or disconnected.
Þ Go to AT-159, «DTC P0750 SHIFT SOLENOID VALVE A»
(*1), AT-215, «SHIFT SOLENOID VALVE A» (*2).

Shift solenoid valve B circuit is short-circuited or disconnected.
Þ Go to AT-164, «DTC P0755 SHIFT SOLENOID VALVE B»
(*1), AT-220, «SHIFT SOLENOID VALVE B» (*2).

AT-95

L

TROUBLE DIAGNOSIS
OD OFF indicator lamp
6th judgement flicker is longer than others.

7th judgement flicker is longer than others.

SCIA5596E

SCIA5597E

Overrun clutch solenoid valve circuit is short-circuited or disconnected.
Þ Go to AT-171, «DTC P1760 OVERRUN CLUTCH SOLENOID
VALVE» (*1), AT-225, «OVERRUN CLUTCH SOLENOID
VALVE» (*2).

Torque converter clutch solenoid valve circuit is short-circuited or
disconnected.
Þ Go to AT-142, «DTC P0740 TORQUE CONVERTER CLUTCH
SOLENOID VALVE» (*1), AT-230, «TORQUE CONVERTER
CLUTCH SOLENOID VALVE» (*2).

8th judgement flicker is longer than others.

9th judgement flicker is longer than others.

SCIA5598E

SCIA5599E

A/T fluid temperature sensor is disconnected or TCM power supply circuit is damaged.
Þ Go to AT-180, «DTC BATT/FLUID TEMP SEN (A/T FLUID
TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)» (*1),
AT-235, «BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR
CIRCUIT AND TCM POWER SOURCE)» (*2).

Engine speed signal circuit is short-circuited or disconnected.
Þ Go to AT-121, «DTC P0725 ENGINE SPEED SIGNAL» (*1),
AT-241, «ENGINE SPEED SIGNAL» (*2).

10th judgement flicker is longer than others.

11th judgement flicker is longer than others.

SCIA7082E

SCIA7083E

Turbine revolution sensor (power train revolution sensor) circuit is
short-circuited or disconnected.
Þ Go to AT-186, «DTC TURBINE REVOLUTION SENSOR»
(*1), AT-245, «TURBINE REVOLUTION SENSOR» (*2).

Line pressure solenoid valve circuit is short-circuited or disconnected.
Þ Go to AT-153, «DTC P0745 LINE PRESSURE SOLENOID
VALVE» (*1), AT-251, «LINE PRESSURE SOLENOID VALVE»
(*2).

AT-96

TROUBLE DIAGNOSIS
OD OFF indicator lamp
12th judgement flicker is longer than others.

A

Lamp turns off.

B

AT

D
SCIA7085E

SCIA4674E

CAN communication line is damaged.
Þ Go to AT-102, «DTC U1000 CAN COMMUNICATION LINE»
(*1), AT-257, «CAN COMMUNICATION LINE» (*2).

Park/neutral position (PNP) switch, overdrive control switch,
closed throttle position signal or wide open throttle position signal
circuit is disconnected or TCM is damaged.
(Because overdrive control switch signal, closed throttle position
signal and wide open throttle position signal are input via CAN
communication line malfunction may continue after self-diagnosis.)
Þ Go to AT-329, «TCM Self-diagnosis Does Not Activate» .

Flickers as shown below.

E

F

G

H

I

J
SCIA4675E

Battery power is low.
Battery has been disconnected for a long time.
Battery is connected reversely.
(When reconnecting TCM connectors.—This is not a malfunction.)
Þ Go to AT-193, «MAIN POWER SUPPLY AND GROUND CIRCUIT» (*1), AT-260, «MAIN POWER SUPPLY AND GROUND
CIRCUIT» (*2).
t1 = 2.5 seconds t2 = 2.0 seconds
*1: For EURO-OBD models
*2: Except for EURO-OBD models

t3 = 1.0 second

2.
3.

L

t4 = 1.0 second

M

How to Erase Self-diagnostic Results
1.

K

If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait for at least
5 seconds and then turn it ON again.
Perform AT-94, «Diagnostic Procedure Without CONSULT-II» .
Turn ignition switch OFF. (The self-diagnostic results will be erased.)

AT-97

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[EURO-OBD]

ON BOARD DIAGNOSTIC (OBD) SYSTEM
Introduction
[EURO-OBD]

PFP:00028
BCS000OC

A/T system has two self-diagnostic systems.
The first is emission-related on board diagnostic system (OBD) performed by the TCM in combination with the
ECM. The malfunction is indicated by the MIL (malfunction indicator lamp) and is stored as a DTC in the ECM
memory but not the TCM memory.
The second is the TCM original self-diagnosis indicated by the OD OFF indicator lamp. The malfunction is
stored in the TCM memory. The detected items are overlapped with OBD self-diagnostic items. For detail,
refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» .

OBD Function for A/T System

BCS000OD

The ECM provides emission-related on board diagnostic (OBD) functions for the A/T system. One function is
to receive a signal from the TCM used with OBD-related parts of the A/T system. The signal is sent to the ECM
when a malfunction occurs in the corresponding OBD-related part. The other function is to indicate a diagnostic result by means of the MIL (malfunction indicator lamp) on the instrument panel. Sensors, switches and
solenoid valves are used as sensing elements.
The MIL automatically illuminates in One or Two Trip Detection Logic when a malfunction is sensed in relation
to A/T system parts.

One or Two Trip Detection Logic of OBD

BCS000OE

ONE TRIP DETECTION LOGIC
If a malfunction is sensed during the first test drive, the MIL will illuminate and the malfunction will be stored in
the ECM memory as a DTC. The TCM is not provided with such a memory function.

TWO TRIP DETECTION LOGIC
When a malfunction is sensed during the first test drive, it is stored in the ECM memory as a 1st trip DTC
(diagnostic trouble code) or 1st trip freeze frame data. At this point, the MIL will not illuminate. — 1st trip
If the same malfunction as that experienced during the first test drive is sensed during the second test drive,
the MIL will illuminate. — 2nd trip
The “trip” in the “One or Two Trip Detection Logic” means a driving mode in which self-diagnosis is performed
during vehicle operation.

OBD Diagnostic Trouble Code (DTC)

BCS000OF

HOW TO READ DTC AND 1ST TRIP DTC
DTC and 1st trip DTC can be read by the following methods.
( with CONSULT-II or
GST) CONSULT-II or GST (Generic Scan Tool) Examples: P0705, P0720 etc.
These DTC are prescribed by SAE J2012.
(CONSULT-II also displays the malfunctioning component or system.)
●
1st trip DTC No. is the same as DTC No.
●
Output of the diagnostic trouble code indicates that the indicated circuit has a malfunction. However, in case of the Mode II and GST, they do not indicate whether the malfunction is still occurring
or occurred in the past and returned to normal.
CONSULT-II can identify them as shown below, therefore, CONSULT-II (if available) is recommended.
A sample of CONSULT-II display for DTC and 1st trip DTC is shown
on the next page. DTC or 1st trip DTC of a malfunction is displayed
in SELF-DIAGNOSTIC RESULTS mode for “ENGINE” with CONSULT-II. Time data indicates how many times the vehicle was driven
after the last detection of a DTC.

SAT014K

AT-98

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[EURO-OBD]
If the DTC is being detected currently, the time data will be “0”.
A

B

AT
SAT015K

D

If a 1st trip DTC is stored in the ECM, the time data will be “1t”.
E

F

G
SAT016K

Freeze Frame Data and 1st Trip Freeze Frame Data
The ECM has a memory function, which stores the driving condition such as fuel system status, calculated
load value, engine coolant temperature, short term fuel trim, long term fuel trim, engine speed and vehicle
speed at the moment the ECM detects a malfunction.
Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data,
and the data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II
or GST. The 1st trip freeze frame data can only be displayed on the CONSULT-II screen, not on the GST. For
detail, refer to EC-102, «CONSULT-II Function (ENGINE)» .
Only one set of freeze frame data (either 1st trip freeze frame data of freeze frame data) can be stored in the
ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no priority
for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once
freeze frame data (2nd trip detection/MIL on) is stored in the ECM memory, 1st trip freeze frame data is no
longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the following priorities to update the data.
Priority
1

Items
Freeze frame data

2
3

Misfire — DTC: P0300 — P0306
Fuel Injection System Function — DTC: P0171, P0172, P0174, P0175
Except the above items (Includes A/T related items)

1st trip freeze frame data

Both 1st trip freeze frame data and freeze frame data (along with the DTC) are cleared when the ECM memory is erased.

HOW TO ERASE DTC
The diagnostic trouble code can be erased by CONSULT-II, GST or ECM DIAGNOSTIC TEST MODE as
described following.
●
If the battery cable is disconnected, the diagnostic trouble code will be cleared within 24 hours.
●
When you erase the DTC, using CONSULT-II or GST is easier and quicker than switching the mode
selector on the ECM.
The following emission-related diagnostic information is cleared from the ECM memory when erasing DTC
related to OBD. For details, refer to EC-48, «Emission-related Diagnostic Information» .
●
Diagnostic trouble codes (DTC)
●
1st trip diagnostic trouble codes (1st trip DTC)
●
Freeze frame data

AT-99

H

I

J

K

L

M

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[EURO-OBD]
●
●
●

1st trip freeze frame data
System readiness test (SRT) codes
Test values

HOW TO ERASE DTC (WITH CONSULT-II)
●

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

If a DTC is displayed for both ECM and TCM, it is necessary to be erased for both ECM and TCM.
If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10
seconds and then turn it ON (engine stopped) again.
Turn CONSULT-II “ON” and touch “A/T”.
Touch “SELF-DIAG RESULTS”.
Touch “ERASE”. (The DTC in the TCM will be erased.) Then touch “BACK” twice.
Touch “ENGINE”.
Touch “SELF-DIAG RESULTS”.
Touch “ERASE”. (The DTC in the ECM will be erased.)

SCIA7155E

HOW TO ERASE DTC (WITH GST)
1.
2.

3.

If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10
seconds and then turn it ON (engine stopped) again.
Perform “TCM SELF-DIAGNOSTIC PROCEDURE (No Tools)”. Refer to AT-94, «Diagnostic Procedure
Without CONSULT-II» . (The engine warm-up step can be skipped when performing the diagnosis only to
erase the DTC.)
Select Mode 4 with Generic Scan Tool (GST). For details, refer to EC-111, «Generic Scan Tool (GST)
Function» .

AT-100

ON BOARD DIAGNOSTIC (OBD) SYSTEM
[EURO-OBD]
HOW TO ERASE DTC (NO TOOLS)
A
The OD OFF indicator lamp is located on the combination meter.
1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10
seconds and then turn it ON (engine stopped) again.
B
2. Perform “TCM SELF-DIAGNOSTIC PROCEDURE (No Tools)”. Refer to AT-94, «Diagnostic Procedure
Without CONSULT-II» . (The engine warm-up step can be skipped when performing the diagnosis only to
erase the DTC.)
AT
3. Perform “OBD SELF-DIAGNOSTIC PROCEDURE (No tools)”. Refer to EC-57, «How to Erase DTC» .

Malfunction Indicator Lamp (MIL)

BCS000OG

DESCRIPTION

D

The MIL is located on the instrument panel.
1. The MIL will light up when the ignition switch is turned ON without the engine running. This is a bulb check.
● If the MIL does not light up, refer to DI-32, «WARNING
LAMPS» , or see EC-448, «MI & DATA LINK CONNECTORS»
.
2. When the engine is started, the MIL should go off.
● If the MIL remains on, the on board diagnostic system has
detected an engine system malfunction.

E

F

G
SAT652J

H

I

J

K

L

M

AT-101

DTC U1000 CAN COMMUNICATION LINE
[EURO-OBD]

DTC U1000 CAN COMMUNICATION LINE
Description

PFP:31940
BCS000OH

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent malfunction detection ability.
Many electronic control units are equipped onto a vehicle, and each control unit shares information and links
with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission
with less wiring. Each control unit transmits/receives data but selectively reads required data only.

On Board Diagnosis Logic
●
●

BCS000OI

This is an OBD self-diagnostic item.
Diagnostic trouble code “U1000 CAN COMM CIRCUIT” with CONSULT-II or 12th judgement flicker without CONSULT-II is detected when TCM cannot communicate to other control units.

Possible Cause

BCS000OJ

Harness or connector
(CAN communication line is open or shorted.)

DTC Confirmation Procedure

BCS000OK

CAUTION:
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at
least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON.
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Touch “START”.
Wait at least 6 seconds or start engine and wait for at least 6
seconds.
If DTC is detected, go to AT-104, «Diagnostic Procedure» .

BCIA0031E

WITH GST
Follow the procedure “WITH CONSULT-II”.

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

Turn ignition switch ON.
Wait at least 6 seconds or start engine and wait at least 6 seconds.
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If DTC is detected, go to AT-104, «Diagnostic Procedure» .

AT-102

DTC U1000 CAN COMMUNICATION LINE
[EURO-OBD]

Wiring Diagram — AT — CAN

BCS000OL

A

B

AT

D

E

F

G

H

I

J

K

L

M

MCWA0241E

AT-103

DTC U1000 CAN COMMUNICATION LINE
[EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

Item

Condition

Judgement standard
(Approx.)

5

L

CAN H

—

—

6

Y

CAN L

—

—

Diagnostic Procedure

BCS000OM

1. CHECK CAN COMMUNICATION CIRCUIT
With CONSULT-II
1. Turn ignition switch ON and start engine.
2. Select “SELF-DIAG RESULTS” mode for “A/T” with CONSULTII.
Is any malfunction of the “U1000 CAN COMM CIRCUIT” indicated?
YES >> Print out CONSULT-II screen, GO TO LAN section.
Refer to LAN-3, «Precautions When Using CONSULT-II»
.
NO
>> INSPECTION END

SCIA7135E

AT-104

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH
[EURO-OBD]

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH
Description

PFP:32006

A
BCS000ON

The PNP switch assembly includes a transaxle range switch.
The transaxle range switch detects the selector lever position and sends a signal to the TCM.

●
●

CONSULT-II Reference Value

BCS000OO

Remarks: Specification data are reference values.
Item name
Condition
PN POSI SW

R POSITION SW

D POSITION SW

2 POSITION SW

1 POSITION SW

●

When setting selector lever to “N” or “P” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “R” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “D” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “2” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “1” position.

ON

When setting selector lever to other positions.

OFF

●

D

E

F

G
BCS000OP

This is an OBD self-diagnostic item.
Diagnostic trouble code “P0705 PNP SW/CIRC” with CONSULT-II is detected when TCM does not
receive the correct voltage signal from the switch based on the gear position.
BCS000OQ

Harness or connectors
[The PNP switch circuit is open or shorted.]
PNP switch

J

DTC Confirmation Procedure

BCS000OR

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

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

5.

H

I

Possible Cause
●

AT

Display value

On Board Diagnosis Logic
●

B

K

L

M

Turn ignition switch ON. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Touch “START”.
Start engine and maintain the following conditions for at least 5
consecutive seconds.
VEHICLE SPEED: 10 km/h (6 MPH) or more
THROTTLE POSI: More than 1.0/8
SLCT LVR POSI: “D” position
If the check result is NG, go to AT-107, «Diagnostic Procedure» .
BCIA0031E

WITH GST
Follow the procedure “WITH CONSULT-II”.

AT-105

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH
[EURO-OBD]

Wiring Diagram — AT — PNP/SW

BCS000OS

MCWA0242E

AT-106

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH
[EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Wire color

Item

Battery voltage

Y

PNP switch “1” position

When setting selector lever to “1” position.

26

When setting selector lever to other positions.

0V
Battery voltage

L

PNP switch “2” position

When setting selector lever to “2” position.

27

When setting selector lever to other positions.

0V

When setting selector lever to “D” position.

Battery voltage

LG

PNP switch “D” position

34

35

L

PNP switch “R” position

36

R

PNP switch “N” or
“P” position

Condition

Judgement standard
(Approx.)

Terminal

and

B

AT

When setting selector lever to other positions.

0V

When setting selector lever to “R” position.

Battery voltage

When setting selector lever to other positions.

0V

When setting selector lever to “N” or “P” position.

Battery voltage

When setting selector lever to other positions.

0V

Diagnostic Procedure

A

D

E

BCS000OT

F

1. CHECK INPUT SIGNAL
G

With CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for
“A/T” with CONSULT-II.
3. Read out “P·N”, “R”, “D”, “2” and “1” position switches moving
selector lever to each position.

H

I
Item name

Condition

Display value
ON

PN POSI SW

When setting selector lever to “N” or “P” position.
When setting selector lever to other positions.

OFF

When setting selector lever to “R” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “D” positions.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “2” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “1” position.

ON

When setting selector lever to other positions.

OFF

R POSITION SW

D POSITION SW

2 POSITION SW

1 POSITION SW

J

SAT701J

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 3.

AT-107

K

L

M

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH
[EURO-OBD]

2. CHECK INPUT SIGNAL
Without CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Check voltage between TCM connector terminals and ground
while moving selector lever through each position.
Terminal
Selector lever position

36

35

34

27

26

P, N

B

0

0

0

0

R

0

B

0

0

0

D

0

0

B

0

0

2

0

0

0

B

0

1

0

0

0

0

B

B: Battery voltage
0: 0V

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 3.

SCIA7162E

3. CHECK PNP SWITCH
1.
2.
3.

Turn ignition switch OFF.
Disconnect PNP switch harness connector.
Check continuity between PNP switch harness connector terminals.
Selector lever position

Terminal

Continuity

P

1 — 2, 3 — 7

R

3-8

Yes
*Continuity
should not
exist in positions other
than the
specified
positions.

N

Connector

F12

1 — 2, 3 — 9

D

3-6

2

3-5

1

3-4

SCIA3553E

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

4. CHECK CONTROL CABLE ADJUSTMENT
Check PNP switch again with control cable disconnected from manual shaft of A/T assembly. Refer to test
group 3.
OK or NG
OK
>> Adjust control cable. Refer to AT-336, «Adjustment of A/T Position» .
NG
>> Repair or replace PNP switch. Refer to AT-349, «Park/Neutral Position (PNP) Switch» .

AT-108

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH
[EURO-OBD]

5. DETECT MALFUNCTIONING ITEM

A

Check the following items:
●
Harness for short or open between ignition switch and PNP switch.
●
Harness for short or open between PNP switch and TCM.
●
Harness for short or open between combination meter and PNP switch.
●
Harness for short or open between combination meter and TCM.
●
10A fuse (No.60, located in the IPDM E/R)
●
Combination meter. Refer to DI-4, «COMBINATION METERS» .
●
Ignition switch. Refer to PG-38, «GROUND» .
OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace damaged parts.

B

AT

D

E

6. CHECK DTC
F

Perform AT-105, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 7.

G

7. CHECK TCM
H

1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

Component Inspection

I

BCS000OU

J

PNP SWITCH
1.

Check continuity between PNP switch harness connector terminals.
Selector lever position

Connector

Terminal

Continuity

“P”

1 — 2, 3 — 7

“R”

3-8

Yes
*Continuity
should not
exist in positions other
than the
specified
positions.

“N”
“D”

2.

3.
4.
5.
6.

1 — 2, 3 — 9
F12

3-6

“2”

3-5

“1”

3-4

If NG, check again with control cable (2) disconnected from
manual shaft of A/T assembly. Refer to step 1.
(1): Lock nut
(3): Manual shaft
If OK on step 2, adjust control cable (2). Refer to AT-336,
«Adjustment of A/T Position» .
If NG on step 2, remove PNP switch from A/T and check continuity of PNP switch terminals. Refer to step 1.
If OK on step 4, adjust PNP switch. Refer to AT-350, «PARK/
NEUTRAL POSITION (PNP) SWITCH ADJUSTMENT» .
If NG on step 4, replace PNP switch. Refer to AT-349, «Park/
Neutral Position (PNP) Switch» .

AT-109

K

L

M
SCIA5588E

SCIA6370J

DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT
[EURO-OBD]

DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT
Description

PFP:31940
BCS000OV

The A/T fluid temperature sensor detects the A/T fluid temperature and sends a signal to the TCM.

CONSULT-II Reference Value

BCS000OW

Remarks: Specification data are reference values.
Item name
Condition
FLUID TEMP SE

Display value (Approx.)

When A/T fluid temperature is 20°C (68°F).

1.5V

When A/T fluid temperature is 80°C (176°F).

0.5V

On Board Diagnosis Logic
●
●

BCS000OX

This is an OBD self-diagnostic item.
Diagnostic trouble code “P0710 ATF TEMP SEN/CIRC” with CONSULT-II is detected when TCM receives
an excessively low or high voltage from the sensor.

Possible Cause
●

●

BCS000OY

Harness or connector
(The sensor circuit is open or shorted.)
A/T fluid temperature sensor

DTC Confirmation Procedure

BCS000OZ

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.

4.

Turn ignition switch ON and select “DATA MONITOR” mode for
“A/T” with CONSULT-II.
Touch “START”.
Start engine and maintain the following conditions for at least 10
minutes (Total). (It is not necessary to maintain continuously.)
ENGINE SPEED: 450 rpm or more
VEHICLE SPEED: 10 km/h (6 MPH) or more
THROTTLE POSI: More than 1.0/8
SLCT LVR POSI: “D” position
If the check result is NG, go to AT-112, «Diagnostic Procedure» .
BCIA0031E

WITH GST
Follow the procedure “With CONSULT-II”.

AT-110

DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT
[EURO-OBD]

Wiring Diagram — AT — FTS

BCS000P0

A

B

AT

D

E

F

G

H

I

J

K

L

M

MCWA0243E

AT-111

DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT
[EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

42

B

47

BR

Item
Sensor ground
A/T fluid temperature
sensor

Condition

Judgement standard (Approx.)

Always

0V

and

When A/T fluid temperature is
20°C (68°F).

1.5V

When A/T fluid temperature is
80°C (176°F).

0.5V

Diagnostic Procedure

BCS000P1

1. CHECK INPUT SIGNAL
With CONSULT-II
1. Start engine.
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Read out the value of “FLUID TEMP SE”.
Item name

Condition

Display value
(Approx.)

FLUID TEMP
SE

When A/T fluid temperature is 20°C (68°F).

1.5V

When A/T fluid temperature is 80°C (176°F).

0.5V

LCIA0090E

Without CONSULT-II
1. Start engine.
2. Check voltage TCM connector terminals while warming up A/T.

Item

A/T fluid
temperature
sensor

Connector

E107

Terminal

47 — 42

Condition

Judgement standard
(Approx.)

When A/T fluid temperature is 20°C (68°F).

1.5V

When A/T fluid temperature is 80°C (176°F).

0.5V

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 2.

SCIA2658E

2. DETECT MALFUNCTIONING ITEMS
Check the following.
●
Harness for short or open between TCM, ECM and terminal cord assembly
●
Ground circuit for ECM, Refer to EC-128, «POWER SUPPLY AND GROUND CIRCUIT» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace damaged parts.

AT-112

DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT
[EURO-OBD]

3.

CHECK FLUID TEMPERATURE SENSOR CIRCUIT

1.
2.
3.

Turn ignition switch OFF.
Disconnect the TCM connector.
Check resistance between TCM connector terminals.
Item

Connector

A/T fluid
temperature sensor

E107

Terminal

A

B

Temperature [°C (°F)]

Resistance
(Approx.)

20 (68)

2.5 kΩ

80 (176)

0.3 kΩ

AT

47 — 42

D

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 4.

E
SCIA2338E

4.
1.
2.
3.

CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR

F

Turn ignition switch OFF.
Disconnect terminal cord assembly harness connector and TCM connector.
Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal.

G

Item
TCM
Terminal cord assembly
harness connector
TCM
Terminal cord assembly
harness connector

Connector

Terminal

E107

42

F13

7

E107

47

F13

6

H

Continuity
Yes

I
Yes

J
SCIA2660E

4. If OK, check harness for short to ground and short to power.
5. If OK, check continuity between ground and transaxle assembly.
6. Reinstall any part removed.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

K

L

5. CHECK A/T FLUID TEMPERATURE SENSOR WITH TERMINAL CORD ASSEMBLY
1.
2.
3.

M

Turn ignition switch OFF.
Disconnect terminal cord assembly harness connector in engine room.
Check resistance between terminal cord assembly harness connector terminals.
Temperature [°C (°F)]

Resistance (Approx.)

20 (68)

2.5 kΩ

80 (176)

0.3 kΩ

4. Reinstall any part removed.
OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace damaged parts.

SCIA4948E

AT-113

DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT
[EURO-OBD]

6. DETECT MALFUNCTIONING ITEM
1.
2.
–

•

Remove oil pan. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following.
A/T fluid temperature sensor
Check resistance between terminal cord assembly harness connector terminals while changing temperature as shown.
Temperature [°C (°F)]

Resistance (Approx.)

20 (68)

2.5 kΩ

80 (176)

0.3 kΩ

–
Harness of terminal cord assembly for short or open
OK or NG
OK
>> GO TO 7.
NG
>> Repair or replace damaged parts.

SAT298F

7. CHECK DTC
Perform AT-110, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 8.

8. CHECK TCM
1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

Component Inspection

BCS000P2

A/T FLUID TEMPERATURE SENSOR
●

●

Remove oil pan. Refer to AT-345, «Control Valve Assembly and
Accumulators» .
Check resistance between terminal cord assembly harness connector terminals while changing temperature as shown.
Temperature [°C (°F)]

Resistance (Approx.)

20 (68)

2.5 kΩ

80 (176)

0.3 kΩ

SAT298F

AT-114

DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)
[EURO-OBD]

DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)
Description

PFP:32702

A
BCS000P3

The revolution sensor detects the revolution of the idler gear parking pawl lock gear and emits a pulse signal.
The pulse signal is sent to the TCM which converts it into vehicle speed.

CONSULT-II Reference Value

BCS000P4

Remarks: Specification data are reference values.
Item name
Condition
VHCL/S SE-A/T

●

During driving

Approximately matches the speedometer reading.
BCS000P5

This is an OBD self-diagnostic item.
Diagnostic trouble code “P0720 VHCL SPEED SEN-AT” with CONSULT-II or 1st judgement flicker without
CONSULT-II is detected when TCM does not receive the proper voltage signal from the sensor.

Possible Cause
●

●

AT

Display value

On Board Diagnosis Logic
●

B

D

E

BCS000P6

Harness or connector
(The sensor circuit is open or shorted.)
Revolution sensor

F

G

DTC Confirmation Procedure

BCS000P7

CAUTION:
●
Always drive vehicle at a safe speed.
●
Be careful not to rev engine into the red zone on the tachometer.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

H

I

WITH CONSULT-II
1.
2.
3.

4.
5.
6.

7.

Turn ignition switch ON and select “DATA MONITOR” mode for
“A/T” with CONSULT-II.
Touch “START”.
Drive vehicle and check for an increase of “VHCL/S SE-MTR”
value.
If the check result is NG, go to AT-118, «Diagnostic Procedure» .
If the check result is OK, go to following step.
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Touch “START”.
Start engine and maintain the following conditions for at least 5
BCIA0031E
consecutive seconds.
VEHICLE SPEED: 30 km/h (19 MPH) or more
THROTTLE POSI: More than 1.0/8
SLCT LVR POSI: “D” position
Driving location: Driving the vehicle uphill (increased engine load) will help maintain the driving
conditions required for this test.
If the check result is NG, go to AT-118, «Diagnostic Procedure» .
If the check result is OK, go to following step.
Maintain the following conditions for at least 5 consecutive seconds.
ENGINE SPEED: 3,500 rpm or more
THROTTLE POSI: More than 1.0/8
SLCT LVR POSI: “D” position
Driving location: Driving the vehicle uphill (increased engine load) will help maintain the driving
conditions required for this test.

WITH GST
Follow the procedure “WITH CONSULT-II”.

AT-115

J

K

L

M

DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)
[EURO-OBD]
WITHOUT CONSULT-II
1.
2.

3.
4.

Start engine.
Drive vehicle under the following conditions for more than 5 seconds.
Selector lever position: “D” position
Vehicle speed: 30 km/h (19 MPH) or more
Throttle position: greater than 1.0/8 of the full throttle position
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-118, «Diagnostic Procedure» .

AT-116

DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)
[EURO-OBD]

Wiring Diagram — AT — VSSA/T

BCS000P8

A

B

AT

D

E

F

G

H

I

J

K

L

M

MCWA0245E

AT-117

DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)
[EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

Item

Condition

29

V

Revolution sensor

42

B

Sensor ground

When driving at 20 km/h (12 MPH)
Always

Diagnostic Procedure

Judgement standard
(Approx.)
150 Hz
0V
BCS000P9

1. CHECK INPUT SIGNAL
With CONSULT-II
1. Start engine.
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Read out the value of “VHCL/S SE-A/T” while driving.
Check the value changes according to driving speed.
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 2.

LCIA0090E

2.

CHECK REVOLUTION SENSOR

With CONSULT-II
1. Start engine.
2. Check power supply to revolution sensor by voltage between TCM connector terminals. Refer to AT-194,
«Wiring Diagram — AT — MAIN» and AT-117, «Wiring Diagram — AT — VSSA/T» .
Item

Connector

Terminal

TCM

E106, E107

Judgement standard (Approx.)

10 — 42

3.

19 — 42

Battery voltage

If OK, check the pulse when vehicle cruises.
Item

Condition
When driving at 20 km/h (12 MPH), use the CONSULT-II
pulse frequency measuring function.*1

Revolution sensor

CAUTION:
Connect the diagnosis data link cable to the data link
connector.
*1: A circuit tester cannot be used to test this item.

Item

Connector

Terminal

Condition

Judgement standard (Approx.)

TCM

E107

29

When driving at 20
km/h (12 MPH)

150 Hz

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 3.

SCIA2344E

AT-118

DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)
[EURO-OBD]

3.
1.
2.
3.
4.

CHECK POWER AND SENSOR GROUND

A

Turn ignition switch OFF.
Disconnect the revolution sensor harness connector.
Turn ignition switch ON. (Do not start engine.)
Check voltage between revolution sensor harness connector
terminals.

B

AT
Item

Connector

Terminal

Judgement standard
(Approx.)

Revolution sensor

F41

1-3

Battery voltage

D

E
SCIA2614E

5.

Item

Connector

Terminal

Judgement standard
(Approx.)

Revolution sensor

F41

1 — ground

Battery voltage

6. If OK, check harness for short to ground and short to power.
7. Reinstall any part removed.
OK or NG
OK
>> GO TO 4.
NG — 1 >> Battery voltage is not supplied between terminals 1 and
3, terminals 1 and ground: GO TO 6.
NG — 2 >> Battery voltage is not supplied between terminals 1 and 3 only: GO TO 7.

4.
1.
2.
3.

F

Check voltage between revolution sensor harness connector
terminal and ground.

G

H

SCIA2615E

I

J

CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR
K

Turn ignition switch OFF.
Disconnect the TCM connector and revolution sensor harness connector.
Check continuity between TCM connector terminal and revolution sensor harness connector terminal.
Item

Connector

Terminal

TCM

E107

29

Revolution sensor

F41

2

L

Continuity

M

Yes

4. If OK, check harness for short to ground and short to power.
5. Reinstall any part removed.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

5. CHECK TCM
1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, re-check TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> GO TO 8.
NG
>> Repair or replace damaged parts.

AT-119

SCIA2616E

DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)
[EURO-OBD]

6.
1.
2.
3.

CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR (POWER)
Turn ignition switch OFF.
Disconnect the TCM connector and revolution sensor harness connector.
Check continuity between TCM connector terminals and revolution sensor harness connector terminal. Refer to AT-52, «Circuit
Diagram» and AT-194, «Wiring Diagram — AT — MAIN» .
Item

Connector

Terminal

TCM

E106

10

Revolution sensor

F41

1

TCM

E106

19

Revolution sensor

F41

1

Continuity
Yes

Yes

4. If OK, check harness for short to ground and short to power.
5. Reinstall any part removed.
OK or NG
OK
>> 10A fuse (No.38, located in the IPDM E/R) or ignition switch are malfunctioning.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

7.
1.
2.
3.

SCIA2617E

CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR (SENSOR GROUND)
Turn ignition switch OFF.
Disconnect the TCM connector and revolution sensor harness connector.
Check continuity between TCM connector terminal and revolution sensor harness connector terminal.
Item

Connector

Terminal

TCM

E107

42

Revolution sensor

F41

3

Continuity
Yes

4. If OK, check harness for short to ground and short to power.
5. Reinstall any part removed.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

8. CHECK DTC
Perform AT-115, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.

AT-120

SCIA2618E

DTC P0725 ENGINE SPEED SIGNAL
[EURO-OBD]

DTC P0725 ENGINE SPEED SIGNAL
Description

PFP:24825

A
BCS000PA

The engine speed signal is sent from the ECM to the TCM.
B

CONSULT-II Reference Value

BCS000PB

Remarks: Specification data are reference values.
Item name
Condition
ENGINE SPEED

Display value

Engine running

Approximately matches the tachometer reading.

On Board Diagnosis Logic
●
●

AT

BCS000PC

This is an OBD self-diagnostic item.
Diagnostic trouble code “P0725 ENGINE SPEED SIG” with CONSULT-II or 9th judgement flicker without
CONSULT-II is detected when TCM does not receive the proper voltage signal from ECM.

Possible Cause

D

E

BCS000PD

Harness or connector
(Circuit is open or shorted.)

F

DTC Confirmation Procedure

BCS000PE

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

G

H

WITH CONSULT-II
1.
2.
3.

4.

I

Turn ignition switch ON and select “DATA MONITOR” mode for
“A/T” with CONSULT-II.
Touch “START”.
Start engine and maintain the following conditions for at least 10
consecutive seconds.
VEHICLE SPEED: 10 km/h (6 MPH) or more
THROTTLE POSI: More than 1.0/8
SLCT LVR POSI: “D” position
If the check result is NG, go to AT-123, «Diagnostic Procedure» .

J

K

BCIA0031E

L

WITH GST
M

Follow the procedure “WITH CONSULT-II”.

WITHOUT CONSULT-II
1.
2.

3.
4.

Start engine.
Drive vehicle under the following conditions for more than 10 seconds.
Selector lever position: “D” position
Vehicle speed: Higher than 10 km/h (6 MPH)
Throttle position: Greater than 1.0/8 of the full throttle position
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-123, «Diagnostic Procedure» .

AT-121

DTC P0725 ENGINE SPEED SIGNAL
[EURO-OBD]

Wiring Diagram — AT — ENGSS

BCS000PF

MCWA0244E

AT-122

DTC P0725 ENGINE SPEED SIGNAL
[EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

39

L

Item

Condition

Judgement standard (Approx.)
Refer to EC-95 .

Engine speed signal

B

and

Diagnostic Procedure

BCS000PG

1. CHECK DTC WITH ECM

AT

Check DTC with CONSULT-II “ENGINE”.
Turn ignition switch ON and select “SELF-DIAGNOSTIC RESULTS” mode for “ENGINE” with CONSULT-II.
Refer to EC-102, «CONSULT-II Function (ENGINE)» .
OK or NG
OK
>> GO TO 2.
NG
>> Check ignition signal circuit for engine control. Refer to EC-433, «IGNITION SIGNAL» .

2. CHECK INPUT SIGNAL
1.
2.
3.

A

D

E

F

With CONSULT-II
Start engine.
Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
Read out the value of “ENGINE SPEED”. Check engine speed
changes according to throttle position.

Item name

Condition

Display value

ENGINE SPEED (rpm)

Engine running

Approximately matches the tachometer reading.

G

H

I

J
SCIA4730E

K

Without CONSULT-II
1. Start engine.
2. Check voltage between TCM harness connector terminal and
ground.
item

Connector

Terminal

Condition

Judgement standard
(Approx.)

Engine
speed signal

E107

39 Ground

and

Refer to EC-95 .

L

M

SCIA3265E

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

AT-123

DTC P0725 ENGINE SPEED SIGNAL
[EURO-OBD]

3.

CHECK HARNESS BETWEEN TCM AND ECM

1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM connector and TCM connector.
Check continuity between ECM connector and TCM connector.
Item

Connector

Terminal

TCM

E107

39

ECM

F50

13

Continuity
Yes

4.
5.

If OK, check harness for short to ground and short to power.
If OK, check continuity between body ground and transaxle
assembly.
6. Reinstall any part removed.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK DTC
Perform AT-121, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.

5. CHECK TCM
1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-124

SCIA7173E

DTC P0731 A/T 1ST GEAR FUNCTION
[EURO-OBD]

DTC P0731 A/T 1ST GEAR FUNCTION
Description
●

●

PFP:31940

A
BCS000PH

This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis
malfunction.
B
This malfunction is detected when the A/T does not shift into first gear position as instructed by the TCM.
This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such
as control valve sticking, improper solenoid valve operation, etc.
AT
Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

On Board Diagnosis Logic
●
●

●

●

BCS000PI

This is an OBD self-diagnostic item.
Diagnostic trouble code “P0731 A/T 1ST GR FNCTN” with CONSULT-II is detected when A/T cannot be
shifted to the 1st gear position even if electrical circuit is good.
This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM
as follows:
Torque converter slip ratio = A x C/B
A: Output shaft revolution signal from revolution sensor
B: Engine speed signal from ECM
C: Gear ratio determined as gear position which TCM supposes
If the actual gear position is higher than the position (1st) supposed by TCM, the slip ratio will be more
than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction.
This malfunction will be caused when either shift solenoid valve A is stuck open or shift solenoid valve B is
stuck open.
Gear positions supposed by TCM are as follows:
In case of gear position with no malfunctions: 1 , 2, 3 and 4 positions
In case of gear position with shift solenoid valve A stuck open: 2* , 2, 3 and 3 positions
In case of gear position with shift solenoid valve B stuck open: 4* , 3, 3 and 4 positions to each gear position above
*: “P0731 A/T 1ST GR FNCTN” is detected.

Possible Cause
●
●
●
●

D

BCS000PJ

Shift solenoid valve A
Shift solenoid valve B
Each clutch
Hydraulic control circuit

E

F

G

H

I

J

K

L

M

AT-125

DTC P0731 A/T 1ST GEAR FUNCTION
[EURO-OBD]

DTC Confirmation Procedure

BCS000PK

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.

4.
5.

–

6.

–
–

7.
8.

Start engine and select “DATA MONITOR” mode for “A/T” with
CONSULT-II.
Touch “START”.
Make sure that output voltage of A/T fluid temperature sensor is
within the range below.
FLUID TEMP SE: 0.4 — 1.5V
If out of range, drive the vehicle to decrease the voltage (warm
up the fluid) or stop engine to increase the voltage (cool down
the fluid).
Select “1ST GR FNCTN P0731” of “DTC WORK SUPPORT”
BCIA0031E
mode for “A/T” with CONSULT-II and touch “START”.
Accelerate vehicle to 20 to 25 km/h (12 to 16 MPH) under the following conditions and release the accelerator pedal completely.
THROTTLE POSI: Less than 1.0/8 (at all times during step 4)
SLCT LVR POSI: “D” position
Make sure that “GEAR” shows “2” after releasing pedal.
Depress accelerator pedal to WOT (more than 7.0/8 of “THROTTLE POSI”) quickly from a speed of 20 to
25 km/h (12 to 16 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETED”. (It will take
approximately 3 seconds.)
If the check result NG appears on CONSULT-II screen, go to AT-127, «Diagnostic Procedure» .
If “STOP VEHICLE” appears on CONSULT-II screen, go to the following step.
Make sure that “GEAR” shows “1” when depressing accelerator pedal to WOT.
If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for
“A/T”. In case a DTC other than “P0731 A/T 1ST GR FNCTN” is shown, refer to AT-85, «Display
Items List (For EURO-OBD models)» .
Stop vehicle.
Follow the instruction displayed. (Check for normal shifting referring to the table below.)

Vehicle condition

Gear on actual transmission shift pattern when screen is changed to 1 → 2 → 3 → 4
1→2→3→4

No malfunction exists.

2→2→3→3

Malfunction for “A/T 1ST GR FNCTN ” exists.

9.

4→3→3→4

Make sure that “OK” is displayed. (If “NG” is displayed, refer to “Diagnostic Procedure”.)
Refer to AT-127, «Diagnostic Procedure» .
Refer to AT-67, «Vehicle Speed at Which Gear Shifting Occurs» .

WITH GST
Follow the procedure “WITH CONSULT-II”.

AT-126

DTC P0731 A/T 1ST GEAR FUNCTION
[EURO-OBD]

Diagnostic Procedure

BCS000PL

1. CHECK VALVE RESISTANCE
1.
–
–

2.

A

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Shift solenoid valve A
Shift solenoid valve B
Check resistance between terminal cord assembly harness connector terminals and ground. Refer to AT-160, «Wiring Diagram
— AT — SSV/A» and AT-165, «Wiring Diagram — AT — SSV/B»
.
Solenoid valve
Shift solenoid valve A
Shift solenoid valve B

Terminal
2
1

Ground

B

AT

D

Resistance
(Approx.)
20 — 30 Ω

E

5 — 20 Ω

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace damaged parts.

F

G

H

I
SCIA3594E

2. CHECK VALVE OPERATION

J

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
–
Shift solenoid valve A
–
Shift solenoid valve B
2. Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminals and ground. Refer to
AT-160, «Wiring Diagram — AT — SSV/A» and AT-165, «Wiring
Diagram — AT — SSV/B» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace shift solenoid valve assembly.

1.

K

L

M

SCIA3595E

AT-127

DTC P0731 A/T 1ST GEAR FUNCTION
[EURO-OBD]

3. CHECK CONTROL VALVE
Disassemble control valve assembly. Refer to AT-392, «Control Valve Assembly» .
Check to ensure that:
–
Valve, sleeve and plug slide along valve bore under their own weight.
–
Valve, sleeve and plug are free from burrs, dents and scratches.
–
Control valve springs are free from damage, deformation and fatigue.
–
Hydraulic line is free from obstacles.
OK or NG
OK
>> GO TO 4.
NG
>> Repair control valve assembly.
1.
2.

4. CHECK DTC
Perform AT-126, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> Check control valve again. If NG, repair or replace control valve assembly.

AT-128

DTC P0732 A/T 2ND GEAR FUNCTION
[EURO-OBD]

DTC P0732 A/T 2ND GEAR FUNCTION
Description
●

●

PFP:31940

A
BCS000PM

This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis
malfunction.
B
This malfunction is detected when the A/T does not shift into second gear position as instructed by the
TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction
such as control valve sticking, improper solenoid valve operation, etc.
AT
Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

On Board Diagnosis Logic
●
●

●

●

BCS000PN

This is an OBD self-diagnostic item.
Diagnostic trouble code “P0732 A/T 2ND GR FNCTN” with CONSULT-II is detected when A/T cannot be
shifted to the 2nd gear position even if electrical circuit is good.
This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM
as follows:
Torque converter slip ratio = A x C/B
A: Output shaft revolution signal from revolution sensor
B: Engine speed signal from ECM
C: Gear ratio determined as gear position which TCM supposes
If the actual gear position is higher than the position (2nd) supposed by TCM, the slip ratio will be more
than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction.
This malfunction will be caused when shift solenoid valve B is stuck open.
Gear positions supposed by TCM are as follows:
In case of gear position with no malfunctions: 1, 2 , 3 and 4 positions
In case of gear position with shift solenoid valve B stuck open: 4, 3* , 3 and 4 positions to each gear position above
*: “P0732 A/T 2ND GR FNCTN” is detected.

Possible Cause
●
●
●

D

E

F

G

H

I

J

BCS000PO

Shift solenoid valve B
Each clutch
Hydraulic control circuit

K

L

M

AT-129

DTC P0732 A/T 2ND GEAR FUNCTION
[EURO-OBD]

DTC Confirmation Procedure

BCS000PP

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.

4.
5.

–

6.

–
–

7.
8.

Start engine and select “DATA MONITOR” mode for “A/T” with
CONSULT-II.
Touch “START”.
Make sure that output voltage of A/T fluid temperature sensor is
within the range below.
FLUID TEMP SE: 0.4 — 1.5V
If out of range, drive the vehicle to decrease the voltage (warm
up the fluid) or stop engine to increase the voltage (cool down
the fluid).
Select “2ND GR FNCTN P0732” of “DTC WORK SUPPORT”
BCIA0031E
mode for “A/T” with CONSULT-II and touch “START”.
Accelerate vehicle to 45 to 50 km/h (28 to 31 MPH) under the following conditions and release the accelerator pedal completely.
THROTTLE POSI: Less than 1.0/8
SLCT LVR POSI: “D” position
Make sure that “GEAR” shows “3” or “4” after releasing pedal.
Depress accelerator pedal to WOT (more than 7.0/8 of “THROTTLE POSI”) quickly from a speed of 45 to
50 km/h (28 to 31 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETE”. (It will take
approximately 3 seconds.)
If the check result NG appears on CONSULT-II screen, go to AT-131, «Diagnostic Procedure» .
If “STOP VEHICLE” appears on CONSULT-II screen, go to following step.
Make sure that “GEAR” shows “2” when depressing accelerator pedal to WOT.
If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for
“A/T”. In case a DTC other than “P0732 A/T 2ND GR FNCTN” is shown, refer to AT-85, «Display
Items List (For EURO-OBD models)» .
Stop vehicle.
Follow the instruction displayed. (Check for normal shifting referring to the table below.)

Vehicle condition

Gear on actual transmission shift pattern when screen is changed to 1 → 2 → 3 → 4

No malfunction exists

1→2→3→4

Malfunction for “A/T 2ND GR FNCTN” exists.

4→3→3→4

9.

Make sure that “OK” is displayed. (If “NG” is displayed, refer to “Diagnostic Procedure”.)
Refer to AT-131, «Diagnostic Procedure» .
Refer to AT-67, «Vehicle Speed at Which Gear Shifting Occurs» .

WITH GST
Follow the procedure “WITH CONSULT-II”.

AT-130

DTC P0732 A/T 2ND GEAR FUNCTION
[EURO-OBD]

Diagnostic Procedure

BCS000PQ

1. CHECK VALVE RESISTANCE
1.
–

2.

A

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Shift solenoid valve B
Check resistance between terminal cord assembly harness connector terminal and ground. Refer to AT-165, «Wiring Diagram
— AT — SSV/B» .
Solenoid valve
Shift solenoid valve B

Terminal
1

Ground

B

AT

Resistance
(Approx.)

D

5 — 20 Ω

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace shift solenoid valve assembly.

E
SCIA3454E

2. CHECK VALVE OPERATION

F

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
–
Shift solenoid valve B
2. Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground. Refer to AT165, «Wiring Diagram — AT — SSV/B» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace shift solenoid valve assembly.

1.

G

H

I

J
SCIA2058E

3. CHECK CONTROL VALVE

K

Disassemble control valve assembly. Refer to AT-392, «Control Valve Assembly» .
Check to ensure that:
–
Valve, sleeve and plug slide along valve bore under their own weight.
–
Valve, sleeve and plug are free from burrs, dents and scratches.
–
Control valve springs are free from damage, deformation and fatigue.
–
Hydraulic line is free from obstacles.
OK or NG
OK
>> GO TO 4.
NG
>> Repair control valve assembly.

1.
2.

4. CHECK DTC
Perform AT-130, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> Check control valve again. If NG, repair or replace control valve assembly.

AT-131

L

M

DTC P0733 A/T 3RD GEAR FUNCTION
[EURO-OBD]

DTC P0733 A/T 3RD GEAR FUNCTION
Description
●

●

PFP:31940
BCS000PR

This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis
malfunction.
This malfunction is detected when the A/T does not shift into third gear position as instructed by the TCM.
This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such
as control valve sticking, improper solenoid valve operation, malfunctioning servo piston or brake band,
etc.
Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

On Board Diagnosis Logic
●
●

●

●

BCS000PS

This is an OBD self-diagnostic item.
Diagnostic trouble code “P0733 A/T 3RD GR FNCTN” with CONSULT-II is detected when A/T cannot be
shifted to the 3rd gear position even if electrical circuit is good.
This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM
as follows:
Torque converter slip ratio = A x C/B
A: Output shaft revolution signal from revolution sensor
B: Engine speed signal from ECM
C: Gear ratio determined as gear position which TCM supposes
If the actual gear position is higher than the position (3rd) supposed by TCM, the slip ratio will be more
than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction.
This malfunction will be caused when shift solenoid valve A is stuck closed.
Gear positions supposed by TCM are as follows.
In case of gear position with no malfunctions: 1, 2, 3 and 4 positions
In case of gear position with shift solenoid valve A stuck closed: 1, 1, 4* and 4 positions to each gear
position above
*: “P0733 A/T 3RD GR FNCTN” is detected.

Possible Cause
●
●
●

BCS000PT

Shift solenoid valve A
Each clutch
Hydraulic control circuit

AT-132

DTC P0733 A/T 3RD GEAR FUNCTION
[EURO-OBD]

DTC Confirmation Procedure

BCS000PU

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.

4.
5.

–

6.

–

–

7.
8.

D

E

F

G

H

I

J

K

L

Gear on actual transmission shift pattern when screen is changed to 1 → 2 → 3 → 4

No malfunction exists.

1→2→3→4

Malfunction for “A/T 3RD GR FNCTN” exists.

1→1→4→4

9.

B

AT

Start engine and select “DATA MONITOR” mode for “A/T” with
CONSULT-II.
Touch “START”.
Make sure that output voltage of A/T fluid temperature sensor is
within the range below.
FLUID TEMP SE: 0.4 — 1.5V
If out of range, drive the vehicle to decrease the voltage (warm
up the fluid) or stop engine to increase the voltage (cool down
the fluid).
Select “3RD GR FNCTN P0733” of “DTC WORK SUPPORT”
BCIA0031E
mode for “A/T” with CONSULT-II and touch “START”.
Accelerate vehicle to 60 to 75 km/h (37 to 47 MPH) under the following conditions and release the accelerator pedal completely.
THROTTLE POSI: Less than 1.0/8 (at all times during step 4)
SLCT LVR POSI: “D” position
Make sure that “GEAR” shows “4” after releasing pedal.
Depress accelerator pedal steadily with 3.5/8 — 4.5/8 of “THROTTLE POSI” from a speed of 60 to 75 km/h
(37 to 47 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.)
If the check result NG appears on CONSULT-II screen, go to AT-134, «Diagnostic Procedure» .
If “STOP VEHICLE” appears on CONSULT-II screen, go to following step.
Make sure that “GEAR” shows “3” when depressing accelerator pedal with 3.5/8 — 4.5/8 of
“THROTTLE POSI”.
If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for
“A/T”. In case a DTC other than “P0733 A/T 3RD GR FNCTN” is shown, refer to AT-85, «Display
Items List (For EURO-OBD models)» .
Stop vehicle.
Follow the instruction displayed. (Check for normal shifting referring to the table below.)

Vehicle condition

A

Make sure that “OK” is displayed. (If “NG” is displayed, refer to “Diagnostic Procedure”.)
Refer to AT-134, «Diagnostic Procedure» .
Refer to AT-67, «Vehicle Speed at Which Gear Shifting Occurs» .

WITH GST
Follow the procedure “WITH CONSULT-II”.

AT-133

M

DTC P0733 A/T 3RD GEAR FUNCTION
[EURO-OBD]

Diagnostic Procedure

BCS000PV

1. CHECK VALVE RESISTANCE
1.
–
–

2.

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Shift solenoid valve A
Shift solenoid valve B
Check resistance between terminal cord assembly harness connector terminals and ground. Refer to AT-160, «Wiring Diagram
— AT — SSV/A» and AT-165, «Wiring Diagram — AT — SSV/B»
.
Solenoid valve
Shift solenoid valve A
Shift solenoid valve B

Terminal
2
1

Ground

Resistance
(Approx.)
20 — 30 Ω
5 — 20 Ω

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace shift solenoid valve assembly.

SCIA3594E

2. CHECK VALVE OPERATION
Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
–
Shift solenoid valve A
–
Shift solenoid valve B
2. Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminals and ground. Refer to
AT-160, «Wiring Diagram — AT — SSV/A» and AT-165, «Wiring
Diagram — AT — SSV/B» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace shift solenoid valve assembly.
1.

SCIA3595E

AT-134

DTC P0733 A/T 3RD GEAR FUNCTION
[EURO-OBD]

3. CHECK CONTROL VALVE

A

Disassemble control valve assembly. Refer to AT-392, «Control Valve Assembly» .
Check to ensure that:
–
Valve, sleeve and plug slide along valve bore under their own weight.
–
Valve, sleeve and plug are free from burrs, dents and scratches.
–
Control valve springs are free from damage, deformation and fatigue.
–
Hydraulic line is free from obstacles.
OK or NG
OK
>> GO TO 4.
NG
>> Repair control valve assembly.

1.
2.

4. CHECK DTC

B

AT

D

E

Perform AT-133, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> Check control valve again. If NG, repair or replace control valve assembly.

F

G

H

I

J

K

L

M

AT-135

DTC P0734 A/T 4TH GEAR FUNCTION
[EURO-OBD]

DTC P0734 A/T 4TH GEAR FUNCTION
Description
●

●

PFP:31940
BCS000PW

This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis
malfunction.
This malfunction is detected when the A/T does not shift into fourth gear position or the torque converter
clutch does not lock up as instructed by the TCM. This is not caused by electrical malfunction (circuits
open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve
operation, malfunctioning oil pump or torque converter clutch, etc.
Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

CONSULT-II Reference Value

BCS000PX

Remarks: Specification data are reference values.
Item name
Condition
LINE PRES DTY

Display value (Approx.)

Small throttle opening (Low line pressure) ⇔ Large
throttle opening (High line pressure)

On Board Diagnosis Logic
●
●

●

●

BCS000PY

This is an OBD self-diagnostic item.
Diagnostic trouble code “P0734 A/T 4TH GR FNCTN” with CONSULT-II is detected when A/T cannot be
shifted to the 4th gear position even if electrical circuit is good.
This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM
as follows:
Torque converter slip ratio = A x C/B
A: Output shaft revolution signal from revolution sensor
B: Engine speed signal from ECM
C: Gear ratio determined as gear position which TCM supposes
If the actual gear position is much lower than the position (4th) supposed by TCM, the slip ratio will be
much less than normal. In case the ratio does not reach the specified value, TCM judges this diagnosis
malfunction.
This malfunction will be caused when shift solenoid valve A is stuck open or shift solenoid valve B is stuck
closed.
Gear positions supposed by TCM are as follows.
In case of gear position with no malfunctions: 1, 2, 3 and 4 positions
In case of gear position with shift solenoid valve A stuck open: 2, 2, 3 and 3* positions
In case of gear position with shift solenoid valve B stuck closed: 1, 2, 2 and 1* positions to each gear
position above
*: “P0734 A/T 4TH GR FNCTN” is detected.

Possible Cause
●
●
●
●
●

0% ⇔ 94%

BCS000PZ

Shift solenoid valve A
Shift solenoid valve B
Line pressure solenoid valve
Each clutch
Hydraulic control circuit

AT-136

DTC P0734 A/T 4TH GEAR FUNCTION
[EURO-OBD]

DTC Confirmation Procedure

BCS000Q0

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.

4.
5.

–

6.

–

–

7.
8.

D

E

F

G

H

I

J

K

L

Gear on actual transmission shift pattern when screen is changed to 1 → 2 → 3 → 4
1→2→3→4

No malfunction exists

2→2→3→3

Malfunction for “A/T 4TH GR FNCTN” exists.

9.

B

AT

Start engine and select “DATA MONITOR” mode for “A/T” with
CONSULT-II.
Touch “START”.
Make sure that output voltage of A/T fluid temperature sensor is
within the range below.
FLUID TEMP SE: 0.4 — 1.5V
If out of range, drive the vehicle to decrease the voltage (warm
up the fluid) or stop engine to increase the voltage (cool down
the fluid).
Select “4TH GR FNCTN P0734” of “DTC WORK SUPPORT”
BCIA0031E
mode for “A/T” with CONSULT-II and touch “START”.
Accelerate vehicle to 55 to 65 km/h (34 to 40 MPH) under the following conditions and release the accelerator pedal completely.
THROTTLE POSI: Less than 5.5/8 (at all times during step 4)
SLCT LVR POSI: “D” position
Make sure that “GEAR” shows “3” after releasing pedal.
Depress accelerator pedal steadily with 1.0/8 — 2.0/8 of “THROTTLE POSI” from a speed of 55 to 65 km/h
(34 to 40 MPH) until “TESTING” has turned to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.)
If the check result NG appears on CONSULT-II screen, go to AT-138, «Diagnostic Procedure» .
If “STOP VEHICLE” appears on CONSULT-II screen, go to following step.
Make sure that “GEAR” shows “4” when depressing accelerator pedal with 1.0/8 — 2.0/8 of
“THROTTLE POSI”.
If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for
“A/T”. In case a DTC other than “P0734 A/T 4TH GR FNCTN” is shown, refer to AT-85, «Display
Items List (For EURO-OBD models)» .
Stop vehicle.
Follow the instruction displayed. (Check for normal shifting referring to the table below.)

Vehicle condition

A

1→2→2→1

Make sure that “OK” is displayed. (If “NG” is displayed, refer to “Diagnostic Procedure”.)
Refer to AT-138, «Diagnostic Procedure» .
Refer to AT-67, «Vehicle Speed at Which Gear Shifting Occurs» .

WITH GST
Follow the procedure “WITH CONSULT-II”.

AT-137

M

DTC P0734 A/T 4TH GEAR FUNCTION
[EURO-OBD]

Diagnostic Procedure

1. CHECK SHIFT-UP (D3

BCS000Q1

TO D4 )

During AT-61, «Cruise Test — Part 1» .
Does A/T shift from D3 to D4 at the specified speed?
YES >> GO TO 11.
NO
>> GO TO 2.

SCIA7190E

2. CHECK LINE PRESSURE
Perform line pressure test. Refer to AT-56, «LINE PRESSURE TEST» .
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 7.

3. CHECK VALVE RESISTANCE
1.
–
–

2.

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Shift solenoid valve A
Shift solenoid valve B
Check resistance between terminal cord assembly harness connector terminals and ground. Refer to AT-160, «Wiring Diagram
— AT — SSV/A» and AT-165, «Wiring Diagram — AT — SSV/B»
.
Solenoid valve
Shift solenoid valve A
Shift solenoid valve B

Terminal
2
1

Ground

Resistance
(Approx.)
20 — 30 Ω
5 — 20 Ω

OK or NG
OK
>> GO TO 4.
NG
>> Replace solenoid valve assembly.

SCIA3594E

AT-138

DTC P0734 A/T 4TH GEAR FUNCTION
[EURO-OBD]

4. CHECK VALVE OPERATION

A

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
–
Shift solenoid valve A
–
Shift solenoid valve B
2. Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminals and ground. Refer to
AT-160, «Wiring Diagram — AT — SSV/A» and AT-165, «Wiring
Diagram — AT — SSV/B» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace solenoid valve assembly.

1.

B

AT

D

E

F

G

H

SCIA3595E

I

5. CHECK CONTROL VALVE
J

Disassemble control valve assembly. Refer to AT-392, «Control Valve Assembly» .
Check to ensure that:
–
Valve, sleeve and plug slide along valve bore under their own weight.
–
Valve, sleeve and plug are free from burrs, dents and scratches.
–
Control valve springs are free from damage, deformation and fatigue.
–
Hydraulic line is free from obstacles.
OK or NG
OK
>> GO TO 6.
NG
>> Repair control valve.

1.
2.

6. CHECK SHIFT-UP (D3

K

L

M

TO D4 )

During AT-61, «Cruise Test — Part 1» .
Does A/T shift from D3 to D4 at the specified speed?
YES >> GO TO 11.
NO
>> Check control valve again. Repair or replace control
valve assembly.

SCIA7190E

AT-139

DTC P0734 A/T 4TH GEAR FUNCTION
[EURO-OBD]

7. CHECK VALVE RESISTANCE
1.
–

2.

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Line pressure solenoid valves
Check resistance between terminal cord assembly harness connector terminal and ground. Refer to AT-154, «Wiring Diagram
— AT — LPSV» .
Solenoid valve

Terminal

Line pressure solenoid valve

4

Ground

Resistance
(Approx.)
2.5 — 5 Ω

OK or NG
OK
>> GO TO 8.
NG
>> Replace solenoid valve assembly.
SCIA3457E

8. CHECK VALVE OPERATION
Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Line pressure solenoid valves
2. Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground. Refer to AT154, «Wiring Diagram — AT — LPSV» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace solenoid valve assembly.
1.

–

SCIA3275E

9. CHECK CONTROL VALVE
Disassemble control valve assembly. Refer to AT-392, «Control Valve Assembly» .
Check line pressure circuit valves for sticking.
–
Pilot valve
–
Shift solenoid valve A
–
Shift solenoid valve B
OK or NG
OK
>> GO TO 10.
NG
>> Repair control valve.
1.
2.

10. CHECK SHIFT-UP (D3

TO D4 )

During AT-61, «Cruise Test — Part 1» .
Does A/T shift from D3 to D4 at the specified speed?
YES >> GO TO 11.
NO
>> Check control valve again. Repair or replace control
valve assembly.

SCIA7190E

AT-140

DTC P0734 A/T 4TH GEAR FUNCTION
[EURO-OBD]

11. CHECK DTC

A

Perform AT-137, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> Perform AT-61, «Cruise Test — Part 1» again and return to the start point of this test group.

B

AT

D

E

F

G

H

I

J

K

L

M

AT-141

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE
[EURO-OBD]

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE
Description

PFP:31940
BCS000Q2

The torque converter clutch solenoid valve is activated, with the gear in D4 and D3 , by the TCM in
response to signals sent from the vehicle speed sensor and the ECM (throttle opening). Lock-up piston
operation will then be controlled.
Lock-up operation, however, is prohibited when A/T fluid temperature is too low.
When the accelerator pedal is depressed (less than 2/8) on lock-up condition, the engine speed should
not change abruptly. If there is an abrupt change in engine speed, there is no lock-up.

●

●
●

CONSULT-II Reference Value

BCS000Q3

Remarks: Specification data are reference values.
Item name
Condition
TCC S/V DUTY

Display value (Approx)

Lock-up OFF ⇔ Lock-up ON

4% ⇔ 94%

On Board Diagnosis Logic
●
●

BCS000Q4

This is an OBD self-diagnostic item.
Diagnostic trouble code “P0740 T/C CLUTCH SOL/V” with CONSULT-II or 7th judgement flicker without
CONSULT-II is detected when TCM detects an improper voltage drop while it tries to operate solenoid
valve.

Possible Cause
●
●

BCS000Q5

Torque converter clutch solenoid valve
Harness or connector
(The solenoid circuit is open or shorted.)

DTC Confirmation Procedure

BCS000Q6

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

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

5.

Turn ignition switch ON. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II and
wait at least 1 second.
Touch “START”.
Start engine and maintain the following conditions for at least 5
consecutive seconds.
VEHICLE SPEED: 80 km/h (50 MPH) or more
THROTTLE POSI: 0.5/8 — 1.0/8
SLCT LVR POSI: “D” position
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
If the check result is NG, go to AT-144, «Diagnostic Procedure» .

WITH GST
Follow the procedure “WITH CONSULT-II”.

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

Start engine.
Drive vehicle in D1 → D2 → D3 → D4 → D4 lock-up position.
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-144, «Diagnostic Procedure» .

AT-142

BCIA0031E

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE
[EURO-OBD]

Wiring Diagram — AT — TCV

BCS000Q7

A

B

AT

D

E

F

G

H

I

J

K

L

M

MCWA0246E

AT-143

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE
[EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

Item

Condition

3

O

Torque converter clutch
solenoid valve

When A/T performs lock-up.
When A/T does not perform lock-up.

Diagnostic Procedure

Judgement standard
(Approx.)
8 — 15V
0V
BCS000Q8

1. CHECK INPUT SIGNAL
With CONSULT-II
1. Start engine.
2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Read out the value of “TCC S/V DUTY” while driving. Check the
value changes according to driving speed.
Monitor item

Condition

Display value
(Approx)

TCC S/V DUTY

Lock-up OFF ⇔ Lock-up ON

4% ⇔ 94%

SCIA3257E

Without CONSULT-II
1. Start engine.
2. Check voltage between TCM connector terminal and ground.
Name
Torque converter clutch
solenoid
valve

Connector

E106

Terminal

3 — Ground

Condition

Judgement
standard
(Approx.)

When A/T performs lockup.

8 — 15V

When A/T does not perform lock-up.

0V

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.

SCIA3261E

2. CHECK TORQUE CONVERTER CLUTCH SOLENOID VALVE CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect TCM connector.
Check resistance between TCM connector terminal and ground.
Solenoid Valve

Torque converter clutch
solenoid valve

Connector

Terminal

Resistance
(Approx.)

E106

3 — Ground

5 — 20 Ω

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
SCIA3262E

AT-144

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE
[EURO-OBD]

3.
1.
2.
3.

CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR
Turn ignition switch OFF.
Disconnect terminal cord assembly harness connector and TCM connector.
Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal.
Item

Connector

Terminal

TCM

E106

3

F13

5

A

B

Continuity

AT

Yes

Terminal cord assembly
harness connector

D

4. If OK, check harness for short to ground and short to power.
5. If OK, check continuity between ground and transaxle assembly.
6. Reinstall any part removed.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

SCIA3263E

E

F

4. CHECK VALVE RESISTANCE
1.
2.
3.

G

Turn ignition switch OFF.
Disconnect terminal cord assembly connector in engine room.
Check resistance between terminal cord assembly harness connector terminal and ground.
Solenoid valve

Connector

Terminal

Resistance (Approx.)

Torque converter clutch
solenoid valve

F13

5 — Ground

5 — 20 Ω

H

I

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace damaged parts.

J

SCIA3456E

K

5. CHECK DTC
L

Perform AT-142, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.

M

6. CHECK TCM
1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-145

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE
[EURO-OBD]

Component Inspection

BCS000Q9

TORQUE CONVERTER CLUTCH SOLENOID VALVE
●

For removal, refer to AT-345, «Control Valve Assembly and Accumulators» .

Resistance Check
●

Check resistance between terminal and ground.
Solenoid valve
Torque converter
clutch solenoid
valve

Resistance
(Approx.)

Terminal

5

Ground

5 — 20 Ω

SCIA2063E

Operation Check
●

Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground.

SCIA2066E

AT-146

DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP)
[EURO-OBD]

DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP)
Description
●

●

PFP:31940

A
BCS000QA

This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis
malfunction.
B
This malfunction is detected when the A/T does not shift into fourth gear position or the torque converter
clutch does not lock-up as instructed by the TCM. This is not caused by electrical malfunction (circuits
open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve AT
operation, malfunctioning oil pump or torque converter clutch, etc.

CONSULT-II Reference Value

BCS000QB

D

Remarks: Specification data are reference values.
Item name
Condition
TCC S/V DUTY

Display value (Approx)

Lock-up OFF ⇔ Lock-up ON

4% ⇔ 94%

E

On Board Diagnosis Logic
●
●

●

●

BCS000QC

This is an OBD self-diagnostic item.
Diagnostic trouble code “P0744 A/T TCC S/V FNCTN” with CONSULT-II is detected when A/T cannot perform lock-up even if electrical circuit is good.
This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM
as follows:
Torque converter slip ratio = A x C/B
A: Output shaft revolution signal from revolution sensor
B: Engine speed signal from ECM
C: Gear ratio determined as gear position which TCM supposes
If the actual gear position is much lower than the position (4th) supposed by TCM, the slip ratio will be
much less than normal. In case the ratio does not reach the specified value, TCM judges this diagnosis
malfunction.
This malfunction will be caused when shift solenoid valve B is stuck closed.
Gear positions supposed by TCM are as follows.
In case of gear position with no malfunctions: 1, 2, 3 and 4 positions
In case of gear position with shift solenoid valve B stuck closed: 1, 2, 2 and 1* positions to each gear position above
*: “P0744 A/T TCC S/V FNCTN” is detected.

Possible Cause
●
●
●
●

F

G

H

I

J

K

BCS000QD

Line pressure solenoid valve
Torque converter clutch solenoid valve
Each clutch
Hydraulic control circuit

L

M

AT-147

DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP)
[EURO-OBD]

DTC Confirmation Procedure

BCS000QE

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.

4.
5.

–
–
–

6.

Start engine and select “DATA MONITOR” mode for “A/T” with
CONSULT-II.
Touch “START”.
Make sure that output voltage of A/T fluid temperature sensor is
within the range below.
FLUID TEMP SE: 0.4 — 1.5V
If out of range, drive vehicle to decrease voltage (warm up the
fluid) or stop engine to increase voltage (cool down the fluid).
Select “TCC S/V FNCTN P0744” of “DTC WORK SUPPORT”
mode for “A/T” with CONSULT-II and touch “START”.
BCIA0031E
Accelerate vehicle to more than 80 km/h (50 MPH) and maintain
the following conditions continuously until “TESTING” has turned to “COMPLETE”. (It will take approximately 30 seconds after “TESTING” shows.)
THROTTLE POSI: 1.0/8 — 2.0/8 (at all times during step 4)
SLCT LVR POSI: “D” position
TCC S/V DUTY: More than 94%
VEHICLE SPEED: Constant speed of more than 80 km/h (50 MPH)
Make sure that “GEAR” shows “4”.
For shift schedule, refer to AT-67, «Vehicle Speed at Which Gear Shifting Occurs» .
If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS”. In
case a DTC other than “P0744 A/T TCC S/V FNCTN” is shown, refer to AT-85, «Display Items List
(For EURO-OBD models)» .
Make sure that “OK” is displayed. (If “NG” is displayed, refer to “DIAGNOSTIC PROCEDURE”.)
Refer to AT-149, «Diagnostic Procedure» .
Refer to AT-67, «Vehicle Speed at Which Lock-up Occurs/Releases» .

WITH GST
Follow the procedure “WITH CONSULT-II”.

AT-148

DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP)
[EURO-OBD]

Diagnostic Procedure

1. CHECK SHIFT-UP (D3

BCS000QF

A

TO D4 )

During AT-61, «Cruise Test — Part 1» .
Does A/T shift from D3 to D4 at the specified speed?
YES >> GO TO 11.
NO
>> GO TO 2.

B

AT

D
SCIA7190E

E

2. CHECK LINE PRESSURE
Perform line pressure test. Refer to AT-56, «LINE PRESSURE TEST» .
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 6.

F

G

3. CHECK CONTROL VALVE
Disassemble control valve assembly. Refer to AT-392, «Control Valve Assembly» .
Check to ensure that:
–
Valve, sleeve and plug slide along valve bore under their own weight.
–
Valve, sleeve and plug are free from burrs, dents and scratches.
–
Control valve springs are free from damage, deformation and fatigue.
–
Hydraulic line is free from obstacles.
OK or NG
OK
>> GO TO 4.
NG
>> Repair control valve.

1.
2.

4. CHECK SHIFT-UP (D3

H

I

J

K

TO D4 )

During AT-61, «Cruise Test — Part 1» .
Does A/T shift from D3 to D4 at the specified speed?
YES >> GO TO 5.
NO
>> Check control valve again. Repair or replace control
valve assembly.

L

M

SCIA7190E

5. CHECK DTC
Perform AT-148, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 11. Check for proper lock-up.

AT-149

DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP)
[EURO-OBD]

6. CHECK VALVE RESISTANCE
1.
–

2.

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Line pressure solenoid valve
Check resistance between terminal cord assembly harness connector terminal and ground. Refer to AT-154, «Wiring Diagram
— AT — LPSV» .
Solenoid valve
Line pressure solenoid valve

Terminal
4

Ground

Resistance
(Approx.)
2.5 — 5Ω

OK or NG
OK
>> GO TO 7.
NG
>> Replace solenoid valve assembly.
SCIA3457E

7. CHECK VALVE OPERATION
Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Line pressure solenoid valve
2. Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground. Refer to AT154, «Wiring Diagram — AT — LPSV» .
OK or NG
OK
>> GO TO 8.
NG
>> Replace solenoid valve assembly.
1.

–

SCIA3275E

8. CHECK CONTROL VALVE
Disassemble control valve assembly. Refer to AT-392, «Control Valve Assembly» .
Check line pressure circuit valves for sticking.
–
Pressure regulator valve
–
Pilot valve
–
Pressure modifier valve
OK or NG
OK
>> GO TO 9.
NG
>> Repair control valve.
1.
2.

9. CHECK SHIFT-UP (D3

TO D4 )

During AT-61, «Cruise Test — Part 1» .
Does A/T shift from D3 to D4 at the specified speed?
YES >> GO TO 10.
NO
>> Check control valve again. Repair or replace control
valve assembly.

SCIA7190E

AT-150

DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP)
[EURO-OBD]

10. CHECK DTC

A

Perform AT-148, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 11. Check for proper lock-up.

B

11. CHECK LOCK-UP

AT

During AT-61, «Cruise Test — Part 1» .
A/T perform lock-up at the specified speed?
YES >> Perform “Cruise test — Part 1” again and return to the
start point of this test group.
NO
>> GO TO 12.

D

E

F
SCIA7191E

12. CHECK VALVE RESISTANCE
1.
–

2.

G

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Torque converter clutch solenoid valve
Check resistance between terminal cord assembly harness connector terminal and ground. Refer to AT-143, «Wiring Diagram
— AT — TCV» .
Solenoid valve
Torque converter clutch solenoid valve

I

Resistance
(Approx.)

Terminal
5

H

Ground

J

5 — 20 Ω

OK or NG
OK
>> GO TO 13.
NG
>> Replace solenoid valve assembly.

K
SCIA2063E

13. CHECK VALVE OPERATION

L

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
–
Torque converter clutch solenoid valve
2. Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground. Refer to AT143, «Wiring Diagram — AT — TCV» .
OK or NG
OK
>> GO TO 14.
NG
>> Replace solenoid valve assembly.
1.

M

SCIA2066E

AT-151

DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP)
[EURO-OBD]

14. CHECK CONTROL VALVE
Disassemble control valve assembly. Refer to AT-392, «Control Valve Assembly» .
Check control valves for sticking.
–
Torque converter clutch control valve
–
Torque converter clutch relief valve
OK or NG
OK
>> GO TO 15.
NG
>> Repair control valve.
1.
2.

15. CHECK LOCK-UP
During AT-61, «Cruise Test — Part 1» .
A/T perform lock-up at the specified speed?
YES >> GO TO 16.
NO
>> Check control valve again. Repair or replace control
valve assembly.

SCIA7191E

16. CHECK DTC
Perform AT-148, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> Perform “Cruise test — Part 1” again and return to the start point of this test group.

AT-152

DTC P0745 LINE PRESSURE SOLENOID VALVE
[EURO-OBD]

DTC P0745 LINE PRESSURE SOLENOID VALVE
Description

PFP:31940

A
BCS000QG

The line pressure solenoid valve regulates the oil pump discharge pressure to suit the driving condition in
response to signals sent from the TCM.
The line pressure duty cycle value is not constant when the closed throttle position switch is ON. To
confirm the line pressure duty cycle at low-pressure, the accelerator (throttle) should be open until the
closed throttle position switch is OFF.

CONSULT-II Reference Value
Display value (Approx.)

Small throttle opening (Low line pressure) ⇔ Large
throttle opening (High line pressure)

●

BCS000QI

This is an OBD self-diagnostic item.
Diagnostic trouble code “P0745 LINE PRESSURE S/V” with CONSULT-II or 11th judgement flicker without CONSULT-II is detected when TCM detects an improper voltage drop while it tries to operate the solenoid valve.

Possible Cause
●

●

D

0% ⇔ 94%

On Board Diagnosis Logic
●

AT

BCS000QH

Remarks: Specification data are reference values.
Item name
Condition
LINE PRES DTY

B

BCS000QJ

Harness or connector
(The solenoid circuit is open or shorted.)
Line pressure solenoid valve

E

F

G

H

DTC Confirmation Procedure

BCS000QK

CAUTION:
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at
least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

I

J

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

Turn ignition switch ON and select “DATA MONITOR” mode for
“A/T” with CONSULT-II.
Touch “START”.
Depress accelerator pedal completely and wait at least 1 second.
If the check result is NG, go to AT-155, «Diagnostic Procedure» .

K

L

M
BCIA0031E

WITH GST
Follow the procedure “WITH CONSULT-II”.

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

Start engine.
With brake pedal depressed, shift the lever from “P” → “N” → “D” → “N” → “P” positions.
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-155, «Diagnostic Procedure» .

AT-153

DTC P0745 LINE PRESSURE SOLENOID VALVE
[EURO-OBD]

Wiring Diagram — AT — LPSV

BCS000QL

MCWA0247E

AT-154

DTC P0745 LINE PRESSURE SOLENOID VALVE
[EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

1

2

Wire color

Item

Condition
When releasing accelerator pedal after
warming up engine.

Line pressure solenoid
valve

P

When depressing accelerator pedal fully
after warming up engine.
When releasing accelerator pedal after
warming up engine.

Line pressure solenoid
valve (with dropping
resistor)

V

When depressing accelerator pedal fully
after warming up engine.

Diagnostic Procedure

Judgement standard
(Approx.)
1.5 — 3.0V

A

B

0V

AT

4 — 14V
0V

D
BCS000QM

1. CHECK INPUT SIGNAL

E

With CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Read out the value of “LINE PRES DTY” while driving. Check
the value changes according to driving speed.
Item name

Condition

Display value

LINE PRES DTY

Small throttle opening (Low line pressure)
⇔ Large throttle opening (High line pressure)

0% ⇔ 94%

F

G

H

I
SCIA3251E

J

Without CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Check voltage between TCM connector terminals and ground.

Item

Line pressure solenoid valve

Line pressure solenoid valve
(with dropping resistor)

Connector

E106

E106

Terminal

1 — Ground

2 — Ground

K

Condition

Judgement standard
(Approx.)

L

When releasing accelerator pedal after warming
up engine.

1.5 — 3.0V

M

When depressing accelerator pedal fully after
warming up engine.

0V

When releasing accelerator pedal after warming
up engine.

4 — 14V

When depressing accelerator pedal fully after
warming up engine.

0V

SCIA3267E

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.

AT-155

DTC P0745 LINE PRESSURE SOLENOID VALVE
[EURO-OBD]

2. CHECK DROPPING RESISTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect dropping resistor harness connector in engine room.
Check resistance between terminals.
Item

Dropping resistor

Connector

Terminal

Resistance (Approx.)

E58

1-2

12 Ω

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace damaged parts.

SCIA4950E

3. CHECK VALVE RESISTANCE
1.
2.
3.

Turn ignition switch OFF.
Disconnect terminal cord assembly connector in engine room.
Check resistance between terminal cord assembly harness connector terminal and ground.
Solenoid valve

Connector

Terminal

Resistance (Approx.)

Line pressure solenoid
valve

F13

4 — Ground

2.5 — 5.0 Ω

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace damaged parts.
SCIA3457E

AT-156

DTC P0745 LINE PRESSURE SOLENOID VALVE
[EURO-OBD]

4.
1.
2.
3.

CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR
Turn ignition switch OFF.
Disconnect terminal cord assembly harness connector and TCM connector.
Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal.
Item

Connector

Terminal

TCM

E106

1

F13

4

Terminal cord assembly
harness connector

B

Continuity

AT

Yes

D

SCIA3272E

4.

Check continuity between terminal cord assembly harness connector terminal and dropping resistor harness connector terminal.
Item

A

Connector

Terminal

Dropping resistor harness
connector

E58

2

Terminal cord assembly
harness connector

F13

4

E

F

Continuity

G

Yes

H

SCIA7194E

I

5.

Check continuity between dropping resistor harness connector
terminal and TCM connector terminal.
Item

Connector

Terminal

TCM

E106

2

E58

1

Dropping resistor harness
connector

J

Continuity
Yes

6. If OK, check harness for short to ground and short to power.
7. If OK, check continuity between ground and transaxle assembly.
8. Reinstall any part removed.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK DTC
Perform AT-153, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.

6. CHECK TCM
1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-157

K

L
SCIA7195E

M

DTC P0745 LINE PRESSURE SOLENOID VALVE
[EURO-OBD]

Component Inspection

BCS000QN

LINE PRESSURE SOLENOID VALVE
●

For removal, refer to AT-345, «Control Valve Assembly and Accumulators» .

Resistance Check
●

Check resistance between terminal and ground.
Solenoid valve

Resistance
(Approx.)

Terminal

Line pressure
solenoid valve

4

Ground

2.5 — 5 Ω

SCIA3457E

Operation Check
●

Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground.

SCIA3275E

DROPPING RESISTOR
●

Check resistance between terminals.
Item
Dropping resistor

Connector

Terminal

Resistance (Approx.)

E58

1-2

12 Ω

SCIA4950E

AT-158

DTC P0750 SHIFT SOLENOID VALVE A
[EURO-OBD]

DTC P0750 SHIFT SOLENOID VALVE A
Description

PFP:31940

A
BCS000QO

Shift solenoid valves A and B are turned ON or OFF by the TCM in response to signals sent from the PNP
switch, vehicle speed and ECM (throttle opening). Gears will then be shifted to the optimum position.
Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

CONSULT-II Reference Value

D
Display value

When shift solenoid valve A operates.
(When driving in “D1 ” or “D4 ”.)

ON

When shift solenoid valve A does not operate.
(When driving in “D2 ” or “D3 ”.)

OFF

On Board Diagnosis Logic
●
●

●

E

BCS000QQ

This is an OBD self-diagnostic item.
Diagnostic trouble code “P0750 SHIFT SOLENOID/V A” with CONSULT-II or 4th judgement flicker without
CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid
valve.

Possible Cause
●

BCS000QR

Harness or connector
(The solenoid circuit is open or shorted.)
Shift solenoid valve A

WITH CONSULT-II

5.

H

WITH GST
Follow the procedure “WITH CONSULT-II”.

WITHOUT CONSULT-II
Start engine.
Drive vehicle in D1 → D2 position.
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-161, «Diagnostic Procedure» .

AT-159

J

K

L

Turn ignition switch ON and select “DATA MONITOR” mode for
“A/T” with CONSULT-II.
Touch “START”.
Start engine.
Drive vehicle in “D” position and allow the transaxle to shift 1 →
2 (“GEAR”).
If the check result is NG, go to AT-161, «Diagnostic Procedure» .

M

BCIA0031E

1.
2.
3.
4.

G

BCS000QS

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

2.
3.
4.

F

I

DTC Confirmation Procedure

1.

AT

BCS000QP

Remarks: Specification data are reference values.
Item name
Condition

SHIFT S/V A

B

DTC P0750 SHIFT SOLENOID VALVE A
[EURO-OBD]

Wiring Diagram — AT — SSV/A

BCS000QT

MCWA0248E

AT-160

DTC P0750 SHIFT SOLENOID VALVE A
[EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

11

R

Item

Condition

Shift solenoid valve A

Judgement standard
(Approx.)

When shift solenoid valve A operates.
(When driving in “D1 ” or “D4 ”.)

Battery voltage

When shift solenoid valve A does not
operate.
(When driving in “D2 ” or “D3 ”.)

0V

Diagnostic Procedure

BCS000QU

D

With CONSULT-II
Start engine.
Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
Read out the value of “SHIFT S/V A” while driving.
Check the value changes according to driving speed.

Item name

SHIFT S/V A

B

AT

1. CHECK INPUT SIGNAL
1.
2.
3.

A

Condition

Display value

When shift solenoid valve A operates.
(When driving in “D1 ” or “D4 ”.)

ON

When shift solenoid valve A does not operate.
(When driving in “D2 ” or “D3 ”.)

OFF

E

F

G

H
SCIA3251E

I

1.
2.

Without CONSULT-II
Start engine.
Check voltage between TCM connector terminal and ground.

Item

Shift solenoid valve A

Connector

E106

Terminal

11 Ground

Condition

Judgement standard
(Approx.)

When shift solenoid valve
A operates.
(When driving in “D1 ” or
“D4 ”.)

Battery
voltage

When shift solenoid valve
A does not operate.
(When driving in “D2 ” or
“D3 ”.)

0V

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.

AT-161

J

K

L

SCIA3248E

M

DTC P0750 SHIFT SOLENOID VALVE A
[EURO-OBD]

2. CHECK SHIFT SOLENOID VALVE A CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect TCM connector.
Check resistance between TCM connector terminal and ground.
Solenoid Valve

Shift solenoid valve A

Connector

Terminal

Resistance
(Approx.)

E106

11 — Ground

20 — 30 Ω

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
SCIA3249E

3.
1.
2.
3.

CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR
Turn ignition switch OFF.
Disconnect terminal cord assembly harness connector and TCM connector.
Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal.
Item

Connector

Terminal

TCM

E106

11

F13

2

Terminal cord assembly
harness connector

Continuity
Yes

4. If OK, check harness for short to ground and short to power.
5. If OK, check continuity between ground and transaxle assembly.
6. Reinstall any part removed.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

SCIA3250E

4. CHECK VALVE RESISTANCE
1.
2.
3.

Turn ignition switch OFF.
Disconnect terminal cord assembly connector in engine room.
Check resistance between terminal cord assembly harness connector terminal and ground.
Solenoid valve

Shift solenoid valve A

Connector

Terminal

Resistance (Approx.)

F13

2 — Ground

20 — 30 Ω

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace damaged parts.
SCIA3453E

5. CHECK DTC
Perform AT-159, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.

AT-162

DTC P0750 SHIFT SOLENOID VALVE A
[EURO-OBD]

6. CHECK TCM

A

1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

B

AT

Component Inspection

BCS000QV

SHIFT SOLENOID VALVE A
●

For removal, refer to AT-345, «Control Valve Assembly and Accumulators» .

D

Resistance Check
●

Check resistance between terminal and ground.
E
Solenoid valve
Shift solenoid valve A

Resistance
(Approx.)

Terminal
2

Ground

20 — 30 Ω

F

G
SCIA2049E

H

Operation Check
●

Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground.

I

J

K
SCIA2052E

L

M

AT-163

DTC P0755 SHIFT SOLENOID VALVE B
[EURO-OBD]

DTC P0755 SHIFT SOLENOID VALVE B
Description

PFP:31940
BCS000QW

Shift solenoid valves A and B are turned ON or OFF by the TCM in response to signals sent from the PNP
switch, vehicle speed and ECM (throttle opening). Gears will then be shifted to the optimum position.
Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

CONSULT-II Reference Value

BCS000QX

Remarks: Specification data are reference values.
Item name
Condition

SHIFT S/V B

Display value

When shift solenoid valve B operates.
(When driving in “D1 ” or “D2 ”.)

ON

When shift solenoid valve B does not operate.
(When driving in “D3 ” or “D4 ”.)

OFF

On Board Diagnosis Logic
●
●

BCS000QY

This is an OBD self-diagnostic item.
Diagnostic trouble code “P0755 SHIFT SOLENOID/V B” with CONSULT-II or 5th judgement flicker without
CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid
valve.

Possible Cause
●

●

BCS000QZ

Harness or connector
(The solenoid circuit is open or shorted.)
Shift solenoid valve B

DTC Confirmation Procedure

BCS000R0

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and select “DATA MONITOR” mode for
“A/T” with CONSULT-II.
Touch “START”.
Start engine.
Drive vehicle in D position and allow the transaxle to shift 1 → 2
→ 3 (“GEAR”).
If the check result is NG, go to AT-166, «Diagnostic Procedure» .

BCIA0031E

WITH GST
Follow the procedure “WITH CONSULT-II”.

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

Start engine.
Drive vehicle in D1 → D2 → D3 position.
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-166, «Diagnostic Procedure» .

AT-164

DTC P0755 SHIFT SOLENOID VALVE B
[EURO-OBD]

Wiring Diagram — AT — SSV/B

BCS000R1

A

B

AT

D

E

F

G

H

I

J

K

L

M

MCWA0249E

AT-165

DTC P0755 SHIFT SOLENOID VALVE B
[EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

12

SB

Item

Condition

Shift solenoid valve B

Judgement standard
(Approx.)

When shift solenoid valve B operates.
(When driving in “D1 ” or “D2 ”.)

Battery voltage

When shift solenoid valve B does not
operate.
(When driving in “D3 ” or “D4 ”.)

0V

Diagnostic Procedure

BCS000R2

1. CHECK INPUT SIGNAL
1.
2.
3.

With CONSULT-II
Start engine.
Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
Read out the value of “SHIFT S/V B” while driving.
Check the value changes according to driving speed.

Item name

SHIFT S/V B

Condition

Display value

When shift solenoid valve B operates.
(When driving in “D1 ” or “D2 ”.)

ON

When shift solenoid valve B does not operate.
(When driving in “D3 ” or “D4 ”.)

OFF

SCIA3251E

1.
2.

Without CONSULT-II
Start engine.
Check voltage between TCM connector terminal and ground.

Item

Shift solenoid valve B

Connector

E106

Terminal

12 Ground

Condition

Judgement standard
(Approx.)

When shift solenoid valve
B operates.
(When driving in “D1 ” or
“D2 ”.)

Battery
voltage

When shift solenoid valve
B does not operate.
(When driving in “D3 ” or
“D4 ”.)

0V

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.

AT-166

SCIA3253E

DTC P0755 SHIFT SOLENOID VALVE B
[EURO-OBD]

2. CHECK SHIFT SOLENOID VALVE B CIRCUIT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect TCM connector.
Check resistance between TCM connector terminal and ground.
Solenoid Valve

Shift solenoid valve B

Connector

Terminal

Resistance
(Approx.)

E106

12 — Ground

5 — 20 Ω

B

AT

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.

D

SCIA3254E

3.
1.
2.
3.

E

CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR
F

Turn ignition switch OFF.
Disconnect terminal cord assembly harness connector and TCM connector.
Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal.
Item

Connector

Terminal

TCM

E106

12

F13

1

Terminal cord assembly
harness connector

G

Continuity

H
Yes

4. If OK, check harness for short to ground and short to power.
5. If OK, check continuity between ground and transaxle assembly.
6. Reinstall any part removed.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

I

SCIA3255E

J

K

4. CHECK VALVE RESISTANCE
1.
2.
3.

L

Turn ignition switch OFF.
Disconnect terminal cord assembly connector in engine room.
Check resistance between terminal cord assembly harness connector terminal and ground.
Solenoid valve

Shift solenoid valve B

Connector

Terminal

Resistance (Approx.)

F13

1 — Ground

5 — 20 Ω

M

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace damaged parts.
SCIA3454E

5. CHECK DTC
Perform AT-164, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.

AT-167

DTC P0755 SHIFT SOLENOID VALVE B
[EURO-OBD]

6. CHECK TCM
1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

Component Inspection

BCS000R3

SHIFT SOLENOID VALVE B
●

For removal, refer to AT-345, «Control Valve Assembly and Accumulators» .

Resistance Check
●

Check resistance between terminal and ground.
Solenoid valve
Shift solenoid valve B

Resistance
(Approx.)

Terminal
1

Ground

5 — 20Ω

SCIA2055E

Operation Check
●

Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground.

SCIA2058E

AT-168

DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR
[EURO-OBD]

DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR
Description

PFP:22620

A
BCS000R4

Electric throttle control actuator consists of throttle control motor, accelerator pedal position sensor, throttle
position sensor, etc. The actuator sends signals to the ECM, and ECM sends signals to TCM via CAN communication.

CONSULT-II Reference Value

BCS000R5

AT

Remarks: Specification data are reference values.
Item name
Condition
THROTTLE POSI

Display value (Approx.)

Released accelerator pedal.

0.0/8

Fully depressed accelerator pedal.

8.0/8

On Board Diagnosis Logic
●
●

B

D
BCS000R6

This is an OBD self-diagnostic item.
Diagnostic trouble code “P1705 THROTTLE POSI SEN” with CONSULT-II or 3rd judgement flicker without CONSULT-II is detected when TCM does not receive the proper accelerator pedal position signals
(input via CAN communication) from ECM.

Possible Cause

E

F

BCS000R7

Harness or connector
(The sensor circuit is open or shorted.)

G

DTC Confirmation Procedure

BCS000R8

CAUTION:
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at
least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

H

I

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

Turn ignition switch ON. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Depress accelerator pedal fully and release it, then wait for 5
seconds.
If DTC is detected, go to AT-170, «Diagnostic Procedure» .

J

K

L

BCIA0031E

WITH GST
Follow the procedure “WITH CONSULT-II”.

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

Turn ignition switch ON. (Do not start engine.)
Depress accelerator pedal fully and release it, then wait for 5 seconds.
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-170, «Diagnostic Procedure» .

AT-169

M

DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR
[EURO-OBD]

Diagnostic Procedure

BCS000R9

1. CHECK CAN COMMUNICATION LINE
Perform self-diagnosis. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» , AT-94, «Diagnostic Procedure
Without CONSULT-II» .
Is any malfunction of the “U1000 CAN COMM CIRCUIT” indicated?
YES >> Check the CAN communication line. Refer to AT-102, «DTC U1000 CAN COMMUNICATION
LINE» .
NO
>> GO TO 2.

2. CHECK INPUT SIGNAL
With CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T”
with CONSULT-II.
3. Read out the value of “THROTTLE POSI”.
Item name
THROTTLE POSI

Condition

Display value
(Approx.)

Released accelerator pedal.

0.0/8

Fully depressed accelerator pedal.

8.0/8

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

SCIA3251E

3. CHECK DTC WITH ECM
With CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Select “SELF-DIAG RESULTS” mode for “ENGINE” with CONSULT-II. Refer to EC-104, «SELF-DIAG RESULTS MODE» .
OK or NG
OK
>> GO TO 4.
NG
>> Check the DTC Detected Item. Go to EC-104, «SELFDIAG RESULTS MODE» .

BCIA0030E

4. CHECK DTC
Perform “DTC Confirmation Procedure”. Refer to AT-169, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.

5. CHECK TCM
1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-170

DTC P1760 OVERRUN CLUTCH SOLENOID VALVE
[EURO-OBD]

DTC P1760 OVERRUN CLUTCH SOLENOID VALVE
Description

PFP:31940

A
BCS000RA

The overrun clutch solenoid valve is activated by the TCM in response to signals sent from the PNP switch,
overdrive control switch, vehicle speed and ECM (throttle opening). The overrun clutch operation will then be
controlled.

CONSULT-II Reference Value

BCS000RB

AT

Remarks: Specification data are reference values.
Item name
Condition

OVERRUN/C S/V

Display value

When overrun clutch solenoid valve operates. (When
overrun clutch disengaged. Refer to AT-22 .)

ON

When overrun clutch solenoid valve does not operate.
(When overrun clutch engaged. Refer to AT-22 .)

OFF

●

BCS000RC

This is an OBD self-diagnostic item.
Diagnostic trouble code “P1760 OVERRUN CLUTCH S/V” with CONSULT-II or 6th judgement flicker without CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate solenoid
valve.

Possible Cause
●

●

D

E

On Board Diagnosis Logic
●

BCS000RD

Harness or connector
(The solenoid circuit is open or shorted.)
Overrun clutch solenoid valve

WITH CONSULT-II

5.
6.

WITH GST
Follow the procedure “WITH CONSULT-II”.

WITHOUT CONSULT-II

3.
4.

Start engine.
Drive vehicle under the following conditions:
Selector lever position: “D” position (OD ON)
Vehicle speed: Higher than 10 km/h (6 MPH)
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-173, «Diagnostic Procedure» .

AT-171

I

J

K

Turn ignition switch ON and select “DATA MONITOR” mode for
“A/T” with CONSULT-II.
Touch “START”.
Start engine.
Accelerate vehicle to a speed of more than 10 km/h (6 MPH)
with “D” position (OD ON).
Release accelerator pedal completely with “D” position (OD
OFF).
If the check result is NG, go to AT-173, «Diagnostic Procedure» .

L

M

BCIA0031E

1.
2.

G

BCS000RE

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

2.
3.
4.

F

H

DTC Confirmation Procedure

1.

B

DTC P1760 OVERRUN CLUTCH SOLENOID VALVE
[EURO-OBD]

Wiring Diagram — AT — OVRCSV

BCS000RF

MCWA0250E

AT-172

DTC P1760 OVERRUN CLUTCH SOLENOID VALVE
[EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

20

Wire color

Item

Condition

Overrun clutch solenoid
valve

LG

Judgement standard
(Approx.)

When overrun clutch solenoid valve
operates. (When overrun clutch disengaged. Refer to AT-22 .)

Battery voltage

When overrun clutch solenoid valve
dose not operate. (When overrun
clutch engaged. Refer to AT-22 .)

0V

Diagnostic Procedure

BCS000RG

D

With CONSULT-II
1. Start engine.
2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Read out the value of “OVERRUN/C S/V” while driving.
Check the value changes according to driving speed.
Condition

OVERRUN/C S/V

E

F

Display value

G

When overrun clutch solenoid valve operates. (When overrun clutch disengaged.
Refer to AT-22 .)

ON

When overrun clutch solenoid valve does
not operate. (When overrun clutch
engaged. Refer to AT-22 .)

OFF

H

SCIA3257E

Without CONSULT-II
1. Start engine.
2. Check voltage between TCM connector terminal and ground.

Item

Overrun
clutch solenoid valve

Connector

E106

Terminal

20 Ground

B

AT

1. CHECK INPUT SIGNAL

Item name

A

J

Judgement standard
(Approx.)

Condition

When overrun clutch
solenoid valve operates.
(When overrun clutch
disengaged. Refer to AT22 .)

I

K

L
Battery
voltage

When overrun clutch
solenoid valve dose not
operate. (When overrun
clutch engaged. Refer to
AT-22 .)

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.

AT-173

M
SCIA3258E

0V

DTC P1760 OVERRUN CLUTCH SOLENOID VALVE
[EURO-OBD]

2. CHECK OVERRUN CLUTCH SOLENOID VALVE CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect TCM connector.
Check resistance between TCM connector terminal and ground.
Solenoid Valve

Connector

Terminal

Resistance
(Approx.)

Overrun clutch solenoid
valve

E106

20 — Ground

20 — 30 Ω

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
SCIA3259E

3.
1.
2.
3.

CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR
Turn ignition switch OFF.
Disconnect terminal cord assembly harness connector and TCM connector.
Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal.
Item

Connector

Terminal

TCM

E106

20

F13

3

Terminal cord assembly
harness connector

Continuity
Yes

4. If OK, check harness for short to ground and short to power.
5. If OK, check continuity between ground and transaxle assembly.
6. Reinstall any part removed.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

SCIA3260E

4. CHECK VALVE RESISTANCE
1.
2.
3.

Turn ignition switch OFF.
Disconnect terminal cord assembly connector in engine room.
Check resistance between terminal cord assembly harness connector terminal and ground.
Solenoid valve

Connector

Terminal

Resistance (Approx.)

Overrun clutch solenoid
valve

F13

3 — Ground

20 — 30 Ω

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace damaged parts.
SCIA3455E

5. CHECK DTC
Perform AT-171, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.

AT-174

DTC P1760 OVERRUN CLUTCH SOLENOID VALVE
[EURO-OBD]

6. CHECK TCM

A

1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

B

AT

Component Inspection

BCS000RH

OVERRUN CLUTCH SOLENOID VALVE
●

For removal, refer to AT-345, «Control Valve Assembly and Accumulators» .

D

Resistance Check
●

Check resistance between terminal and ground.
E
Solenoid valve
Overrun clutch
solenoid valve

Resistance
(Approx.)

Terminal
3

Ground

F

20 — 30Ω

G
SCIA2059E

H

Operation Check
●

Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground.

I

J

K
SCIA2062E

L

M

AT-175

DTC VEHICLE SPEED SENSOR MTR
[EURO-OBD]

DTC VEHICLE SPEED SENSOR MTR
Description

PFP:24814
BCS000RI

The vehicle speed sensor·MTR is built into the speedometer assembly. The sensor functions as an auxiliary
device to the revolution sensor when it is malfunctioning. The TCM will then use a signal sent from the vehicle
speed sensor·MTR.

CONSULT-II Reference Value

BCS000RJ

Remarks: Specification data are reference values.
Item name
Condition
VHCL/S SE-MTR

Display value

During driving

Approximately matches the speedometer reading.

On Board Diagnosis Logic
●
●

BCS000RK

This is not an OBD self-diagnostic item.
Diagnostic trouble code “VHCL SPEED SEN-MTR” with CONSULT-II or 2nd judgement flicker without
CONSULT-II is detected when TCM does not receive the proper voltage signal from the sensor.

Possible Cause
●

●

BCS000RL

Harness or connector
(The sensor circuit is open or shorted.)
Vehicle speed sensor

DTC Confirmation Procedure

BCS000RM

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

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

Turn ignition switch ON and select “DATA MONITOR” mode for
“A/T” with CONSULT-II.
Touch “START”.
Start engine and accelerate vehicle from 0 to 25 km/h (0 to 16
MPH).
If the check result is NG, go to AT-178, «Diagnostic Procedure» .

BCIA0031E

WITHOUT CONSULT-II
1.
2.

3.
4.

Start engine.
Drive vehicle under the following conditions:
Selector lever position: “D” position
Vehicle speed: Higher than 25 km/h (16 MPH)
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-178, «Diagnostic Procedure» .

AT-176

DTC VEHICLE SPEED SENSOR MTR
[EURO-OBD]

Wiring Diagram — AT — VSSMTR

BCS000RN

A

B

AT

D

E

F

G

H

I

J

K

L

M

MCWA0251E

AT-177

DTC VEHICLE SPEED SENSOR MTR
[EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

40

R

Item

Condition
When driving vehicle at 2 to 3 km/h (1
to 2 MPH) for 1 m (3 ft) or more.

Vehicle speed sensor

Diagnostic Procedure

Judgement standard
(Approx.)
Voltage varies between
less than 0V and more
than 4.5V
BCS000RO

1. CHECK INPUT SIGNAL
With CONSULT-II
1. Start engine.
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for
“A/T” with CONSULT-II.
3. Read out the value of “VHCL/S SE-MTR” while driving. Check
the value changes according to driving speed.
Item name

Condition

Display value

VHCL/S SE-MTR

During driving

Approximately matches
the speedometer reading.

LCIA0090E

Without CONSULT-II
1. Start engine.
2. Check voltage between TCM connector terminal and ground.
Item

Vehicle
speed sensor

Connector

E107

Terminal

Condition

Judgement
standard
(Approx.)

40 Ground

When driving vehicle at
2 to 3 km/h (1 to 2 MPH)
for 1 m (3 ft) or more.

Voltage varies between
less than 0V
and more than
4.5V

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

SCIA3246E

2. DETECT MALFUNCTIONING ITEM
Check the following items:
●
Combination meter. Refer to DI-4, «COMBINATION METERS» .
●
Harness for short or open between TCM and combination meter.
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace damaged parts.

3. CHECK DTC
Perform AT-176, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 4.

AT-178

DTC VEHICLE SPEED SENSOR MTR
[EURO-OBD]

4. CHECK TCM

A

1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

B

AT

D

E

F

G

H

I

J

K

L

M

AT-179

DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM
POWER SOURCE)
[EURO-OBD]

DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM
POWER SOURCE)
PFP:31940
Description

BCS000RP

The A/T fluid temperature sensor detects the A/T fluid temperature and sends a signal to the TCM.

CONSULT-II Reference Value

BCS000RQ

Remarks: Specification data are reference values.
Item name
Condition
FLUID TEMP SE

Display value

When A/T fluid temperature is 20°C (68°F).

1.5V

When A/T fluid temperature is 80°C (176°F).

0.5V

On Board Diagnosis Logic
●
●

BCS000RR

This is not an OBD self-diagnostic item.
Diagnostic trouble code “BATT/FLUID TEMP SEN” with CONSULT-II or 8th judgement flicker without
CONSULT-II is detected when TCM receives an excessively low or high voltage from the sensor.

Possible Cause
●

●

BCS000RS

Harness or connector
(The sensor circuit is open or shorted.)
A/T fluid temperature sensor

DTC Confirmation Procedure

BCS000RT

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

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

5.

Start engine.
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Touch “START”.
Drive vehicle under the following conditions.
SLCT LVR POSI: “D” position
VEHICLE SPEED: Higher than 20 km/h (12 MPH)
If the check result is NG, go to AT-182, «Diagnostic Procedure» .

BCIA0031E

WITHOUT CONSULT-II
1.
2.

3.
4.

Start engine.
Drive vehicle under the following conditions.
Selector lever position: D position
Vehicle speed: higher than 20 km/h (12 MPH)
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-182, «Diagnostic Procedure» .

AT-180

DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM
POWER SOURCE)
[EURO-OBD]

Wiring Diagram — AT — BA/FTS

BCS000RU

A

B

AT

D

E

F

G

H

I

J

K

L

M

MCWA0253E

AT-181

DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM
POWER SOURCE)
[EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

10

Item

R

Condition

Power supply

or
19

R

28

Power supply

Power supply
(memory back-up)

LG

42

B

47

When turning ignition switch to
“ON”.

Battery voltage

When turning ignition switch to
“OFF”.

0V

When turning ignition switch to
“ON”.

Battery voltage

When turning ignition switch to
“OFF”.

0V
Battery voltage

Always

Sensor ground
A/T fluid temperature
sensor

BR

Judgement standard (Approx.)

0V

and

Diagnostic Procedure

When A/T fluid temperature is
20°C (68°F).

1.5V

When A/T fluid temperature is
80°C (176°F).

0.5V

BCS000RV

1. CHECK TCM POWER SOURCE
1.
2.

Turn ignition switch ON. (Do not start engine.)
Check voltage between TCM connector terminals and ground.
Item

Connector

Power supply

E106

Power supply
(Memory back-up)

E107

Terminal

Judgement standard (Approx.)

10

Battery voltage

19

Battery voltage

28

Battery voltage

SCIA2656E

3.
4.

Turn ignition switch OFF.
Check voltage between TCM connector terminals and ground.
Item

Connector

Power supply

E106

Power supply
(memory back-up)

E107

Terminal

Judgement standard (Approx.)

10

0V

19

0V

28

Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

SCIA2657E

AT-182

DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM
POWER SOURCE)
[EURO-OBD]

2. DETECT MALFUNCTIONING ITEM

A

Check the following items:
●
Harness for short or open between ignition switch and TCM terminals 10, 19
●
Harness for short or open between battery and TCM terminal 28
●
10A fuse (No.7, located in the fuse block) and 10A fuse (No.58, located in the IPDM E/R)
●
Ignition switch. Refer to PG-38, «GROUND» .
OK or NG
OK
>> GO TO 9.
NG
>> Repair or replace damaged parts.

B

AT

D

3. CHECK INPUT SIGNAL OF A/T FLUID TEMPERATURE SENSOR
E

With CONSULT-II
1. Start engine.
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Read out the value of “FLUID TEMP SE”.
Item name
FLUID TEMP
SE

Condition

Display value

When A/T fluid temperature is 20°C (68°F).

1.5V

When A/T fluid temperature is 80°C
(176°F).

0.5V

F

G

H

I
LCIA0090E

Without CONSULT-II
1. Start engine.
2. Check voltage TCM connector terminals while warming up A/T.

Item

A/T fluid
temperature
sensor

Connector

E107

Terminal

47 — 42

J

K

Judgement standard
(Approx.)

Condition

When A/T fluid temperature is 20°C (68°F).

1.5V

When A/T fluid temperature is 80°C (176°F).

0.5V

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 4.

L

M
SCIA2658E

4. DETECT MALFUNCTIONING ITEM
Check the following items:
●
Harness for short or open between TCM, ECM and terminal cord assembly
●
Ground circuit for ECM
Refer to EC-128, «POWER SUPPLY AND GROUND CIRCUIT» .
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace damaged parts.

AT-183

DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM
POWER SOURCE)
[EURO-OBD]

5.

CHECK FLUID TEMPERATURE SENSOR CIRCUIT

1.
2.
3.

Turn ignition switch OFF.
Disconnect the TCM connector.
Check resistance between terminals.
Item

A/T fluid
temperature sensor

Connector

Terminal

E107

47 — 42

Temperature °C (°F)

Resistance
(Approx.)

20 (68)

2.5 kΩ

80 (176)

0.3 kΩ

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 6.
SCIA2338E

6.
1.
2.
3.

CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR
Turn ignition switch OFF.
Disconnect terminal cord assembly harness connector and TCM connector.
Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal.
Item

Connector

Terminal

TCM

E107

42

F13

7

E107

47

F13

6

Terminal cord assembly
harness connector
TCM
Terminal cord assembly
harness connector

Continuity
Yes

Yes
SCIA2660E

4. If OK, check harness for short to ground and short to power.
5. If OK, check continuity between ground and transaxle assembly.
6. Reinstall any part removed.
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

7. CHECK A/T FLUID TEMPERATURE SENSOR WITH TERMINAL CORD ASSEMBLY
1.
2.
3.

Turn ignition switch OFF.
Disconnect terminal cord assembly connector in engine room.
Check resistance between terminal cord assembly terminals.
Temperature °C (°F)

Resistance (Approx.)

20 (68)

Approx. 2.5 kΩ

80 (176)

Approx. 0.3 kΩ

4. Reinstall any part removed.
OK or NG
OK
>> GO TO 8.
NG
>> Repair or replace damaged parts.
SCIA4948E

AT-184

DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM
POWER SOURCE)
[EURO-OBD]

8. DETECT MALFUNCTIONING ITEM
1.
2.
–

•

A

Remove oil pan. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
A/T fluid temperature sensor
Check resistance between terminal cord assembly harness connector terminals while changing temperature as shown.

B

AT
Temperature [°C (°F)]

Resistance (Approx.)

20 (68)

2.5 kΩ

80 (176)

0.3 kΩ

Harness of terminal cord assembly for short or open
OK or NG
OK
>> GO TO 9.
NG
>> Repair or replace damaged parts.

D

–

E
SAT298F

9. CHECK DTC

F

Perform AT-180, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 10.

G

H

10. CHECK TCM
1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

Component Inspection

I

J
BCS000RW

A/T FLUID TEMPERATURE SENSOR
●

●

K

Remove oil pan. Refer to AT-345, «Control Valve Assembly and
Accumulators» .
Check resistance between terminal cord assembly harness connector terminals while changing temperature as shown.
Temperature [°C (°F)]

Resistance (Approx.)

20 (68)

2.5 kΩ

80 (176)

0.3 kΩ

L

M

SAT298F

AT-185

DTC TURBINE REVOLUTION SENSOR
[EURO-OBD]

DTC TURBINE REVOLUTION SENSOR
Description

PFP:31935
BCS000RX

The turbine revolution sensor (power train revolution sensor) detects forward clutch drum rpm (revolutions per
minute). It is located on the input side of the automatic transaxle. The vehicle speed sensor A/T (Revolution
sensor) is located on the output side of the automatic transaxle. With the two sensors, input and output rpms
are accurately detected. As a result, optimal shift timing during deceleration and shift quality can be improved.

CONSULT-II Reference Value

BCS000RY

Remarks: Specification data are reference values.
Item name
Condition
TURBINE REV

Display value

During driving (lock-up ON)

Approximately matches the engine speed.

On Board Diagnosis Logic
●
●

BCS000RZ

This is not an OBD self-diagnostic item.
Diagnostic trouble code “TURBINE SENSOR” with CONSULT-II or 10th judgement flicker without CONSULT-II is detected when TCM does not receive the proper voltage signal from the sensor.

Possible Cause
●

●

BCS000S0

Harness or connector
(The sensor circuit is open or shorted.)
Turbine revolution sensor (power train revolution sensor)

DTC Confirmation Procedure

BCS000S1

CAUTION:
●
Always drive vehicle at a safe speed.
●
Be careful not to rev engine into the red zone on the tachometer.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

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

5.

Start engine.
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Touch “START”.
Drive vehicle under the following conditions for more than 5 seconds.
SLCT LVR POSI: “D” position
VEHICLE SPEED: Higher than 40 km/h (25 MPH)
ENGINE SPEED: Higher than 1,500 rpm
THROTTLE POSI: Greater than 1.0/8 of the full throttle position
If the check result is NG, go to AT-188, «Diagnostic Procedure» .
BCIA0031E

WITHOUT CONSULT-II
1.
2.

3.
4.

Start engine.
Drive vehicle under the following conditions for more than 5 seconds.
Selector lever position: “D” position
Vehicle speed: Higher than 40 km/h (25 MPH)
Engine speed: Higher than 1,500 rpm
Throttle position: 1.0/8 of the full throttle position
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-188, «Diagnostic Procedure» .

AT-186

DTC TURBINE REVOLUTION SENSOR
[EURO-OBD]

Wiring Diagram — AT — PT/SEN

BCS000S2

A

B

AT

D

E

F

G

H

I

J

K

L

M

MCWA0254E

AT-187

DTC TURBINE REVOLUTION SENSOR
[EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

38

LG

42

B

Item

Condition

Turbine revolution sensor (power train revolution sensor)

Judgement standard
(Approx.)

When driving at 20 km/h (12 MPH).

Sensor ground

Always

Diagnostic Procedure

360 Hz
0V
BCS000S3

1. CHECK INPUT SIGNAL
With CONSULT-II
1. Start engine.
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Read out the value of “TURBINE REV” while driving. Check the
value changes according to driving speed.
Item name

Condition

Display value

TURBINE REV

During driving (lock-up
ON)

Approximately matches
the engine speed.

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 2.
SCIA4730E

2.
1.
2.

CHECK TURBINE REVOLUTION SENSOR (POWER TRAIN REVOLUTION SENSOR)

With CONSULT-II
Start engine.
Check power supply to turbine revolution sensor (power train revolution sensor) by voltage between TCM
connector terminals. Refer to AT-194, «Wiring Diagram — AT — MAIN» and AT-187, «Wiring Diagram —
AT — PT/SEN» .
Item

Connector

TCM

E106, E107

Terminal
10 — 42

Judgement standard (Approx.)
Battery voltage

19 — 42

3.

If OK, check the pulse when vehicle cruises.
Name

Condition

Turbine revolution
sensor (power train
revolution sensor)

When driving at 20 km/h (12 MPH), use the CONSULT-II
pulse frequency measuring function.*1
CAUTION:
Connect the diagnosis data link cable to the vehicle
diagnosis connector.
*1: A circuit tester cannot be used to test this item.

Item

Connector

Terminal

Name

Judgement
standard
(Approx.)

TCM

E107

38

Turbine revolution sensor
(power train revolution sensor)

360 Hz

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 3.

SCIA2769E

AT-188

DTC TURBINE REVOLUTION SENSOR
[EURO-OBD]

3.
1.
2.
3.
4.

CHECK POWER AND SENSOR GROUND

A

Turn ignition switch OFF.
Disconnect the turbine revolution sensor (power train revolution sensor) harness connector.
Turn ignition switch ON.
Check voltage between turbine revolution sensor (power train
revolution sensor) harness connector terminals.

B

AT
Item

Connector

Terminal

Judgement
standard
(Approx.)

Turbine revolution sensor
(power train revolution sensor)

F11

1-3

Battery voltage

D

E
SCIA2770E

5.

F

Check voltage between turbine revolution sensor (power train
revolution sensor) harness connector terminal and ground.
Item

Connector

Terminal

Judgement
standard
(Approx.)

Turbine revolution sensor
(power train revolution sensor)

F11

1 — ground

Battery voltage

G

H

6. If OK, check harness for short to ground and short to power.
7. Reinstall any part removed.
SCIA2771E
OK or NG
OK
>> GO TO 4.
NG — 1 >> Battery voltage is not supplied between terminals 1 and 3, terminals 1 and ground: GO TO 6.
NG — 2 >> Battery voltage is not supplied between terminals 1 and 3 only: GO TO 7.

I

J

4.

CHECK HARNESS BETWEEN TCM AND TURBINE REVOLUTION SENSOR (POWER TRAIN REVOLUTION SENSOR)

K

1.
2.

L

3.

Turn ignition switch OFF.
Disconnect the turbine revolution sensor (power train revolution sensor) harness connector and TCM connector.
Check continuity between TCM connector terminal and turbine
revolution sensor (power train revolution sensor) harness connector terminal.
Item

Connector

Terminal

TCM

E107

38

Turbine revolution sensor
(power train revolution sensor)

F48

2

Continuity
Yes

4. If OK, check harness for short to ground and short to power.
5. Reinstall any part removed.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

AT-189

SCIA2772E

M

DTC TURBINE REVOLUTION SENSOR
[EURO-OBD]

5. CHECK TCM
1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, re-check TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> GO TO 8.
NG
>> Repair or replace damaged parts.

6.

CHECK HARNESS BETWEEN TCM AND TURBINE REVOLUTION SENSOR [(POWER TRAIN REVOLUTION SENSOR) POWER]
1.
2.
3.

Turn ignition switch OFF.
Disconnect the turbine revolution sensor (power train revolution sensor) harness connector.
Check continuity between TCM connector terminals and turbine
revolution sensor (power train revolution sensor) harness connector terminal. Refer to AT-52, «Circuit Diagram» and AT-194,
«Wiring Diagram — AT — MAIN» .
Item

Connector

Terminal

TCM

E106

10

Turbine revolution sensor
(power train revolution sensor)

F11

1

TCM

E106

19

Turbine revolution sensor
(power train revolution sensor)

F11

1

Continuity
Yes

Yes

SCIA2773E

4. If OK, check harness for short to ground and short to power.
5. Reinstall any part removed.
OK or NG
OK
>> 10A fuse (No.58, located in the IPDM E/R) or ignition switch are malfunctioning.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

7.

CHECK HARNESS BETWEEN TCM AND TURBINE REVOLUTION [(POWER TRAIN REVOLUTION
SENSOR) SENSOR GROUND]
1.
2.
3.

Turn ignition switch OFF.
Disconnect the turbine revolution sensor (power train revolution sensor) harness connector.
Check continuity between TCM connector terminal and turbine
revolution sensor (power train revolution sensor) harness connector terminal.
Item

Connector

Terminal

TCM

E107

42

Turbine revolution sensor
(power train revolution sensor)

F11

3

Continuity
Yes

4. If OK, check harness for short to ground and short to power.
5. Reinstall any part removed.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

AT-190

SCIA2774E

DTC TURBINE REVOLUTION SENSOR
[EURO-OBD]

8. CHECK DTC

A

Perform AT-186, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.

B

AT

D

E

F

G

H

I

J

K

L

M

AT-191

CONTROL UNIT (RAM), CONTROL UNIT (ROM)
[EURO-OBD]

CONTROL UNIT (RAM), CONTROL UNIT (ROM)
Description

PFP:31036
BCS000S4

The TCM consists of a microcomputer and connectors for signal
input and output and for power supply. The unit controls the A/T.

SAT574J

On Board Diagnosis Logic
●
●

BCS000S5

This is not an OBD self-diagnostic item.
Diagnostic trouble code “CONTROL UNIT (RAM)”, “CONTROL UNIT (ROM)” with CONSULT-II is
detected when TCM memory (RAM) or (ROM) is malfunctioning.

Possible Cause

BCS000S6

TCM.

DTC Confirmation Procedure

BCS000S7

CAUTION:
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at
least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and select “DATA MONITOR” mode for
A/T with CONSULT-II.
Touch “START”.
Start engine.
Run engine for at least 2 seconds at idle speed.
If the check result is NG, go to AT-192, «Diagnostic Procedure» .

BCIA0031E

Diagnostic Procedure

BCS000S8

1. CHECK DTC
With CONSULT-II
1. Turn ignition switch ON and select “SELF-DIAG RESULTS” mode for A/T with CONSULT-II.
2. Touch “ERASE”.
3. Perform AT-192, «DTC Confirmation Procedure» .
Is the “CONTROL UNIT (RAM)” or “CONTROL UNIT (ROM)” displayed again?
YES >> Replace TCM. Refer to AT-330, «Removal and Installation (LHD)» .
NO
>> INSPECTION END

AT-192

MAIN POWER SUPPLY AND GROUND CIRCUIT
[EURO-OBD]

MAIN POWER SUPPLY AND GROUND CIRCUIT
Description

PFP:00100

A
BCS000S9

When the power supply to the TCM is cut OFF, for example because the battery is removed, and the self-diagnosis memory function stops, malfunction is detected.

On Board Diagnosis Logic
●
●

●

B

BCS000SA

This is not an OBD self-diagnostic item.
AT
Diagnostic trouble code “INITIAL START” with CONSULT-II is detected when TCM dose not receive the
voltage signal from the battery power supply.
This is not a malfunction message. (Whenever shutting OFF a power supply to the TCM, this message D
appears on the screen.)

Possible Cause

BCS000SB

E

Harness or connector
(Battery or ignition switch and TCM circuit is open or shorted.)

DTC Confirmation Procedure

BCS000SC

CAUTION:
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at
least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

F

G

WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Touch “START”.
Wait for at least 2 consecutive seconds.
If DTC is detected, go to AT-195, «Diagnostic Procedure» .

H

I

J

BCIA0031E

K

L

M

AT-193

MAIN POWER SUPPLY AND GROUND CIRCUIT
[EURO-OBD]

Wiring Diagram — AT — MAIN

BCS000SD

MCWA0255E

AT-194

MAIN POWER SUPPLY AND GROUND CIRCUIT
[EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Condition

Judgement standard
(Approx.)

Terminal

Wire color

Item

10

R

Power supply

19

R

Power supply

25

B

Ground

Always

0V

28

LG

Power supply
(memory back-up)

Always

Battery voltage

48

B

Ground

Always

0V

or

When turning ignition switch to “ON”.

Battery voltage

When turning ignition switch to “OFF”.

0V

When turning ignition switch to “ON”.

Battery voltage

When turning ignition switch to “OFF”.

0V

A

B

AT

D

E

Diagnostic Procedure

BCS000SE

1. CHECK TCM POWER SOURCE
1.
2.

F

Turn ignition switch ON. (Do not start engine.)
Check voltage between TCM connector terminals and ground.
Item

Connector

Power supply

E106

Power supply
(Memory back-up)

E107

Terminal

Judgement standard (Approx.)

10

Battery voltage

19

Battery voltage

28

Battery voltage

G

H

I
SCIA2656E

3.
4.

J

Turn ignition switch OFF.
Check voltage between TCM connector terminals and ground.
Item

Connector

Power supply

E106

Power supply
(Memory back-up)

E107

Terminal

Judgement standard (Approx.)

10

0V

19

0V

28

Battery voltage

K

L

M

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

SCIA2657E

2. DETECT MALFUNCTIONING ITEM
Check the following items:
●
Harness for short or open between ignition switch and TCM terminals 10, 19
●
Harness for short or open between battery and TCM terminal 28
●
10A fuse (No.7, located in the fuse block) and 10A fuse (No.58, located in the IPDM E/R)
●
Ignition switch. Refer to PG-38, «GROUND» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace damaged parts.

AT-195

MAIN POWER SUPPLY AND GROUND CIRCUIT
[EURO-OBD]

3. CHECK TCM GROUND CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect TCM connector.
Check continuity between TCM connector terminals and ground.
Item

Connector

Terminal

Continuity

Ground

E107

25, 48 — Ground

Yes

OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.
SCIA2671E

4. CHECK DTC
Perform AT-193, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.

5. CHECK TCM
1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-196

PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT
[EURO-OBD]

PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION
SIGNAL CIRCUIT
PFP:31918
CONSULT-II Reference Value

A

BCS000SF

Remarks: Specification data are reference values.
Item name
Condition

B
Display value

When setting selector lever to “N” or “P” position.

PN POSI SW

R POSITION SW

D POSITION SW

2 POSITION SW

1 POSITION SW

OVERDRIVE SW

CLOSED THL/SW

W/O THRL/P-SW

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “R” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “D” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “2” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “1” position.

ON

When setting selector lever to other positions.

OFF

When overdrive control switch is depressed.

ON

When overdrive control switch is released.

OFF

Released accelerator pedal.

ON

Depressed accelerator pedal.

OFF

Fully depressed accelerator pedal.

ON

Released accelerator pedal.

OFF

AT

D

E

F

G

H

TCM Terminals and Reference Value

BCS000SG

I

TCM terminal data are reference values, measured between each terminal and ground.
Terminal
26

27

34

35

36

Wire color
Y

L

LG

L

R

Item

Condition

PNP switch “1” position

When setting selector lever to “1” position.

PNP switch “2” position

When setting selector lever to “2” position.

PNP switch “D” position
PNP switch “R” position
PNP switch “N” or “P”
position

When setting selector lever to other positions.

When setting selector lever to other positions.
When setting selector lever to “D” position.
and

When setting selector lever to other positions.
When setting selector lever to “R” position.

Judgement standard
(Approx.)

0V
Battery voltage

K

0V
Battery voltage

L

0V
Battery voltage

When setting selector lever to other positions.

0V

When setting selector lever to “N” or “P” positions.

Battery voltage

When setting selector lever to other positions.

0V

AT-197

J

Battery voltage

M

PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT
[EURO-OBD]

Diagnostic Procedure

BCS000SH

1. CHECK CAN COMMUNICATION LINE
Perform self-diagnosis. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» .
Is a malfunction in the CAN communication indicated in the results?
YES >> Check CAN communication line. Refer to AT-102, «DTC U1000 CAN COMMUNICATION LINE» .
NO (With CONSULT-II) >>GO TO 2.
NO (Without CONSULT-II) >>GO TO 3.

2. CHECK PNP SWITCH CIRCUIT
With CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for
“A/T” with CONSULT-II.
3. Read out “P·N”, “R”, “D”, “2” and “1” position switches moving
selector lever to each position.
Item name

Condition

Display value

PN POSI SW

When setting selector lever to “N” or “P” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “R” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “D” positions.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “2” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “1” position.

ON

When setting selector lever to other positions.

OFF

R POSITION SW

D POSITION SW

2 POSITION SW

1 POSITION SW

SAT701J

OK or NG
OK
>> GO TO 4.
NG
>> Check PNP switch circuit. Refer to AT-105, «DTC P0705 PARK/NEUTRAL POSITION (PNP)
SWITCH» .

AT-198

PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT
[EURO-OBD]

3. CHECK PNP SWITCH CIRCUIT

A

Without CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Check voltage between TCM connector terminals and ground
while moving selector lever through each position. Refer to AT106, «Wiring Diagram — AT — PNP/SW» .

B

AT

Terminal
Selector lever position

36

35

34

27

26

“P”, “N”

B

0

0

0

0

“R”

0

B

0

0

0

“D”

0

0

B

0

0

“2”

0

0

0

B

0

“1”

0

0

0

0

B

D

E

F

B: Battery voltage
0: 0V

OK or NG
OK
>> GO TO 4.
NG
>> Check PNP switch circuit. Refer to AT-105, «DTC P0705
PARK/NEUTRAL POSITION (PNP) SWITCH» .

G

H
SCIA7162E

I

4. CHECK PNP SWITCH
1.
2.
3.

Turn ignition switch OFF.
Disconnect PNP switch harness connector.
Check continuity between PNP switch harness connector terminals. Refer to AT-106, «Wiring Diagram — AT — PNP/SW» .
Selector lever position

Terminal

Continuity

“P”

1 — 2, 3 — 7

“R”

3-8

Yes
*Continuity
should not
exist in positions other
than the
specified
positions.

“N”

Connector

F12

1 — 2, 3 — 9

“D”

3-6

“2”

3-5

“1”

3-4

J

K

L

M
SCIA5588E

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. CHECK CONTROL CABLE ADJUSTMENT
Check PNP switch again with control cable disconnected from manual shaft of A/T assembly. Refer to test
group 4.
OK or NG
OK
>> Adjust control cable. Refer to AT-336, «Adjustment of A/T Position» .
NG
>> Repair or replace PNP switch. Refer to AT-349, «Park/Neutral Position (PNP) Switch» .

AT-199

PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT
[EURO-OBD]

6. DETECT MALFUNCTIONING ITEM
Check the following.
●
Harness for short or open between ignition switch and PNP switch
●
Harness for short or open between PNP switch and TCM
●
Harness for short or open between PNP switch and combination meter
●
Harness for short or open between combination meter and TCM
●
10A fuse (No.60, located in the IPDM E/R)
●
Combination meter. Refer to DI-4, «COMBINATION METERS» .
●
Ignition switch. Refer to PG-38, «GROUND» .
OK or NG
OK
>> GO TO 7.
NG
>> Repair or replace damaged parts.

7. CHECK OVERDRIVE CONTROL SWITCH CIRCUIT
With CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for
“A/T” with CONSULT-II.
3. Read out “OVERDRIVE SW”. Check the signal of overdrive control switch is indicated properly.
Overdrive control switch
Condition

Item name
OVERDRIVE SW

Display value

Depressed

ON

Released

OFF
SCIA4730E

1.
2.

Without CONSULT-II
Turn ignition switch ON. (Do not start engine.)
Check voltage between A/T device harness connector terminal
and ground. Refer to AT-296, «EXC.F/EURO-OBD» .
Item

Connector

Terminal

M52

1 — Ground

A/T device harness
connector (Overdrive
control switch)

Overdrive
control switch
Condition

Judgement
standard
(Approx.)

Released

Battery
voltage

Depressed

0V

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 8.

SCIA5336E

AT-200

PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT
[EURO-OBD]

8. CHECK OVERDRIVE CONTROL SWITCH
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect A/T device harness connector.
Check continuity between A/T device harness connector terminals. Refer to AT-296, «EXC.F/EURO-OBD» .
Item

Connector

Terminal

A/T device harness connector (Overdrive control switch)

M52

1-2

Overdrive control
switch condition

Continuity

Released

No

Depressed

Yes

B

AT

D

OK or NG
OK
>> GO TO 9.
NG
>> Repair or replace damaged parts.

SCIA5330E

E

9. DETECT MALFUNCTIONING ITEM
F

Check the following.
●
Harness for short or open between combination meter and A/T device harness connector
●
Harness for short or open between A/T device harness connector and ground
●
Combination meter. Refer to DI-4, «COMBINATION METERS» .
OK or NG
OK
>> GO TO 10.
NG
>> Repair or replace damaged parts.

G

H

10. CHECK CLOSED THROTTLE POSITION AND WIDE OPEN THROTTLE POSITION SIGNAL CIR-

I

CUIT
With CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for A/T with CONSULT-II.
3. Read out “CLOSED THL/SW” and “W/O THRL/P-SW” depressing and releasing accelerator pedal.
Check that the signals of throttle position are indicated properly.

J

K

L

M

SCIA4731E

Data monitor

Accelerator pedal condition
CLOSED THL/SW

W/O THRL/P-SW

Released

ON

OFF

Fully depressed

OFF

ON

OK or NG
OK
>> GO TO 11.
NG
>> Check the following. If any items are damaged, repair or replace damaged parts.
● Accelerator pedal position sensor. Refer to AT-169, «DTC P1705 ACCELERATOR PEDAL
POSITION (APP) SENSOR» .

AT-201

PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT
[EURO-OBD]

11. PERFORM SELF-DIAGNOSIS
Without CONSULT-II
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
OK or NG
OK
>> INSPECTION END
NG − 1 >> Self-diagnosis does not activate: GO TO 12.
NG − 2 >> DTC is displayed: Check the malfunctioning system. Refer to AT-95, «Judgement of Self-diagnosis Code» .

12. CHECK TCM
1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

Component Inspection

BCS000SI

OVERDRIVE CONTROL SWITCH
Check continuity between A/T device harness connector terminals.

●

Item

Connector

Terminal

A/T device harness connector (Overdrive control switch)

M52

1-2

Overdrive control
switch condition

Continuity

Released

No

Depressed

Yes

SCIA5330E

PNP SWITCH
1.

Check continuity between PNP switch harness connector terminals.
Selector lever position

Terminal

Continuity

“P”

1 — 2, 3 — 7

“R”

3-8

Yes
*Continuity
should not
exist in positions other
than the
specified
positions.

“N”

2.

3.
4.
5.
6.

Connector

F12

1 — 2, 3 — 9

“D”

3-6

“2”

3-5

“1”

3-4

If NG, check again with control cable (2) disconnected from
manual shaft of A/T assembly. Refer to step 1.
(1): Lock nut
(3): Manual shaft
If OK on step 2, adjust control cable (2). Refer to AT-336,
«Adjustment of A/T Position» .
If NG on step 2, remove PNP switch from A/T assembly and
check continuity of PNP switch terminals. Refer to step 1.
If OK on step 4, adjust PNP switch. Refer to AT-350, «PARK/
NEUTRAL POSITION (PNP) SWITCH ADJUSTMENT» .
If NG on step 4, replace PNP switch. Refer to AT-349, «Park/
Neutral Position (PNP) Switch» .

AT-202

SCIA5588E

SCIA6370J

VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)
[EXC.F/EURO-OBD]

VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)
Description
[EXC.F/EURO-OBD]

PFP:32702

A
BCS000SJ

The revolution sensor detects the revolution of the idler gear parking pawl lock gear and emits a pulse signal.
The pulse signal is sent to the TCM which converts it into vehicle speed.

CONSULT-II Reference Value

BCS000SK

Remarks: Specification data are reference values.
Item name
Condition
VHCL/S SE-A/T

B

AT

Display value

During driving

Approximately matches the speedometer reading.

On Board Diagnosis Logic

BCS000SL

D

Diagnostic trouble code “VHCL SPEED SEN-A/T” with CONSULT-II or 1st judgement flicker without CONSULT-II is detected when TCM does not receive the proper voltage signal from the sensor.
E

Possible Cause
●

●

BCS000SM

Harness or connector
(Sensor circuit is open or shorted.)
Revolution sensor

F

DTC Confirmation Procedure

BCS000SN

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.

4.
5.
6.

7.

H

I

Turn ignition switch ON and select “DATA MONITOR” mode for
“A/T” with CONSULT-II.
Touch “START”.
Drive vehicle and check for an increase of “VHCL/S SE-MTR”
value.
If the check result is NG, go to AT-206, «Diagnostic Procedure» .
If the check result is OK, go to following step.
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Touch “START”.
Start engine and maintain the following conditions for at least 5
BCIA0031E
consecutive seconds.
VEHICLE SPEED: 30 km/h (19 MPH) or more
THROTTLE POSI: More than 1.0/8
SLCT LVR POSI: “D” position
Driving location: Driving the vehicle uphill (increased engine load) will help maintain the driving
conditions required for this test.
If the check result is NG, go to AT-206, «Diagnostic Procedure» .
If the check result is OK, go to following step.
Maintain the following conditions for at least 5 consecutive seconds.
ENGINE SPEED: 3,500 rpm or more
THROTTLE POSI: More than 1.0/8
SLCT LVR POSI: “D” position
Driving location: Driving the vehicle uphill (increased engine load) will help maintain the driving
conditions required for this test.

WITHOUT CONSULT-II
1.
2.

G

Start engine.
Drive vehicle under the following conditions for more than 5 seconds.
Selector lever position: “D” position
Vehicle speed: 30 km/h (19 MPH) or more

AT-203

J

K

L

M

VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)
[EXC.F/EURO-OBD]
3.
4.

Throttle position: greater than 1.0/8 of the full throttle position
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-206, «Diagnostic Procedure» .

AT-204

VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)
[EXC.F/EURO-OBD]

Wiring Diagram — AT — VSSAT

BCS000SO

A

B

AT

D

E

F

G

H

I

J

K

L

M

MCWA0245E

AT-205

VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)
[EXC.F/EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

Item

Condition

29

V

Revolution sensor

42

B

Sensor ground

When driving at 20 km/h (12 MPH)
Always

Diagnostic Procedure

Judgement standard
(Approx.)
150 Hz
0V
BCS000SP

1. CHECK INPUT SIGNAL
With CONSULT-II
1. Start engine.
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Read out the value of “VHCL/S SE·A/T” while driving.
Check the value changes according to driving speed.
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 2.

SCIA4730E

2.
1.
2.

CHECK REVOLUTION SENSOR
Start engine.
Check power supply to revolution sensor by voltage between TCM connector terminals. Refer to AT-261,
«Wiring Diagram — AT — MAIN» and AT-205, «Wiring Diagram — AT — VSSAT» .
Item

Connector

Terminal

TCM

E106, E107

Judgement standard (Approx.)

10 — 42

3.

Battery voltage

19 — 42

If OK, check the pulse when vehicle cruises.
Item

Condition
When driving at 20 km/h (12 MPH), use the CONSULT-II
pulse frequency measuring function.*1

Revolution sensor

CAUTION:
Connect the diagnosis data link cable to the data link
connector.
*1: A circuit tester cannot be used to test this item.

Item

Connector

Terminal

Condition

Judgement
standard
(Approx.)

TCM

E107

29

When driving at 20 km/h
(12 MPH)

150 Hz

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 3.

SCIA4939E

AT-206

VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)
[EXC.F/EURO-OBD]

3.
1.
2.
3.
4.

CHECK POWER AND SENSOR GROUND

A

Turn ignition switch OFF.
Disconnect the revolution sensor harness connector.
Turn ignition switch ON. (Do not start engine.)
Check voltage between revolution sensor harness connector
terminals.

B

AT
Item

Connector

Terminal

Judgement standard
(Approx.)

Revolution sensor

F41

1-3

Battery voltage

D

E
SCIA2614E

5.

Item

Connector

Terminal

Judgement standard
(Approx.)

Revolution sensor

F41

1 — ground

Battery voltage

6. If OK, check harness for short to ground and short to power.
7. Reinstall any part removed.
OK or NG
OK
>> GO TO 4.
NG — 1 >> Battery voltage is not supplied between terminals 1 and
3, terminals 1 and ground.:GO TO 6.
NG — 2 >> Battery voltage is not supplied between terminals 1 and 3 only.: GO TO 7.

4.
1.
2.
3.

F

Check voltage between revolution sensor harness connector
terminal and ground.

G

H

SCIA2615E

I

J

CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR
K

Turn ignition switch OFF.
Disconnect the TCM connector and revolution sensor harness connector.
Check continuity between TCM connector terminal and revolution sensor harness connector terminal.
Item

Connector

Terminal

TCM

E107

29

Revolution sensor

F41

2

L

Continuity

M

Yes

4. If OK, check harness for short to ground and short to power.
5. Reinstall any part removed.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

5. CHECK TCM
1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, re-check TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> GO TO 8.
NG
>> Repair or replace damaged parts.

AT-207

SCIA2616E

VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)
[EXC.F/EURO-OBD]

6.
1.
2.
3.

CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR (POWER)
Turn ignition switch OFF.
Disconnect the TCM connector and revolution sensor harness connector.
Check continuity between TCM connector terminals and revolution sensor harness connector terminal. Refer to AT-52, «Circuit
Diagram» and AT-261, «Wiring Diagram — AT — MAIN» .
Item

Connector

Terminal

TCM

E106

10

Revolution sensor

F41

1

TCM

E106

19

Revolution sensor

F41

1

Continuity
Yes

Yes

4. If OK, check harness for short to ground and short to power.
5. Reinstall any part removed.
OK or NG
OK
>> 10A fuse (No.38, located in the IPDM E/R) or ignition switch are malfunctioning.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

7.
1.
2.
3.

SCIA2617E

CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR (SENSOR GROUND)
Turn ignition switch OFF.
Disconnect the TCM connector and revolution sensor harness connector.
Check continuity between TCM connector terminal and revolution sensor harness connector terminal.
Item

Connector

Terminal

TCM

E107

42

Revolution sensor

F41

3

Continuity
Yes

4. If OK, check harness for short to ground and short to power.
5. Reinstall any part removed.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

8. CHECK DTC
Perform AT-203, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.

AT-208

SCIA2618E

VEHICLE SPEED SENSOR MTR
[EXC.F/EURO-OBD]

VEHICLE SPEED SENSOR MTR
Description

PFP:24814

A
BCS000SQ

The vehicle speed sensor·MTR is built into the speedometer assembly. The sensor functions as an auxiliary
device to the revolution sensor when it is malfunctioning. The TCM will then use a signal sent from the vehicle
speed sensor·MTR.

CONSULT-II Reference Value

BCS000SR

AT

Remarks: Specification data are reference values.
Item name
Condition
VHCL/S SE-MTR

Display value

During driving

Approximately matches the speedometer reading.

D

On Board Diagnosis Logic

BCS000SS

Diagnostic trouble code “VHCL SPEED SEN-MTR” with CONSULT-II or 2nd judgement flicker without CONSULT-II is detected when TCM does not receive the proper voltage signal from the sensor.

Possible Cause
●

●

B

E

BCS000ST

Harness or connector
(Sensor circuit is open or shorted.)
Vehicle speed sensor

F

DTC Confirmation Procedure

BCS000SU

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

G

H

I

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

Turn ignition switch ON and select “DATA MONITOR” mode for
“A/T” with CONSULT-II.
Touch “START”.
Start engine and accelerate vehicle from 0 to 25 km/h (0 to 16
MPH).
If the check result is NG, go to AT-211, «Diagnostic Procedure» .

J

K

L
BCIA0031E

M

WITHOUT CONSULT-II
1.
2.

3.
4.

Start engine.
Drive vehicle under the following conditions:
Selector lever position: “D” position
Vehicle speed: Higher than 25 km/h (16 MPH)
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-211, «Diagnostic Procedure» .

AT-209

VEHICLE SPEED SENSOR MTR
[EXC.F/EURO-OBD]

Wiring Diagram — AT — VSSMTR

BCS000SV

MCWA0251E

AT-210

VEHICLE SPEED SENSOR MTR
[EXC.F/EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

40

R

Item

Condition
When driving vehicle at 2 to 3 km/h
(1 to 2 MPH) for 1 m (3 ft) or more.

Vehicle speed sensor

Diagnostic Procedure

Judgement standard
(Approx.)
Voltage varies between
less than 0V and more
than 4.5V
BCS000SW

1. CHECK INPUT SIGNAL
With CONSULT-II
1. Start engine.
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for
“A/T” with CONSULT-II.
3. Read out the value of “VHCL/S SE-MTR” while driving.
Check the value changes according to driving speed.
Item name

Condition

Display value

VHCL/S SE-MTR

During driving

Approximately matches
the speedometer reading.

Vehicle
speed sensor

B

AT

D

E

F

SCIA4730E

Without CONSULT-II
1. Start engine.
2. Check voltage between TCM connector terminal and ground.
Item

A

G

H

Connector

Terminal

Condition

Judgement
standard
(Approx.)

I

E107

40 Ground

When driving vehicle at
2 to 3 km/h (1 to 2 MPH)
for 1 m (3 ft) or more.

Voltage varies
between less
than 0V and
more than 4.5V

J

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

K
SCIA4940E

2. DETECT MALFUNCTIONING ITEM

L

Check the following items:
●
Combination meter. Refer to DI-4, «COMBINATION METERS» .
●
Harness for short or open between TCM and combination meter.
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace damaged parts.

3. CHECK DTC
Perform AT-209, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 4.

AT-211

M

VEHICLE SPEED SENSOR MTR
[EXC.F/EURO-OBD]

4. CHECK TCM
1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-212

ACCELERATOR PEDAL POSITION (APP) SENSOR
[EXC.F/EURO-OBD]

ACCELERATOR PEDAL POSITION (APP) SENSOR
Description

PFP:22620

A
BCS000SX

Electric throttle control actuator consists of throttle control motor, accelerator pedal position sensor, throttle
position sensor, etc. The actuator sends signals to the ECM, and ECM sends signals to TCM via CAN communication.

CONSULT-II Reference Value

BCS000SY

AT

Remarks: Specification data are reference values.
Item name
Condition
THROTTLE POSI

B

Display value (Approx.)

Released accelerator pedal.

0.0/8

Fully depressed accelerator pedal.

8.0/8

On Board Diagnosis Logic

D
BCS000SZ

Diagnostic trouble code “THROTTLE POSI SEN” with CONSULT-II or 3rd judgement flicker without CONSULT-II is detected when TCM does not receive the proper accelerator pedal position signals (input via CAN
communication) from ECM.

E

Possible Cause

F
BCS000T0

Harness or connector
(Sensor circuit is open or shorted.)

G

DTC Confirmation Procedure

BCS000T1

CAUTION:
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at
least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

I

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

H

Turn ignition switch ON. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Depress accelerator pedal fully and release it, then wait for 5
seconds.
If DTC is detected, go to AT-214, «Diagnostic Procedure» .

J

K

L
BCIA0031E

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

M

Turn ignition switch ON. (Do not start engine.)
Depress accelerator pedal fully and release it, then wait for 5 seconds.
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-214, «Diagnostic Procedure» .

AT-213

ACCELERATOR PEDAL POSITION (APP) SENSOR
[EXC.F/EURO-OBD]

Diagnostic Procedure

BCS000T2

1. CHECK CAN COMMUNICATION LINE
Perform self-diagnosis. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» , AT-94, «Diagnostic Procedure
Without CONSULT-II» .
Is any malfunction of the “U1000 CAN COMM CIRCUIT” indicated?
YES >> Check the CAN communication line. Refer to AT-257, «CAN COMMUNICATION LINE» .
NO
>> GO TO 2.

2. CHECK INPUT SIGNAL
With CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T”
with CONSULT-II.
3. Read out the value of “THROTTLE POSI”.
Item name

Condition

Display value
(Approx.)

Released accelerator pedal.

0.0/8

Fully depressed accelerator pedal.

8.0/8

THROTTLE POSI

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

SCIA3251E

3. CHECK DTC WITH ECM
With CONSULT-II
Turn ignition switch ON. (Do not start engine.)
Select “SELF-DIAG RESULTS” mode for “ENGINE” with CONSULT-II. Refer to EC-521, «SELF-DIAG RESULTS MODE» .
OK or NG
OK
>> GO TO 4.
NG
>> Check the DTC Detected Item. Go to EC-521, «SELFDIAG RESULTS MODE» .
1.
2.

BCIA0030E

4. CHECK DTC
Perform “DTC Confirmation Procedure”. Refer to AT-213, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.

5. CHECK TCM
1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-214

SHIFT SOLENOID VALVE A
[EXC.F/EURO-OBD]

SHIFT SOLENOID VALVE A
Description

PFP:31940

A
BCS000T3

Shift solenoid valves A and B are turned ON or OFF by the TCM in response to signals sent from the PNP
switch, vehicle speed and ECM (throttle opening). Gears will then be shifted to the optimum position.
Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

CONSULT-II Reference Value

D
Display value

When shift solenoid valve A operates.
(When driving in “D1 ” or “D4 ”.)

ON

When shift solenoid valve A does not operate.
(When driving in “D2 ” or “D3 ”.)

OFF

On Board Diagnosis Logic

E

BCS000T5

Diagnostic trouble code “SHIFT SOLENOID/V A” with CONSULT-II or 4th judgement flicker without CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid valve.

Possible Cause
●

●

AT

BCS000T4

Remarks: Specification data are reference values.
Item name
Condition

SHIFT S/V A

B

F

G

BCS000T6

Harness or connector
(Solenoid circuit is open or shorted.)
Shift solenoid valve A

H

DTC Confirmation Procedure

BCS000T7

I

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

J

K

WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and select “DATA MONITOR” mode for
“A/T” with CONSULT-II.
Touch “START”.
Start engine.
Drive vehicle in “D” position and allow the transaxle to shift 1 →
2 (“GEAR”).
If the check result is NG, go to AT-217, «Diagnostic Procedure» .

L

M

BCIA0031E

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

Start engine.
Drive vehicle in D1 → D2 position.
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-217, «Diagnostic Procedure» .

AT-215

SHIFT SOLENOID VALVE A
[EXC.F/EURO-OBD]

Wiring Diagram — AT — SSV/A

BCS000T8

MCWA0248E

AT-216

SHIFT SOLENOID VALVE A
[EXC.F/EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

11

R

Item

Condition

Shift solenoid valve A

Judgement standard
(Approx.)

When shift solenoid valve A operates.
(When driving in “D1 ” or “D4 ”.)

Battery voltage

When shift solenoid valve A does not
operate.
(When driving in “D2 ” or “D3 ”.)

0V

Diagnostic Procedure

BCS000T9

D

With CONSULT-II
Start engine.
Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
Read out the value of “SHIFT S/V A” while driving.
Check the value changes according to driving speed.

Item name

SHIFT S/V A

B

AT

1. CHECK INPUT SIGNAL
1.
2.
3.

A

Condition

Display value

When shift solenoid valve A operates.
(When driving in “D1 ” or “D4 ”.)

ON

When shift solenoid valve A does not operate.
(When driving in “D2 ” or “D3 ”.)

OFF

E

F

G

H
SCIA3251E

I

1.
2.

Without CONSULT-II
Start engine.
Check voltage between TCM connector terminal and ground.
Item

Shift solenoid valve A

Connector

E106

Terminal

11 Ground

J

Judgement
standard
(Approx.)

Condition
When shift solenoid
valve A operates.
(When driving in “D1 ”
or “D4 ”.)

Battery voltage

When shift solenoid
valve A does not operate.
(When driving in “D2 ”
or “D3 ”.)

0V

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.

AT-217

K

L

SCIA3248E

M

SHIFT SOLENOID VALVE A
[EXC.F/EURO-OBD]

2. CHECK SHIFT SOLENOID VALVE A CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect TCM connector.
Check resistance between TCM connector terminal and ground.
Solenoid Valve

Shift solenoid valve A

Connector

Terminal

Resistance
(Approx.)

E106

11 — Ground

20 — 30 Ω

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
SCIA3249E

3.
1.
2.
3.

CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR
Turn ignition switch OFF.
Disconnect terminal cord assembly harness connector and TCM connector.
Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal.
Item

Connector

Terminal

TCM

E106

11

Terminal cord assembly
harness connector

F13

2

Continuity
Yes

4. If OK, check harness for short to ground and short to power.
5. If OK, check continuity between ground and transaxle assembly.
6. Reinstall any part removed.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

SCIA3250E

4. CHECK VALVE RESISTANCE
1.
2.
3.

Turn ignition switch OFF.
Disconnect terminal cord assembly connector in engine room.
Check resistance between terminal cord assembly harness connector terminal and ground.
Solenoid valve

Shift solenoid valve A

Connector

Terminal

Resistance (Approx.)

F13

2 — Ground

20 — 30 Ω

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace damaged parts.
SCIA4942E

5. CHECK DTC
Perform AT-215, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.

AT-218

SHIFT SOLENOID VALVE A
[EXC.F/EURO-OBD]

6. CHECK TCM

A

1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

B

AT

Component Inspection

BCS000TA

SHIFT SOLENOID VALVE A
●

For removal, refer to AT-345, «Control Valve Assembly and Accumulators» .

D

Resistance Check
●

Check resistance between terminal and ground.
E
Solenoid valve
Shift solenoid valve A

Resistance
(Approx.)

Terminal
2

Ground

20 — 30 Ω

F

G
SCIA2049E

H

Operation Check
●

Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground.

I

J

K
SCIA2052E

L

M

AT-219

SHIFT SOLENOID VALVE B
[EXC.F/EURO-OBD]

SHIFT SOLENOID VALVE B
Description

PFP:31940
BCS000TB

Shift solenoid valves A and B are turned ON or OFF by the TCM in response to signals sent from the PNP
switch, vehicle speed and ECM (throttle opening). Gears will then be shifted to the optimum position.
Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

CONSULT-II Reference Value

BCS000TC

Remarks: Specification data are reference values.
Item name
Condition

SHIFT S/V B

Display value

When shift solenoid valve B operates.
(When driving in “D1 ” or “D2 ”.)

ON

When shift solenoid valve B does not operate.
(When driving in “D3 ” or “D4 ”.)

OFF

On Board Diagnosis Logic

BCS000TD

Diagnostic trouble code “SHIFT SOLENOID/V B” with CONSULT-II or 5th judgement flicker without CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid valve.

Possible Cause
●

●

BCS000TE

Harness or connector
(Solenoid circuit is open or shorted.)
Shift solenoid valve B

DTC Confirmation Procedure

BCS000TF

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.

WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON and select “DATA MONITOR” mode for
“A/T” with CONSULT-II.
Touch “START”.
Start engine.
Drive vehicle in “D” position and allow the transaxle to shift 1 →
2 → 3 (“GEAR”).
If the check result is NG, go to AT-222, «Diagnostic Procedure» .

BCIA0031E

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

Start engine.
Drive vehicle in D1 → D2 → D3 position.
Perform self-diagnosis.
Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-222, «Diagnostic Procedure» .

AT-220

SHIFT SOLENOID VALVE B
[EXC.F/EURO-OBD]

Wiring Diagram — AT — SSV/B

BCS000TG

A

B

AT

D

E

F

G

H

I

J

K

L

M

MCWA0249E

AT-221

SHIFT SOLENOID VALVE B
[EXC.F/EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

12

SB

Item

Condition

Shift solenoid valve B

Judgement standard
(Approx.)

When shift solenoid valve B operates.
(When driving in “D1 ” or “D2 ”.)

Battery voltage

When shift solenoid valve B does not
operate.
(When driving in “D3 ” or “D4 ”.)

0V

Diagnostic Procedure

BCS000TH

1. CHECK INPUT SIGNAL
1.
2.
3.

With CONSULT-II
Start engine.
Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
Read out the value of “SHIFT S/V B” while driving.
Check the value changes according to driving speed.

Item name

SHIFT S/V B

Condition

Display value

When shift solenoid valve B operates.
(When driving in “D1 ” or “D2 ”.)

ON

When shift solenoid valve B does not operate.
(When driving in “D3 ” or “D4 ”.)

OFF

SCIA3251E

1.
2.

Without CONSULT-II
Start engine.
Check voltage between TCM connector terminal and ground.
Item

Shift solenoid valve B

Connector

E106

Terminal

12 Ground

Condition

Judgement
standard
(Approx.)

When shift solenoid
valve B operates.
(When driving in “D1 ” or
“D2 ”.)

Battery voltage

When shift solenoid
valve B does not operate.
(When driving in “D3 ” or
“D4 ”.)

0V

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.

AT-222

SCIA3253E

SHIFT SOLENOID VALVE B
[EXC.F/EURO-OBD]

2. CHECK SHIFT SOLENOID VALVE B CIRCUIT
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect TCM connector.
Check resistance between TCM connector terminal and ground.
Solenoid Valve

Shift solenoid valve B

Connector

Terminal

Resistance
(Approx.)

E106

12 — Ground

5 — 20 Ω

B

AT

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.

D

SCIA3254E

3.
1.
2.
3.

E

CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR
F

Turn ignition switch OFF.
Disconnect terminal cord assembly harness connector and TCM connector.
Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal.
Item

Connector

Terminal

TCM

E106

12

Terminal cord assembly
harness connector

F13

1

G

Continuity

H
Yes

4. If OK, check harness for short to ground and short to power.
5. If OK, check continuity between ground and transaxle assembly.
6. Reinstall any part removed.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

I

SCIA4943E

J

K

4. CHECK VALVE RESISTANCE
1.
2.
3.

L

Turn ignition switch OFF.
Disconnect terminal cord assembly connector in engine room.
Check resistance between terminal cord assembly harness connector terminal and ground.
Solenoid valve

Shift solenoid valve B

Connector

Terminal

Resistance (Approx.)

F13

1 — Ground

5 — 20 Ω

M

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace damaged parts.
SCIA4944E

5. CHECK DTC
Perform AT-220, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.

AT-223

SHIFT SOLENOID VALVE B
[EXC.F/EURO-OBD]

6. CHECK TCM
1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

Component Inspection

BCS000TI

SHIFT SOLENOID VALVE B
●

For removal, refer to AT-345, «Control Valve Assembly and Accumulators» .

Resistance Check
●

Check resistance between terminal and ground.
Solenoid valve
Shift solenoid valve B

Resistance
(Approx.)

Terminal
1

Ground

5 — 20Ω

SCIA2055E

Operation Check
●

Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground.

SCIA2058E

AT-224

OVERRUN CLUTCH SOLENOID VALVE
[EXC.F/EURO-OBD]

OVERRUN CLUTCH SOLENOID VALVE
Description

PFP:31940

A
BCS000TJ

The overrun clutch solenoid valve is activated by the TCM in response to signals sent from the PNP switch,
overdrive control switch, vehicle speed and ECM (throttle opening). The overrun clutch operation will then be
controlled.

CONSULT-II Reference Value

BCS000TK

AT

Remarks: Specification data are reference values.
Item name
Condition

OVERRUN/C S/V

Display value

When overrun clutch solenoid valve operates. (When
overrun clutch disengaged. Refer to AT-22 .)

ON

When overrun clutch solenoid valve does not operate.
(When overrun clutch engaged. Refer to AT-22 .)

OFF

D

E

On Board Diagnosis Logic

BCS000TL

Diagnostic trouble code “OVERRUN CLUTCH S/V” with CONSULT-II or 6th judgement flicker without CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid valve.

Possible Cause
●

●

Harness or connector
(Solenoid circuit is open or shorted.)
Overrun clutch solenoid valve

G

BCS000TN

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II

2.
3.
4.
5.
6.

Turn ignition switch ON and select “DATA MONITOR” mode for
“A/T” with CONSULT-II.
Touch “START”.
Start engine.
Accelerate vehicle to a speed of more than 10 km/h (6 MPH)
with “D” position (OD ON).
Release accelerator pedal completely with “D” position (OD
OFF).
If the check result is NG, go to AT-227, «Diagnostic Procedure» .

WITHOUT CONSULT-II

3.
4.

Start engine.
Drive vehicle under the following conditions:
Selector lever position: “D” position (OD ON)
Vehicle speed: Higher than 10 km/h (6 MPH)
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-227, «Diagnostic Procedure» .

AT-225

H

I

J

K

L

M
BCIA0031E

1.
2.

F

BCS000TM

DTC Confirmation Procedure

1.

B

OVERRUN CLUTCH SOLENOID VALVE
[EXC.F/EURO-OBD]

Wiring Diagram — AT — OVRCSV

BCS000TO

MCWA0250E

AT-226

OVERRUN CLUTCH SOLENOID VALVE
[EXC.F/EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

20

Wire color

Item

Condition

Overrun clutch solenoid
valve

LG

Judgement standard
(Approx.)

When overrun clutch solenoid valve
operates. (When overrun clutch disengaged. Refer to AT-22 .)

Battery voltage

When overrun clutch solenoid valve
dose not operate. (When overrun
clutch engaged. Refer to AT-22 .)

0V

Diagnostic Procedure

BCS000TP

D

With CONSULT-II
1. Start engine.
2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Read out the value of “OVERRUN/C S/V” while driving.
Check the value changes according to driving speed.
Condition

OVERRUN/C S/V

E

F

Display value

G

When overrun clutch solenoid valve operates. (When overrun clutch disengaged.
Refer to AT-22 .)

ON

When overrun clutch solenoid valve dose
not operate. (When overrun clutch
engaged. Refer to AT-22 .)

OFF

H

SCIA3257E

Without CONSULT-II
1. Start engine.
2. Check voltage between TCM connector terminal and ground.
Item

Overrun
clutch solenoid valve

Connector

E106

Terminal

20 Ground

B

AT

1. CHECK INPUT SIGNAL

Item name

A

J

Judgement
standard
(Approx.)

Condition
When overrun clutch
solenoid valve operates. (When overrun
clutch disengaged.
Refer to AT-22 .)

K

L

Battery voltage

When overrun clutch
solenoid valve dose not
operate. (When overrun clutch engaged.
Refer to AT-22 .)

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.

AT-227

I

M
SCIA3258E

0V

OVERRUN CLUTCH SOLENOID VALVE
[EXC.F/EURO-OBD]

2. CHECK OVERRUN CLUTCH SOLENOID VALVE CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect TCM connector.
Check resistance between TCM connector terminal and ground.
Solenoid Valve

Connector

Terminal

Resistance
(Approx.)

Overrun clutch solenoid
valve

E106

20 — Ground

20 — 30 Ω

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
SCIA3259E

3.
1.
2.
3.

CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR
Turn ignition switch OFF.
Disconnect terminal cord assembly harness connector and TCM connector.
Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal.
Item

Connector

Terminal

TCM

E106

20

Terminal cord assembly
harness connector

F13

3

Continuity
Yes

4. If OK, check harness for short to ground and short to power.
5. If OK, check continuity between ground and transaxle assembly.
6. Reinstall any part removed.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

SCIA3260E

4. CHECK VALVE RESISTANCE
1.
2.
3.

Turn ignition switch OFF.
Disconnect terminal cord assembly connector in engine room.
Check resistance between terminal cord assembly harness connector terminal and ground.
Solenoid valve

Connector

Terminal

Resistance (Approx.)

Overrun clutch solenoid
valve

F13

3 — Ground

20 — 30 Ω

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace damaged parts.
SCIA4945E

5. CHECK DTC
Perform AT-225, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.

AT-228

OVERRUN CLUTCH SOLENOID VALVE
[EXC.F/EURO-OBD]

6. CHECK TCM

A

1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

B

AT

Component Inspection

BCS000TQ

OVERRUN CLUTCH SOLENOID VALVE
●

For removal, refer to AT-345, «Control Valve Assembly and Accumulators» .

D

Resistance Check
●

Check resistance between terminal and ground.
E
Solenoid valve
Overrun clutch
solenoid valve

Resistance
(Approx.)

Terminal
3

Ground

20 — 30 Ω

F

G
SCIA2059E

H

Operation Check
●

Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground.

I

J

K
SCIA2062E

L

M

AT-229

TORQUE CONVERTER CLUTCH SOLENOID VALVE
[EXC.F/EURO-OBD]

TORQUE CONVERTER CLUTCH SOLENOID VALVE
Description

PFP:31940
BCS000TR

The torque converter clutch solenoid valve is activated, with the gear in D4 and D3 , by the TCM in
response to signals sent from the vehicle speed sensor and the ECM (throttle opening). Lock-up piston
operation will then be controlled.
Lock-up operation, however, is prohibited when A/T fluid temperature is too low.
When the accelerator pedal is depressed (less than 2/8) on lock-up condition, the engine speed should
not change abruptly. If there is an abrupt change in engine speed, there is no lock-up.

●

●
●

CONSULT-II Reference Value

BCS000TS

Remarks: Specification data are reference values.
Item name
Condition
TCC S/V DUTY

Display value (Approx.)

Lock-up OFF ⇔ Lock-up ON

4% ⇔ 94%

On Board Diagnosis Logic

BCS000TT

Diagnostic trouble code “T/C CLUTCH SOL/V” with CONSULT-II or 7th judgement flicker without CONSULT-II
is detected when TCM detects an improper voltage drop while it tries to operate the solenoid valve.

Possible Cause
●
●

BCS000TU

Torque converter clutch solenoid valve
Harness or connector
(Solenoid circuit is open or shorted.)

DTC Confirmation Procedure

BCS000TV

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

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

5.

Turn ignition switch ON. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II and
wait at least 1 second.
Touch “START”.
Start engine and maintain the following conditions for at least 5
consecutive seconds.
VEHICLE SPEED: 80 km/h (50 MPH) or more
THROTTLE POSI: 0.5/8 — 1.0/8
SLCT LVR POSI: “D” position
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
If the check result is NG, go to AT-232, «Diagnostic Procedure» .

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

Start engine.
Drive vehicle in D1 → D2 → D3 → D4 → D4 lock-up position.
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-232, «Diagnostic Procedure» .

AT-230

BCIA0031E

TORQUE CONVERTER CLUTCH SOLENOID VALVE
[EXC.F/EURO-OBD]

Wiring Diagram — AT — TCV

BCS000TW

A

B

AT

D

E

F

G

H

I

J

K

L

M

MCWA0246E

AT-231

TORQUE CONVERTER CLUTCH SOLENOID VALVE
[EXC.F/EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

Item

Condition

3

O

Torque converter clutch
solenoid valve

When A/T performs lock-up.
When A/T does not perform lock-up.

Diagnostic Procedure

Judgement standard
(Approx.)
8 — 15V
0V
BCS000TX

1. CHECK INPUT SIGNAL
With CONSULT-II
1. Start engine.
2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Read out the value of “TCC S/V DUTY” while driving. Check the
value changes according to driving speed.
Item name

Condition

Display value
(Approx.)

TCC S/V
DUTY

Lock-up OFF ⇔ Lock-up ON

4% ⇔ 94%

SCIA3257E

Without CONSULT-II
1. Start engine.
2. Check voltage between TCM connector terminal and ground.

Item

Torque converter clutch
solenoid
valve

Connector

E106

Terminal

3 — Ground

Condition

Judgement standard
(Approx.)

When A/T performs lockup.

8 — 15V

When A/T does not perform lock-up.

0V

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.

SCIA3261E

2. CHECK TORQUE CONVERTER CLUTCH SOLENOID VALVE CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect TCM connector.
Check resistance between TCM connector terminal and ground.
Solenoid Valve

Torque converter clutch
solenoid valve

Connector

Terminal

Resistance
(Approx.)

E106

3 — Ground

5 — 20 Ω

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 3.
SCIA3262E

AT-232

TORQUE CONVERTER CLUTCH SOLENOID VALVE
[EXC.F/EURO-OBD]

3.
1.
2.
3.

CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR
Turn ignition switch OFF.
Disconnect terminal cord assembly harness connector and TCM connector.
Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal.
Item

Connector

Terminal

TCM

E106

3

Terminal cord assembly
harness connector

F13

5

A

B

Continuity

AT

Yes

D

4. If OK, check harness for short to ground and short to power.
5. If OK, check continuity between ground and transaxle assembly.
6. Reinstall any part removed.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

SCIA3263E

E

F

4. CHECK VALVE RESISTANCE
1.
2.
3.

G

Turn ignition switch OFF.
Disconnect terminal cord assembly connector in engine room.
Check resistance between terminal cord assembly harness connector terminal and ground.
Solenoid valve

Connector

Terminal

Resistance (Approx.)

Torque converter clutch
solenoid valve

F13

5 — Ground

5 — 20 Ω

H

I

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace damaged parts.

J

SCIA4946E

K

5. CHECK DTC
L

Perform AT-230, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.

M

6. CHECK TCM
1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-233

TORQUE CONVERTER CLUTCH SOLENOID VALVE
[EXC.F/EURO-OBD]

Component Inspection

BCS000TY

TORQUE CONVERTER CLUTCH SOLENOID VALVE
●

For removal, refer to AT-345, «Control Valve Assembly and Accumulators» .

Resistance Check
●

Check resistance between terminal and ground.
Solenoid valve
Torque converter
clutch solenoid
valve

Resistance
(Approx.)

Terminal

5

Ground

5 — 20 Ω

SCIA2063E

Operation Check
●

Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground.

SCIA2066E

AT-234

BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)
[EXC.F/EURO-OBD]

BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER
SOURCE)
PFP:31940
Description

A

BCS000TZ

The A/T fluid temperature sensor detects the A/T fluid temperature and sends the signal to the TCM.

CONSULT-II Reference Value

BCS000U0

Remarks: Specification data are reference values.
Item name
Condition
FLUID TEMP SE

B

AT

Display value (Approx.)

When A/T fluid temperature is 20°C (68°F).

1.5V

When A/T fluid temperature is 80°C (176°F).

0.5V

On Board Diagnosis Logic

D
BCS000U1

Diagnostic trouble code “BATT/FLUID TEMP SEN” with CONSULT-II or 8th judgement flicker without CONSULT-II is detected when TCM receives an excessively low or high voltage from the sensor.

Possible Cause
●

●

E

BCS000U2

F

Harness or connector
(Sensor circuit is open or shorted.)
A/T fluid temperature sensor

G

DTC Confirmation Procedure

BCS000U3

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

H

I

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

5.

Start engine.
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Touch “START”.
Drive vehicle under the following conditions.
SLCT LVR POSI: “D” position
VEHICLE SPEED: Higher than 20 km/h (12 MPH)
If the check result is NG, go to AT-237, «Diagnostic Procedure» .

J

K

L

M
BCIA0031E

WITHOUT CONSULT-II
1.
2.

3.
4.

Start engine.
Drive vehicle under the following conditions.
Selector lever position: “D” position
Vehicle speed: Higher than 20 km/h (12 MPH)
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-237, «Diagnostic Procedure» .

AT-235

BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)
[EXC.F/EURO-OBD]

Wiring Diagram — AT — BA/FTS

BCS000U4

MCWA0253E

AT-236

BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)
[EXC.F/EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

10

Item

R

Condition

Power supply

or
19

R

28

LG

42

B

47

Power supply

When turning ignition switch to
“ON”.

Battery voltage

When turning ignition switch to
“OFF”.

0V

When turning ignition switch to
“ON”.

Battery voltage

When turning ignition switch to
“OFF”.

0V

Always

Battery voltage

Sensor ground

Always

0V

and

Diagnostic Procedure

When A/T fluid temperature is
20°C (68°F).

1.5V

When A/T fluid temperature is
80°C (176°F).

0.5V

Connector

BCS000U5

Power supply

E106

Power supply
(memory back-up)

E107

Terminal

Judgement standard
(Approx.)

10

Battery voltage

19

Battery voltage

28

Battery voltage

AT

F

Turn ignition switch ON. (Do not start engine.)
Check voltage between TCM connector terminal and ground.
Item

B

E

1. CHECK TCM POWER SOURCE
1.
2.

A

D

Power supply
(memory back-up)

A/T fluid temperature
sensor

BR

Judgement standard (Approx.)

G

H

I

J

K
SCIA2656E

3.
4.

Turn ignition switch OFF.
Check voltage between TCM connector terminal and ground.
Item
Power supply

Power supply
(memory back-up)

Connector
E106
E107

Terminal

Judgement standard
(Approx.)

10

0V

19

0V

28

Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

L

M

SCIA2657E

AT-237

BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)
[EXC.F/EURO-OBD]

2. DETECT MALFUNCTIONING ITEM
Check the following items:
●
Harness for short or open between ignition switch and TCM terminals 10, 19
●
Harness for short or open between battery and TCM terminal 28
●
10A fuse (No.7, located in the fuse block) and 10A fuse (No.58, located in the IPDM E/R)
●
Ignition switch. Refer to PG-38, «GROUND» .
OK or NG
OK
>> GO TO 9.
NG
>> Repair or replace damaged parts.

3. CHECK INPUT SIGNAL OF A/T FLUID TEMPERATURE SENSOR
With CONSULT-II
1. Start engine.
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Read out the value of “FLUID TEMP SE”.
Item name
FLUID TEMP
SE

Condition

Display value
(Approx.)

When A/T fluid temperature is 20°C (68°F).

1.5V

When A/T fluid temperature is 80°C
(176°F).

0.5V

SCIA4730E

Without CONSULT-II
1. Start engine.
2. Check voltage TCM connector terminals while warming up A/T.
Item

A/T fluid
temperature
sensor

Connector

E107

Condition

Judgement
standard
(Approx.)

When A/T fluid temperature is 20°C (68°F).

1.5V

When A/T fluid temperature is 80°C (176°F).

0.5V

Terminal

47 — 42

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 4.

SCIA2658E

4. DETECT MALFUNCTIONING ITEM
Check the following items:
●
Harness for short or open between TCM, ECM and terminal cord assembly
●
Ground circuit for ECM
Refer to EC-543, «POWER SUPPLY AND GROUND CIRCUIT» .
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace damaged parts.

AT-238

BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)
[EXC.F/EURO-OBD]

5.

CHECK FLUID TEMPERATURE SENSOR CIRCUIT

1.
2.
3.

Turn ignition switch OFF.
Disconnect the TCM connector.
Check resistance between TCM connector terminals.
Item

Connector

A/T fluid
temperature sensor

E107

Terminal

A

B

Temperature °C (°F)

Resistance
(Approx.)

20 (68)

2.5 kΩ

80 (176)

0.3 kΩ

AT

47 — 42

D

OK or NG
OK
>> GO TO 9.
NG
>> GO TO 6.

E
SCIA4947E

6.
1.
2.
3.

CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR

F

Turn ignition switch OFF.
Disconnect terminal cord assembly harness connector and TCM connector.
Check continuity between terminal cord assembly harness connector terminals and TCM connector terminals.

G

Item

Connector

Terminal

TCM

E107

42

F13

7

E107

47

F13

6

Terminal cord assembly
harness connector
TCM
Terminal cord assembly
harness connector

H

Continuity
Yes

I
Yes

J
SCIA2660E

4. If OK, check harness for short to ground and short to power.
5. If OK, check continuity between ground and transaxle assembly.
6. Reinstall any part removed.
OK or NG
OK
>> GO TO 7.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

K

L

7. CHECK A/T FLUID TEMPERATURE SENSOR WITH TERMINAL CORD ASSEMBLY
1.
2.
3.

M

Turn ignition switch OFF.
Disconnect terminal cord assembly connector in engine room.
Check resistance between terminal cord assembly harness connector terminals.
Temperature °C (°F)

Resistance (Approx.)

20 (68)

2.5 kΩ

80 (176)

0.3 kΩ

4. Reinstall any part removed.
OK or NG
OK
>> GO TO 8.
NG
>> Repair or replace damaged parts.

SCIA4948E

AT-239

BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)
[EXC.F/EURO-OBD]

8. DETECT MALFUNCTIONING ITEM
1.
2.
–

•

Remove oil pan. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
A/T fluid temperature sensor
Check resistance between terminal cord assembly harness connector terminals while changing temperature as shown.
Temperature [°C (°F)]

Resistance (Approx.)

20 (68)

2.5 kΩ

80 (176)

0.3 kΩ

–
Harness of terminal cord assembly for short or open
OK or NG
OK
>> GO TO 9.
NG
>> Repair or replace damaged parts.

SAT298F

9. CHECK DTC
Perform AT-235, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 10.

10. CHECK TCM
1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

Component Inspection

BCS000U6

A/T FLUID TEMPERATURE SENSOR
●

●

For removal, refer to AT-345, «Control Valve Assembly and
Accumulators» .
Check resistance between terminal cord assembly harness connector terminals while changing temperature as shown.
Temperature [°C (°F)]

Resistance (Approx.)

20 (68)

2.5 kΩ

80 (176)

0.3 kΩ

SAT298F

AT-240

ENGINE SPEED SIGNAL
[EXC.F/EURO-OBD]

ENGINE SPEED SIGNAL
Description

PFP:24825

A
BCS000U7

The engine speed signal is sent from the ECM to the TCM.
B

CONSULT-II Reference Value

BCS000U8

Remarks: Specification data are reference values.
Item name
Condition
ENGINE SPEED

Display value

Engine running

Approximately matches the tachometer reading.

On Board Diagnosis Logic

AT

BCS000U9

Diagnostic trouble code “ENGINE SPEED SIG” with CONSULT-II or 9th judgement flicker without CONSULTII is detected when TCM does not receive the proper voltage signal from ECM.

Possible Cause

BCS000UA

D

E

Harness or connector
(Circuit is open or shorted.)

DTC Confirmation Procedure

BCS000UB

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

F

G

H

WITH CONSULT-II
1.
2.
3.

4.

Turn ignition switch ON and select “DATA MONITOR” mode for
“A/T” with CONSULT-II.
Touch “START”.
Start engine and maintain the following conditions for at least 10
consecutive seconds.
VEHICLE SPEED: 10 km/h (6 MPH) or more
THROTTLE POSI: More than 1.0/8
SLCT LVR POSI: “D” position
If the check result is NG, go to AT-243, «Diagnostic Procedure» .

I

J

K
BCIA0031E

L

WITHOUT CONSULT-II
1.
2.

3.
4.

Start engine.
Drive vehicle under the following conditions for more than 10 seconds.
Selector lever position: “D” position
Vehicle speed: Higher than 10 km/h (6 MPH)
Throttle position: Greater than 1.0/8 of the full throttle position
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-243, «Diagnostic Procedure» .

AT-241

M

ENGINE SPEED SIGNAL
[EXC.F/EURO-OBD]

Wiring Diagram — AT — ENGSS

BCS000UC

MCWA0244E

AT-242

ENGINE SPEED SIGNAL
[EXC.F/EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

39

L

Item

Condition

A

Judgement standard (Approx.)
Refer to EC-512 .

Engine speed signal

B

and

Diagnostic Procedure

BCS000UD

1. CHECK DTC WITH ECM

AT

Check DTC with CONSULT-II “ENGINE”.
Turn ignition switch ON and select “SELF-DIAGNOSTIC RESULTS” mode for “ENGINE” with CONSULT-II.
Refer to EC-521, «SELF-DIAG RESULTS MODE» .
OK or NG
OK
>> GO TO 2.
NG
>> Check ignition signal circuit for engine control. Refer to EC-784, «IGNITION SIGNAL» .

2. CHECK INPUT SIGNAL
1.
2.
3.

D

E

F

With CONSULT-II
Start engine.
Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
Read out the value of “ENGINE SPEED”. Check engine speed
changes according to throttle position.

Item name

Condition

Display value

ENGINE
SPEED

Engine running

Approximately matches the
tachometer reading.

G

H

I

J
SCIA4730E

K

Without CONSULT-II
1. Start engine.
2. Check voltage between TCM harness connector terminal and
ground.
Item

Connector

Terminal

Condition

Judgement standard
(Approx.)

Engine
speed signal

E107

39 Ground

and

Refer to EC-512 .

L

M

SCIA3265E

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

AT-243

ENGINE SPEED SIGNAL
[EXC.F/EURO-OBD]

3.

CHECK HARNESS BETWEEN TCM AND ECM

1.
2.
3.

Turn ignition switch OFF.
Disconnect ECM connector and TCM connector.
Check continuity between ECM connector and TCM connector.
Item

Connector

Terminal

TCM

E107

39

ECM

F50

13

Continuity
Yes

4.
5.

If OK, check harness for short to ground and short to power.
If OK, check continuity between body ground and transaxle
assembly.
6. Reinstall any part removed.
OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK DTC
Perform AT-241, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.

5. CHECK TCM
1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-244

SCIA7173E

TURBINE REVOLUTION SENSOR
[EXC.F/EURO-OBD]

TURBINE REVOLUTION SENSOR
Description

PFP:31935

A
BCS000UE

The turbine revolution sensor (power train revolution sensor) detects forward clutch drum rpm (revolutions per
minute). It is located on the input side of the automatic transaxle. The vehicle speed sensor A/T (Revolution
sensor) is located on the output side of the automatic transaxle. With the two sensors, input and output rpms
are accurately detected. As a result, optimal shift timing during deceleration and shift quality can be improved.

CONSULT-II Reference Value

BCS000UF

Remarks: Specification data are reference values.
Item name
Condition
TURBINE REV

During driving (lock-up ON)

Approximately matches the engine speed.

D

BCS000UG

Diagnostic trouble code “TURBINE SENSOR” with CONSULT-II or 10st judgement flicker without CONSULT-II
is detected when TCM does not receive the proper voltage signal from the sensor.

Possible Cause

●

AT

Display value

On Board Diagnosis Logic

●

B

E

BCS000UH

F

Harness or connector
(Sensor circuit is open or shorted.)
Turbine revolution sensor (power train revolution sensor)

DTC Confirmation Procedure

G
BCS000UI

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

H

I

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

5.

Start engine.
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Touch “START”.
Drive vehicle under the following conditions for more than 5 seconds.
SLCT LVR POSI: “D” position
VEHICLE SPEED: Higher than 40 km/h (25 MPH)
ENGINE SPEED: Higher than 1,500 rpm
THROTTLE POSI: Greater than 1.0/8 of the full throttle position
If the check result is NG, go to AT-247, «Diagnostic Procedure» .

J

K

L

M
BCIA0031E

WITHOUT CONSULT-II
1.
2.

3.
4.

Start engine.
Drive vehicle under the following conditions for more than 5 seconds.
Selector lever position: “D” position
Vehicle speed: Higher than 40 km/h (25 MPH)
Engine speed: Higher than 1,500 rpm
Throttle position: 1.0/8 of the full throttle position
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-247, «Diagnostic Procedure» .

AT-245

TURBINE REVOLUTION SENSOR
[EXC.F/EURO-OBD]

Wiring Diagram — AT — PT/SEN

BCS000UJ

MCWA0254E

AT-246

TURBINE REVOLUTION SENSOR
[EXC.F/EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

38

LG

42

B

Item

Condition

Turbine revolution sensor (power train revolution sensor)

When driving at 20 km/h (12 MPH)

Sensor ground

Always

Judgement standard
(Approx.)

A

B

360 Hz
0V

AT

Diagnostic Procedure

BCS000UK

1. CHECK INPUT SIGNAL
D

With CONSULT-II
1. Start engine.
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Read out the value of “TURBINE REV” while driving. Check the
value changes according to driving speed.

E

F

Item name

Condition

Display value

TURBINE REV

During driving (lock-up
ON)

Approximately matches
the engine speed.

G

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 2.

H
SCIA4730E

2.
1.
2.

CHECK TURBINE REVOLUTION SENSOR

I

Start engine.
Check power supply to turbine revolution sensor (power train revolution sensor) by voltage between TCM
connector terminals. Refer to AT-261, «Wiring Diagram — AT — MAIN» and AT-246, «Wiring Diagram —
AT — PT/SEN» .

J

Item

Connector

TCM

E106, E107

Terminal
10 — 42

K

Judgement standard (Approx.)
Battery voltage

L

19 — 42

3.

If OK, check the pulse when vehicle cruises.
Name

Turbine revolution
sensor (power train
revolution sensor)

Condition

M

When driving at 20 km/h (12 MPH), use the CONSULT-II
pulse frequency measuring function.*1
CAUTION:
Connect the diagnosis data link cable to the vehicle
diagnosis connector.
*1: A circuit tester cannot be used to test this item.

Item

Connector

Terminal

Name

Judgement standard
(Approx.)

TCM

E107

38

Turbine revolution sensor
(power train revolution sensor)

360 Hz

OK or NG
OK
>> GO TO 8.
NG
>> GO TO 3.

SCIA4949E

AT-247

TURBINE REVOLUTION SENSOR
[EXC.F/EURO-OBD]

3.
1.
2.
3.
4.

CHECK POWER AND SENSOR GROUND
Turn ignition switch OFF.
Disconnect the turbine revolution sensor (power train revolution sensor) harness connector.
Turn ignition switch ON.
Check voltage between turbine revolution sensor (power train
revolution sensor) harness connector terminals.
Item

Connector

Terminal

Judgement
standard
(Approx.)

Turbine revolution sensor
(power train revolution sensor)

F11

1-3

Battery voltage

SCIA2770E

5.

Check voltage between turbine revolution sensor (power train
revolution sensor) harness connector terminal and ground.
Item

Connector

Terminal

Judgement
standard
(Approx.)

Turbine revolution sensor
(power train revolution sensor)

F11

1 — ground

Battery voltage

6. If OK, check harness for short to ground and short to power.
7. Reinstall any part removed.
SCIA2771E
OK or NG
OK
>> GO TO 4.
NG — 1 >> Battery voltage is not supplied between terminals 1 and 3, terminals 1 and ground.: GO TO 6.
NG — 2 >> Battery voltage is not supplied between terminals 1 and 3 only.: GO TO 7.

4.

CHECK HARNESS BETWEEN TCM AND TURBINE REVOLUTION SENSOR (POWER TRAIN REVOLUTION SENSOR)
1.
2.
3.

Turn ignition switch OFF.
Disconnect the turbine revolution sensor (power train revolution sensor) harness connector.
Check continuity between TCM connector terminal and turbine
revolution sensor (power train revolution sensor) harness connector terminal.
Item

Connector

Terminal

TCM

E107

38

Turbine revolution sensor
(power train revolution sensor)

F11

2

Continuity
Yes

4. If OK, check harness for short to ground and short to power.
5. Reinstall any part removed.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

AT-248

SCIA2772E

TURBINE REVOLUTION SENSOR
[EXC.F/EURO-OBD]

5. CHECK TCM

A

1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, re-check TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> GO TO 8.
NG
>> Repair or replace damaged parts.

B

AT

6.

CHECK HARNESS BETWEEN TCM AND TURBINE REVOLUTION SENSOR [(POWER TRAIN REVOLUTION SENSOR) POWER]
1.
2.
3.

D

Turn ignition switch OFF.
Disconnect the turbine revolution sensor (power train revolution sensor) harness connector.
Check continuity between TCM connector terminals and turbine
revolution sensor (power train revolution sensor) harness connector terminal. Refer to AT-52, «Circuit Diagram» and AT-261,
«Wiring Diagram — AT — MAIN» .

E

F
Item

Connector

Terminal

TCM

E106

10

Turbine revolution sensor
(power train revolution sensor)

F11

1

TCM

E106

19

Turbine revolution sensor
(power train revolution sensor)

F11

1

Continuity
Yes

Yes

G

SCIA2773E

4. If OK, check harness for short to ground and short to power.
5. Reinstall any part removed.
OK or NG
OK
>> 10A fuse (No.58, located in the IPDM E/R) or ignition switch are malfunctioning.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

H

I

J

7.

CHECK HARNESS BETWEEN TCM AND TURBINE REVOLUTION SENSOR [(POWER TRAIN REVOLUTION SENSOR) SENSOR GROUND]
1.
2.
3.

Turn ignition switch OFF.
Disconnect the turbine revolution sensor (power train revolution sensor) harness connector.
Check continuity between TCM connector terminal and turbine
revolution sensor (power train revolution sensor) harness connector terminal.
Item

Connector

Terminal

TCM

E107

42

Turbine revolution sensor
(power train revolution sensor)

F11

3

L

M

Continuity
Yes

4. If OK, check harness for short to ground and short to power.
5. Reinstall any part removed.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

AT-249

K

SCIA2774E

TURBINE REVOLUTION SENSOR
[EXC.F/EURO-OBD]

8. CHECK DTC
Perform AT-245, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.

AT-250

LINE PRESSURE SOLENOID VALVE
[EXC.F/EURO-OBD]

LINE PRESSURE SOLENOID VALVE
Description

PFP:31940

A
BCS000UL

The line pressure solenoid valve regulates the oil pump discharge pressure to suit the driving condition in
response to signals sent from the TCM.
The line pressure duty cycle value is not constant when the closed throttle position switch is ON. To
confirm the line pressure duty cycle at low-pressure, the accelerator (throttle) should be open until the
closed throttle position switch is OFF.

CONSULT-II Reference Value
Display value (Approx.)

Small throttle opening (Low line pressure) ⇔ Large
throttle opening (High line pressure)

D

0% ⇔ 94%

On Board Diagnosis Logic

BCS000UN

Diagnostic trouble code “LINE PRESSURE S/V” with CONSULT-II or 11th judgement flicker without CONSULT-II is detected when TCM detects an improper voltage drop while it tries to operate the solenoid valve.

Possible Cause
●

●

Harness or connector
(Solenoid circuit is open or shorted.)
Line pressure solenoid valve
BCS000UP

H

I

J

WITH CONSULT-II

4.

F

G

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

2.
3.

E

BCS000UO

DTC Confirmation Procedure

1.

AT

BCS000UM

Remarks: Specification data are reference values.
Item name
Condition
LINE PRES DTY

B

Turn ignition switch ON and select “DATA MONITOR” mode for
“A/T” with CONSULT-II.
Touch “START”.
Depress accelerator pedal completely and wait at least 1 second.
If the check result is NG, go to AT-253, «Diagnostic Procedure» .

K

L

M
BCIA0031E

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

Start engine.
With brake pedal depressed, shift the lever from “P” → “N” → “D” → “N” → “P” positions.
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If the check result is NG, go to AT-253, «Diagnostic Procedure» .

AT-251

LINE PRESSURE SOLENOID VALVE
[EXC.F/EURO-OBD]

Wiring Diagram — AT — LPSV

BCS000UQ

MCWA0247E

AT-252

LINE PRESSURE SOLENOID VALVE
[EXC.F/EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

1

2

Wire color

Item

Condition
When releasing accelerator pedal after
warming up engine.

Line pressure solenoid
valve

P

When depressing accelerator pedal
fully after warming up engine.
When releasing accelerator pedal after
warming up engine.

Line pressure solenoid
valve (with dropping
resistor)

V

When depressing accelerator pedal
fully after warming up engine.

Diagnostic Procedure

Judgement standard
(Approx.)
1.5 — 3.0V

A

B

0V

AT

4 — 14V
0V

D
BCS000UR

1. CHECK INPUT SIGNAL

E

With CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
3. Read out the value of “LINE PRES DTY” while driving. Check
the value changes according to driving speed.

F

G

Display value
(Approx.)

Item name

Condition

LINE PRES DTY

Small throttle opening (Low line pressure)
⇔ Large throttle opening (High line pressure)

H
0% ⇔ 94%

I
SCIA3251E

J

Without CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Check voltage between TCM connector terminals and ground.

Item

Line pressure solenoid valve

Line pressure solenoid valve
(with dropping resistor)

Connector

E106

E106

Terminal

1 — Ground

2 — Ground

K

Condition

Judgement standard
(Approx.)

L

When releasing accelerator pedal after warming
up engine.

1.5 — 3.0V

M

When depressing accelerator pedal fully after
warming up engine.

0V

When releasing accelerator pedal after warming
up engine.

4 — 14V

When depressing accelerator pedal fully after
warming up engine.

0V

SCIA3267E

OK or NG
OK
>> GO TO 5.
NG
>> GO TO 2.

AT-253

LINE PRESSURE SOLENOID VALVE
[EXC.F/EURO-OBD]

2. CHECK DROPPING RESISTOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect dropping resistor harness connector in engine room.
Check resistance between terminals.
Item

Dropping resistor

Connector

Terminal

Resistance (Approx.)

E58

1-2

12 Ω

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace damaged parts.

SCIA4950E

3. CHECK VALVE RESISTANCE
1.
2.
3.

Turn ignition switch OFF.
Disconnect terminal cord assembly connector in engine room.
Check resistance between terminal cord assembly harness connector terminal and ground.
Solenoid valve

Connector

Terminal

Resistance (Approx.)

Line pressure solenoid
valve

F13

4 — Ground

2.5 — 5.0 Ω

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace damaged parts.
SCIA4951E

AT-254

LINE PRESSURE SOLENOID VALVE
[EXC.F/EURO-OBD]

4.
1.
2.
3.

CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR
Turn ignition switch OFF.
Disconnect terminal cord assembly harness connector and TCM connector.
Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal.
Item

Connector

Terminal

TCM

E106

1

F13

4

Terminal cord assembly
harness connector

B

Continuity

AT

Yes

D

SCIA3272E

4.

Check continuity between terminal cord assembly harness connector terminal and dropping resistor harness connector terminal.
Item

Dropping resistor harness
connector
Terminal cord assembly
harness connector

A

Connector

Terminal

E106

2

F13

4

E

F

Continuity

G

Yes

H

SCIA7194E

I

5.

Check continuity between dropping resistor harness connector
terminal and TCM connector terminal.
Item

Connector

Terminal

TCM

E106

2

E58

1

Dropping resistor harness
connector

J

Continuity
Yes

6. If OK, check harness for short to ground and short to power.
7. If OK, check continuity between ground and transaxle assembly.
8. Reinstall any part removed.
OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK DTC
Perform AT-251, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.

6. CHECK TCM
1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-255

K

L
SCIA7195E

M

LINE PRESSURE SOLENOID VALVE
[EXC.F/EURO-OBD]

Component Inspection

BCS000US

LINE PRESSURE SOLENOID VALVE
●

For removal, refer to AT-345, «Control Valve Assembly and Accumulators» .

Resistance Check
●

Check resistance between terminal and ground.
Solenoid valve

Resistance
(Approx.)

Terminal

Line pressure
solenoid valve

4

Ground

2.5 — 5 Ω

SCIA4951E

Operation Check
●

Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground.

SCIA3275E

DROPPING RESISTOR
●

Check resistance between terminals.
Item
Dropping resistor

Connector

Terminal

Resistance (Approx.)

E58

1-2

12 Ω

SCIA4950E

AT-256

CAN COMMUNICATION LINE
[EXC.F/EURO-OBD]

CAN COMMUNICATION LINE
Description

PFP:31940

A
BCS000UT

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent malfunction detection ability. B
Many electronic control units are equipped onto a vehicle, and each control unit shares information and links
with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission
AT
with less wiring. Each control unit transmits/receives data but selectively reads required data only.

On Board Diagnosis Logic

BCS000UU

Diagnostic trouble code “U1000 CAN COMM CIRCUIT” with CONSULT-II or 12th judgement flicker without
CONSULT-II is detected when TCM cannot communicate to other control units.

Possible Cause

BCS000UV

D

E

Harness or connector
(CAN communication line is open or shorted.)

DTC Confirmation Procedure

BCS000UW

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON.
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Touch “START”.
Wait at least 6 seconds or start engine and wait for at least 6
seconds.
If DTC is detected, go to AT-259, «Diagnostic Procedure» .

F

G

H

I

J

K
BCIA0031E

L

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

Turn ignition switch ON.
Wait at least 6 seconds or start engine and wait at least 6 seconds.
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
If DTC is detected, go to AT-259, «Diagnostic Procedure» .

AT-257

M

CAN COMMUNICATION LINE
[EXC.F/EURO-OBD]

Wiring Diagram — AT — CAN

BCS000UX

MCWA0241E

AT-258

CAN COMMUNICATION LINE
[EXC.F/EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

Item

Condition

Judgement standard
(Approx.)

5

L

CAN H

—

—

6

Y

CAN L

—

—

Diagnostic Procedure

A

B
BCS000UY

1. CHECK CAN COMMUNICATION CIRCUIT

AT

With CONSULT-II
1. Turn ignition switch ON and start engine.
2. Select “SELF-DIAG RESULTS” mode for “A/T” with CONSULTII.
Is any malfunction of the “CAN COMM CIRCUIT” indicated?
YES >> Print out CONSULT-II screen, GO TO LAN section.
Refer to LAN-3, «Precautions When Using CONSULT-II»
.
NO
>> INSPECTION END

D

E

F

G
SCIA7135E

H

I

J

K

L

M

AT-259

MAIN POWER SUPPLY AND GROUND CIRCUIT
[EXC.F/EURO-OBD]

MAIN POWER SUPPLY AND GROUND CIRCUIT
Description

PFP:00100
BCS000UZ

When the power supply to the TCM is cut “OFF”, for example because the battery is removed, and the selfdiagnostics memory function stops, malfunction is detected.

On Board Diagnosis Logic
●

●

BCS000V0

Diagnostic trouble code “INITIAL START” with CONSULT-II is detected when TCM does not receive the
voltage signal from the battery power supply.
This is not a malfunction message. (Whenever shutting “OFF” a power supply to the TCM, this message
appears on the screen.)

Possible Cause

BCS000V1

Harness or connector
(Battery or ignition switch and TCM circuit is open or shorted.)

DTC Confirmation Procedure

BCS000V2

CAUTION:
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at
least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.
4.
5.

Turn ignition switch ON. (Do not start engine.)
Select “DATA MONITOR” mode for “A/T” with CONSULT-II.
Touch “START”.
Wait for at least 2 consecutive seconds.
If DTC is detected, go to AT-262, «Diagnostic Procedure» .

BCIA0031E

AT-260

MAIN POWER SUPPLY AND GROUND CIRCUIT
[EXC.F/EURO-OBD]

Wiring Diagram — AT — MAIN

BCS000V3

A

B

AT

D

E

F

G

H

I

J

K

L

M

MCWA0255E

AT-261

MAIN POWER SUPPLY AND GROUND CIRCUIT
[EXC.F/EURO-OBD]
TCM terminal data are reference values, measured between each terminal and ground.
Condition

Judgement standard
(Approx.)

Terminal

Wire color

Item

10

R

Power supply

19

R

Power supply

25

B

Ground

Always

0V

28

LG

Power supply
(memory back-up)

Always

Battery voltage

48

B

Ground

Always

0V

or

When turning ignition switch to “ON”.

Battery voltage

When turning ignition switch to “OFF”.

0V

When turning ignition switch to “ON”.

Battery voltage

When turning ignition switch to “OFF”.

0V

Diagnostic Procedure

BCS000V4

1. CHECK TCM POWER SOURCE
1.
2.

Turn ignition switch ON. (Do not start engine.)
Check voltage between TCM connector terminals and ground.
Name

Connector

Power supply

E106

Power supply
(memory back-up)

E107

Terminal

Judgement standard (Approx.)

10

Battery voltage

19

Battery voltage

28

Battery voltage

SCIA2656E

3.
4.

Turn ignition switch OFF.
Check voltage between TCM connector terminals and ground.
Name

Connector

Power supply

E106

Power supply
(memory back-up)

E107

Terminal

Judgement standard (Approx.)

10

0V

19

0V

28

Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 2.

SCIA2657E

2. DETECT MALFUNCTIONING ITEM
Check the following items:
Harness for short or open between ignition switch and TCM terminals 10, 19
●
Harness for short or open between battery and TCM terminal 28
●
10A fuse (No.7, located in the fuse block) and 10A fuse (No.58, located in the IPDM E/R)
●
Ignition switch. Refer to PG-38, «GROUND» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace damaged parts.
●

AT-262

MAIN POWER SUPPLY AND GROUND CIRCUIT
[EXC.F/EURO-OBD]

3. CHECK TCM GROUND CIRCUIT
1.
2.

A

Turn ignition switch OFF.
Check continuity between TCM connector terminals and ground.
B
Item

Connector

Terminal

Continuity

Ground

E107

25, 48 — Ground

Yes

AT

OK or NG
OK
>> GO TO 4.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

D
SCIA2671E

E

4. CHECK DTC
Perform AT-260, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.

F

G

5. CHECK TCM
1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

H

I

J

K

L

M

AT-263

A/T 1ST GEAR FUNCTION
[EXC.F/EURO-OBD]

A/T 1ST GEAR FUNCTION
Description
●

●

PFP:31940
BCS000V5

This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis
malfunction.
This malfunction is detected when the A/T does not shift into first gear position as instructed by the TCM.
This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such
as control valve sticking, improper solenoid valve operation, etc.
Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

On Board Diagnosis Logic
●

●

●

BCS000V6

Diagnostic trouble code “A/T 1ST GR FNCTN” with CONSULT-II is detected when A/T cannot be shifted
to the 1st gear position even if electrical circuit is good.
This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM
as follows:
Torque converter slip ratio = A x C/B
A: Output shaft revolution signal from revolution sensor
B: Engine speed signal from ECM
C: Gear ratio determined as gear position which TCM supposes
If the actual gear position is higher than the position (1st) supposed by TCM, the slip ratio will be more
than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction.
This malfunction will be caused when either shift solenoid valve A is stuck open or shift solenoid valve B is
stuck open.
Gear positions supposed by TCM are as follows:
In case of gear position with no malfunctions: 1 , 2, 3 and 4 positions
In case of gear position with shift solenoid valve A stuck open: 2* , 2, 3 and 3 positions
In case of gear position with shift solenoid valve B stuck open: 4* , 3, 3 and 4 positions to each gear position above
*: “A/T 1ST GR FNCTN” is detected.

Possible Cause
●
●
●
●

BCS000V7

Shift solenoid valve A
Shift solenoid valve B
Each clutch
Hydraulic control circuit

AT-264

A/T 1ST GEAR FUNCTION
[EXC.F/EURO-OBD]

DTC Confirmation Procedure

BCS000V8

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.

4.
5.

–

6.

–
–

7.
8.

Gear on actual transmission shift pattern when screen is changed to 1 → 2 → 3 → 4

D

E

F

G

H

I

J

K

L

1→2→3→4

No malfunction exists.

2→2→3→3

Malfunction for “A/T 1ST GR FNCTN ” exists.

9.

B

AT

Start engine and select “DATA MONITOR” mode for “A/T” with
CONSULT-II.
Touch “START”.
Make sure that output voltage of A/T fluid temperature sensor is
within the range below.
FLUID TEMP SE: 0.4 — 1.5V
If out of range, drive the vehicle to decrease the voltage (warm
up the fluid) or stop engine to increase the voltage (cool down
the fluid).
Select “1ST GR FNCTN P0731” of “DTC WORK SUPPORT”
BCIA0031E
mode for “A/T” with CONSULT-II and touch “START”.
Accelerate vehicle to 20 to 25 km/h (12 to 16 MPH) under the following conditions and release the accelerator pedal completely.
THROTTLE POSI: Less than 1.0/8 (at all times during step 4)
SLCT LVR POSI: “D” position
Make sure that “GEAR” shows “2” after releasing pedal.
Depress accelerator pedal to WOT (more than 7.0/8 of “THROTTLE POSI”) quickly from a speed of 20 to
25 km/h (12 to 16 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETED”. (It will take
approximately 3 seconds.)
If the check result NG appears on CONSULT-II screen, go to AT-266, «Diagnostic Procedure» .
If “STOP VEHICLE” appears on CONSULT-II screen, go to the following step.
Make sure that “GEAR” shows “1” when depressing accelerator pedal to WOT.
If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for
“A/T”. In case a DTC other than “A/T 1ST GR FNCTN” is shown, refer to AT-86, «Display Items List
(Except for EURO-OBD models)» .
Stop vehicle.
Follow the instruction displayed. (Check for normal shifting referring to the table below.)

Vehicle condition

A

4→3→3→4

Make sure that “OK” is displayed. (If “NG” is displayed, refer to “Diagnostic Procedure”.)
Refer to AT-266, «Diagnostic Procedure» .
Refer to AT-67, «Vehicle Speed at Which Gear Shifting Occurs» .

AT-265

M

A/T 1ST GEAR FUNCTION
[EXC.F/EURO-OBD]

Diagnostic Procedure

BCS000V9

1. CHECK VALVE RESISTANCE
1.
–
–

2.

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Shift solenoid valve A
Shift solenoid valve B
Check resistance between terminal cord assembly harness connector terminals and ground. Refer to AT-216, «Wiring Diagram
— AT — SSV/A» and AT-221, «Wiring Diagram — AT — SSV/B»
.
Solenoid valve
Shift solenoid valve A
Shift solenoid valve B

Terminal
2
1

Ground

Resistance
(Approx.)
20 — 30 Ω
5 — 20 Ω

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace damaged parts.

SCIA3594E

2. CHECK VALVE OPERATION
Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
–
Shift solenoid valve A
–
Shift solenoid valve B
2. Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminals and ground. Refer to
AT-216, «Wiring Diagram — AT — SSV/A» and AT-221, «Wiring
Diagram — AT — SSV/B» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace shift solenoid valve assembly.
1.

SCIA3595E

AT-266

A/T 1ST GEAR FUNCTION
[EXC.F/EURO-OBD]

3. CHECK CONTROL VALVE

A

Disassemble control valve assembly. Refer to AT-392, «Control Valve Assembly» .
Check to ensure that:
–
Valve, sleeve and plug slide along valve bore under their own weight.
–
Valve, sleeve and plug are free from burrs, dents and scratches.
–
Control valve springs are free from damage, deformation and fatigue.
–
Hydraulic line is free from obstacles.
OK or NG
OK
>> GO TO 4.
NG
>> Repair control valve assembly.

1.
2.

4. CHECK DTC

B

AT

D

E

Perform AT-265, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> Check control valve again. Repair or replace control valve assembly.

F

G

H

I

J

K

L

M

AT-267

A/T 2ND GEAR FUNCTION
[EXC.F/EURO-OBD]

A/T 2ND GEAR FUNCTION
Description
●

●

PFP:31940
BCS000VA

This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis
malfunction.
This malfunction is detected when the A/T does not shift into second gear position as instructed by the
TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction
such as control valve sticking, improper solenoid valve operation, etc.
Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

On Board Diagnosis Logic
●

●

●

BCS000VB

Diagnostic trouble code “A/T 2ND GR FNCTN” with CONSULT-II is detected when A/T cannot be shifted
to the 2nd gear position even if electrical circuit is good.
This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM
as follows:
Torque converter slip ratio = A x C/B
A: Output shaft revolution signal from revolution sensor
B: Engine speed signal from ECM
C: Gear ratio determined as gear position which TCM supposes
If the actual gear position is higher than the position (2nd) supposed by TCM, the slip ratio will be more
than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction.
This malfunction will be caused when shift solenoid valve B is stuck open.
Gear positions supposed by TCM are as follows:
In case of gear position with no malfunctions: 1, 2 , 3 and 4 positions
In case of gear position with shift solenoid valve B stuck open: 4, 3* , 3 and 4 positions to each gear position above
*: “A/T 2ND GR FNCTN” is detected.

Possible Cause
●
●
●

BCS000VC

Shift solenoid valve B
Each clutch
Hydraulic control circuit

AT-268

A/T 2ND GEAR FUNCTION
[EXC.F/EURO-OBD]

DTC Confirmation Procedure

BCS000VD

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.

4.
5.

–

6.

–
–

7.
8.

Gear on actual transmission shift pattern when screen is changed to 1 → 2 → 3 → 4

No malfunction exists

1→2→3→4

Malfunction for “A/T 2ND GR FNCTN” exists.

4→3→3→4

9.

B

AT

Start engine and select “DATA MONITOR” mode for “A/T” with
CONSULT-II.
Touch “START”.
Make sure that output voltage of A/T fluid temperature sensor is
within the range below.
FLUID TEMP SE: 0.4 — 1.5V
If out of range, drive the vehicle to decrease the voltage (warm
up the fluid) or stop engine to increase the voltage (cool down
the fluid).
Select “2ND GR FNCTN P0732” of “DTC WORK SUPPORT”
BCIA0031E
mode for “A/T” with CONSULT-II and touch “START”.
Accelerate vehicle to 45 to 50 km/h (28 to 31 MPH) under the following conditions and release the accelerator pedal completely.
THROTTLE POSI: Less than 1.0/8
SLCT LVR POSI: “D” position
Make sure that “GEAR” shows “3” or “4” after releasing pedal.
Depress accelerator pedal to WOT (more than 7.0/8 of “THROTTLE POSI”) quickly from a speed of 45 to
50 km/h (28 to 31 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETE”. (It will take
approximately 3 seconds.)
If the check result NG appears on CONSULT-II screen, go to AT-270, «Diagnostic Procedure» .
If “STOP VEHICLE” appears on CONSULT-II screen, go to following step.
Make sure that “GEAR” shows “2” when depressing accelerator pedal to WOT.
If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for
“A/T”. In case a DTC other than “A/T 2ND GR FNCTN” is shown, refer to AT-86, «Display Items List
(Except for EURO-OBD models)» .
Stop vehicle.
Follow the instruction displayed. (Check for normal shifting referring to the table below.)

Vehicle condition

A

Make sure that “OK” is displayed. (If “NG” is displayed, refer to “Diagnostic Procedure”.)
Refer to AT-270, «Diagnostic Procedure» .
Refer to AT-67, «Vehicle Speed at Which Gear Shifting Occurs» .

AT-269

D

E

F

G

H

I

J

K

L

M

A/T 2ND GEAR FUNCTION
[EXC.F/EURO-OBD]

Diagnostic Procedure

BCS000VE

1. CHECK VALVE RESISTANCE
1.
–

2.

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Shift solenoid valve B
Check resistance between terminal cord assembly harness connector terminal and ground. Refer to AT-221, «Wiring Diagram
— AT — SSV/B» .
Solenoid valve
Shift solenoid valve B

Terminal
1

Ground

Resistance
(Approx.)
5 — 20 Ω

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace shift solenoid valve assembly.
SCIA2055E

2. CHECK VALVE OPERATION
Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
–
Shift solenoid valve B
2. Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground. Refer to AT221, «Wiring Diagram — AT — SSV/B» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace shift solenoid valve assembly.
1.

SCIA2058E

3. CHECK CONTROL VALVE
Disassemble control valve assembly. Refer to AT-392, «Control Valve Assembly» .
Check to ensure that:
–
Valve, sleeve and plug slide along valve bore under their own weight.
–
Valve, sleeve and plug are free from burrs, dents and scratches.
–
Control valve springs are free from damage, deformation and fatigue.
–
Hydraulic line is free from obstacles.
OK or NG
OK
>> GO TO 4.
NG
>> Repair control valve assembly.
1.
2.

4. CHECK DTC
Perform AT-269, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> Check control valve again. Repair or replace control valve assembly.

AT-270

A/T 3RD GEAR FUNCTION
[EXC.F/EURO-OBD]

A/T 3RD GEAR FUNCTION
Description
●

●

PFP:31940

A
BCS000VF

This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis
malfunction.
B
This malfunction is detected when the A/T does not shift into third gear position as instructed by the TCM.
This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such
as control valve sticking, improper solenoid valve operation, malfunctioning servo piston or brake band, AT
etc.
Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

On Board Diagnosis Logic
●

●

●

BCS000VG

Diagnostic trouble code “A/T 3RD GR FNCTN” with CONSULT-II is detected when A/T cannot be shifted
to the 3rd gear position even if electrical circuit is good.
This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM
as follows:
Torque converter slip ratio = A x C/B
A: Output shaft revolution signal from revolution sensor
B: Engine speed signal from ECM
C: Gear ratio determined as gear position which TCM supposes
If the actual gear position is higher than the position (3rd) supposed by TCM, the slip ratio will be more
than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction.
This malfunction will be caused when shift solenoid valve A is stuck closed.
Gear positions supposed by TCM are as follows.
In case of gear position with no malfunctions: 1, 2, 3 and 4 positions
In case of gear position with shift solenoid valve A stuck closed: 1, 1, 4* and 4 positions to each gear
position above
*: “A/T 3RD GR FNCTN” is detected.

Possible Cause
●
●
●

D

E

F

G

H

I

J

BCS000VH

Shift solenoid valve A
Each clutch
Hydraulic control circuit

K

L

M

AT-271

A/T 3RD GEAR FUNCTION
[EXC.F/EURO-OBD]

DTC Confirmation Procedure

BCS000VI

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.

4.
5.

–

6.

–

–

7.
8.

Start engine and select “DATA MONITOR” mode for “A/T” with
CONSULT-II.
Touch “START”.
Make sure that output voltage of A/T fluid temperature sensor is
within the range below.
FLUID TEMP SE: 0.4 — 1.5V
If out of range, drive the vehicle to decrease the voltage (warm
up the fluid) or stop engine to increase the voltage (cool down
the fluid).
Select “3RD GR FNCTN P0733” of “DTC WORK SUPPORT”
BCIA0031E
mode for “A/T” with CONSULT-II and touch “START”.
Accelerate vehicle to 60 to 75 km/h (37 to 47 MPH) under the following conditions and release the accelerator pedal completely.
THROTTLE POSI: Less than 1.0/8 (at all times during step 4)
SLCT LVR POSI: “D” position
Make sure that “GEAR” shows “4” after releasing pedal.
Depress accelerator pedal steadily with 3.5/8 — 4.5/8 of “THROTTLE POSI” from a speed of 60 to 75 km/h
(37 to 47 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.)
If the check result NG appears on CONSULT-II screen, go to AT-273, «Diagnostic Procedure» .
If “STOP VEHICLE” appears on CONSULT-II screen, go to following step.
Make sure that “GEAR” shows “3” when depressing accelerator pedal with 3.5/8 — 4.5/8 of
“THROTTLE POSI”.
If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for
“A/T”. In case a DTC other than “A/T 3RD GR FNCTN” is shown, refer to AT-86, «Display Items List
(Except for EURO-OBD models)» .
Stop vehicle.
Follow the instruction displayed. (Check for normal shifting referring to the table below.)

Vehicle condition

Gear on actual transmission shift pattern when screen is changed to 1 → 2 → 3 → 4

No malfunction exists.

1→2→3→4

Malfunction for “A/T 3RD GR FNCTN” exists.

1→1→4→4

9.

Make sure that “OK” is displayed. (If “NG” is displayed, refer to “Diagnostic Procedure”.)
Refer to AT-273, «Diagnostic Procedure» .
Refer to AT-67, «Vehicle Speed at Which Gear Shifting Occurs» .

AT-272

A/T 3RD GEAR FUNCTION
[EXC.F/EURO-OBD]

Diagnostic Procedure

BCS000VJ

1. CHECK VALVE RESISTANCE
1.
–
–

2.

A

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Shift solenoid valve A
Shift solenoid valve B
Check resistance between terminal cord assembly harness connector terminals and ground. Refer to AT-216, «Wiring Diagram
— AT — SSV/A» and AT-221, «Wiring Diagram — AT — SSV/B»
.
Solenoid valve
Shift solenoid valve A
Shift solenoid valve B

Terminal
2
1

Ground

B

AT

D

Resistance
(Approx.)
20 — 30 Ω

E

5 — 20 Ω

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace shift solenoid valve assembly.

F

G

H

I
SCIA3594E

2. CHECK VALVE OPERATION

J

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
–
Shift solenoid valve A
–
Shift solenoid valve B
2. Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminals and ground. Refer to
AT-216, «Wiring Diagram — AT — SSV/A» and AT-221, «Wiring
Diagram — AT — SSV/B» .
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace shift solenoid valve assembly.

1.

K

L

M

SCIA3595E

AT-273

A/T 3RD GEAR FUNCTION
[EXC.F/EURO-OBD]

3. CHECK CONTROL VALVE
Disassemble control valve assembly. Refer to AT-392, «Control Valve Assembly» .
Check to ensure that:
–
Valve, sleeve and plug slide along valve bore under their own weight.
–
Valve, sleeve and plug are free from burrs, dents and scratches.
–
Control valve springs are free from damage, deformation and fatigue.
–
Hydraulic line is free from obstacles.
OK or NG
OK
>> GO TO 4.
NG
>> Repair control valve assembly.
1.
2.

4. CHECK DTC
Perform AT-272, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> Check control valve again. Repair or replace control valve assembly.

AT-274

A/T 4TH GEAR FUNCTION
[EXC.F/EURO-OBD]

A/T 4TH GEAR FUNCTION
Description
●

●

PFP:31940

A
BCS000VK

This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis
malfunction.
B
This malfunction is detected when the A/T does not shift into fourth gear position or the torque converter
clutch does not lock up as instructed by the TCM. This is not caused by electrical malfunction (circuits
open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve AT
operation, malfunctioning oil pump or torque converter clutch, etc.
Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
Item name
Condition
LINE PRES DTY

●

●

●
●
●
●

0% ⇔ 94%

F
BCS000VL

Diagnostic trouble code “A/T 4TH GR FNCTN” with CONSULT-II is detected when A/T cannot be shifted
to the 4th gear position even if electrical circuit is good.
This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM
as follows:
Torque converter slip ratio = A x C/B
A: Output shaft revolution signal from revolution sensor
B: Engine speed signal from ECM
C: Gear ratio determined as gear position which TCM supposes
If the actual gear position is much lower than the position (4th) supposed by TCM, the slip ratio will be
much less than normal. In case the ratio does not reach the specified value, TCM judges this diagnosis
malfunction.
This malfunction will be caused when shift solenoid valve B is stuck closed.
Gear positions supposed by TCM are as follows.
In case of gear position with no malfunctions: 1, 2, 3 and 4 positions
In case of gear position with shift solenoid valve A stuck open: 2, 2, 3 and 3* positions
In case of gear position with shift solenoid valve B stuck closed: 1, 2, 2 and 1* positions to each gear
position above
*: “A/T 4TH GR FNCTN” is detected.

Possible Cause
●

E

Display value (Approx.)

Small throttle opening (Low line pressure) ⇔ Large
throttle opening (High line pressure)

On Board Diagnosis Logic
●

D

G

H

I

J

K

L

BCS000VM

M

Shift solenoid valve A
Shift solenoid valve B
Line pressure solenoid valve
Each clutch
Hydraulic control circuit

AT-275

A/T 4TH GEAR FUNCTION
[EXC.F/EURO-OBD]

DTC Confirmation Procedure

BCS000VN

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.

4.
5.

–

6.

–

–

7.
8.

Start engine and select “DATA MONITOR” mode for “A/T” with
CONSULT-II.
Touch “START”.
Make sure that output voltage of A/T fluid temperature sensor is
within the range below.
FLUID TEMP SE: 0.4 — 1.5V
If out of range, drive the vehicle to decrease the voltage (warm
up the fluid) or stop engine to increase the voltage (cool down
the fluid).
Select “4TH GR FNCTN P0734” of “DTC WORK SUPPORT”
BCIA0031E
mode for “A/T” with CONSULT-II and touch “START”.
Accelerate vehicle to 55 to 65 km/h (34 to 40 MPH) under the following conditions and release the accelerator pedal completely.
THROTTLE POSI: Less than 5.5/8 (at all times during step 4)
SLCT LVR POSI: “D” position
Make sure that “GEAR” shows “3” after releasing pedal.
Depress accelerator pedal steadily with 1.0/8 — 2.0/8 of “THROTTLE POSI” from a speed of 55 to 65 km/h
(34 to 40 MPH) until “TESTING” has turned to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.)
If the check result NG appears on CONSULT-II screen, go to AT-277, «Diagnostic Procedure» .
If “STOP VEHICLE” appears on CONSULT-II screen, go to following step.
Make sure that “GEAR” shows “4” when depressing accelerator pedal with 1.0/8 — 2.0/8 of
“THROTTLE POSI”.
If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for
“A/T”. In case a DTC other than “A/T 4TH GR FNCTN” is shown, refer to AT-86, «Display Items List
(Except for EURO-OBD models)» .
Stop vehicle.
Follow the instruction displayed. (Check for normal shifting referring to the table below.)

Vehicle condition

Gear on actual transmission shift pattern when screen is changed to 1 → 2 → 3 → 4
1→2→3→4

No malfunction exists

2→2→3→3

Malfunction for “A/T 4TH GR FNCTN” exists.

9.

1→2→2→1

Make sure that “OK” is displayed. (If “NG” is displayed, refer to “Diagnostic Procedure”.)
Refer to AT-277, «Diagnostic Procedure» .
Refer to AT-67, «Vehicle Speed at Which Gear Shifting Occurs» .

AT-276

A/T 4TH GEAR FUNCTION
[EXC.F/EURO-OBD]

Diagnostic Procedure

1. CHECK SHIFT-UP (D3

BCS000VO

A

TO D4 )

During AT-61, «Cruise Test — Part 1» .
Does A/T shift from D3 to D4 at the specified speed?
YES >> GO TO 11.
NO
>> GO TO 2.

B

AT

D
SCIA7190E

E

2. CHECK LINE PRESSURE
Perform line pressure test. Refer to AT-56, «LINE PRESSURE TEST» .
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 7.

F

G

3. CHECK VALVE RESISTANCE
1.
–
–

2.

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Shift solenoid valve A
Shift solenoid valve B
Check resistance between terminal cord assembly harness connector terminals and ground. Refer to AT-216, «Wiring Diagram
— AT — SSV/A» and AT-221, «Wiring Diagram — AT — SSV/B»
.
Solenoid valve
Shift solenoid valve A
Shift solenoid valve B

Terminal
2
1

Ground

H

I

J

Resistance
(Approx.)

K

20 — 30 Ω
5 — 20 Ω

OK or NG
OK
>> GO TO 4.
NG
>> Replace solenoid valve assembly.

L

M

SCIA3594E

AT-277

A/T 4TH GEAR FUNCTION
[EXC.F/EURO-OBD]

4. CHECK VALVE OPERATION
Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
–
Shift solenoid valve A
–
Shift solenoid valve B
2. Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminals and ground. Refer to
AT-216, «Wiring Diagram — AT — SSV/A» and AT-221, «Wiring
Diagram — AT — SSV/B» .
OK or NG
OK
>> GO TO 5.
NG
>> Replace solenoid valve assembly.
1.

SCIA3595E

5. CHECK CONTROL VALVE
Disassemble control valve assembly. Refer to AT-392, «Control Valve Assembly» .
Check to ensure that:
–
Valve, sleeve and plug slide along valve bore under their own weight.
–
Valve, sleeve and plug are free from burrs, dents and scratches.
–
Control valve springs are free from damage, deformation and fatigue.
–
Hydraulic line is free from obstacles.
OK or NG
OK
>> GO TO 6.
NG
>> Repair control valve.
1.
2.

6. CHECK SHIFT-UP (D3

TO D4 )

During AT-61, «Cruise Test — Part 1» .
Does A/T shift from D3 to D4 at the specified speed?
YES >> GO TO 11.
NO
>> Check control valve again. Repair or replace control
valve assembly.

SCIA7190E

AT-278

A/T 4TH GEAR FUNCTION
[EXC.F/EURO-OBD]

7. CHECK VALVE RESISTANCE
1.
–

2.

A

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Line pressure solenoid valves
Check resistance between terminal cord assembly harness connector terminal and ground. Refer to AT-252, «Wiring Diagram
— AT — LPSV» .
Solenoid valve
Line pressure solenoid valve

Terminal
4

Ground

B

AT

Resistance
(Approx.)
2.5 — 5 Ω

D

OK or NG
OK
>> GO TO 8.
NG
>> Replace solenoid valve assembly.
SCIA4951E

E

8. CHECK VALVE OPERATION
F

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
–
Line pressure solenoid valves
2. Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground. Refer to AT252, «Wiring Diagram — AT — LPSV» .
OK or NG
OK
>> GO TO 9.
NG
>> Replace solenoid valve assembly.

1.

G

H

I

SCIA3275E

J

9. CHECK CONTROL VALVE
K

Disassemble control valve assembly. Refer to AT-392, «Control Valve Assembly» .
Check line pressure circuit valves for sticking.
–
Pilot valve
–
Shift solenoid valve A
–
Shift solenoid valve B
OK or NG
OK
>> GO TO 10.
NG
>> Repair or replace control valve.

1.
2.

10. CHECK SHIFT-UP (D3

L

M

TO D4 )

During AT-61, «Cruise Test — Part 1» .
Does A/T shift from D3 to D4 at the specified speed?
YES >> GO TO 11.
NO
>> Check control valve again. Repair or replace control
valve assembly.

SCIA7190E

AT-279

A/T 4TH GEAR FUNCTION
[EXC.F/EURO-OBD]

11. CHECK DTC
Perform AT-276, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> Perform AT-61, «Cruise Test — Part 1» again and return to the start point of this test group.

AT-280

A/T TCC S/V FUNCTION (LOCK-UP)
[EXC.F/EURO-OBD]

A/T TCC S/V FUNCTION (LOCK-UP)
Description
●

●

PFP:31940

A
BCS000VP

This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis
malfunction.
B
This malfunction is detected when the A/T does not shift into fourth gear position or the torque converter
clutch does not lock-up as instructed by the TCM. This is not caused by electrical malfunction (circuits
open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve AT
operation, malfunctioning oil pump or torque converter clutch, etc.

CONSULT-II Reference Value

BCS000VQ

D

Remarks: Specification data are reference values.
Item name
Condition
TCC S/V DUTY

Display value (Approx.)

Lock-up OFF ⇔ Lock-up ON

4% ⇔ 94%

E

On Board Diagnosis Logic
●

●

●

BCS000VR

Diagnostic trouble code “A/T TCC S/V FNCTN” with CONSULT-II is detected when A/T cannot perform
lock-up even if electrical circuit is good.
This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM
as follows:
Torque converter slip ratio = A x C/B
A: Output shaft revolution signal from revolution sensor
B: Engine speed signal from ECM
C: Gear ratio determined as gear position which TCM supposes
If the actual gear position is much lower than the position (4th) supposed by TCM, the slip ratio will be
much less than normal. In case the ratio does not reach the specified value, TCM judges this diagnosis
malfunction.
This malfunction will be caused when shift solenoid valve B is stuck closed.
Gear positions supposed by TCM are as follows.
In case of gear position with no malfunctions: 1, 2, 3 and 4 positions
In case of gear position with shift solenoid valve B stuck closed: 1, 2, 2 and 1* positions to each gear position above
*: “A/T TCC S/V FNCTN” is detected.

Possible Cause
●
●
●
●

BCS000VS

Line pressure solenoid valve
Torque converter clutch solenoid valve
Each clutch
Hydraulic control circuit

F

G

H

I

J

K

L

M

AT-281

A/T TCC S/V FUNCTION (LOCK-UP)
[EXC.F/EURO-OBD]

DTC Confirmation Procedure

BCS000VT

CAUTION:
●
Always drive vehicle at a safe speed.
●
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

WITH CONSULT-II
1.
2.
3.

4.
5.

–
–
–

6.

Start engine and select “DATA MONITOR” mode for “A/T” with
CONSULT-II.
Touch “START”.
Make sure that output voltage of A/T fluid temperature sensor is
within the range below.
FLUID TEMP SE: 0.4 — 1.5V
If out of range, drive vehicle to decrease voltage (warm up the
fluid) or stop engine to increase voltage (cool down the fluid).
Select “TCC S/V FNCTN P0744” of “DTC WORK SUPPORT”
mode for “A/T” with CONSULT-II and touch “START”.
BCIA0031E
Accelerate vehicle to more than 80 km/h (50 MPH) and maintain
the following conditions continuously until “TESTING” has turned to “COMPLETE”. (It will take approximately 30 seconds after “TESTING” shows.)
THROTTLE POSI: 1.0/8 — 2.0/8 (at all times during step 4)
SLCT LVR POSI: “D” position
TCC S/V DUTY: More than 94%
VEHICLE SPEED: Constant speed of more than 80 km/h (50 MPH)
Make sure that “GEAR” shows “4”.
For shift schedule, refer to AT-67, «Vehicle Speed at Which Gear Shifting Occurs» .
If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS”. In
case a DTC other than “A/T TCC S/V FNCTN” is shown, refer to AT-86, «Display Items List (Except
for EURO-OBD models)» .
Make sure that “OK” is displayed. (If “NG” is displayed, refer to “DIAGNOSTIC PROCEDURE”.)
Refer to AT-283, «Diagnostic Procedure» .
Refer to AT-67, «Vehicle Speed at Which Lock-up Occurs/Releases» .

AT-282

A/T TCC S/V FUNCTION (LOCK-UP)
[EXC.F/EURO-OBD]

Diagnostic Procedure

1. CHECK SHIFT-UP (D3

BCS000VU

A

TO D4 )

During AT-61, «Cruise Test — Part 1» .
Does A/T shift from D3 to D4 at the specified speed?
YES >> GO TO 11.
NO
>> GO TO 2.

B

AT

D
SCIA7190E

E

2. CHECK LINE PRESSURE
Perform line pressure test. Refer to AT-56, «LINE PRESSURE TEST» .
OK or NG
OK
>> GO TO 3.
NG
>> GO TO 6.

F

G

3. CHECK CONTROL VALVE
Disassemble control valve assembly. Refer to AT-392, «Control Valve Assembly» .
Check to ensure that:
–
Valve, sleeve and plug slide along valve bore under their own weight.
–
Valve, sleeve and plug are free from burrs, dents and scratches.
–
Control valve springs are free from damage, deformation and fatigue.
–
Hydraulic line is free from obstacles.
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace control valve.

1.
2.

4. CHECK SHIFT-UP (D3

H

I

J

K

TO D4 )

During AT-61, «Cruise Test — Part 1» .
Does A/T shift from D3 to D4 at the specified speed?
YES >> GO TO 5.
NO
>> Check control valve again. Repair or replace control
valve assembly.

L

M

SCIA7190E

5. CHECK DTC
Perform AT-282, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 11. Check for proper lock-up.

AT-283

A/T TCC S/V FUNCTION (LOCK-UP)
[EXC.F/EURO-OBD]

6. CHECK VALVE RESISTANCE
1.
–

2.

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Line pressure solenoid valve
Check resistance between terminal cord assembly harness connector terminal and ground. Refer to AT-252, «Wiring Diagram
— AT — LPSV» .
Solenoid valve
Line pressure solenoid valve

Terminal
4

Ground

Resistance
(Approx.)
2.5 — 5 Ω

OK or NG
OK
>> GO TO 7.
NG
>> Replace solenoid valve assembly.
SCIA4951E

7. CHECK VALVE OPERATION
Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Line pressure solenoid valve
2. Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground. Refer to AT252, «Wiring Diagram — AT — LPSV» .
OK or NG
OK
>> GO TO 8.
NG
>> Replace solenoid valve assembly.
1.

–

SCIA3275E

8. CHECK CONTROL VALVE
Disassemble control valve assembly. Refer to AT-392, «Control Valve Assembly» .
Check line pressure circuit valves for sticking.
–
Pressure regulator valve
–
Pilot valve
–
Pressure modifier valve
OK or NG
OK
>> GO TO 9.
NG
>> Repair or replace control valve.
1.
2.

9. CHECK SHIFT-UP (D3

TO D4 )

During AT-61, «Cruise Test — Part 1» .
Does A/T shift from D3 to D4 at the specified speed?
YES >> GO TO 10.
NO
>> Check control valve again. Repair or replace control
valve assembly.

SCIA7190E

AT-284

A/T TCC S/V FUNCTION (LOCK-UP)
[EXC.F/EURO-OBD]

10. CHECK DTC

A

Perform AT-282, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 11.

B

11. CHECK LOCK-UP

AT

During AT-61, «Cruise Test — Part 1» .
A/T perform lock-up at the specified speed?
YES >> Perform AT-61, «Cruise Test — Part 1» again and return
to the start point of this test group.
NO
>> GO TO 12.

D

E

F
SCIA7191E

12. CHECK VALVE RESISTANCE
1.
–

2.

G

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Torque converter clutch solenoid valve
Check resistance between terminal cord assembly harness connector terminal and ground. Refer to AT-231, «Wiring Diagram
— AT — TCV» .
Solenoid valve
Torque converter clutch solenoid valve

I

Resistance
(Approx.)

Terminal
5

H

Ground

J

5 — 20 Ω

OK or NG
OK
>> GO TO 13.
NG
>> Replace solenoid valve assembly.

K
SCIA2063E

13. CHECK VALVE OPERATION

L

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
–
Torque converter clutch solenoid valve
2. Check solenoid valve by listening for its operating sound while
applying battery voltage to the terminal and ground. Refer to AT231, «Wiring Diagram — AT — TCV» .
OK or NG
OK
>> GO TO 14.
NG
>> Replace solenoid valve assembly.
1.

M

SCIA2066E

AT-285

A/T TCC S/V FUNCTION (LOCK-UP)
[EXC.F/EURO-OBD]

14. CHECK CONTROL VALVE
Disassemble control valve assembly. Refer to AT-392, «Control Valve Assembly» .
Check control valves for sticking.
–
Torque converter clutch control valve
–
Torque converter clutch relief valve
OK or NG
OK
>> GO TO 15.
NG
>> Repair or replace control valve.
1.
2.

15. CHECK LOCK-UP
During AT-61, «Cruise Test — Part 1» .
A/T perform lock-up at the specified speed?
YES >> GO TO 16.
NO
>> Check control valve again. Repair or replace control
valve assembly.

SCIA7191E

16. CHECK DTC
Perform AT-282, «DTC Confirmation Procedure» .
OK or NG
OK
>> INSPECTION END
NG
>> Perform AT-61, «Cruise Test — Part 1» again and return to the start point of this test group.

AT-286

CONTROL UNIT (RAM), CONTROL UNIT (ROM)
[EXC.F/EURO-OBD]

CONTROL UNIT (RAM), CONTROL UNIT (ROM)
Description

PFP:31036

A
BCS000VV

The TCM consists of a microcomputer and connectors for signal
input and output and for power supply. The unit controls the A/T.

B

AT

D
SAT574J

E

On Board Diagnosis Logic

BCS000VW

Diagnostic trouble code “CONTROL UNIT (RAM)”, “CONTROL UNIT (ROM)” with CONSULT-II is detected
when TCM memory (RAM) or (ROM) is malfunctioning.

Possible Cause
TCM.

G

DTC Confirmation Procedure

BCS000VY

CAUTION:
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at
least 10 seconds before continuing.
After the repair, perform the following procedure to confirm the malfunction is eliminated.

2.
3.
4.
5.

H

I

WITH CONSULT-II
1.

F

BCS000VX

Turn ignition switch ON and select “DATA MONITOR” mode for
A/T with CONSULT-II.
Touch “START”.
Start engine.
Run engine for at least 2 seconds at idle speed.
If the check result is NG, go to AT-287, «Diagnostic Procedure» .

J

K

L
BCIA0031E

Diagnostic Procedure

BCS000VZ

1. CHECK DTC
With CONSULT-II
1. Turn ignition switch ON and select “SELF-DIAG RESULTS” mode for A/T with CONSULT-II.
2. Touch “ERASE”.
3. Perform AT-287, «DTC Confirmation Procedure» .
Is the “CONTROL UNIT (RAM)” or “CONTROL UNIT (ROM)” displayed again?
YES >> Replace TCM.
NO
>> INSPECTION END

AT-287

M

PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT
[EXC.F/EURO-OBD]

PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION
SIGNAL CIRCUIT
PFP:31918
CONSULT-II Reference Value

BCS000W0

Remarks: Specification data are reference values.
Item name
Condition
PN POSI SW

R POSITION SW

D POSITION SW

2 POSITION SW

1 POSITION SW

OVERDRIVE SW

CLOSED THL/SW

W/O THRL/P-SW

Display value

When setting selector lever to “N” or “P” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “R” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “D” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “2” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “1” position.

ON

When setting selector lever to other positions.

OFF

When overdrive control switch is depressed.

ON

When overdrive control switch is released.

OFF

Released accelerator pedal.

ON

Depressed accelerator pedal.

OFF

Fully depressed accelerator pedal.

ON

Released accelerator pedal.

OFF

TCM Terminals and Reference Value

BCS000W1

TCM terminal data are reference values, measured between each terminal and ground.
Terminal

Wire color

26

Y

27

34

35

36

L

LG

L

R

Item

Condition

PNP switch “1” position

When setting selector lever to “1” position.

PNP switch “2” position

When setting selector lever to “2” position.

PNP switch “D” position
PNP switch “R” position
PNP switch “N” or “P”
position

When setting selector lever to other positions.

When setting selector lever to other positions.
When setting selector lever to “D” position.
and

When setting selector lever to other positions.
When setting selector lever to “R” position.

Judgement standard
(Approx.)
Battery voltage
0V
Battery voltage
0V
Battery voltage
0V
Battery voltage

When setting selector lever to other positions.

0V

When setting selector lever to “N” or “P” positions.

Battery voltage

When setting selector lever to other positions.

0V

AT-288

PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT
[EXC.F/EURO-OBD]

Diagnostic Procedure

BCS000W2

1. CHECK CAN COMMUNICATION LINE

A

Perform the self-diagnosis. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» .
Is a malfunction in the CAN communication indicated in the results?
YES >> Check CAN communication line. Refer to AT-257, «CAN COMMUNICATION LINE» .
NO (With CONSULT-II) >>GO TO 2.
NO (Without CONSULT-II) >>GO TO 3.

B

AT

2. CHECK PNP SWITCH CIRCUIT
D

With CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for
“A/T” with CONSULT-II.
3. Read out “P·N”, “R”, “D”, “2” and “1” position switches moving
selector lever to each position.
Item name

Condition

Display value

PN POSI SW

When setting selector lever to “N” or “P” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “R” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “D” positions.

ON

When setting selector lever to other positions.

OFF

R POSITION SW

D POSITION SW

2 POSITION SW

1 POSITION SW

E

F

G

SAT701J

When setting selector lever to “2” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “1” position.

ON

When setting selector lever to other positions.

OFF

H

I

J

K

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 4.

L

M

AT-289

PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT
[EXC.F/EURO-OBD]

3. CHECK PNP SWITCH CIRCUIT
Without CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Check voltage between TCM connector terminals and ground
while moving selector lever through each position. Refer to AT296, «EXC.F/EURO-OBD» .
Terminal
Selector lever position

36

35

34

27

26

“P”, “N”

B

0

0

0

0

“R”

0

B

0

0

0

“D”

0

0

B

0

0

“2”

0

0

0

B

0

“1”

0

0

0

0

B

B: Battery voltage
0: 0V

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 4.

SCIA7162E

4. CHECK PNP SWITCH
1.
2.
3.

Turn ignition switch OFF.
Disconnect PNP switch harness connector.
Check continuity between PNP switch harness connector terminals.
Selector lever position

Terminal

Continuity

“P”

1 — 2, 3 — 7

“R”

3-8

Yes
*Continuity
should not
exist in positions other
than the
specified
positions.

“N”

Connector

F12

1 — 2, 3 — 9

“D”

3-6

“2”

3-5

“1”

3-4

SCIA5588E

OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. CHECK CONTROL CABLE ADJUSTMENT
Check PNP switch again with control cable disconnected from manual shaft of A/T assembly. Refer to test
group 4.
OK or NG
OK
>> Adjust control cable. Refer to AT-336, «Adjustment of A/T Position» .
NG
>> Repair or replace PNP switch. Refer to AT-349, «Park/Neutral Position (PNP) Switch» .

AT-290

PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT
[EXC.F/EURO-OBD]

6. DETECT MALFUNCTIONING ITEM

A

Check the following.
●
Harness for short or open between ignition switch and PNP switch
●
Harness for short or open between PNP switch and TCM
●
Harness for short or open between PNP switch and combination meter
●
Harness for short or open between combination meter and TCM
●
10A fuse (No.60, located in the IPDM E/R)
●
Combination meter. Refer to DI-4, «COMBINATION METERS» .
●
Ignition switch. Refer to PG-38, «GROUND» .
OK or NG
OK
>> GO TO 7.
NG
>> Repair or replace damaged parts.

B

AT

D

E

7. CHECK OVERDRIVE CONTROL SWITCH CIRCUIT
F

With CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for
“A/T” with CONSULT-II.
3. Read out “OVERDRIVE SW”. Check the signal of overdrive control switch is indicated properly.
Overdrive control switch
Condition

Item name
OVERDRIVE SW

G

H

Display value

Depressed

ON

Released

OFF

I

SCIA4730E

1.
2.

Without CONSULT-II
Turn ignition switch ON. (Do not start engine.)
Check voltage between A/T device harness connector terminal
and ground. Refer to AT-296, «EXC.F/EURO-OBD» .
Item

Connector

A/T device harness
connector (Overdrive
control switch)

M52

Terminal

1 — Ground

Overdrive
control switch
Condition

Judgement
standard
(Approx.)

Released

Battery
voltage

Depressed

0V

OK or NG
OK
>> GO TO 10.
NG
>> GO TO 8.

K

L

M

SCIA5336E

AT-291

J

PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT
[EXC.F/EURO-OBD]

8. CHECK OVERDRIVE CONTROL SWITCH
1.
2.
3.

Turn ignition switch OFF.
Disconnect A/T device harness connector.
Check continuity between A/T device harness connector terminals. Refer to AT-296, «EXC.F/EURO-OBD» .
Item

Connector

Terminal

A/T device harness connector (Overdrive control switch)

M52

1-2

Overdrive control
switch condition

Continuity

Released

No

Depressed

Yes

OK or NG
OK
>> GO TO 9.
NG
>> Repair or replace damaged parts.

SCIA5330E

9. DETECT MALFUNCTIONING ITEM
Check the following.
●
Harness for short or open between combination meter and A/T device harness connector
●
Harness for short or open between A/T device harness connector and ground
●
Combination meter. Refer to DI-4, «COMBINATION METERS» .
OK or NG
OK
>> GO TO 10.
NG
>> Repair or replace damaged parts.

10. CHECK CLOSED THROTTLE POSITION AND WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT
With CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for A/T with CONSULT-II.
3. Read out “CLOSED THL/SW” and “W/O THRL/P-SW” depressing and releasing accelerator pedal.
Check that the signals of throttle position are indicated properly.

SCIA4731E

Data monitor

Accelerator pedal condition
CLOSED THL/SW

W/O THRL/P-SW

Released

ON

OFF

Fully depressed

OFF

ON

OK or NG
OK
>> GO TO 11.
NG
>> Check the following. If any items are damaged, repair or replace damaged parts.
● Accelerator pedal position sensor. Refer to AT-213, «ACCELERATOR PEDAL POSITION (APP)
SENSOR» .

AT-292

PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT
[EXC.F/EURO-OBD]

11. PERFORM SELF-DIAGNOSIS

A

Without CONSULT-II
Perform self-diagnosis. Refer to AT-94, «Diagnostic Procedure Without CONSULT-II» .
B
OK or NG
OK
>> INSPECTION END
NG − 1 >> Self-diagnosis does not activate: GO TO 12.
NG − 2 >> DTC is displayed: Check the malfunctioning system. Refer to AT-95, «Judgement of Self-diagno- AT
sis Code» .

12. CHECK TCM

D

1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

Component Inspection

E

F
BCS000W3

OVERDRIVE CONTROL SWITCH
Check continuity between A/T device harness connector terminals.

●

Item

Connector

Terminal

A/T device harness connector (Overdrive control switch)

M52

1-2

Overdrive control
switch condition

Continuity

Released

No

Depressed

Yes

G

H

I

SCIA5330E

J

PNP SWITCH
1.

Check continuity between PNP switch harness connector terminals.
Selector lever position

Terminal

Continuity

“P”

1 — 2, 3 — 7

“R”

3-8

Yes
*Continuity
should not
exist in positions other
than the
specified
positions.

“N”

2.

3.
4.
5.
6.

Connector

F12

1 — 2, 3 — 9

“D”

3-6

“2”

3-5

“1”

3-4

If NG, check again with control cable (2) disconnected from
manual shaft of A/T assembly. Refer to step 1.
(1): Lock nut
(3): Manual shaft
If OK on step 2, adjust control cable (2). Refer to AT-336,
«Adjustment of A/T Position» .
If NG on step 2, remove PNP switch from A/T assembly and
check continuity of PNP switch terminals. Refer to step 1.
If OK on step 4, adjust PNP switch. Refer to AT-350, «PARK/
NEUTRAL POSITION (PNP) SWITCH ADJUSTMENT» .
If NG on step 4, replace PNP switch. Refer to AT-349, «Park/
Neutral Position (PNP) Switch» .

AT-293

K

L

M

SCIA5588E

SCIA6370J

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

TROUBLE DIAGNOSIS FOR SYMPTOMS
Wiring Diagram — AT — NONDTC
[ALL]

PFP:00007
BCS000YJ

EURO-OBD

MCWA0258E

AT-294

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]
TCM terminal data are reference values. measured between each terminal and ground.
Terminal

Wire color

Item

Condition

Judgement standard
(Approx.)

5

L

CAN H

—

—

6

Y

CAN L

—

—

30

L

CONSULT-II (RX)

—

—

31

BR

CONSULT-II (TX)

—

—

A

B

AT

D

E

F

G

H

I

J

K

L

M

AT-295

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

EXC.F/EURO-OBD

BCS000W4

MCWA0256E

AT-296

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]
A

B

AT

D

E

F

G

H

I

J

K

L

M

MCWA0259E

AT-297

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]
TCM terminal data are reference values, measured between each terminal and ground.
Terminal

26

Wire
color

Y

Item

Condition

PNP switch “1” position

and
27

L

PNP switch “2” position

Judgement standard (Approx.)

When setting selector lever to
“1” position.

Battery voltage

When setting selector lever to
other positions.

0V

When setting selector lever to
“2” position.

Battery voltage

When setting selector lever to
other positions.

0V

30

L

CONSULT- II (RX)

—

—

31

BR

CONSULT- II (TX)

—

—

34

35

LG

L

PNP switch “D” position

PNP switch “R” position
and

36

R

PNP switch “N” or “P”
position

AT-298

When setting selector lever to
“D” position.

Battery voltage

When setting selector lever to
other positions.

0V

When setting selector lever to
“R” position.

Battery voltage

When setting selector lever to
other positions.

0V

When setting selector lever to
“N” or “P” position.

Battery voltage

When setting selector lever to
other positions.

0V

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

OD OFF Indicator Lamp Does Not Come On

BCS000W5

SYMPTOM:
OD OFF indicator lamp does not come on for about 2 seconds when turning ignition switch to ON.

1. CHECK CAN COMMUNICATION LINE

A

B

Perform self-diagnosis. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» .
Is a malfunction in CAN communication indicated in the results?
AT
YES >> Check CAN communication line. Refer to AT-102, «DTC U1000 CAN COMMUNICATION LINE»
(EURO-OBD) or AT-257, «CAN COMMUNICATION LINE» (Except for EURO-OBD).
NO
>> GO TO 2.
D
CHECK TCM POWER SOURCE

2.
1.
2.

Turn ignition switch ON. (Do not start engine.)
Check voltage between TCM connector terminals and ground.
Refer to AT-194, «Wiring Diagram — AT — MAIN» (EURO-OBD)
or AT-261, «Wiring Diagram — AT — MAIN» (Except for EUROOBD).
Item

Connector
E106

TCM connector

Terminal

F

Judgement standard (Approx.)

G

10
19

E107

E

Battery voltage

28

H
SCIA2656E

3.
4.

Turn ignition switch OFF.
Check voltage between TCM connector terminals and ground.
Item

TCM connector

Connector
E106
E107

Terminal

Judgement standard (Approx.)

10

0V

19

0V

28

Battery voltage

I

J

K

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

L
SCIA2657E

3. DETECT MALFUNCTIONING ITEM

M

Check the following.
●
Harness for short or open between ignition switch and TCM connector terminals 10, 19
●
Harness for short or open between battery and TCM connector terminal 28
●
10A fuse (No.7, located in the fuse block) and 10A fuse (No.58, located in the IPDM E/R)
●
Ignition switch. Refer to PG-4, «POWER SUPPLY ROUTING CIRCUIT» .
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace damaged parts.

AT-299

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

4. CHECK TCM GROUND CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect TCM connector.
Check continuity between TCM connector terminals and ground.
Refer to AT-194, «Wiring Diagram — AT — MAIN» (EURO-OBD)
or AT-261, «Wiring Diagram — AT — MAIN» (Except for EUROOBD).
Item

Connector

Terminal

Continuity

TCM connector

E107

25, 48 — Ground

Yes

OK or NG
OK
>> GO TO 5.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

5. DETECT MALFUNCTIONING ITEM
Check the following.
Harness for short or open between ignition switch and combination meter
●
Combination meter. Refer to DI-4, «COMBINATION METERS» .
OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace damaged parts.
●

6. CHECK SYMPTOM
Check again. Refer to AT-58, «Check Before Engine is Started» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 7.

7. CHECK TCM
1. Check TCM input/output. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-300

SCIA2671E

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

Engine Cannot Be Started in “P” and “N” Position

BCS000W6

A

SYMPTOM:
●
Engine cannot be started with selector lever in “P” or “N” position.
●
Engine can be started with selector lever in “D”, “2”, “1” or “R” position.

B

1. CHECK SELF-DIAGNOSIS RESULTS
Perform self-diagnosis. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT-94, «Diagnostic Proce- AT
dure Without CONSULT-II» .
Is any malfunction detected by self-diagnostic results?
YES >> Check the malfunctioning system. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT- D
95, «Judgement of Self-diagnosis Code» .
NO
>> GO TO 2.

2. CHECK PNP SWITCH

E

Check continuity between PNP switch harness connector terminals.
Refer to AT-106, «Wiring Diagram — AT — PNP/SW» (EURO-OBD)
or AT-296, «EXC.F/EURO-OBD» (Except for EURO-OBD).

F

Selector lever position
“P”, “N”

Connector
F12

terminal
1-2

Other positions

Continuity

G

Yes
No

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

H
SCIA5606E

I

3. CHECK CONTROL CABLE ADJUSTMENT
Check PNP switch again with control cable disconnected from manual shaft of A/T assembly. Refer to test
group 2.
OK or NG
OK
>> Adjust control cable. Refer to AT-336, «Adjustment of A/T Position» .
NG
>> 1. Check PNP switch (Refer to test group 2.) again after adjusting PNP switch (Refer to AT-350 ).
– If OK, INSPECTION END
– If NG, repair or replace PNP switch. Refer to AT-349, «Park/Neutral Position (PNP) Switch» .

J

K

L

4. CHECK STARTING SYSTEM
Check starting system. Refer to SC-45, «STARTING SYSTEM» .
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-301

M

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

In “P” Position, Vehicle Moves Forward or Backward When Pushed

BCS000W7

SYMPTOM:
Vehicle moves when it is pushed forward or backward with selector lever in “P” position.

1. CHECK CONTROL CABLE
Check control cable. Refer to AT-337, «Checking of A/T Position» .
OK or NG
OK
>> GO TO 2.
NG
>> Adjust control cable. Refer to AT-336, «Adjustment of A/T Position» .

2. CHECK PARKING COMPONENTS
Check parking components. Refer to AT-360, «Components» and
AT-369, «DISASSEMBLY» .
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

SAT282F

In “N” Position, Vehicle Moves

BCS000W8

SYMPTOM:
Vehicle moves forward or backward when selecting “N” position.

1. CHECK CONTROL CABLE
Check control cable. Refer to AT-337, «Checking of A/T Position» .
OK or NG
OK
>> GO TO 2.
NG
>> Adjust control cable. Refer to AT-336, «Adjustment of A/T Position» .

2. CHECK A/T FLUID LEVEL
Check A/T fluid level. Refer to AT-18, «Checking A/T Fluid» .
OK or NG
OK
>> GO TO 3.
NG
>> Refill ATF.

3. CHECK A/T FLUID CONDITION
1. Remove oil pan. Refer to AT-360, «Components» .
2. Check A/T fluid condition. Refer to AT-53, «Fluid Condition Check» .
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

AT-302

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

4. DETECT MALFUNCTIONING ITEM

A

Disassemble A/T. Refer to AT-369, «Disassembly» .
Check the following items:
–
Forward clutch assembly. Refer to AT-419, «Forward and Overrun Clutches» .
–
Overrun clutch assembly. Refer to AT-419, «Forward and Overrun Clutches» .
–
Reverse clutch assembly. Refer to AT-408, «Reverse Clutch» .
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace damaged parts.

1.
2.

B

AT

D

5. CHECK SYMPTOM
Check again. Refer to AT-59, «Check at Idle» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.

E

F

6. CHECK TCM
G

1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

Large Shock “N” → “R” Position

H

BCS000W9

I

SYMPTOM:
There is a large shock when changing from “N” to “R” position.

1. CHECK SELF-DIAGNOSTIC RESULTS

J

Perform self-diagnosis. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT-94, «Diagnostic Procedure Without CONSULT-II» .
Is any malfunction detected by self-diagnostic results?
YES >> Check the malfunctioning system. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT95, «Judgement of Self-diagnosis Code» .
NO
>> GO TO 2.

2. CHECK LINE PRESSURE

K

L

M

Check line pressure at idle with selector lever in “D” position. Refer to AT-56, «LINE PRESSURE TEST» .
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

AT-303

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

3. DETECT MALFUNCTIONING ITEM
Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
–
Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot filter)
–
Line pressure solenoid valve
–
Oil pump assembly. Refer to AT-388, «Oil Pump» .
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace damaged parts.
1.
2.

4. CHECK SYMPTOM
Check again. Refer to AT-59, «Check at Idle» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.

5. CHECK TCM
1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

Vehicle Does Not Creep Backward in “R” Position

BCS000WA

SYMPTOM:
Vehicle does not creep backward when selecting “R” position.

1. CHECK A/T FLUID LEVEL
Check A/T fluid level. Refer to AT-18, «Checking A/T Fluid» .
OK or NG
OK
>> GO TO 2.
NG
>> Refill ATF.

2. CHECK LINE PRESSURE
Check line pressure at idle with selector lever in “R” position. Refer to AT-56, «LINE PRESSURE TEST» .
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

AT-304

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

3. DETECT MALFUNCTIONING ITEM

A
Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
–
Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot fil- B
ter)
–
Line pressure solenoid valve
AT
3. Disassemble A/T. Refer to AT-369, «Disassembly» .
4. Check the following item:
–
Oil pump assembly. Refer to AT-388, «Oil Pump» .
D
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace damaged parts.
E

1.
2.

4. CHECK STALL REVOLUTION
Check stall revolution with selector lever in “1” and “R” positions. Refer to AT-53, «STALL TEST» .
OK or NG
OK
>> GO TO 6.
OK in “1” position, NG in “R” position>> GO TO 5.
NG in both “1” and “R” positions>> GO TO 7.

5. DETECT MALFUNCTIONING ITEM

F

G

H

Disassemble A/T. Refer to AT-369, «Disassembly» .
Check the following items:
–
Low & reverse brake assembly. Refer to AT-426, «Low & Reverse Brake» .
–
Reverse clutch assembly. Refer to AT-408, «Reverse Clutch» .
OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace damaged parts.

1.
2.

6. CHECK A/T FLUID CONDITION

I

J

K

1. Remove oil pan. Refer to AT-360, «Components» .
2. Check A/T fluid condition. Refer to AT-53, «Fluid Condition Check» .
OK or NG
OK
>> GO TO 8.
NG
>> GO TO 7.

7. DETECT MALFUNCTIONING ITEM
1.
2.

Disassemble A/T. Refer to AT-369, «Disassembly» .
Check the following items:
–
Reverse clutch assembly. Refer to AT-408, «Reverse Clutch» .
–
High clutch assembly. Refer to AT-413, «High Clutch» .
–
Low & reverse brake assembly. Refer to AT-426, «Low & Reverse Brake» .
–
Forward clutch assembly. Refer to AT-419, «Forward and Overrun Clutches» .
–
Overrun clutch assembly. Refer to AT-419, «Forward and Overrun Clutches» .
OK or NG
OK
>> GO TO 8.
NG
>> Repair or replace damaged parts.

AT-305

L

M

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

8. CHECK SYMPTOM
Check again. Refer to AT-59, «Check at Idle» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 9.

9. CHECK TCM
1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

Vehicle Does Not Creep Forward in “D”, “2” or “1” Position

BCS000WB

SYMPTOM:
Vehicle does not creep forward when selecting “D”, “2” or “1” position.

1. CHECK A/T FLUID LEVEL
Check A/T fluid level. Refer to AT-18, «Checking A/T Fluid» .
OK or NG
OK
>> GO TO 2.
NG
>> Refill ATF.

2. CHECK LINE PRESSURE
Check line pressure at idle with selector lever in “D” position. Refer to AT-56, «LINE PRESSURE TEST» .
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

3. DETECT MALFUNCTIONING ITEM
Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
–
Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot filter)
–
Line pressure solenoid valve
3. Disassemble A/T. Refer to AT-369, «Disassembly» .
4. Check the following item:
–
Oil pump assembly. Refer to AT-388, «Oil Pump» .
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace damaged parts.
1.
2.

4. CHECK STALL REVOLUTION
Check stall revolution with selector lever in “D” position. Refer to AT-53, «STALL TEST» .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

AT-306

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

5. DETECT MALFUNCTIONING ITEM

A

Disassemble A/T. Refer to AT-369, «Disassembly» .
Check the following items:
–
Oil pump assembly. Refer to AT-388, «Oil Pump» .
–
Forward clutch assembly. Refer to AT-419, «Forward and Overrun Clutches» .
–
Forward one-way clutch. Refer to AT-431, «Rear Internal Gear and Forward Clutch Hub» .
–
Low one-way clutch. Refer to AT-369, «Disassembly» .
–
Torque converter. Refer to AT-369, «Disassembly» .
OK or NG
OK
>> GO TO 7.
NG
>> Repair or replace damaged parts.

1.
2.

B

AT

D

E

6. CHECK A/T FLUID CONDITION
1. Remove oil pan. Refer to AT-360, «Components» .
2. Check A/T fluid condition. Refer to AT-53, «Fluid Condition Check» .
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 5.

F

G

7. CHECK SYMPTOM
H

Check again. Refer to AT-59, «Check at Idle» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 8.

I

8. CHECK TCM

J

1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

K

L

Vehicle Cannot Be Started from D1

BCS000WC

SYMPTOM:
Vehicle cannot be started from D1 on “Cruise Test — Part 1”.

1. CHECK SYMPTOM
Check symptom. Refer to AT-59, «Check at Idle» .
Is “Vehicle Dose Not Creep Backward in “R” Position” OK?
OK
>> GO TO 2.
NG
>> GO TO AT-304, «Vehicle Does Not Creep Backward in “R” Position» .

2. CHECK SELF-DIAGNOSTIC RESULTS
Perform self-diagnosis. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT-94, «Diagnostic Procedure Without CONSULT-II» .
Is any malfunction detected by self-diagnostic results?
YES >> Check the malfunctioning system. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT95, «Judgement of Self-diagnosis Code» .
NO
>> GO TO 3.

AT-307

M

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

3. CHECK ACCELERATOR PEDAL POSITION SENSOR
Check accelerator pedal position sensor. Refer to AT-169, «DTC P1705 ACCELERATOR PEDAL POSITION
(APP) SENSOR» (EURO-OBD) or AT-213, «ACCELERATOR PEDAL POSITION (APP) SENSOR» (Except
for EURO-OBD).
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace accelerator pedal position sensor.

4. CHECK LINE PRESSURE
Check line pressure at stall point with selector lever in “D” position. Refer to AT-56, «LINE PRESSURE TEST» .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

5. DETECT MALFUNCTIONING ITEM
Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
–
Shift valve A
–
Shift valve B
–
Shift solenoid valve A
–
Shift solenoid valve B
–
Pilot valve
–
Pilot filter
3. Disassemble A/T. Refer to AT-369, «Disassembly» .
4. Check the following items:
–
Forward clutch assembly. Refer to AT-419, «Forward and Overrun Clutches» .
–
Low one-way clutch. Refer to AT-369, «Disassembly» .
–
Forward one-way clutch. Refer to AT-431, «Rear Internal Gear and Forward Clutch Hub» .
–
High clutch assembly. Refer to AT-413, «High Clutch» .
–
Torque converter. Refer to AT-369, «Disassembly» .
–
Oil pump assembly. Refer to AT-388, «Oil Pump» .
OK or NG
OK
>> GO TO 8.
NG
>> Repair or replace damaged parts.
1.
2.

6. CHECK A/T FLUID CONDITION
1. Remove oil pan. Refer to AT-360, «Components» .
2. Check A/T fluid condition. Refer to AT-53, «Fluid Condition Check» .
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 5.

AT-308

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

7. DETECT MALFUNCTIONING ITEM

A

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
–
Shift valve A
–
Shift valve B
–
Shift solenoid valve A
–
Shift solenoid valve B
–
Pilot valve
–
Pilot filter
OK or NG
OK
>> GO TO 8.
NG
>> Repair or replace damage parts.

1.
2.

B

AT

D

E

8. CHECK SYMPTOM
F

Check again. Refer to AT-61, «Cruise Test — Part 1» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 9.

G

9. CHECK TCM
H

1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2

I

BCS000WD

SYMPTOM:
A/T does not shift from D1 to D2 at the specified speed on “Cruise Test — Part 1”.
A/T does not shift from D4 to D2 when depressing accelerator pedal fully at the specified speed on
“Cruise Test — Part 2”.

1. CHECK SYMPTOM

J

K

L

Check symptom . Refer to AT-59, «Check at Idle» and AT-61, «Cruise Test — Part 1» .
Are “Vehicle Dose Not Creep Forward in “D”, “2” or “1” Position” and “Vehicle Cannot Be Started from D1 ”
OK?
YES >> GO TO 2.
NG
>> GO TO AT-306, «Vehicle Does Not Creep Forward in “D”, “2” or “1” Position» and AT-307, «Vehicle
Cannot Be Started from D1» .

2. CHECK CONTROL CABLE
Check control cable. Refer to AT-337, «Checking of A/T Position» .
OK or NG
OK
>> GO TO 3.
NG
>> Adjust control cable. Refer to AT-336, «Adjustment of A/T Position» .

3. CHECK VEHICLE SPEED SENSOR·A/T AND VEHICLE SPEED SENSOR·MTR CIRCUIT
Check vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR circuit. Refer to AT-115,
«DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)» (EURO-OBD) or AT-203, «VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)» (Except for EURO-OBD) and AT-176, «DTC VEHICLE

AT-309

M

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]
SPEED SENSOR MTR» (EURO-OBD) or AT-209, «VEHICLE SPEED SENSOR MTR» (Except for EUROOBD).
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR
circuits.

4. CHECK ACCELERATOR PEDAL POSITION SENSOR
Check accelerator pedal position sensor. Refer to AT-169, «DTC P1705 ACCELERATOR PEDAL POSITION
(APP) SENSOR» (EURO-OBD) or AT-213, «ACCELERATOR PEDAL POSITION (APP) SENSOR» (Except
for EURO-OBD).
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace accelerator pedal position sensor.

5. CHECK A/T FLUID CONDITION
1. Remove oil pan. Refer to AT-360, «Components» .
2. Check A/T fluid condition. Refer to AT-53, «Fluid Condition Check» .
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

6. DETECT MALFUNCTIONING ITEM
Remove control valve. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
–
Shift valve A
–
Shift valve B
–
Shift solenoid valve A
–
Shift solenoid valve B
–
Pilot valve
–
Pilot filter
3. Disassemble A/T. Refer to AT-369, «Disassembly» .
4. Check the following items:
–
Servo piston assembly
–
Brake band
OK or NG
OK
>> GO TO 8.
NG
>> Repair or replace damaged parts.
1.
2.

AT-310

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

7. DETECT MALFUNCTIONING ITEM

A

Remove control valve. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
–
Shift valve A
–
Shift valve B
–
Shift solenoid valve A
–
Shift solenoid valve B
–
Pilot valve
–
Pilot filter
OK or NG
OK
>> GO TO 8.
NG
>> Repair or replace damaged parts.

1.
2.

B

AT

D

E

8. CHECK SYMPTOM
F

Check again. Refer to AT-61, «Cruise Test — Part 1» and AT-64, «Cruise Test — Part 2» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 9.

G

9. CHECK TCM
H

1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

A/T Does Not Shift: D2 → D3

I

BCS000WE

SYMPTOM:
A/T does not shift from D2 to D3 at the specified speed on “Cruise Test — Part 1” and “Cruise Test —
Part 2”.

J

K

1. CHECK SYMPTOM
Check symptom. Refer to AT-59, «Check at Idle» and AT-61, «Cruise Test — Part 1» .
Are “Vehicle Does Not Creep Forward in “D”, “2” or “1” Position” and “Vehicle Cannot Be Started from D1 ”
OK?
YES >> GO TO 2.
NO
>> Go to AT-306, «Vehicle Does Not Creep Forward in “D”, “2” or “1” Position» and AT-307, «Vehicle
Cannot Be Started from D1» .

2. CHECK CONTROL CABLE
Check control cable. Refer to AT-337, «Checking of A/T Position» .
OK or NG
OK
>> GO TO 3.
NG
>> Adjust control cable. Refer to AT-336, «Adjustment of A/T Position» .

3. CHECK VEHICLE SPEED SENSOR·A/T AND VEHICLE SPEED SENSOR·MTR CIRCUIT
Check vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR circuit. Refer to AT-115,
«DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)» (EURO-OBD) or AT-203, «VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)» (Except for EURO-OBD) and AT-176, «DTC VEHICLE

AT-311

L

M

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]
SPEED SENSOR MTR» (EURO-OBD) or AT-209, «VEHICLE SPEED SENSOR MTR» (Except for EUROOBD).
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR
circuits.

4. CHECK ACCELERATOR PEDAL POSITION SENSOR
Check accelerator pedal position sensor. Refer to AT-169, «DTC P1705 ACCELERATOR PEDAL POSITION
(APP) SENSOR» (EURO-OBD) or AT-213, «ACCELERATOR PEDAL POSITION (APP) SENSOR» (Except
for EURO-OBD).
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace accelerator pedal position sensor.

5. CHECK A/T FLUID CONDITION
1. Remove oil pan. Refer to AT-360, «Components» .
2. Check A/T fluid condition. Refer to AT-53, «Fluid Condition Check» .
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

6. DETECT MALFUNCTIONING ITEM
Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
–
Shift valve B
–
Shift solenoid valve B
–
Pilot valve
–
Pilot filter
3. Disassemble A/T. Refer to AT-369, «Disassembly» .
4. Check the following items:
–
Servo piston assembly
–
High clutch assembly. Refer to AT-413, «High Clutch» .
–
Oil pump assembly. Refer to AT-388, «Oil Pump» .
OK or NG
OK
>> GO TO 8.
NG
>> Repair or replace damaged parts.
1.
2.

7. DETECT MALFUNCTIONING ITEM
Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
–
Shift valve B
–
Shift solenoid valve B
–
Pilot valve
–
Pilot filter
OK or NG
OK
>> GO TO 8.
NG
>> Repair or replace damaged parts.
1.
2.

AT-312

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

8. CHECK SYMPTOM

A

Check again. Refer to AT-61, «Cruise Test — Part 1» and AT-64, «Cruise Test — Part 2» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 9.

9. CHECK TCM

B

AT

1. Check TCM input/output signal. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

D

E

F

G

H

I

J

K

L

M

AT-313

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

A/T Does Not Shift: D3 → D4

BCS000WF

SYMPTOM:
●
A/T does not shift from D3 to D4 at the specified speed on “Cruise Test — Part 1” and “Cruise Test
— Part 2”.
●
A/T must be warm before D3 to D4 shift will occur.

1. CHECK SYMPTOM
Check symptom. Refer to AT-59, «Check at Idle» and AT-61, «Cruise Test — Part 1» .
Are “Vehicle Does Not Creep Forward in “D”, “2” or “1” Position” and “Vehicle Cannot Be Started from D1 ”
OK?
YES >> GO TO 2.
NO
>> Go to AT-306, «Vehicle Does Not Creep Forward in “D”, “2” or “1” Position» and AT-307, «Vehicle
Cannot Be Started from D1» .

2. CHECK SELF-DIAGNOSTIC RESULTS
Perform self-diagnosis. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT-94, «Diagnostic Procedure Without CONSULT-II» .
Is any malfunction detected by self-diagnostic results?
YES >> Check the malfunctioning system. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT95, «Judgement of Self-diagnosis Code» .
NO
>> GO TO 3.

3. CHECK ACCELERATOR PEDAL POSITION SENSOR
Check accelerator pedal position sensor. Refer to AT-169, «DTC P1705 ACCELERATOR PEDAL POSITION
(APP) SENSOR» (EURO-OBD) or AT-213, «ACCELERATOR PEDAL POSITION (APP) SENSOR» (Except
for EURO-OBD).
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace accelerator pedal position sensor.

4. CHECK A/T FLUID CONDITION
1. Remove oil pan. Refer to AT-360, «Components» .
2. Check A/T fluid condition. Refer to AT-53, «Fluid Condition Check» .
OK or NG
OK
>> GO TO 6.
NG
>> GO TO 5.

AT-314

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

5. DETECT MALFUNCTIONING ITEM

A

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
–
Shift valve A
–
Overrun clutch control valve
–
Shift solenoid valve A
–
Overrun clutch solenoid valve
–
Pilot valve
–
Pilot filter
3. Disassemble A/T. Refer to AT-369, «Disassembly» .
4. Check the following items:
–
Servo piston assembly
–
Brake band
–
Torque converter. Refer to AT-369, «Disassembly» .
–
Oil pump assembly. Refer to AT-388, «Oil Pump» .
OK or NG
OK
>> GO TO 7.
NG
>> Repair or replace damaged parts.

1.
2.

B

AT

D

E

F

G

6. DETECT MALFUNCTIONING ITEM
H

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
–
Shift valve A
–
Overrun clutch control valve
–
Shift solenoid valve A
–
Pilot valve
–
Pilot filter
OK or NG
OK
>> GO TO 7.
NG
>> Repair or replace damaged parts.

1.
2.

I

J

K

7. CHECK SYMPTOM

L

Check again. Refer to AT-61, «Cruise Test — Part 1» and AT-64, «Cruise Test — Part 2» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 8.

M

8. CHECK TCM
1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-315

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

A/T Does Not Perform Lock-up

BCS000WG

SYMPTOM:
A/T does not perform lock-up at the specified speed on “Cruise Test — Part 1”.

1. CHECK SELF-DIAGNOSTIC RESULTS
Perform self-diagnosis. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT-94, «Diagnostic Procedure Without CONSULT-II» .
Is any malfunction detected by self-diagnostic results?
YES >> Check the malfunctioning system. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT95, «Judgement of Self-diagnosis Code» .
NO
>> GO TO 2.

2. CHECK ACCELERATOR PEDAL POSITION SENSOR
Check accelerator pedal position sensor. Refer to AT-169, «DTC P1705 ACCELERATOR PEDAL POSITION
(APP) SENSOR» (EURO-OBD) or AT-213, «ACCELERATOR PEDAL POSITION (APP) SENSOR» (Except
for EURO-OBD).
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace accelerator pedal position sensor.

3. DETECT MALFUNCTIONING ITEM
Remove control valve. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check following items:
–
Torque converter clutch control valve
–
Torque converter clutch solenoid valve
–
Torque converter relief valve
–
Pilot valve
–
Pilot filter
3. Disassemble A/T. Refer to AT-369, «Disassembly» .
4. Check the following items:
–
Torque converter. Refer to AT-369, «Disassembly» .
OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace damaged parts.
1.
2.

4. CHECK SYMPTOM
Check again. Refer to AT-61, «Cruise Test — Part 1» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 5.

5. CHECK TCM
1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-316

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

A/T Does Not Hold Lock-up Condition
SYMPTOM:
A/T does not hold lock-up condition for more than 30 seconds on “Cruise Test — Part 1”.

1. CHECK SELF-DIAGNOSTIC RESULTS

BCS000WH

A

B

Perform self-diagnosis. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT-94, «Diagnostic Procedure Without CONSULT-II» .
AT
Is any malfunction detected by self-diagnostic results?
YES >> Check the malfunctioning system. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT95, «Judgement of Self-diagnosis Code» .
D
NO
>> GO TO 2.

2. CHECK A/T FLUID CONDITION
1. Remove oil pan. Refer to AT-360, «Components» .
2. Check A/T fluid condition. Refer to AT-53, «Fluid Condition Check» .
OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

3. DETECT MALFUNCTIONING ITEM

E

F

G

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
–
Torque converter clutch control valve
–
Torque converter clutch solenoid valve
–
Pilot valve
–
Pilot filter
3. Disassemble A/T. Refer to AT-369, «Disassembly» .
4. Check the following items:
–
Torque converter. Refer to AT-369, «Disassembly» .
–
Oil pump assembly. Refer to AT-388, «Oil Pump» .
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace damaged parts.

1.
2.

H

I

J

K

L

4. DETECT MALFUNCTIONING ITEM
Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
–
Torque converter clutch control valve
–
Torque converter clutch solenoid valve
–
Pilot valve
–
Pilot filter
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace damaged parts.

1.
2.

5. CHECK SYMPTOM
Check again. Refer to AT-61, «Cruise Test — Part 1» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 6.

AT-317

M

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

6. CHECK TCM
1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

Lock-up Is Not Released

BCS000WI

SYMPTOM:
Lock-up is not released when accelerator pedal is released on “Cruise Test — Part 1”.

1.

CHECK SELF-DIAGNOSTIC RESULTS

Perform self-diagnosis. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT-94, «Diagnostic Procedure Without CONSULT-II» .
Is any malfunction detected by self-diagnostic results?
YES >> Check the malfunctioning system. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT95, «Judgement of Self-diagnosis Code» .
NO
>> GO TO 2.

2. CHECK SYMPTOM
Check again. Refer to AT-61, «Cruise Test — Part 1» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 3.

3. CHECK TCM
1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

Engine Speed Does Not Return to Idle (Light Braking D4 → D3 )

BCS000WJ

SYMPTOM:
Engine speed does not smoothly return to idle when A/T shifts from D4 to D3 on “Cruise Test — Part
1”.

1. CHECK SELF-DIAGNOSTIC RESULTS
Perform self-diagnosis. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT-94, «Diagnostic Procedure Without CONSULT-II» .
Is any malfunction detected by self-diagnostic results?
YES >> Check the malfunctioning system. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT95, «Judgement of Self-diagnosis Code» .
NO
>> GO TO 2.

2. CHECK ACCELERATOR PEDAL POSITION SENSOR
Check accelerator pedal position sensor. Refer to AT-169, «DTC P1705 ACCELERATOR PEDAL POSITION
(APP) SENSOR» (EURO-OBD) or AT-213, «ACCELERATOR PEDAL POSITION (APP) SENSOR» (Except
for EURO-OBD).
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace accelerator pedal position sensor.

AT-318

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

3. CHECK A/T FLUID CONDITION

A

1. Remove oil pan. Refer to AT-360, «Components» .
2. Check A/T fluid condition. Refer to AT-53, «Fluid Condition Check» .
OK or NG
OK
>> GO TO 5.
NG
>> GO TO 4.

B

AT

4. DETECT MALFUNCTIONING ITEM
Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
–
Overrun clutch control valve
–
Overrun clutch reducing valve
–
Overrun clutch solenoid valve
3. Disassemble A/T. Refer to AT-369, «Disassembly» .
4. Check the following items:
–
Overrun clutch assembly. Refer to AT-419, «Forward and Overrun Clutches» .
OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace damaged parts.
1.
2.

5. DETECT MALFUNCTIONING ITEM

D

E

F

G

H

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
–
Overrun clutch control valve
–
Overrun clutch reducing valve
–
Overrun clutch solenoid valve
OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace damaged parts.

1.
2.

I

J

K

6. CHECK SYMPTOM
Check again. Refer to AT-61, «Cruise Test — Part 1» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 7.

7. CHECK TCM
1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

AT-319

L

M

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

A/T Does Not Shift: D4 → D3 , When OD OFF

BCS000WK

SYMPTOM:
A/T does not shift from D4 to D3 when OD OFF (OD OFF indicator lamp is on) on “Cruise Test — Part
3”.

1. CHECK CAN COMMUNICATION LINE
Perform self-diagnosis. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT-94, «Diagnostic Procedure Without CONSULT-II» .
Is a malfunction in CAN communication indicated in the results?
YES >> Check CAN communication line. Refer to AT-102, «DTC U1000 CAN COMMUNICATION LINE»
(EURO-OBD) or AT-257, «CAN COMMUNICATION LINE» (Except for EURO-OBD).
NO
>> GO TO 2.

2. CHECK OVERDRIVE CONTROL SWITCH CIRCUIT
With CONSULT-II
1. Turn ignition switch ON. (Do not start engine)
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for
“A/T” with CONSULT-II.
3. Read out “OVERDRIVE SW”.
Check the signal of the overdrive control switch is indicated
properly.
Item name
OVERDRIVE SW

Overdrive control switch
Condition

Display value

Depressed

ON

Released

OFF
SCIA4730E

1.
2.

Without CONSULT-II
Turn ignition switch ON. (Do not start engine)
Check voltage between A/T device harness connector terminal
and ground. Refer to AT-296, «EXC.F/EURO-OBD» .
Item

A/T device harness
connector (Overdrive
control switch)

Connector

M52

Terminal

1 — Ground

Overdrive
control switch
Condition

Judgement
standard
(Approx.)

Released

Battery
voltage

Depressed

0V

OK or NG
SCIA5336E
OK
>> GO TO AT-311, «A/T Does Not Shift: D2 → D3» .
NG
>> Check overdrive control switch circuit. Refer to AT-197, «PNP, OD SWITCH AND CLOSED
THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT» (EURO-OBD) or AT-288,
«PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL
CIRCUIT» (Except for EURO-OBD).

AT-320

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

A/T Does Not Shift: D3 → 22 , When Selector Lever “D” → “2” Position

BCS000WL

SYMPTOM:
A/T does not shift from D3 to 22 when changing selector lever from “D” to “2” position on “Cruise
Test — Part 3”.

A

B

1. CHECK SYMPTOM
Check symptom. Refer to AT-61, «Cruise Test — Part 1» or AT-64, «Cruise Test — Part 2» .
Is “A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2 ” OK?
YES (With CONSULT-II) >>GO TO 2.
YES (Without CONSULT-II) >>GO TO 3.
NO
>> GO TO AT-309, «A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2» .

AT

D

2. CHECK PNP SWITCH CIRCUIT
E

With CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for
“A/T” with CONSULT-II.
3. Read out “P·N”, “R”, “D”, “2” and “1” position switches moving
selector lever to each position.
Monitor item

Condition

Display value

When setting selector lever to “N” or “P” position.

ON

PN POSI SW

When setting selector lever to other positions.

OFF

When setting selector lever to “R” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “D” positions.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “2” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “1” position.

ON

When setting selector lever to other positions.

OFF

R POSITION SW

D POSITION SW

2 POSITION SW

1 POSITION SW

F

G

H

SAT701J

OK or NG
OK
>> INSPECTION END
NG
>> Check PNP switch circuit. Refer to AT-105, «DTC P0705 PARK/NEUTRAL POSITION (PNP)
SWITCH» (EURO-OBD) or AT-288, «PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN
THROTTLE POSITION SIGNAL CIRCUIT» (Except for EURO-OBD).

AT-321

I

J

K

L

M

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

3. CHECK PNP SWITCH CIRCUIT
Without CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Check voltage between TCM connector terminals and ground
while moving selector lever through each position. Refer to AT106, «Wiring Diagram — AT — PNP/SW» (EURO-OBD) or AT296, «EXC.F/EURO-OBD» (Except for EURO-OBD).
Terminal

Selector lever position
36

35

34

27

26

“P”, “N”

B

0

0

0

0

“R”

0

B

0

0

0

“D”

0

0

B

0

0

“2”

0

0

0

B

0

“1”

0

0

0

0

B

B: Battery voltage
0: 0V

OK or NG
OK
>> INSPECTION END
NG
>> Check PNP switch circuit. Refer to AT-105, «DTC P0705
PARK/NEUTRAL POSITION (PNP) SWITCH» (EUROOBD) or AT-288, «PNP, OD SWITCH AND CLOSED
THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT» (Except for EURO-OBD).

AT-322

SCIA7162E

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

A/T Does Not Shift: 22 → 11 , When Selector Lever “2” → “1” Position

BCS000WM

SYMPTOM:
A/T does not shift from 22 to 11 when changing selector lever from “2” to “1” position on “Cruise Test
— Part 3”.

B

1. CHECK PNP SWITCH CIRCUIT
With CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for
“A/T” with CONSULT-II.
3. Read out “P·N”, “R”, “D”, “2” and “1” position switches moving
selector lever to each position.
Monitor item

Condition

Display value

When setting selector lever to “N” or “P” position.

ON

PN POSI SW

When setting selector lever to other positions.

OFF

When setting selector lever to “R” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “D” positions.

ON

When setting selector lever to other positions.

OFF

R POSITION SW

D POSITION SW

2 POSITION SW

1 POSITION SW

A

AT

D

E

F
SAT701J

When setting selector lever to “2” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “1” position.

ON

When setting selector lever to other positions.

OFF

OK or NG
OK
>> GO TO 3
NG
>> Check PNP switch circuit. Refer to AT-105, «DTC P0705 PARK/NEUTRAL POSITION (PNP)
SWITCH» (EURO-OBD) or AT-288, «PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN
THROTTLE POSITION SIGNAL CIRCUIT» (Except for EURO-OBD).

G

H

I

J

K

L

M

AT-323

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

2. CHECK PNP SWITCH CIRCUIT
Without CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Check voltage between TCM connector terminals and ground
while moving selector lever through each position. Refer to AT106, «Wiring Diagram — AT — PNP/SW» (EURO-OBD) or AT296, «EXC.F/EURO-OBD» (Except for EURO-OBD).
Terminal

Selector lever position
36

35

34

27

26

“P”, “N”

B

0

0

0

0

“R”

0

B

0

0

0

“D”

0

0

B

0

0

“2”

0

0

0

B

0

“1”

0

0

0

0

B

B: Battery voltage
0: 0V

OK or NG
OK
>> GO TO 3
NG
>> Check PNP switch circuit. Refer to AT-105, «DTC P0705
PARK/NEUTRAL POSITION (PNP) SWITCH» (EUROOBD) or AT-288, «PNP, OD SWITCH AND CLOSED
THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT» (Except for EURO-OBD).

SCIA7162E

3. CHECK CONTROL CABLE
Check control cable. Refer to AT-337, «Checking of A/T Position» .
OK or NG
OK
>> GO TO 4.
NG
>> Adjust control cable. Refer to AT-336, «Adjustment of A/T Position» .

4. CHECK VEHICLE SPEED SENSOR·A/T AND VEHICLE SPEED SENSOR·MTR CIRCUIT
Check vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR circuit. Refer to AT-115,
«DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)» (EURO-OBD) or AT-203, «VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)» (Except for EURO-OBD) and AT-176, «DTC VEHICLE
SPEED SENSOR MTR» (EURO-OBD) or AT-209, «VEHICLE SPEED SENSOR MTR» (Except for EUROOBD).
OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR
circuits.

5. CHECK A/T FLUID CONDITION
1. Remove oil pan. Refer to AT-360, «Components» .
2. Check A/T fluid condition. Refer to AT-53, «Fluid Condition Check» .
OK or NG
OK
>> GO TO 7.
NG
>> GO TO 6.

AT-324

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

6. DETECT MALFUNCTIONING ITEM

A

Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following items:
–
Shift valve A
–
Shift solenoid valve A
–
Overrun clutch control valve
–
Overrun clutch solenoid valve
3. Disassemble A/T. Refer to AT-369, «Disassembly» .
4. Check the following items:
–
Servo piston assembly
–
Brake band
OK or NG
OK
>> GO TO 7.
NG
>> Repair or replace damaged parts.

1.
2.

B

AT

D

E

F

7. CHECK SYMPTOM
Check again. Refer to AT-65, «Cruise Test — Part 3» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 8.

G

H

I

SAT778B

J

8. CHECK TCM
1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

Vehicle Does Not Decelerate by Engine Brake

K

L

BCS000WN

SYMPTOM:
●
Vehicle does not decelerate by engine brake when shifting from 22 (12 ) to 11 “Cruise Test — Part
3”.
●
Vehicle does not decelerate by engine brake when OD OFF (OD OFF indicator lamp is on) on
“Cruise Test — Part 3”.
●
Vehicle does not decelerate by engine brake when shifting A/T from “D” to “2” position on “Cruise
Test — Part 3”.

1. CHECK CAN COMMUNICATION LINE
Perform self-diagnosis. Refer to AT-85, «SELF-DIAGNOSTIC RESULT MODE» or AT-94, «Diagnostic Procedure Without CONSULT-II» .
Is a malfunction in CAN communication indicated in the results?
YES >> Check CAN communication line. Refer to AT-102, «DTC U1000 CAN COMMUNICATION LINE»
(EURO-OBD) or AT-257, «CAN COMMUNICATION LINE» (Except for EURO-OBD).
NO
>> GO TO 2.

AT-325

M

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

2. CHECK OVERDRIVE CONTROL SWITCH CIRCUIT
With CONSULT-II
Turn ignition switch ON. (Do not start engine)
Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for
“A/T” with CONSULT-II.
3. Read out “OVERDRIVE SW”.
Check the signal of the overdrive control switch is indicated
properly.
1.
2.

Item name
OVERDRIVE SW

Overdrive control switch
Condition

Display value

Depressed

ON

Released

OFF
SCIA4730E

Without CONSULT-II
1. Turn ignition switch ON. (Do not start engine)
2. Check voltage between A/T device harness connector terminal
and ground. Refer to AT-296, «EXC.F/EURO-OBD» .
Item

A/T device harness
connector (Overdrive
control switch)

Connector

Terminal

M52

1 — Ground

Overdrive
control switch
Condition

Judgement
standard
(Approx.)

Released

Battery
voltage

Depressed

0V

OK or NG
SCIA5336E
OK (With CONSULT-II)>>GO TO 3.
OK (Without CONSULT-II)>>GO TO 4.
NG
>> Check overdrive control switch circuit. Refer to AT-197, «PNP, OD SWITCH AND CLOSED
THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT» (EURO-OBD) or AT-288,
«PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL
CIRCUIT» (Except for EURO-OBD).

AT-326

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

3. CHECK PNP SWITCH CIRCUIT

A

With CONSULT-II
Turn ignition switch ON. (Do not start engine.)
Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for
“A/T” with CONSULT-II.
3. Read out “P·N”, “R”, “D”, “2” and “1” position switches moving
selector lever to each position.
1.
2.

Monitor item

Condition

Display value

PN POSI SW

When setting selector lever to “N” or “P” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “R” position.

ON

R POSITION SW

D POSITION SW

2 POSITION SW

1 POSITION SW

B

AT

D

E
SAT701J

When setting selector lever to other positions.

OFF

When setting selector lever to “D” positions.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “2” position.

ON

When setting selector lever to other positions.

OFF

When setting selector lever to “1” position.

ON

When setting selector lever to other positions.

OFF

F

G

OK or NG
OK
>> GO TO 5
NG
>> Check PNP switch circuit. Refer to AT-105, «DTC P0705 PARK/NEUTRAL POSITION (PNP)
SWITCH» (EURO-OBD) or AT-288, «PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN
THROTTLE POSITION SIGNAL CIRCUIT» (Except for EURO-OBD).

4. CHECK PNP SWITCH CIRCUIT

H

I

J

Without CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Check voltage between TCM connector terminals and ground
while moving selector lever through each position. Refer to AT106, «Wiring Diagram — AT — PNP/SW» (EURO-OBD) or AT296, «EXC.F/EURO-OBD» (Except for EURO-OBD).

K

L

Terminal

Selector lever position
36

35

34

27

26

“P”, “N”

B

0

0

0

0

“R”

0

B

0

0

0

“D”

0

0

B

0

0

“2”

0

0

0

B

0

“1”

0

0

0

0

B

M

B: Battery voltage
0: 0V

OK or NG
OK
>> GO TO 5
NG
>> Check PNP switch circuit. Refer to AT-105, «DTC P0705
PARK/NEUTRAL POSITION (PNP) SWITCH» (EUROOBD) or AT-288, «PNP, OD SWITCH AND CLOSED
THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT» (Except for EURO-OBD).

AT-327

SCIA7162E

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

5. CHECK CONTROL CABLE
Check control cable. Refer to AT-337, «Checking of A/T Position» .
OK or NG
OK
>> GO TO 6.
NG
>> Adjust control cable. Refer to AT-336, «Adjustment of A/T Position» .

6. CHECK VEHICLE SPEED SENSOR·A/T AND VEHICLE SPEED SENSOR·MTR CIRCUIT
Check vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR circuit. Refer to AT-115,
«DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)» (EURO-OBD) or AT-203, «VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)» (Except for EURO-OBD) and AT-176, «DTC VEHICLE
SPEED SENSOR MTR» (EURO-OBD) or AT-209, «VEHICLE SPEED SENSOR MTR» (Except for EUROOBD).
OK or NG
OK
>> GO TO 7.
NG
>> Repair or replace vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR
circuits.

7. CHECK ACCELERATOR PEDAL POSITION SENSOR
Check accelerator pedal position sensor. Refer to AT-169, «DTC P1705 ACCELERATOR PEDAL POSITION
(APP) SENSOR» (EURO-OBD) or AT-213, «ACCELERATOR PEDAL POSITION (APP) SENSOR» (Except
for EURO-OBD).
OK or NG
OK
>> GO TO 8.
NG
>> Repair or replace accelerator pedal position sensor.

8. CHECK A/T FLUID CONDITION
1. Remove oil pan. Refer to AT-360, «Components» .
2. Check A/T fluid condition. Refer to AT-53, «Fluid Condition Check» .
OK or NG
OK
>> GO TO 10.
NG
>> GO TO 9.

9. DETECT MALFUNCTIONING ITEM
Remove control valve assembly. Refer to AT-345, «Control Valve Assembly and Accumulators» .
Check the following.
–
Shift valve A
–
Overrun clutch solenoid valve
3. Disassemble A/T. Refer to AT-369, «Disassembly» .
4. Check the following.
–
Overrun clutch assembly. Refer to AT-419, «Forward and Overrun Clutches» .
–
Low & reverse brake assembly. Refer to AT-426, «Low & Reverse Brake» .
OK or NG
OK
>> GO TO 10.
NG
>> Repair or replace damaged parts.
1.
2.

10. CHECK SYMPTOM
Check again. Refer to AT-65, «Cruise Test — Part 3» .
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 11.

AT-328

TROUBLE DIAGNOSIS FOR SYMPTOMS
[ALL]

11. CHECK TCM

A

1. Check TCM input/output signals. Refer to AT-80, «TCM Terminals and Reference Value» .
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

TCM Self-diagnosis Does Not Activate

B

AT
BCS000WO

SYMPTOM:
OD OFF indicator lamp does not come on in TCM self-diagnostic procedure even if the lamp circuit is
good.

D

DESCRIPTION
●

E

PNP switch
PNP switch assembly includes a transaxle position switch. The
transaxle position switch detects the selector lever position and
sends a signal to the TCM.

F

G

SCIA7141E

●

Overdrive control switch
Overdrive control switch detects the switch position (ON or OFF)
and sends a signal to the TCM.

H

I

J

K
SCIA7142E

L
●

Closed throttle position signal and wide open throttle position
signal
ECM judges throttle opening based on a signal from accelerator
pedal position sensor, and sends the signal via CAN communication to the TCM.

M

SCIA7143E

DIAGNOSTIC PROCEDURE
NOTE:
The diagnostic procedure includes inspection for the PNP stitch, overdrive control switch, closed throttle position signal and wide open throttle position signal circuit. Refer to AT-197, «PNP, OD SWITCH AND CLOSED
THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT» (EURO-OBD) or AT-288, «PNP, OD
SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT» (Except for
EURO-OBD).

AT-329

TRANSMISSION CONTROL MODULE
[ALL]

TRANSMISSION CONTROL MODULE
Removal and Installation (LHD)

PFP:31036
BCS000WP

COMPONENTS

SCIA6963E

1.

TCM

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

REMOVAL
1.
2.
3.

Disconnect the battery cable from the negative terminal.
Disconnect TCM harness connectors (1) from TCM (2).
(3): Instrument lower finisher
Remove TCM (2).

MCIB0178E

INSTALLATION
Install in the reverse order of removal.

AT-330

TRANSMISSION CONTROL MODULE
[ALL]

Removal and Installation (RHD)

BCS000YK

A

COMPONENTS

B

AT

D

E

F

MCIB0169E

1.

G

TCM

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

H

REMOVAL
1.
2.
3.
4.

Disconnect the battery cable from the negative terminal.
Remove glove box assembly. Refer to IP-12, «GLOVE BOX ASSEMBLY» .
Disconnect TCM harness connectors (1) from TCM (2).
Remove TCM (2).

I

J

K

L
MCIB0170E

INSTALLATION
M

Install in the reverse order of removal.

AT-331

SHIFT CONTROL SYSTEM
[ALL]

SHIFT CONTROL SYSTEM
Control Device Removal and Installation

PFP:34901
BCS000WQ

CONTROL DEVICE COMPONENTS

SCIA6961E

1.

Selector lever knob

2.

Knob cover

3.

Lock pin

4.

Overdrive control switch

5.

Knob finisher

6.

Selector button

7.

Selector button return spring

8.

Position indicator plate

9.

Position lamp

10. Dust cover

11. Bracket

12. Shift lock solenoid and park position
switch assembly

13. A/T device harness connector

14. Plate

15. Control device assembly

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

AT-332

SHIFT CONTROL SYSTEM
[ALL]
CONTROL CABLE COMPONENTS
Refer to the figure below for control cable removal and installation procedure.
NOTE:
Remove battery, air duct (inlet), air duct and air cleaner case before working on the transaxle side. Refer to
SC-51, «Removal and Installation (CR Engine Models)» and EM-18, «AIR CLEANER AND AIR DUCT» .

A

B

AT

D

E

F

G

SCIA6222J

1.

Selector lever knob

2.

Control device assembly

3.

Lock plate

4.

Floor panel

5.

Control cable

6.

Bracket

7.

Lock plate

8.

Lock nut

9.

A/T assembly

10. Bracket

H

I

11. Bracket

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

J

REMOVAL
CAUTION:
Make sure that parking brake is applied before removal/installation.
1. Set selector lever in “N” position.
2. Remove center console assembly. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
3. Disconnect A/T device harness connector (1).
4. Remove key interlock cable from control device assembly. Refer
to AT-342, «KEY INTERLOCK CABLE» .

K

L

M

SCIA6965E

AT-333

SHIFT CONTROL SYSTEM
[ALL]
5.
6.

Remove control device assembly fitting bolts (1).
Remove exhaust front tube, center muffler and heat plates.
Refer to EM-24, «EXHAUST MANIFOLD AND THREE WAY
CATALYST» .

SCIA6966E

7.

Remove plate (1) from control device assembly.
: Vehicle front

SCIA6967E

8.
9.

Remove lock plate (1) from control cable (2).
: Vehicle front
Remove control cable (2) from control device assembly.

SCIA6968E

10. Insert flat-bladed screwdrivers at (A) and (B) as shown in the figure, and press both tabs (E) and (F) at the front (C) and rear (D)
slightly toward the center of control device assembly to remove
control device assembly downward of the vehicle.
: Vehicle front

SCIA6970E

AT-334

SHIFT CONTROL SYSTEM
[ALL]
INSTALLATION
A

Note the following, and install in the reverse order of removal.
●
When installing control cable (1) to control device assembly (2),
make sure that control cable (1) is fully pressed in with the
ribbed (A) surface facing downward of the vehicle.
: Vehicle front
●
After installation is completed, adjust and check A/T position.
Refer to AT-336, «Adjustment of A/T Position» and AT-337,
«Checking of A/T Position» .

B

AT

D
SCIA6253E

Control Device Disassembly and Assembly

BCS000WR

DISASSEMBLY
NOTE:
Refer to AT-332, «CONTROL DEVICE COMPONENTS» to disassemble.
1. Remove selector lever knob from control device assembly. Refer to AT-336, «Selector Lever Knob
Removal and Installation» .
2. Remove position lamp from position indicator plate (1).
3. Insert a flat-bladed screwdriver to (A) (at 4 locations) as shown
in the figure, and bend each hook slightly to raise position indicator plate (1) and remove from control device assembly (2).
4. Remove bracket from control device assembly (2).
5. Remove A/T device harness connector from control device
assembly (2).

SCIA6969E

6.

Release tabs (A) on shift lock solenoid and park position switch
assembly from hooks (B) on control device assembly to shift
lock solenoid and park position switch assembly.

E

F

G

H

I

J

K

L

M
SCIA6977E

ASSEMBLY
Assemble in the reverse order of disassembly.

AT-335

SHIFT CONTROL SYSTEM
[ALL]

Selector Lever Knob Removal and Installation

BCS000WS

REMOVAL
CAUTION:
Make sure that parking brake is applied before removal/installation.
1. Set selector lever knob (1) in “N” position.
2. Slide knob cover (2) downward.
3. Pull out lock pin (3) from selector lever knob (1).
4. Remove selector lever knob (1) and knob cover (2) as a set from
selector lever.
CAUTION:
Do not push selector button.

SCIA6971E

INSTALLATION
1.
2.
3.
4.

Insert lock pin (1) to selector lever knob (2).
Install knob cover (3) to selector lever knob (2).
Set selector lever in “N” position.
Install selector lever knob over selector lever until a click is felt.
CAUTION:
● Do not tilt selector lever knob when installing. Install it
straight, and do not tap or apply any shock to install it.
● Do not push selector button.
SCIA6972E

Adjustment of A/T Position

BCS000WT

Move selector lever from “P” position to “1” position. You should be able to feel the detents in each position. If
the detents cannot be felt or if the pointer indicating the position is improperly aligned, the control cable needs
adjustment.
1. Place selector lever in “P” position.
CAUTION:
Turn wheels more than 1/4 rotations and apply the park lock.
2. Remove air duct (inlet) and air duct. Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
3. Remove lock nut (1) and control cable (2) from manual shaft (3).
4. Place manual shaft (3) in “P” position.
5. Hold the control cable (2) at the end. Push and pull it twice or
three times, and then pull it with a specified force. Temporarily
tighten lock nut (1) with the control cable loose.
Specified force
6.

7.
8.
9.

: 9.8 N (1.0 kg, 2.2 lb)

Tighten lock nut (1) to the specified torque. Refer to AT-333,
«CONTROL CABLE COMPONENTS» .
CAUTION:
Do not apply any force to manual shaft (3) after lock nut (1)
is tightened.
Move selector lever from “P” to “1” position again. Make sure that selector lever moves smoothly.
Check A/T position. AT-337, «Checking of A/T Position» .
Install any part removed.

AT-336

SCIA6370J

SHIFT CONTROL SYSTEM
[ALL]

Checking of A/T Position
1.
2.
3.
4.

5.
6.

7.
8.

BCS000WU

A
Place selector lever in “P” position, and turn ignition switch ON (Do not start engine.).
Make sure selector lever can be shifted to other than “P” position when brake pedal is depressed. Also
make sure selector lever can be shifted from “P” position only when brake pedal is depressed.
B
Move selector lever and check for excessive effort, sticking, noise or rattle.
Confirm selector lever stops at each position with the feel of engagement when it is moved through all the
positions. Check whether or not the actual position selector lever is in matches the position shown by the
AT
shift position indicator and transaxle body.
The method of operating selector lever to individual positions
correctly should be as shown in the figure.
D
Confirm back-up lamps illuminate only when selector lever is
placed in “R” position. Confirm back-up lamps do not illuminate
when selector lever is in “P” or “N” position even if it is pushed
toward “R” position without pressing selector button.
E
Confirm engine can only be started with selector lever in “P” and
“N” positions.
Make sure A/T is locked completely in “P” position.
F
SCIA6984E

G

H

I

J

K

L

M

AT-337

A/T SHIFT LOCK SYSTEM
[ALL]

A/T SHIFT LOCK SYSTEM
Description
●

●

PFP:34950
BCS000WV

The mechanical key interlock mechanism also operates as a shift lock:
With the ignition switch turned to ON, selector lever cannot be shifted from “P” position to any other position unless brake pedal is depressed.
With the key removed, selector lever cannot be shifted from “P” position to any other position.
The key cannot be removed unless selector lever is placed in “P” position.
The shift lock and key interlock mechanisms are controlled by the ON-OFF operation of the shift lock solenoid and by the operation of the rotator and slider located inside key cylinder, respectively.

Shift Lock System Parts Location

BCS000WW

MCIB0180E

1. Park position switch

2. Shift lock solenoid

A. Brake pedal

AT-338

3. Stop lamp switch

A/T SHIFT LOCK SYSTEM
[ALL]

Wiring Diagram — AT — SHIFT

BCS000WX

A

B

AT

D

E

F

G

H

I

J

K

L

M

MCWA0252E

AT-339

A/T SHIFT LOCK SYSTEM
[ALL]

Diagnostic Procedure

BCS000WY

SYMPTOM 1:
●
Selector lever cannot be moved from “P” position with ignition switch in ON position and brake
pedal depressed.
●
Selector lever can be moved from “P” position with ignition key in ON position and brake pedal
released.
●
Selector lever can be moved from “P” position when ignition switch is removed from key cylinder.
SYMPTOM 2:
●
Ignition key cannot be removed when selector lever is set to “P” position.
●
Ignition key can be removed when selector lever is set to any position except “P” position.

1. CHECK KEY INTERLOCK CABLE
Check key interlock cable for damage.
OK or NG
OK
>> GO TO 2.
NG
>> Repair key interlock cable. Refer to AT-342, «KEY INTERLOCK CABLE» .

2. CHECK A/T POSITION
Check A/T position. Refer to AT-337, «Checking of A/T Position» .
OK or NG
OK
>> GO TO 3.
NG
>> Adjust control cable. Refer to AT-336, «Adjustment of A/T Position» .

3. CHECK SHIFT LOCK SOLENOID AND PARK POSITION SWITCH
1.
2.
3.

Turn ignition switch ON. (Do not start engine.)
Selector lever is set in “P” position.
Check operation sound.
Condition

Brake pedal

Operation sound

When ignition switch is turned to ON position and selector lever is set in
“P” position.

Depressed

Yes

Released

No

OK or NG
OK
>> INSPECTION END
NG
>> GO TO 4.

4. CHECK POWER SOURCE
1.
2.

Turn ignition switch ON. (Do not start engine.)
Check voltage between A/T device harness connector terminal
5 and ground.
Voltage

: Battery voltage

OK or NG
OK
>> GO TO 7.
NG
>> GO TO 5.

SCIA7171E

AT-340

A/T SHIFT LOCK SYSTEM
[ALL]

5. CHECK STOP LAMP SWITCH
1.
2.
3.

A

Turn ignition switch OFF.
Disconnect stop lamp switch harness connector.
Check continuity between stop lamp switch harness connector
terminals 3 and 4.
Condition

B

Continuity

When brake pedal is depressed

Yes

When brake pedal is released

No

Check stop lamp switch after adjusting brake pedal. Refer to
BR-6, «BRAKE PEDAL» .
OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace damaged parts.

AT

D

SCIA2126E

6. DETECT MALFUNCTIONING ITEM

F

Check the following. If any items are damaged, repair or replace damaged parts.
●
Harness for short or open between ignition switch and stop lamp switch harness connector
●
Harness for short or open between stop lamp switch harness connector and A/T device harness connector
●
10A fuse [No.4, located in the fuse block (J/B)]
●
Ignition switch, Refer to PG-4, «POWER SUPPLY ROUTING CIRCUIT» .
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace damaged parts.

7. CHECK GROUND CIRCUIT
1.
2.

E

G

H

I

J

Turn ignition switch OFF.
Check continuity between stop lamp switch harness connector
terminal 3 and ground.

K

Continuity should exist.
L

OK or NG
OK
>> Replace shift lock solenoid and park position switch
assembly.
NG
>> Repair open circuit or short to ground or short to power
in harness or connectors.

M

MCIB0176E

AT-341

KEY INTERLOCK CABLE
[ALL]

KEY INTERLOCK CABLE
Removal and Installation

PFP:34908
BCS001EF

COMPONENTS

MCIB0181E

1.

Key interlock cable

2.

Key cylinder

3.

Control device assembly

A.

Lock plate

B.

Holder

C.

Clip

D.

Slider

E.

Key interlock rod

F.

Adjust holder

G.

Casing cap

REMOVAL
CAUTION:
Make sure that parking brake is applied before removal/installation.
1. Set selector lever in “N” position.
2. Remove selector lever knob. Refer to AT-336, «Selector Lever Knob Removal and Installation» .
3. Remove center console assembly. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
4. Slide slider (A) toward casing cap (B) while pressing tabs (C) on
slider to separate slider (A) from adjust holder (D).
5. Remove casing cap (B) from cable bracket on control device
assembly.
6. Remove key interlock cable from key interlock rod (E).

SCIA6975E

AT-342

KEY INTERLOCK CABLE
[ALL]
7.

8.
9.

Remove steering column cover upper/lower and instrument
lower finisher. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Pull out lock plate (A) from holder (B).
Remove key interlock cable (1) from key cylinder (2).

A

B

AT

SCIA6976E

D

10. Remove clip (1), and then remove key interlock cable (2).
E

F

G
MCIB0177E

INSTALLATION
CAUTION:
●
Install key interlock cable in such a way that it will not be damaged by sharp bends, twists or interference with adjacent parts.
●
After installing key interlock cable to control device assembly, make sure that casing cap and
bracket are firmly secured in their positions.
1. Place selector lever in “P” position.
2. Turn ignition switch to “ACC” or “ON” position.
3. Set key interlock cable (1) to key cylinder (2).
4. Install lock plate (A) to holder (B).
5. Turn ignition switch to “LOCK” position.

H

I

J

K

L

M
SCIA6976E

6.
7.

Temporarily install adjust holder (A) to key interlock rod (B).
Install casing cap (C) to cable bracket (D) on control device
assembly.
CAUTION:
● Do not bend or twist key interlock cable excessively
when installing.
● After installing key interlock cable to cable bracket (D) on
control device assembly, make sure casing caps (C) is
firmly secured in cable bracket (D) on control device
assembly.
● If casing cap (C) is loose [less than 39.2 N (4.0 kg, 8.8 lb)
removing force], replace key interlock cable.

AT-343

SCIA6188E

KEY INTERLOCK CABLE
[ALL]
8.

Slide slider (A) toward key interlock rod (D) while pressing pull
lock (B) down to securely connect adjust holder (C) with key
interlock rod (D).
CAUTION:
● Do not press tabs when holding slider (A)
● Do not apply any force at the right angle to key interlock
rod (D) when slider (A).

SCIA6978E

9.
10.
11.
12.
13.

Place clip (1).
(2): Key interlock cable
Install steering column cover upper/lower and instrument lower
finisher. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Install center console assembly. Refer to IP-4, «INSTRUMENT
PANEL ASSEMBLY» .
Install selector lever knob. Refer to AT-336, «Selector Lever
Knob Removal and Installation» .
Check shift lock system. Refer to AT-338, «Description» .
MCIB0177E

AT-344

ON-VEHICLE SERVICE
[ALL]

ON-VEHICLE SERVICE
Control Valve Assembly and Accumulators

PFP:00000

A
BCS000X2

COMPONENTS
B

AT

D

E

F

G

H

I

SCIA6216J

1.

A/T

2.

O-ring

3.

4.

Control valve assembly

5.

Oil pan gasket

6.

Oil pan

7.

Drain plug gasket

8.

Drain plug

9.

Magnet

10. Oil pan fitting bolt

J

Return spring

11. Snap ring

12. O-ring

13. Servo release accumulator piston

14. N-D accumulator piston

15. O-ring

16. Return spring

17. Lip seal

K

L

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

REMOVAL AND INSTALLATION
Removal
1.
2.
3.
4.
5.

6.

M

Disconnect the battery cable from the negative terminal.
Remove engine under cover and fender protector (LH). Refer to EI-14, «FENDER PROTECTOR» .
Drain ATF from drain hole.
Remove oil pan and oil pan gasket.
Check foreign materials in oil pan to help determine cause of
malfunction. If the ATF is very dark, smell burned or contains
foreign particles, friction material (clutches, band) may need
replacement. A tacky film that will not wipe clean indicates varnish build up. Varnish can cause valves, servo, and clutches to
stick and can inhibit pump pressure.
● If ATF contains frictional material (clutch, bands, etc.),
replace radiator and flush cooler line using cleaning solvent and compressed air after repair of A/T. Refer to CO12, «RADIATOR» .
SCIA3476E
Remove magnets from oil pan.

AT-345

ON-VEHICLE SERVICE
[ALL]
7.
8.
9.

Disconnect terminal cord assembly harness connector.
Remove snap ring from terminal body.
Remove terminal cord assembly by pushing terminal body into
transaxle case.

SCIA4853E

10. Remove control valve assembly fitting bolts A , B and C .
Bolt length, number and location:
Bolt symbol
Bolt length “

” mm (in)

Number of bolts

A

B

C

40.0 mm
(1.575 in)

33.0 mm
(1.299 in)

43.5 mm
(1.713 in)

5

6

2

SCIA5911J

11. Remove control valve assembly from transaxle case.
CAUTION:
Be careful not to drop manual valve and servo release accumulator return spring.
12. Remove manual valve from control valve assembly.
CAUTION:
Be careful not to drop manual valve.
13. Remove O-ring from terminal body.
14. Disassemble and inspect control valve assembly if necessary.
Refer to AT-392, «Control Valve Assembly» , AT-401, «Control
Valve Upper Body» and AT-405, «Control Valve Lower Body» .

SCIA3150E

15. Remove servo release accumulator piston and N-D accumulator
piston by applying compressed air if necessary.
CAUTION:
Hold each piston with lint-free cloth.

SCIA4854E

AT-346

ON-VEHICLE SERVICE
[ALL]
a.

Apply compressed air to the oil hole as shown in the figure, and
remove servo release accumulator piston from transaxle case.
CAUTION:
Strong flow of air will push the accumulator piston out
along with a splash of ATF. Cover the area with lint-free
cloth and blow air little by little to avoid this.

A

B

AT
SAT019DA

D

b.

Apply compressed air to the oil hole as shown in the figure, and
remove N-D accumulator piston and return spring from transaxle
case.
CAUTION:
Strong flow of air will push the accumulator piston out
along with a splash of ATF. Cover the area with lint-free
cloth and blow air little by little to avoid this.

E

F

G
SAT020D

c.

Remove O-rings (1) from servo release accumulator piston (2)
and N-D accumulator piston (3).
CAUTION:
Wrap the removed servo release accumulator piston (2) and
N-D accumulator piston (3) in a lint-free cloth.

H

I

J

SCIA6033J

K

16. Remove lip seals (1) from transaxle case.
L

M

SCIA5895J

AT-347

ON-VEHICLE SERVICE
[ALL]
Inspection
●

●

Inspect the sliding surfaces of each accumulator piston and
transaxle case, and replace if damaged or dented.
(1): Servo release accumulator piston
(2): N-D accumulator piston
Inspect the sliding surfaces of manual valve and valve body, and
replace if damaged or dented.

SCIA6035J

●

Inspect each return spring, and replace if damaged, deformed or
worn. Refer to AT-476, «Accumulator» for free length (L1 ) and
length (L2 ).
(1): Return spring (Servo release accumulator)
(2): Return spring (N-D accumulator)
CAUTION:
Do not remove spring retainer (3).

SCIA6955E

Installation
Note the following, and install in the reverse order of removal.
●
Set manual shaft in “N” position, then align manual plate (1) with
groove in manual valve (2).
●
After installing control valve assembly to transaxle case, make
sure that selector lever can be moved to all positions.
●
After completing installation, check for A/T fluid leakage and A/T
fluid level. Refer to AT-18, «Checking A/T Fluid» .
CAUTION:
●
Completely remove all moisture, oil and old gasket, etc.
from the oil pan gasket mounting surface of transaxle case
and oil pan.
●
Do not reuse O-rings, lip seals, oil pan gasket and oil pan
fitting bolts.
●
Apply ATF to manual valve, O-rings, lip seals and sliding surfaces transaxle case.

AT-348

SCIA7090E

ON-VEHICLE SERVICE
[ALL]

Park/Neutral Position (PNP) Switch

BCS000X3

A

COMPONENTS

B

AT

D

E

F

SCIA6932J

1.

A/T

2.

G

PNP switch

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

H

REMOVAL AND INSTALLATION
Removal
1.
2.
3.
4.
5.
6.
7.

Disconnect the battery cable from the negative terminal.
Remove air duct (inlet). Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
Remove control cable (1) from manual shaft. Refer to AT-333,
«CONTROL CABLE COMPONENTS» .
Disconnect PNP switch harness connector (2).
Remove PNP switch fitting bolts.
Set manual shaft in “P” position.
Remove PNP switch from A/T.

I

J

K

L
SCIA6028J

M

Installation
Note the following, and install in the reverse order of removal.
●
Align PNP switch position when installing.
●
After installation is completed, adjust and check A/T position. Refer to AT-336, «Adjustment of A/T Position» , AT-337, «Checking of A/T Position» .
●
After installation is completed, check continuity of PNP switch. Refer to AT-202, «PNP SWITCH» .

AT-349

ON-VEHICLE SERVICE
[ALL]
PARK/NEUTRAL POSITION (PNP) SWITCH ADJUSTMENT
1.
2.

Set selector lever and manual shaft (1) in “N” position.
Remove air duct (inlet). Refer to EM-18, «AIR CLEANER AND
AIR DUCT» .
3. Remove control cable from manual shaft (1). Refer to AT-333,
«CONTROL CABLE COMPONENTS»
4. Loosen PNP switch fitting bolts.
5. Insert the pin (3) [4 mm (0.16 in) dia.] straight into manual shaft
(1) adjustment hole.
6. Rotate PNP switch (2) until the pin (3) can also be inserted
straight into hole in PNP switch (2).
SCIA6218J
7. Tighten PNP switch fitting bolts to the specified torque. Refer to
AT-349, «COMPONENTS» .
8. Remove the pin (3) from adjustment hole after adjusting PNP switch (2).
9. Check continuity of PNP switch (2). Refer to AT-202, «PNP SWITCH» .
10. Adjust and check A/T position. Refer to AT-336, «Adjustment of A/T Position» , AT-337, «Checking of A/T
Position» .
11. Reinstall any parts removed.

Revolution Sensor

BCS000X4

COMPONENTS

SCIA6933J

1.

A/T

2.

Revolution sensor

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

REMOVAL AND INSTALLATION
Removal
1.
2.

Disconnect the battery cable from the negative terminal.
Remove air duct (inlet), air duct and air cleaner case. Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

AT-350

ON-VEHICLE SERVICE
[ALL]
3.
4.
5.

Disconnect revolution sensor harness connector.
Remove clip (1).
Remove revolution sensor (2) from A/T.
: Bolt (2)

A

B

AT
SCIA6206J

D

Installation
Note the following, and install in the reverse order of removal.
CAUTION:
Ensure revolution sensor harness is firmly secured with bolt.
(1): Revolution sensor
: Bolt (1)

E

F

G

H
SCIA6518J

Turbine Revolution Sensor (Power Train Revolution Sensor)

BCS000X5

COMPONENTS

I

J

K

L

M

SCIA6934J

1.

A/T

2.

O-ring

3.

Turbine revolution sensor (power
train revolution sensor)

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

REMOVAL AND INSTALLATION
Removal
1.
2.

Disconnect the battery cable from the negative terminal.
Remove air duct (inlet). Refer to EM-18, «AIR CLEANER AND AIR DUCT» .

AT-351

ON-VEHICLE SERVICE
[ALL]
3.
4.
5.

Remove control cable (1). Refer to AT-333, «CONTROL CABLE
COMPONENTS» .
Disconnect PNP switch harness connector (2).
Remove bracket (3) of control cable. Refer to AT-333, «CONTROL CABLE COMPONENTS» .

SCIA6262J

6.
7.

8.
9.

Disconnect turbine revolution sensor (power train revolution
sensor) harness connector (1).
Remove turbine revolution sensor (power train revolution sensor) fitting bolt.
: Bolt (1)
Remove turbine revolution sensor (power train revolution sensor) (2) from A/T.
Remove O-ring from turbine revolution sensor (power train revolution sensor) (2).
SCIA6513J

Installation
Note the following, and install in the reverse order of removal.
CAUTION:
●
Do not reuse O-ring.
●
Apply ATF to O-ring.
After installing control cable, adjust and check A/T position. Refer to AT-336, «Adjustment of A/T Position» , AT337, «Checking of A/T Position» .

AT-352

ON-VEHICLE SERVICE
[ALL]

Differential Side Oil Seal

BCS000X6

A

COMPONENTS

B

AT

D

E

F

SCIA6935J

1.

A/T

2.

LH differential side oil seal

3.

G

RH differential side oil seal

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

H

REMOVAL AND INSTALLATION
Removal
1.
2.

Remove front drive shaft. Refer to FAX-13, «Removal and Installation» .
Remove differential side oil seal using a flat-bladed screwdriver.
CAUTION:
Be careful not to scratch transaxle case and converter
housing.

I

J

K

L
SCIA4857E

M

AT-353

ON-VEHICLE SERVICE
[ALL]
Installation
Note the following, and install in the reverse order of removal.
●
Drive each differential side oil seal evenly using a drift (SST and
commercial service tool) so that differential side oil seal protrudes by the dimension “C” or “D” respectively.
(1): LH differential side oil seal
(2): RH differential side oil seal
(A): Transaxle case side
(B): Converter housing side
Unit: mm (in)
Dimension “C”

0 ± 0.5 (0 ± 0.020)

Dimension “D”

1.1 ± 0.5 (0.043 ± 0.020)
SCIA7226E

NOTE:
Differential side oil seal pulling direction is used as the reference.
Drift to be used:
Location

Tool number

Transaxle case side (A)

ST35325000
KV31103000

Converter housing side (B)

Commercial service tool [Inner diameter: 47 mm (1.85 in), outer
diameter: 54 mm (2.13 in)]

After installing differential side oil seal, check A/T fluid leakage and A/T fluid level. Refer to AT-18, «Checking
A/T Fluid» .

AT-354

AIR BREATHER HOSE
[ALL]

AIR BREATHER HOSE
Removal and Installation

PFP:31098

A
BCS000YL

COMPONENTS
B

AT

D

E

F

G
SCIA6208J

1.

Air cleaner case

2.

Air duct

3.

Air breather hose

4.

Clip

5.

Air breather tube

6.

A/T

H

REMOVAL
1.
2.
3.

Remove battery. Refer to SC-14, «Removal and Installation» .
Remove air duct (inlet), air duct and air cleaner case. Refer to EM-118, «AIR CLEANER AND AIR DUCT» .
Remove air breather hose.

I

J

INSTALLATION
Note the following, and install in the reverse order of removal.
●
Install air breather hose (1) to air breather tube (2) so that the
paint mark (3) faces upward. Also make sure air breather hose
end laps with air breather tube 17 mm (0.67 in) or more.
●
When installing air breather hose to air duct and air cleaner
case, make sure to fully insert the hose with clip.
CAUTION:
Make sure air breather hose is not collapsed or blocked due to
folding or bending when installed.

K

L

M

SCIA6350J

AT-355

TRANSAXLE ASSEMBLY
[ALL]

TRANSAXLE ASSEMBLY
Removal and Installation

PFP:32020
BCS000X7

COMPONENTS

SCIA6766J

1.

Rear torque rod

2.

Rear engine mounting bracket

4.

A/T fluid level gauge

5.

O-ring

6.

Fluid cooler tube

7.

Copper washer

8.

Bracket

9.

Fluid cooler tube

10. A/T assembly

11. Engine mounting bracket (LH)

3.

A/T fluid charging pipe

12. Bracket

13. Washer
Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .
: For tightening torque, refer to AT-358, «INSTALLATION» .

REMOVAL
1.
2.
3.

Disconnect the battery cable from the negative terminal.
Remove air duct (inlet), air duct and air cleaner case. Refer to EM-18, «AIR CLEANER AND AIR DUCT» .
Remove air breather hose.

AT-356

TRANSAXLE ASSEMBLY
[ALL]
4.
5.
6.
7.

Remove control cable (1). Refer to AT-333, «CONTROL CABLE
COMPONENTS» .
Disconnect PNP switch harness connector (2).
Remove bracket (3) of control cable.
Remove engine under cover and fender protector. Refer to EI14, «FENDER PROTECTOR» .

A

B

AT
SCIA6262J

D

8.

9.

Disconnect following harness connector and wire harness.
● Turbine revolution sensor (power train revolution sensor) harness connector (1)
● Body ground harness (2)
● Terminal cord assembly harness connector (3)
● Revolution sensor harness connector (4)
Remove starter motor. Refer to SC-51, «Removal and Installation (CR Engine Models)» .

E

F

G

H

I

J

SCIA6812J

10. Turn crankshaft to remove four tightening bolts for drive plate
and torque converter.
CAUTION:
Crankshaft should be rotated clockwise, viewed from front
of engine.
11. Disconnect A/T fluid cooler hoses.
12. Remove front drive shafts. Refer to FAX-13, «Removal and
Installation» .
13. Remove heat insulator. Refer to EM-24, «EXHAUST MANIFOLD
AND THREE WAY CATALYST» .
SCIA6225J
14. Support A/T assembly using a transmission jack.
CAUTION:
When setting the transmission jack, be careful not to allow it to collide against the drain plug.
15. Remove rear torque rod and rear engine mounting bracket. Refer to EM-70, «ENGINE ASSEMBLY» .
16. Support engine assembly using a transmission jack.
CAUTION:
When setting the transmission jack, be careful not to allow it to collide against the drain plug.
17. Remove A/T assembly fixing bolts.
18. Remove engine mounting insulator (LH). Refer to EM-70, «ENGINE ASSEMBLY» .

AT-357

K

L

M

TRANSAXLE ASSEMBLY
[ALL]
19. Remove A/T assembly from engine assembly.
CAUTION:
● Secure torque converter to prevent it from dropping.
● Secure A/T assembly to a transmission jack.
20. Remove engine mounting bracket (LH). Refer to AT-356, «COMPONENTS» .

ATM0479D

21.
22.
23.
24.
25.

Remove fluid cooler tubes (1) and copper washers.
Remove A/T fluid level gauge (2).
Remove A/T fluid charging pipe (3).
Remove O-ring from A/T fluid charging pipe (3).
Remove bracket from A/T assembly.

SCIA6813J

INSPECTION
Installation and Inspection of Torque Converter
●

After inserting a torque converter to a A/T, be sure to check
dimension “A” to ensure it is within the reference value limit.
Dimension “A”:

16.2 mm (0.638 in) or more

SAT430D

INSTALLATION
Note the following, and install in the reverse order of removal, while paying attention to the following work.
CAUTION:
Do not reuse O-ring and copper washers. Refer to AT-356, «COMPONENTS» .
●
When installing A/T assembly to engine assembly, attach fixing bolts in accordance with the following
standard.
Bolt No.

1

2

3

4

Number of bolts

2

2

1

3

40 (1.57)

44 (1.73)

69 (2.72)

49 (1.93)

Bolt length “L”
[mm (in)]
Tightening torque
[N·m (kg-m, ft-lb)]

48 (4.9, 35)

(A): A/T to engine
(B): Engine to A/T
SCIA7096E

AT-358

TRANSAXLE ASSEMBLY
[ALL]
●

Align the positions of tightening bolts for drive plate with those of
torque converter, and temporarily tighten bolts. Then, tighten
bolts to the specified torque.
:

A

51 N·m (5.2 kg-m, 38 ft-lb)

B
CAUTION:
●
When turning crankshaft, turn it clockwise as viewed from
front of engine.
AT
●
When tightening the tighten bolts for the torque converter
after fixing crankshaft pulley bolts, be sure to confirm the
SCIA6225J
tightening torque of crankshaft pulley mounting bolts.
D
Refer to EM-50, «TIMING CHAIN» .
●
After converter is installed to drive plate, rotate crankshaft several turns and check to be sure that
A/T rotates freely without binding.
E
●
After completing installation, check for A/T fluid leakage, A/T fluid level and A/T positions. Refer to AT-18,
«Checking A/T Fluid» and AT-337, «Checking of A/T Position» .
F

G

H

I

J

K

L

M

AT-359

OVERHAUL
[ALL]

OVERHAUL
Components

PFP:00000
BCS000X8

SCIA7177E

AT-360

OVERHAUL
[ALL]
1.

Pinion mate gear thrust washer

2.

Pinion mate gear

3.

Pinion mate shaft

4.

Lock pin

5.

Side gear

6.

Side gear thrust washer

7.

Differential side bearing

8.

Differential case

9.

Final gear

10. Differential side bearing adjusting
shim

11. Plug

12. O-ring

13. Bracket

14. RH differential side oil seal

15. Torque converter

16. Converter housing

17. Differential lubricant tube

18. Clip

19. O-ring

20. O-ring

21. Oil pump housing oil seal

22. Oil pump housing

23. Outer gear

24. Inner gear

25. Oil pump cover

26. Seal ring

27. Oil pump assembly

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

A

B

AT

D

E

F

G

H

I

J

K

L

M

AT-361

OVERHAUL
[ALL]

SCIA5893J

1.

Retaining plate

2.

Driven plate

3.

Dish plate

4.

Snap ring

5.

Spring retainer assembly

6.

Reverse clutch piston

7.

Seal ring

8.

D-ring

9.

Reverse clutch drum

AT-362

OVERHAUL
[ALL]
10. Thrust washer

11. Reverse clutch assembly

12. Drive plate

13. Snap ring

14. Needle bearing

15. Front sun gear

16. Needle bearing

17. High clutch hub

18. Snap ring

19. Retaining plate

20. Drive plate

21. Snap ring

22. Cancel cover

23. Spring retainer assembly

24. High clutch piston

25. Input shaft assembly (high clutch
drum)

26. Needle bearing

27. High clutch assembly

28. Bearing race

29. Seal ring

30. Driven plate

31. Needle bearing

32. Needle bearing

33. Overrun clutch hub

34. End bearing

35. Forward clutch hub

36. Needle bearing

37. Rear planetary carrier

38. Rear sun gear

39. Front planetary carrier

40. Low one-way clutch

41. Snap ring

42. Needle bearing

43. Needle bearing

44. Rear internal gear

45. Thrust washer

46. Forward one-way clutch

47. Thrust washer

48. Thrust washer

49. Forward clutch drum

50. Seal ring

51. Seal ring

52. Overrun clutch piston

53. Spring retainer assembly

54. Snap ring

55. Dish plate

56. Driven plate

57. Retaining plate

58. Snap ring

59. Dish plate

60. Driven plate

61. Retaining plate

62. Snap ring

63. Forward clutch assembly and overrun clutch assembly

64. Drive plate

65. Drive plate

66. D-ring

67. Forward clutch piston

68. D-ring

69. Seal ring

70. Driven plate

71. Snap ring

72. Low & reverse brake assembly

73. Retaining plate

74. Drive plate

75. Retaining plate

76. Dish plate

77. Driven plate

78. Snap ring

79. Spring retainer assembly

80. Low & reverse brake piston

81. D-ring

A

B

AT

D

E

F

G

H

I

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

J

K

L

M

AT-363

OVERHAUL
[ALL]

SCIA7178E

1.

Snap ring

2.

Governor cap

3.

O-ring

4.

Lock nut

5.

Anchor end pin

6.

Transaxle case

7.

Reduction pinion gear bearing

8.

Reduction pinion gear

9.

Brake band

AT-364

OVERHAUL
[ALL]
10. Output shaft

11. Seal ring

12. Output shaft bearing

13. Seal ring

14. Bearing retainer

15. O-ring

16. Servo release accumulator piston

17. Return spring

18. Control valve assembly

19. Oil pan gasket

20. Oil pan

21. Drain plug gasket

22. Drain plug

23. Magnet

24. Oil pan fitting bolt

25. Snap ring

26. O-ring

27. O-ring

28. N-D accumulator piston

29. Return spring

30. O-ring

31. Lip seal

32. Turbine revolution sensor (power
train revolution sensor)

33. O-ring

34. Retaining pin

35. Detent spring

36. Retaining pin

37. Manual shaft

38. Manual shaft oil seal

39. Manual plate

40. Parking rod plate

41. Parking rod

42. OD servo piston retainer

43. Snap ring

44. O-ring

45. OD servo piston

46. D-ring

47. Servo piston retainer

48. O-ring

49. E-ring

50. Spring retainer

51. OD servo return spring

52. D-ring

53. Band servo piston

54. Band servo thrust washer

55. Band servo piston stem

56. 2nd servo return spring

57. PNP switch

58. Parking shaft

59. Return spring

60. Output gear adjusting spacer

61. Output gear bearing

62. Output gear

63. Side cover gasket

64. Side cover

65. Side cover fitting bolt

66. Lock nut

67. Idler gear

68. Idler gear bearing

69. Reduction pinion gear adjusting
shim

70. Parking actuator support

71. Parking pawl

72. LH differential side oil seal

A

B

AT

D

E

F

G

H

73. Revolution sensor
Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

I

However, refer to the following symbol for others.
: Apply locking sealant (Loctite #518).

J

K

L

M

AT-365

OVERHAUL
[ALL]

Oil Channel

BCS000X9

SCIA5925E

AT-366

OVERHAUL
[ALL]

Locations of Adjusting Shims, Needle Bearings and Thrust Washers

BCS000XA

A

B

AT

D

E

F

G

H

I

J

K

L

M

SCIA6051J

●

Refer to AT-474, «SERVICE DATA AND SPECIFICATIONS (SDS)» .

AT-367

OVERHAUL
[ALL]

Locations of Snap Rings

BCS000XB

SCIA6170J

●

Refer to AT-474, «SERVICE DATA AND SPECIFICATIONS (SDS)» .

AT-368

DISASSEMBLY
[ALL]

DISASSEMBLY
Disassembly
1.
2.

PFP:31020

A
BCS000XC

Drain ATF through drain hole.
Remove drain plug gasket from drain plug.

B

AT

D
SCIA0003E

3.

E

Remove torque converter.

F

G

H
SAT008D

4.
a.
b.
c.

Check torque converter one-way clutch using check tool as
shown in the figure.
Insert check tool into groove of bearing support built into oneway clutch outer race.
When fixing bearing support with check tool, rotate one-way
clutch spline using screwdriver.
Check that inner race rotates clockwise only. If not, replace
torque converter assembly.

I

J

K

L

M

SAT009D

AT-369

DISASSEMBLY
[ALL]
5.

6.

Remove turbine revolution sensor (power train revolution sensor) (1) from transaxle case (2).
: Bolt (1)
Remove O-ring (3) from turbine revolution sensor (power train
revolution sensor) (1).

SCIA7004J

7.

Remove revolution sensor (1) from transaxle case (2).
: Bolt (2)

SCIA7170J

8.
9.

Set manual shaft (1) in “P” position.
Remove PNP switch (2) from transaxle case.
: Bolt (3)

SCIA5904J

10. Remove oil pan fitting bolts.
11. Remove oil pan and oil pan gasket.
12. Check foreign materials in oil pan to help determine causes of
malfunction. If the ATF is very dark, smells burned, or contains
foreign particles, frictional material (clutches, band) may need
replacement. A tacky film that will not wipe clean indicates varnish build up. Varnish can cause valves, servo, and clutches to
stick and can inhibit pump pressure.
● If frictional material is detected, replace radiator after
repair of A/T. Refer to CO-12, «RADIATOR» .
13. Remove magnets from oil pan.
SCIA3476E

AT-370

DISASSEMBLY
[ALL]
14. Remove control valve assembly according to the following procedures.
a. Remove snap ring (1) from terminal body (2).
CAUTION:
Do not expand snap ring (1) excessively.
b. Push terminal body (2) into transaxle case.

A

B

AT
SCIA6030J

D

c.

Remove control valve assembly fitting bolts A , B and C .
Bolt length, number and location:

Bolt symbol
Bolt length “

” [mm (in)]

Number of bolts

A

B

C

40.0 mm
(1.575 in)

33.0 mm
(1.299 in)

43.5 mm
(1.713 in)

5

6

2

E

F

G
SCIA5911J

H

d.

Remove control valve assembly from transaxle case.
CAUTION:
Be careful not to drop manual valve.
15. Remove manual valve from control valve assembly.
● Inspect the sliding surfaces of manual valve and valve
body, and replace if damaged or dented.
CAUTION:
Be careful not to drop manual valve.
16. Remove O-ring from terminal body.

I

J

K

L
SCIA3150E

17. Remove return spring from servo release accumulator piston.
M

SCIA3477E

AT-371

DISASSEMBLY
[ALL]
18. Apply compressed air into the oil hole as shown in the figure,
and remove servo release accumulator piston from transaxle
case.
CAUTION:
Strong flow of air will push the accumulator piston out
along with a splash of ATF. Cover the area with lint-free
cloth and blow air little by little to avoid this.

SAT019DA

19. Apply compressed air into the oil hole as shown in the figure,
and remove N-D accumulator piston and return spring from
transaxle case.
CAUTION:
Strong flow of air will push the accumulator piston out
along with a splash of ATF. Cover the area with lint freecloth and blow air little by little to avoid this.

SAT020D

20. Remove O-rings (1) from servo release accumulator piston (2)
and N-D accumulator piston (3).
CAUTION:
Wrap the removed servo release accumulator piston (2) and
N-D accumulator piston (3) in a lint-free cloth.

SCIA6033J

●

Inspect the sliding surfaces of each accumulator piston and
transaxle case, and replace if damaged or dented.
(1): Servo release accumulator piston
(2): N-D accumulator piston

SCIA6035J

AT-372

DISASSEMBLY
[ALL]
●

Inspect each return spring, and replace if deformed or worn.
Refer to AT-476, «Accumulator» for free length (L1 ) and
length (L2 ).
(1): Return spring (Servo release accumulator)
(2): Return spring (N-D accumulator)
CAUTION:
Do not remove spring retainer (3).

A

B

AT

D

E

F

G
SCIA6955E

21. Remove lip seals (1) from transaxle case.

H

I

J

SCIA5895J

22. Remove converter housing according to the following procedures.
a. Remove converter housing fitting bolts (1), (2) and (3) using a
power tool.
b. Remove bracket from converter housing
c. Remove converter housing by tapping it lightly.

K

L

M

SCIA6956E

AT-373

DISASSEMBLY
[ALL]
d.

Remove O-ring (1) from differential lubricant hole.

SCIA5918J

23. Remove plug from converter housing.
24. Remove O-ring from plug.
25. Remove final drive assembly (1) from transaxle case.

SCIA6034J

26. Remove differential side bearing adjusting shim from transaxle
case.

SCIA4938E

27. Remove RH differential side oil seal from converter housing
using a flat-bladed screwdriver.
CAUTION:
Be careful not to scratch converter housing.

SCIA3283E

AT-374

DISASSEMBLY
[ALL]
28. Remove differential lubricant tube and clips from converter
housing.

A

B

AT
SCIA3284E

D

29. Remove oil pump assembly according to the following procedures.
a. Remove O-ring from input shaft assembly (high clutch drum).
E

F

G
SCIA5634E

b.
c.

H

Remove oil pump assembly fitting bolts, and then remove oil
pump assembly (1) from transaxle case.
Remove O-ring from oil pump assembly (1).

I

J

K
SCIA6036J

d.

Remove bearing race (1) and thrust washer (2) from oil pump
assembly (3).

L

M

SCIA6957E

AT-375

DISASSEMBLY
[ALL]
30. Remove brake band according to the following procedures.
a. Loosen lock nut (1), and then remove anchor end pin (2) and
lock nut (1) as a set from transaxle case.

SCIA6037J

b.

Remove brake band from transaxle case.

SAT038D

●

To prevent brake linings from cracking or peeling, do not
stretch the flexible band unnecessarily. When removing
brake band, always secure it with a clip as shown in the
figure.
Leave the clip in position after removing brake band.

SAT039D

c.

Check brake band facing for damage, cracks, wear or burns.

SAT040D

31. Remove input shaft assembly (high clutch assembly) and
reverse clutch assembly according to the following procedures.
a. Remove input shaft assembly (high clutch assembly) (1) with
reverse clutch assembly (2).

SCIA6038J

AT-376

DISASSEMBLY
[ALL]
b.

Remove input shaft assembly (high clutch assembly) (1) from
reverse clutch assembly (2).

A

B

AT

SCIA6958E

c.

Remove needle bearing (1) from input shaft assembly (high
clutch drum) (2).
● Inspect needle bearing (1) and input shaft assembly (high
clutch drum) (2), and replace if damaged or worn.

D

E

F

G
SCIA6959E

32. Remove needle bearing from high clutch hub.
● Inspect needle bearing, and replace if damaged or worn.

H

I

J

SAT371D

33. Remove high clutch hub from front sun gear.
● Inspect high clutch hub, and replace if damaged or worn.

K

L

M

SAT370D

34. Remove needle bearing from front sun gear.
● Inspect needle bearing, and replace if damaged or worn.

SAT369D

AT-377

DISASSEMBLY
[ALL]
35. Remove front sun gear from front planetary carrier.

SAT368D

36. Remove needle bearing (1) from front sun gear (2).
● Inspect needle bearing (1) and front sun gear (2), and
replace if damaged or worn.

SCIA6960E

37. Remove front planetary carrier and low one-way clutch according to the following procedures.
a. Remove snap ring using a flat-bladed screwdriver.

SCIA3633E

b.

Remove low one-way clutch (1) and front planetary carrier (2) as
a set from transaxle case.

SCIA5896J

AT-378

DISASSEMBLY
[ALL]
c.

d.

Check that low one-way clutch rotates counter-clockwise around
front planetary carrier. Then try to turn it clockwise and check
that it is locked.
● Replace low one-way clutch if necessary.
Remove low one-way clutch from front planetary carrier by turning it in the direction of unlock.
● Inspect low one-way clutch, and replace if damaged or
worn.

A

B

AT
SAT048D

D

e.

Remove needle bearing (1) from front planetary carrier (2).
● Inspect needle bearing (1) and front planetary carrier (2),
and replace if damaged or worn.

E

F

G
SCIA6047J

f.

Check clearance between pinion washer and front planetary
carrier using feeler gauge.

H

Standard clearance and allowable limit:
Refer to AT-478, «Planetary Carrier» .
●

I

Replace front planetary carrier if the clearance exceeds
allowable limit.
J

SAT050D

38. Remove rear planetary carrier and rear sun gear according to the following procedures.
a. Remove rear planetary carrier (with rear sun gear) from
transaxle case.

K

L

M

SAT051D

AT-379

DISASSEMBLY
[ALL]
b.

Remove rear sun gear from rear planetary carrier.
● Inspect rear sun gear, and replace if damaged or worn.

SAT052D

c.

Remove needle bearing (1) from rear planetary carrier (2).
● Inspect needle bearing (1) and rear planetary carrier (2),
and replace if damaged or worn.

SCIA5927J

d.

Check clearance between pinion washer and rear planetary carrier using feeler gauge.
Standard clearance and allowable limit:
Refer to AT-478, «Planetary Carrier» .
●

Replace rear planetary carrier if the clearance exceeds
allowable limit.

SAT054D

39. Remove rear internal gear (1) and forward clutch hub (2) as a
set from forward clutch drum.

SCIA5897J

40. Remove needle bearing (1) from rear internal gear (2).
● Inspect needle bearing (1), and replace if damaged or
worn.

SCIA6041J

AT-380

DISASSEMBLY
[ALL]
41. Remove overrun clutch hub (1) from forward clutch drum.
A

B

AT

SCIA5898J

42. Remove thrust washer (1) from overrun clutch hub (2).
● Inspect thrust washer (1) and overrun clutch hub (2), and
replace if damaged or worn.

D

E

F

G
SCIA5899J

43. Remove forward clutch assembly and overrun clutch assembly
(1) from transaxle case.

H

I

J

SCIA5900J

44. Remove needle bearing (1) and thrust washer (2) from bearing
retainer.
● Inspect needle bearing (1) and thrust washer (2), and
replace damaged or worn.

K

L

M

SCIA5901J

45. Remove side cover fitting bolts (1), and then remove side cover
by lightly tapping it using a soft hammer.
CAUTION:
Be careful not to damage side cover.
46. Remove side cover gasket from side cover.

SCIA6039J

AT-381

DISASSEMBLY
[ALL]
47.
a.
b.
c.

Remove output shaft, output gear and reduction gear according to the following procedures.
Set manual shaft in “P” position to fix idler gear and output gear.
Unlock both idler gear and output gear lock nuts using a pin punch.
Remove idler gear and output gear lock nuts.

SAT704D

d.

Remove idler gear (2) and output gear (1) using Tool A.
Tool number:

e.

ST27180001

Remove reduction pinion gear and output shaft from transaxle
case.

SCIA6991E

f.
g.

Remove reduction pinion gear adjusting shim (1) from reduction
pinion gear (2).
Remove output gear adjusting spacer (3) from output shaft (4).

SCIA5902J

48. Remove bearing retainer fitting bolts, and then remove bearing
retainer (1) from transaxle case.

SCIA5909J

AT-382

DISASSEMBLY
[ALL]
49. Remove return spring (2) from parking shaft (3) using a flatbladed screwdriver.
(1): Parking pawl
● Inspect return spring (2), and replace if damaged or worn.

A

B

AT
SCIA6996E

D

50. Draw out parking shaft (1), and then remove parking pawl (2)
from transaxle case.
● Inspect parking shaft (1) and parking pawl (2), and
replace if damaged or worn.

E

F

G
SCIA6997E

51. Remove parking actuator support (1) from transaxle case.
● Inspect parking actuator support (1), and replace if damaged or worn.
52. Remove snap ring from transaxle case using a flat-bladed
screwdriver.
53. Remove governor cap from transaxle case.
54. Remove O-ring from governor cap.

H

I

J

SCIA6998E

55. Remove LH differential side oil seal from transaxle case using a
flat-bladed screwdriver.
CAUTION:
Be careful not to scratch transaxle case.

K

L

M

ATM0076D

AT-383

REPAIR FOR COMPONENT PARTS
[ALL]

REPAIR FOR COMPONENT PARTS
Manual Shaft

PFP:00000
BCS000XD

COMPONENTS

SCIA5907J

1.

Manual shaft oil seal

2.

Parking rod

3.

Retaining pin

4.

Parking rod plate

5.

Retaining pin

6.

Manual plate

7.

Manual shaft

8.

Detent spring

9.

Retaining pin

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

REMOVAL
1.

Remove detent spring from transaxle case.

SAT313G

2.

Drive out retaining pin of manual plate using the pin punch.

SAT076D

AT-384

REPAIR FOR COMPONENT PARTS
[ALL]
3.

Pull out retaining pin (2) of parking rod plate (1) using nippers.
A

B

AT
SCIA5806J

D

4.

Pull out retaining pin (1) of manual shaft using nippers.
E

F

G
SCIA6514J

5.
6.
7.
8.

Remove parking rod plate (with parking rod) (3) from manual
shaft (1).
Remove parking rod from parking rod plate (3).
Remove manual plate (2) from manual shaft (1).
Draw out manual shaft (1) from transaxle case.

H

I

J

SCIA7005E

9.

Remove manual shaft oil seal from transaxle case using a flatbladed screwdriver.
CAUTION:
Be careful not to scratch transaxle case.

K

L

M

SAT080D

INSPECTION
Check component parts, and replace if damaged or worn.

AT-385

REPAIR FOR COMPONENT PARTS
[ALL]
INSTALLATION
1.

2.

Drive manual shaft oil seal into transaxle case using a drift [commercial service tool: 22 mm (0.87 in) dia.].
CAUTION:
● Do not reuse manual shaft oil seal.
● Apply ATF to outer surface of manual shaft oil seal.
Install parking rod to parking rod plate.

SAT081D

3.
4.

Insert manual shaft (1) to transaxle case, and install manual
plate (2) to manual shaft (1).
Install parking rod plate (with parking rod) (3) to manual shaft
(1).

SCIA7005E

5.
6.

Align groove of manual shaft and hole of transaxle case using a
pin punch A [commercial service tool: 2 mm (0.08 in) dia.].
Drive retaining pin of manual shaft into transaxle case using Tool
(B).
Tool number B:

ST23540000

CAUTION:
Do not reuse retaining pin.

SCIA7006E

7.

Set parking rod plate (1) onto manual shaft, and drive retaining
pin (2) of parking rod plate (1).
Tool number A:

ST23540000

CAUTION:
The retaining pin end should protrude approx. 3mm (0.12
in) (B) from the outer surface of parking rod plate (1).

SCIA7107E

AT-386

REPAIR FOR COMPONENT PARTS
[ALL]
8.

Set manual plate (1) onto manual shaft, and drive retaining pin
(2) of manual plate (1).
Tool number A:

A

ST23540000

CAUTION:
The retaining pin end should protrude approx. 3mm (0.12
in) (B) from the outer surface of manual plate (1).

B

AT
SCIA7108E

D

9. Install detent spring on transaxle case.
10. Tighten detent spring fitting bolt to the specified torque. Refer to
AT-384, «COMPONENTS» .

E

F

G
SAT042F

H

I

J

K

L

M

AT-387

REPAIR FOR COMPONENT PARTS
[ALL]

Oil Pump

BCS000XE

COMPONENTS

SCIA5908J

1.

Oil pump housing oil seal

2.

Oil pump housing

3.

Outer gear

4.

Inner gear

5.

Oil pump cover

6.

Seal ring

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

DISASSEMBLY
1.

Remove seal rings (1) from oil pump assembly (2).

SCIA7016E

2.

Remove bolts in the order as shown in the figure, and remove oil
pump cover.

SAT091D

AT-388

REPAIR FOR COMPONENT PARTS
[ALL]
3.

Remove inner gear and outer gear from oil pump housing.
A

B

AT
SAT092D

D

4.

Remove oil pump housing oil seal using a flat-bladed screwdriver.
CAUTION:
Be careful not to scratch oil pump housing.

E

F

G
SCIA2840E

H

I

J

K

L

M

AT-389

REPAIR FOR COMPONENT PARTS
[ALL]
INSPECTION
Oil Pump Housing, Oil Pump Cover, Inner Gear and Outer Gear
Check for wear or damage. Replace if necessary.

Side Clearances
●

Measure side clearance of inner gear and outer gear in at least
four places around each outside edge. Maximum measured values should be within the specified clearance.
Standard clearance:

●

●

Refer to AT-478, «Oil Pump» .

If clearance is less than standard, select inner gear and outer
gear as a set so that clearance is within specifications. Refer to
“Parts Information” for the inner gear and outer gear selection.
If clearance is more than standard, replace whole oil pump
assembly except oil pump cover.

SCIA4957E

●

Measure clearance between outer gear and oil pump housing.
Standard clearance and allowable limit:
Refer to AT-478, «Oil Pump» .

●

If not within allowable limit, replace whole oil pump assembly
except oil pump cover.

SAT096D

Seal Ring Clearance
●

Measure clearance between seal ring and ring groove.
Standard clearance and allowable limit:
Refer to AT-478, «Oil Pump» .

●

If not within allowable limit, replace oil pump cover assembly.

SAT097D

AT-390

REPAIR FOR COMPONENT PARTS
[ALL]
ASSEMBLY
1.

A

Install oil pump housing oil seal on oil pump housing.
CAUTION:
● Do not reuse oil pump housing oil seal.
● Apply ATF to outer surface of oil pump housing oil seal.

B

AT

SAT900DA

2.

Install inner gear and outer gear on oil pump housing.
CAUTION:
Be careful with the direction of inner gear.

D

E

F

G
SAT092D

3.
a.

b.

H

Install oil pump cover on oil pump housing.
Wrap masking tape around splines of oil pump cover assembly
to protect seal. Position oil pump cover assembly on oil pump
housing assembly, then remove masking tape.
Tighten oil pump cover fitting bolts in the order as shown in the
figure, and then tighten them to the specified torque in the same
order. Refer to AT-388, «COMPONENTS» .

I

J

K
SAT101D

4.

L

Install seal rings (1) to oil pump assembly (2) carefully after
packing ring groove with petroleum jelly.
CAUTION:
Do not spread gap of seal rings (1) excessively while installing. The seal rings (1) may be deformed.

M

SCIA7016E

AT-391

REPAIR FOR COMPONENT PARTS
[ALL]

Control Valve Assembly

BCS000XF

COMPONENTS

SCIA5967J

1.

Pilot filter

2.

Control valve upper body

3.

4.

Separating plate

5.

Control valve inter body

6.

Steel ball
Steel ball

7.

Support plate

8.

Separating plate

9.

Control valve lower body

10. Line pressure relief valve spring

11. Check ball

12. Torque converter pressure holding
spring

13. Solenoid valve assembly

14. Terminal body

15. O-ring

16. O-ring

17. O-ring

18. Oil strainer

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

AT-392

REPAIR FOR COMPONENT PARTS
[ALL]
DISASSEMBLY
A

Place control valve assembly with control valve upper body (1) side
down. Remove bolts (A) to (G), reamer bolts (F), nuts and support
plates (4) according to the following procedures. Separate control
valve upper body (1), control valve inter body (2) and control valve
lower body (3).

B

AT

D

E

F

G
SCIA7058E

H

Bolt length, number and location:
Bolt symbol
Bolt length “

” [mm (in)]

Number of bolts
*:

A

B

C

D

E

F*

G

13.5
(0.531)

58.0
(2.283)

40.0
(1.575)

66.0
(2.598)

33.0
(1.299)

78.0
(3.071)

18.0
(0.709)

6

3

6

11

2

2

1

J

Reamer bolt and nut.

1.

I

Remove bolts (A), (D), reamer bolt (F) and nut , and remove oil
strainer (1) from control valve assembly.

K

L

M
SCIA7007E

2.

Remove bolts (A), (C) and (G), and then remove solenoid valve
assembly (1) from control valve assembly.

SCIA7008E

AT-393

REPAIR FOR COMPONENT PARTS
[ALL]
3.

Remove O-rings from solenoid valves and terminal body.

SCIA7180E

4.

Place control valve upper body face down, and remove bolts
(B), reamer bolt (F) and nut.
CAUTION:
Remove bolts with control valve upper body facing down,
because control valve upper body and control valve inter
body may come off and steel ball may fall and be lost.

ATL0020D

5.

Remove control valve lower body (1) from control valve inter
body (2).
(3): Control valve upper body

SCIA7181E

6.
7.

Turn over control valve lower body (1).
Remove bolts (E), support plates (2) and separating plate (3)
from control valve lower body (1).

SCIA7009E

8.

Remove check balls (1), line pressure relief valve springs (2)
and torque converter pressure holding spring (3) from control
valve lower body.
CAUTION:
Be careful not to lose check balls (1), line pressure relief
valve springs (2) and torque converter pressure holding
spring (3).

SCIA6491J

AT-394

REPAIR FOR COMPONENT PARTS
[ALL]
9.

Remove control valve inter body from control valve upper body.
A

B

AT

SCIA4977E

D

10. Remove pilot filter (1) from control valve upper body (2).
11. Remove separating plate from control valve upper body (2).
E

F

G
SCIA7011E

12. Check to see that steel balls are properly positioned in control
valve inter body and then remove them.
CAUTION:
Be careful not to lose steel balls.

H

I

J

SAT870J

13. Check to see that steel balls are properly positioned in control
valve upper body and then remove them.
CAUTION:
Be careful not to lose steel balls.

K

L

M

SAT871J

AT-395

REPAIR FOR COMPONENT PARTS
[ALL]
INSPECTION
Control Valve Lower and Upper Bodies
CAUTION:
Be careful not to lose these parts.
●
Check to see that retainer plates are properly positioned in control valve lower body.

SCIA4978E

●

Check to see that retainer plates are properly positioned in control valve upper body.

SCIA4979E

Oil Strainer
Check wire netting of oil strainer for damage. Replace if necessary.

SCIA3291E

Shift Solenoid Valves “A” and “B”, Line Pressure Solenoid Valve, Torque Converter Clutch
Solenoid Valve and Overrun Clutch Solenoid Valve
Measure resistance.
●
For shift solenoid valve A, refer to AT-163, «Component Inspection» (EURO-OBD) or AT-219, «Component Inspection» (Except
for EURO-OBD).
●
For shift solenoid valve B, refer to AT-168, «Component Inspection» (EURO-OBD) or AT-224, «Component Inspection» (Except
for EURO-OBD).
●
For line pressure solenoid valve, refer to AT-158, «Component
Inspection» (EURO-OBD) or AT-256, «Component Inspection»
(Except for EURO-OBD).
SCIA3485E
●
For torque converter clutch solenoid valve, refer to AT-146,
«Component Inspection» (EURO-OBD) or AT-234, «Component Inspection» (Except for EURO-OBD).
●
For overrun clutch solenoid valve, refer to AT-175, «Component Inspection» (EURO-OBD) or AT-229,
«Component Inspection» (Except for EURO-OBD).

AT-396

REPAIR FOR COMPONENT PARTS
[ALL]
A/T Fluid Temperature Sensor
Measure resistance.
●
For A/T fluid temperature sensor, refer to AT-185, «Component Inspection» (EURO-OBD) or AT-240,
«Component Inspection» (Except for EURO-OBD).

B

Line Pressure Relief Valve Springs and Torque Converter Pressure Holding Spring
●

●

A

Check each spring for damage or deformation. Also measure
free length and outer diameter. Refer to AT-476, «Control
Valves» .
Replace springs if deformed or fatigued.

AT

D

E
SAT138D

ASSEMBLY
1.
a.

F

Install control valve upper, inter and lower body.
Place oil circuit of control valve upper body face up. Install steel
balls in their proper positions.

G

H

I
SAT871J

b.

Install reamer bolts (F) from bottom of control valve upper body
(1). Using reamer bolts (F) as guides, install separating plate (2)
as a set.

J

K

L

SCIA7010E

c.

Install pilot filter (1) on control valve upper body (2).

SCIA7011E

AT-397

M

REPAIR FOR COMPONENT PARTS
[ALL]
d.

Place control valve inter body as shown in figure (side of control
valve lower body face up). Install steel balls in their proper positions.

SAT870J

e.

Install control valve inter body (1) on control valve upper body
(2) using reamer bolts (F) as guides.
CAUTION:
Be careful not to dislocate or drop steel balls.

SCIA7012E

f.

Install check balls (1), line pressure relief valve springs (2) and
torque converter pressure holding spring (3) in their proper positions in control valve lower body (4).

SCIA6491J

g.
h.

Install bolts (E) from bottom of control valve lower body (1).
Using bolts (E) as guides, install separating plate (2) as a set.
Install support plates (3) on control valve lower body (1).

SCIA7013E

i.

Install control valve lower body (1) on control valve inter body (2)
using reamer bolts (F) as guides, and tighten reamer bolts (F)
slightly.

SCIA7014E

AT-398

REPAIR FOR COMPONENT PARTS
[ALL]
2.

Install O-rings on solenoid valves and terminal body.
A

B

AT

SCIA7180E

3.

Install and tighten bolts.
(1): Control valve upper body
(2): Control valve inter body
(3): Control valve lower body
(4): Support plate

D

E

F

G

H

I

J

SCIA7058E

K

Bolt length, number and location:
Bolt symbol
Bolt length “

” [mm (in)]

Number of bolts
Tightening torque
[N·m (kg-m, in-lb)]
*:

a.

A

B

C

D

E

F*

G

13.5
(0.531)

58.0
(2.283)

40.0
(1.575)

66.0
(2.598)

33.0
(1.299)

78.0
(3.071)

18.0
(0.709)

6

3

6

11

2

2

1

L

7.84 (0.80, 69)

3.92
(0.40, 35)

7.84 (0.80, 69)

Reamer bolt and nut.

Install and tighten bolts (B) to the specified torque.
:

7.84 N·m (0.80 kg-m, 69 in-lb)

ATL0032D

AT-399

M

REPAIR FOR COMPONENT PARTS
[ALL]
b.
c.

Install solenoid valve assembly (1) on control valve assembly.
Tighten bolts (A), (C) and (G) to the specified torque.
:

7.84 N·m (0.80 kg-m, 69 in-lb)

SCIA7008E

d.
e.

Remove reamer bolts (F), and then set oil strainer (1) on control
valve assembly
Install and tighten bolts (A), (D), reamer bolts (F) and nuts to the
specified torque.
:

7.84 N·m (0.80 kg-m, 69 in-lb)

SCIA7131E

f.

Tighten bolts (E) to the specified torque.
:

3.92 N·m (0.40 kg-m, 35 in-lb)

ATL0035D

AT-400

REPAIR FOR COMPONENT PARTS
[ALL]

Control Valve Upper Body

BCS000XG

A

COMPONENTS

B

AT

D

E

F

G

H

I

J

K

L

M

SCIA2960J

AT-401

REPAIR FOR COMPONENT PARTS
[ALL]
1.

Retainer plate

2.

Plug

3.

4.

Cooler check valve

5.

Control valve upper body

6.

Cooler check valve spring
Pilot valve

7.

Pilot valve spring

8.

Retainer plate

9.

1-2 accumulator retainer plate

10. 1-2 accumulator piston spring

11.

1-2 accumulator piston

12. Plug

13. Retainer plate

14.

Retainer plate

15. Plug

16. 1st reducing valve

17.

1st reducing valve spring

18. Retainer plate

19. 3-2 timing valve spring

20.

3-2 timing valve

21. Retainer plate

22. Plug

23.

Overrun clutch reducing valve

24. Overrun clutch reducing valve spring

25. Retainer plate

26.

Torque converter relief valve spring 27. Torque converter relief valve

28. Retainer plate

29.

Sleeve

30. Plug

31. Torque converter clutch control valve 32.
spring

Torque converter clutch control
valve

33. Retainer plate

34. Plug

1-2 accumulator valve spring

36. 1-2 accumulator valve

35.

DISASSEMBLY
1.

Remove valves at retainer plates.
CAUTION:
Do not use a magnetic pick-up tool.

SCIA4979E

a.

Use a flat-bladed screwdriver A to remove retainer plates (1).

SCIA7136E

b.

Remove retainer plates (1) while holding spring, plugs (2) or
sleeves using a flat-bladed screwdriver A.
CAUTION:
Remove plugs (2) slowly to prevent internal parts from
jumping out.

SCIA7137E

AT-402

REPAIR FOR COMPONENT PARTS
[ALL]
c.

Place mating surface of valve body face down, and remove
internal parts.
CAUTION:
● If a valve is hard to remove, place valve body face down
and lightly tap it with a soft hammer.
● Be careful not to drop or damage valves and sleeves.

A

B

AT
SAT137D

D

INSPECTION
Valve Springs
●

●

E

Check each valve spring for damage or deformation. Also measure free length and outer diameter. Refer to AT-476, «Control
Valves» .
Replace valve springs if deformed or fatigued.

F

G

H
SAT138D

Control Valves
Check sliding surfaces of valves, sleeves and plugs. Replace if necessary.

I

ASSEMBLY
CAUTION:
●
Apply ATF to all components before installation.
●
Lay control valve body down when installing valves. Do not
stand control valve body upright.

J

K

L

SAT139D

Lubricate control valve body and all valves with ATF. Install control
valves by sliding them carefully into their bores.
CAUTION:
●
Install each control valve one by one.
●
Install control valves after checking, because some of them
are similar.
●
Be careful not to scratch or damage valve body.

SAT140DA

AT-403

M

REPAIR FOR COMPONENT PARTS
[ALL]
●

Wrap a small flat-bladed screwdriver A with vinyl tape and use it
to insert valves into their proper positions.

SCIA7138E

●
–

Install retainer plates (1).
While pushing plug or return spring, install retainer plate (1)
using a flat-bladed screwdriver A.

SCIA7139E

1-2 Accumulator Valve
●

●

Install 1-2 accumulator valve (1), 1-2 accumulator valve spring
and plug. Align 1-2 accumulator retainer plate (2) from opposite
side of control valve body.
Install 1-2 accumulator valve piston spring (3), 1-2 accumulator
piston (4), plug (5) and retainer plate (6).

SCIA7182E

Retainer Plate (Control Valve Upper Body)
Install proper retainer plates. Refer to AT-401, «COMPONENTS» .
Unit: mm (in)
Loca
tion
L14
L15

Retainer plate designation

Width “A”

Pilot valve

Length “B”
21.5 (0.846)

1-2 accumulator valve

40.5 (1.594)

1-2 accumulator piston
L16

1st reducing valve

L17

3-2 timing valve

L18

Overrun clutch reducing valve

24.0 (0.945)

L19

Torque converter relief valve

21.5 (0.846)

L20

Torque converter clutch control valve

28.0 (1.102)

L21

Cooler check valve

24.0 (0.945)

21.5 (0.846)
6.0 (0.236)

AT-404

SAT086F

REPAIR FOR COMPONENT PARTS
[ALL]

Control Valve Lower Body

BCS000XH

A

COMPONENTS

B

AT

D

E

F

G

H

I

J

K

L

M

SCIA2959J

AT-405

REPAIR FOR COMPONENT PARTS
[ALL]
1.

Retainer plate

2.

Pressure modifier piston spring

3.

Pressure modifier piston

4.

Parallel pin

5.

Sleeve

6.

Pressure modifier valve spring

7.

Pressure modifier valve

8.

Control valve lower body

9.

Manual valve

10. Pressure regulator valve

11. Pressure regulator valve spring

12. Spring seat

13. Plug

14. Retainer plate

15. Sleeve

16. Overrun clutch control valve spring

17. Overrun clutch control valve

18. Plug

19. Retainer plate

20. Accumulator control valve spring

21. Accumulator control valve

22. Plug

23. Retainer plate

24. Retainer plate

25. Shift valve A spring

26. Shift valve A

27. Retainer plate

28. Plug

29. Shuttle plug

30. Shuttle valve spring

31. Shuttle valve

32. Shift valve B spring

33. Shift valve B

34. Plug

35. Retainer plate

DISASSEMBLY
Remove valves at retainer plate.
For removal procedures, refer to AT-402, «DISASSEMBLY» .

SCIA4978E

INSPECTION
Valve Springs
●

●

Check each valve spring for damage or deformation. Also measure free length and outer diameter. Refer to AT-476, «Control
Valves» .
Replace valve springs if deformed or fatigued.

SAT138D

Control Valves
Check sliding surfaces of control valves, sleeves and plugs for damage. Replace if necessary.

ASSEMBLY
CAUTION:
●
Apply ATF to all components before installation.
●
Lay control valve body down when installing valves. Do not
stand control valve body upright.

SAT139D

AT-406

REPAIR FOR COMPONENT PARTS
[ALL]
Install control valves.
For installation procedures, refer to AT-403, «ASSEMBLY» .

A

B

AT
SCIA4978E

D

Retainer Plate (Control Valve Lower Body)
Install proper retainer plates. Refer to AT-405, «COMPONENTS» .
Unit: mm (in)
Loca
tion

Retainer plate designation

Width “A”

Length “B”

E

Type

L3

Pressure regulator valve

L4

Overrun clutch control valve

L5

Accumulator control valve

L6

Shift valve A

L7

Shuttle valve

L12

Shift valve B

17.0
(0.669)

24.0
(0.945)

II

L13

Pressure modifier valve

6.0
(0.236)

28.0
(1.102)

I

F
6.0
(0.236)

28.0
(1.102)

I

G

SAT089F

H

I

J

K

L

M

AT-407

REPAIR FOR COMPONENT PARTS
[ALL]

Reverse Clutch

BCS000XI

COMPONENTS

SCIA6939J

1.

Reverse clutch drum

2.

D-ring

3.

Seal ring

4.

Reverse clutch piston

5.

Spring retainer assembly

6.

Snap ring

7.

Dish plate

8.

Driven plate

9.

Retaining plate

10. Snap ring

11. Drive plate

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

DISASSEMBLY
1.
a.
b.
c.
d.

2.
3.

Check operation of reverse clutch
Install seal rings to drum support of oil pump assembly, and set
reverse clutch assembly.
Apply compressed air into the oil hole at the location as shown
in the figure.
Check to see that retaining plate moves to snap ring.
If retaining plate does not contact snap ring:
● D-ring might be damaged.
● Seal ring might be damaged.
● Fluid might be leaking past piston check ball.

SAT155D

Remove snap ring (1) using a flat-bladed screwdriver A.
Remove retaining plate, drive plates, driven plates and dish
plates.

SCIA7024J

AT-408

REPAIR FOR COMPONENT PARTS
[ALL]
4.

5.

Set SST on spring retainer assembly, and remove snap ring
from reverse clutch drum while compressing spring retainer
assembly.
CAUTION:
Set SST directly over return springs.
Remove spring retainer assembly from reverse clutch drum.
CAUTION:
Do not remove return springs from spring retainer.

A

B

AT
SAT157D

D

6.

Install seal rings to drum support of oil pump assembly (1), and
set reverse clutch drum (2). Then apply compressed air into the
oil hole at the location as shown in the figure to remove reverse
clutch piston (3) from reverse clutch drum (2).
CAUTION:
Do not flow air in too quickly or reverse clutch piston (3)
and ATF could jump out. Carefully flow air in little by little
while protecting with lint-free cloth.

E

F

G
SCIA5999J

7.

Remove D-ring (1) and seal ring (2) from reverse clutch piston
(3).

H

I

J

SCIA5998J

K

L

M

AT-409

REPAIR FOR COMPONENT PARTS
[ALL]
INSPECTION
Reverse Clutch Snap Ring
Check for deformation, fatigue or damage. Replace if necessary.

Reverse Clutch Drive Plates
●
●

Check facing for burns, cracks or damage. Replace if necessary.
Measure thickness of facing.
Thickness of drive plate
Standard and allowable limit:
Refer to AT-476, «REVERSE CLUTCH» .
CAUTION:
● Measure the thickness at 3 locations and find the average.
● Inspect ALL drive plates.
● Replace if the thickness is below the allowable limit.

SAT162D

Reverse Clutch Dish Plates
●
●

Check for deformation or damage.
Measure thickness (t) of dish plate. Replace if damaged,
deformed or worn.
Thickness of dish plate (t):

2.87 mm (0.1130 in)

SAT163D

Reverse Clutch Spring Retainer Assembly
Measure length (L) of spring retainer assembly. Replace if damaged,
deformed or worn.
Length (L):

20.1 mm (0.791 in)

CAUTION:
Do not remove return springs (A) from spring retainer (B)

SCIA7025J

Reverse Clutch Piston
●
●

●

Make sure that check balls are not fixed.
Apply compressed air to check ball oil hole opposite from return
spring. Make sure there is no air leakage.
Apply compressed air to oil hole on return spring side to make
sure that air leaks past ball.

SAT164D

Reverse Clutch Drum
Check for deformation or damage. Replace if necessary.

AT-410

REPAIR FOR COMPONENT PARTS
[ALL]
ASSEMBLY
1.

A

Install D-ring (1) and seal ring (2) on reverse clutch piston (3).
CAUTION:
Be careful with the direction of seal ring (2).

B

AT

SCIA5998J

2.

Install reverse clutch piston by turning it slowly.
CAUTION:
Apply ATF to inner surface of reverse clutch drum.

D

E

F

G
SAT159D

3.

H

Install spring retainer assembly (1) to reverse clutch piston (2).

I

J

K
SCIA6000J

4.

Set SST on spring retainer assembly, and install snap ring while
compressing spring retainer assembly.
CAUTION:
Set SST directly over return springs.

L

M

SAT157D

AT-411

REPAIR FOR COMPONENT PARTS
[ALL]
5.

Install dish plates (5), driven plates (4), drive plates (3) and
retaining plate (2).
(1): Snap ring
(2): Retaining plate
(3): Drive plate
(4): Driven plate
(5): Dish plate
Drive plate/Driven plate: 2/2
CAUTION:
Be careful with the order of plates.
SCIA7003J

NOTE:
Install two dish plates fitting each installation direction with
reverse clutch drum groove displaced slightly.

SAT170D

6.

Install snap ring (1) using a flat-bladed screwdriver A.

SCIA7024J

7.

Measure clearance between retaining plate and snap ring using
feeler gauge. If not within allowable limit, select proper retaining
plate. Refer to “Parts Information” for retaining plate selection.
Specified clearance
Standard and allowable limit:
Refer to AT-476, «REVERSE CLUTCH» .

8.

Check operation of reverse clutch. Refer to AT-408, «DISASSEMBLY» .
SAT174D

AT-412

REPAIR FOR COMPONENT PARTS
[ALL]

High Clutch

BCS000XJ

A

COMPONENTS

B

AT

D

E

F

SCIA6741E

1.

Seal ring

2.

Driven plate

3.

G

Retaining plate

4.

Snap ring

5.

Drive plate

6.

Snap ring

7.

Cancel cover

8.

Spring retainer assembly

9.

High clutch Piston

H

10. Input shaft assembly (high clutch
drum)

I

DISASSEMBLY
1.
a.

b.
c.

Check operation of high clutch.
Apply compressed air into the oil hole (A) of input shaft assembly (high clutch drum) at the location as shown in the figure.
CAUTION:
Block the oil hole (A) on the opposite side with lint-free
cloth (B).
Check to see that retaining plate moves to snap ring.
If retaining plate does not contact snap ring:
● High clutch piston seal might be damaged.

J

K

L

SCIA7032E

2.

Remove seal rings from input shaft assembly (high clutch drum).

SCIA4890E

AT-413

M

REPAIR FOR COMPONENT PARTS
[ALL]
3.
4.

Remove snap ring using a flat-bladed screwdriver.
Remove retaining plate, drive plates and driven plates.

SCIA4891E

5.

Set Tool A on cancel cover, and remove snap ring (1) from input
shaft assembly (high clutch drum) while compressing spring
retainer assembly.
Tool number:

KV31103200

CAUTION:
Do not expand snap ring (1) excessively.

SCIA6001J

6.

Remove cancel cover (1) and spring retainer assembly (2) from
input shaft assembly (high clutch drum) (3).
CAUTION:
Do not remove return springs from spring retainers.

SCIA7036E

7.

Apply compressed air into the oil hole (A) at the location as
shown in the figure to remove high clutch piston from input shaft
assembly (high clutch drum).
CAUTION:
● Do not blow air in too quickly, or high clutch piston and
ATF could jump out. Carefully blow air little by little while
protecting with lint-free cloth (B).
● Block the oil hole on the opposite side with lint-free cloth
(B).
SCIA7033E

AT-414

REPAIR FOR COMPONENT PARTS
[ALL]
INSPECTION
High Clutch Snap Ring

A

Check for deformation, fatigue or damage. Replace if necessary.

High Clutch Drive Plates
●
●

B

Check facing for burns, cracks or damage. Replace if necessary.
Measure thickness of facing.
AT

Thickness of drive plate
Standard and allowable limit:
Refer to AT-477, «HIGH CLUTCH» .
CAUTION:
● Measure the thickness at 3 locations and find the average.
● Inspect ALL drive plates.
● Replace if the thickness is below the allowable limit.

D

E
SAT162D

High Clutch Spring Retainer Assembly

F

Check length (L) of springs retainer assembly. Replace if damaged,
deformed or worn.
Length (L):

G

20.6 mm (0.811 in)

CAUTION:
Do not remove return springs (A) from spring retainers (B).

H

I
SCIA7038E

High Clutch Piston and Cancel Cover

J

Check for deformation or damage. Replace if necessary.

Input Shaft Assembly (High Clutch Drum)
K

Check for deformation or damage. Replace if necessary.

Seal Ring Clearance
●

●

Install new seal rings onto input shaft assembly (high clutch
drum).
Measure clearance between seal ring and ring groove.

L

M

Standard clearance and allowable limit:
Refer to AT-478, «Input Shaft» .
●

If not within allowable limit, replace input shaft assembly (high
clutch drum).
SCIA4901E

AT-415

REPAIR FOR COMPONENT PARTS
[ALL]
ASSEMBLY
1.

Install high clutch piston by turning it slowly.
CAUTION:
Apply ATF to inner surface of input shaft assembly (high
clutch drum) and high clutch piston.

SAT111F

2.

Install spring retainer assembly (2) and cancel cover (1) on input
shaft assembly (high clutch drum) (3).

SCIA7036E

3.

Set Tool A on cancel cover, and install snap ring (1) to input
shaft assembly (high clutch drum) while slowly compressing
spring retainer assembly.
Tool number:

KV31103200

CAUTION:
Do not expand snap ring (1) excessively.
● Install spring retainer assembly without tilting.
●

SCIA6001J

●

Do not align snap ring gap with cancel cover stopper.

SAT113F

AT-416

REPAIR FOR COMPONENT PARTS
[ALL]
4.

Install driven plates (4), (5), drive plates (3) and retaining plate
(2).
(1): Snap ring
(2): Retaining plate
(3): Drive plate
(4): Driven plate
(5): Driven plate
Drive plate/Driven plate: 3/6 (1+5)
CAUTION:
Be careful with the order and direction of plates.

A

B

AT
SCIA5996E

D

5.

Install snap ring using a flat-bladed screwdriver.
E

F

G
SCIA4891E

6.

Set dial indicator A on retaining plate (1), and measure clearance between retaining plate (1) and snap ring (2). If not within
allowable limit, select proper retaining plate (1). Refer to “Parts
Information” for retaining plate selection.

H

I

Specified clearance
Standard and allowable limit:
Refer to AT-477, «HIGH CLUTCH» .
7.

J

Check operation of high clutch. Refer to AT-413, «DISASSEMBLY» .
SCIA5858E

8.

K

Install seal rings to input shaft assembly (high clutch drum).
L

M

SCIA4890E

AT-417

REPAIR FOR COMPONENT PARTS
[ALL]
CAUTION:
Roll paper around seal rings to prevent seal rings from spreading.

SAT198D

AT-418

REPAIR FOR COMPONENT PARTS
[ALL]

Forward and Overrun Clutches

BCS000XK

A

COMPONENTS

B

AT

D

E

F

G

H

I
SCIA7183E

1.

Dish plate

2.

Driven plate

3.

Retaining plate

4.

Snap ring

5.

Dish plate

6.

Driven plate

7.

Retaining plate

8.

Snap ring

9.

Forward clutch

10. Drive plate

11. Drive plate

12. Overrun clutch

13. Snap ring

14. Spring retainer assembly

15. Overrun clutch piston

16. D-ring

17. Seal ring

18. Forward clutch piston

19. D-ring

20. Seal ring

21. Forward clutch drum

J

K

L

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

DISASSEMBLY
1.
a.
b.
c.
d.

Check operation of forward clutch.
Install seal rings to bearing retainer, and set forward clutch
drum.
Apply compressed air into oil hole of bearing retainer at the location as shown in the figure.
Check to see that retaining plate moves to snap ring.
If retaining plate does not contact snap ring:
● D-ring might be damaged.
● Seal ring might be damaged.
● Fluid might be leaking past piston check ball.

AT-419

M

SAT201D

REPAIR FOR COMPONENT PARTS
[ALL]
2.
a.
b.
c.
d.

3.
4.

Check operation of overrun clutch.
Install seal rings to bearing retainer, and set forward clutch
drum.
Apply compressed air into oil hole of bearing retainer at the location as shown in the figure.
Check to see that retaining plate moves to snap ring.
If retaining plate does not contact snap ring:
● D-ring might be damaged.
● Seal ring might be damaged.
● Fluid might be leaking past piston check ball.

SAT202D

Remove snap ring for forward clutch from forward clutch drum
using a flat-bladed screwdriver.
Remove retaining plate, drive plates, driven plates and dish
plate for forward clutch.

SCIA4894E

5.
6.

Remove snap ring for overrun clutch from forward clutch drum
using a flat-bladed screwdriver.
Remove retaining plate, drive plates, driven plates and dish
plate for overrun clutch.

SCIA4895E

7.

8.

Set SST on spring retainer assembly, and remove snap ring
from forward clutch drum while compressing spring retainer
assembly.
CAUTION:
● Set SST directly over return springs.
● Do not expand snap ring excessively.
Remove spring retainer assembly from forward clutch drum.
CAUTION:
Do not remove return springs from spring retainer.
SAT205D

9.

Install seal rings to bearing retainer (1), and set forward clutch
drum. Then apply compressed air into the oil hole at the location
as shown in the figure to remove overrun clutch piston from forward clutch piston.
CAUTION:
Do not blow air in too quickly, or overrun clutch piston and
ATF could jump out. Carefully blow air little by little while
protecting with lint-free cloth.

SCIA6004J

AT-420

REPAIR FOR COMPONENT PARTS
[ALL]
10. Install seal rings to bearing retainer (1), and set forward clutch
drum. Then apply compressed air into the oil hole at the location
as shown in the figure to remove forward clutch piston from forward clutch drum.
CAUTION:
Do not blow air in too quickly, or forward clutch piston and
ATF could jump out. Carefully blow air little by little while
protecting with lint-free cloth.

A

B

AT

SCIA6003J

D

11. Remove seal rings (1) and D-rings (2) from forward clutch piston
(3) and overrun clutch piston (4).
E

F

G
SCIA6005J

INSPECTION
Forward Clutch and Overrun Clutch Snap Rings

H

Check for deformation, fatigue or damage. Replace if necessary.

Forward Clutch and Overrun Clutch Drive Plates
●
●

I

Check facing for burns, cracks or damage. Replace if necessary.
Measure thickness of facing.
Thickness of drive plate
Forward clutch
Standard and allowable limit:
Refer to AT-477, «FORWARD CLUTCH» .
Overrun clutch
Standard and allowable limit:
Refer to AT-477, «OVERRUN CLUTCH» .

J

K

L
SAT162D

CAUTION:
● Measure the thickness at 3 locations and find the average.
● Inspect ALL drive plates.
● Replace if the thickness is below the allowable limit.

M

Forward Clutch and Overrun Clutch Dish Plates
●
●

Check for deformation or damage.
Measure thickness (t) of dish plate. Replace if damaged,
deformed or worn.
Thickness of dish plate (t)
Forward clutch:
2.5 mm (0.098 in)
Overrun clutch:
2.15 mm (0.0846 in)

SAT163D

AT-421

REPAIR FOR COMPONENT PARTS
[ALL]
Forward Clutch and Overrun Clutch Spring Retainer Assembly
Check length (L) of spring retainer assembly. Replace if damaged,
deformed or worn.
Length (L):

27.7 mm (0.1091 in)

CAUTION:
Do not remove return springs (A) from spring retainer (B)

SCIA7025J

Forward Clutch Drum
●
●

●

Make sure that check balls are not fixed.
Apply compressed air to check ball oil hole from outside of forward clutch drum. Make sure air leaks past ball.
Apply compressed air to oil hole from inside of forward clutch
drum. Make sure there is no air leakage.

SAT213D

Overrun Clutch Piston
●
●

●

Make sure that check balls are not fixed.
Apply compressed air to check ball oil hole opposite return
spring. Make sure there is no air leakage.
Apply compressed air to oil hole on return spring side. Make
sure that air leaks through ball hole.

SAT212D

ASSEMBLY
1.

Install seal rings (1) and D-rings (2) on forward clutch piston (3)
and overrun clutch piston (4).
CAUTION:
Be careful with the direction of seal rings (1).

SCIA6005J

AT-422

REPAIR FOR COMPONENT PARTS
[ALL]
2.

Install overrun clutch piston on forward clutch piston by turning it
slowly.
CAUTION:
Apply ATF to inner surface of forward clutch piston.

A

B

AT
SAT215D

D

3.

Install forward clutch piston with overrun clutch piston on forward clutch drum by turning it slowly.
CAUTION:
Apply ATF to inner surface of forward clutch drum.

E

F

G
SAT216D

4.

Align notch in forward clutch piston with groove in forward clutch
drum.

H

I

J

SAT217D

5.

K

Install spring retainer assembly (1) on overrun clutch piston (2).
L

M

SCIA6019J

6.

Set SST on spring retainer assembly, and install snap ring while
compressing spring retainer assembly.
CAUTION:
● Set SST directly over return springs.
● Do not expand snap ring excessively.

SAT205D

AT-423

REPAIR FOR COMPONENT PARTS
[ALL]
●

Do not align snap ring gap with spring retainer assembly
stopper.

SAT134F

7.

Install dish plate (5), driven plates (4), drive plates (3) and retaining plate (2) for overrun clutch.
(1): Snap ring
(2): Retaining plate
(3): Drive plate
(4): Driven plate
(5): Dish plate
Drive plate/Driven plate: 3/4
CAUTION:
Be careful with the order of plates.
SCIA5993E

8.

Install snap ring for overrun clutch using a flat-bladed screwdriver.

SCIA4895E

9.

Measure clearance between overrun clutch retaining plate and
snap ring using feeler gauge. If not within allowable limit, select
proper retaining plate. Refer to “Parts Information” for retaining
plate selection.
Specified clearance
Standard and allowable limit:
Refer to AT-477, «OVERRUN CLUTCH» .

SAT227D

10. Install dish plate (5), driven plates (4), drive plates (3) and retaining plate (2) for forward clutch.
(1): Snap ring
(2): Retaining plate
(3): Drive plate
(4): Driven plate
(5): Dish plate
Drive plate/Driven plate: 5/5
CAUTION:
Be careful with the order of plates.
SCIA5992E

AT-424

REPAIR FOR COMPONENT PARTS
[ALL]
11. Install snap ring for forward clutch using a flat-bladed screwdriver.

A

B

AT

SCIA4894E

12. Measure clearance between forward clutch retaining plate and
snap ring using feeler gauge. If not within allowable limit, select
proper retaining plate. Refer to “Parts Information” for retaining
plate selection.

D

E

Specified clearance
Standard and allowable limit:
Refer to AT-477, «FORWARD CLUTCH» .

F

13. Check operation of forward clutch and overrun clutch. Refer to
AT-419, «DISASSEMBLY» .

G
SAT228D

H

I

J

K

L

M

AT-425

REPAIR FOR COMPONENT PARTS
[ALL]

Low & Reverse Brake

BCS000XL

COMPONENTS

SCIA6007J

1.

Seal ring

2.

D-ring

3.

Low & reverse brake piston

4.

Spring retainer assembly

5.

Snap ring

6.

Driven plate

7.

Retaining plate

8.

Driven plate

9.

Retaining plate

10. Snap ring

11. Drive plate

12. Dish plate

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

DISASSEMBLY
1.
a.
b.
c.

Check operation of low & reverse brake.
Apply compressed air into oil hole of transaxle case at the location as shown in the figure.
Check to see that retaining plate moves to snap ring.
If retaining plate does not contact snap ring:
● D-ring might be damaged.
● Seal ring might be damaged.

SAT230D

2.
3.

Remove snap ring (1) using a flat-bladed screwdriver A.
Remove retaining plates, drive plates, driven plates, dish plates.

SCIA7039E

AT-426

REPAIR FOR COMPONENT PARTS
[ALL]
4.

5.

Set SST on spring retainer assembly, and remove snap ring
from transaxle case while compressing spring retainer assembly.
CAUTION:
Set SST directly over return springs.
Remove spring retainer assembly from transaxle case.
CAUTION:
Do not remove return springs from spring retainer.

A

B

AT
SAT242D

D

6.

7.
8.

Apply compressed air into the oil hole on transaxle case as
shown in the figure to raise piston while strongly pressing the
whole low & reverse brake piston by hand. When applying compressed air, strongly press the whole piston and adjust the pressure so that it is raised evenly. Portion (A) (low & reverse brake
pressure) especially tends to tilt.
CAUTION:
Apply air gradually and allow low & reverse brake piston to
come out evenly.
Remove low & reverse brake piston from transaxle case by turning it.
Inspect transaxle case. Replace if damaged or worn.

E

F

G

H

I

J

SCIA6346J

9.

K

Remove seal ring (1) and D-ring (2) from low & reverse brake
piston (3).
L

M

SCIA6516J

AT-427

REPAIR FOR COMPONENT PARTS
[ALL]
INSPECTION
Low & Reverse Brake Snap Rings
Check for deformation, fatigue or damage. Replace if necessary.

Low & Reverse Brake Drive Plates
●
●

Check facing for burns, cracks or damage. Replace if necessary.
Measure thickness of facing.
Thickness of drive plate
Standard and allowable limit:
Refer to AT-477, «LOW & REVERSE BRAKE» .
CAUTION:
● Measure the thickness at 3 locations and find the average.
● Inspect ALL drive plates.
● Replace if the thickness is below the allowable limit.

SAT162D

Low & Reverse Brake Dish Plates
●
●

Check for deformation or damage.
Measure thickness (t) of dish plate. Replace if damaged,
deformed or worn.
Thickness of dish plate (t):

2.93 mm (0.1154 in)

SAT163D

Low & Reverse Brake Spring Retainer Assembly
Check length (L) of spring retainer assembly. Replace if damaged,
deformed or worn.
Length (L):

26.3 mm (1.035 in)

CAUTION:
Do not remove return springs (A) from spring retainer (B)

SCIA7025J

ASSEMBLY
1.

Install seal ring (1) and D-ring (2) on low & reverse brake piston
(3).

SCIA6516J

AT-428

REPAIR FOR COMPONENT PARTS
[ALL]
2.

Install low & reverse brake piston in transaxle case while turning
it.
CAUTION:
Apply ATF to inner surface of transaxle case.

A

B

AT
SAT239D

D

3.

Install spring retainer assembly (1) on low & reverse brake piston (2).
E

F

G
SCIA6020J

4.

Set SST on spring retainer assembly, and install snap ring while
compressing spring retainer assembly.
CAUTION:
Set SST directly over return springs.

H

I

J

SAT242D

5.

Install driven plates (4), dish plates (6), retaining plates (2), (5)
and drive plates (3).
(1): Snap ring
(2): Retaining plate
(3): Drive plate
(4): Driven plate
(5): Retaining plate
(6): Dish plate
Drive plate/Driven plate: 4/4
CAUTION:
Be careful with the order of plates

AT-429

K

L

M

SCIA5994E

REPAIR FOR COMPONENT PARTS
[ALL]
NOTE:
Install two dish plates fitting each installation direction with
groove displaced slightly.

SAT254E

6.

Install snap ring (1) using a flat-bladed screwdriver A.

SCIA7039E

7.

Measure clearance between retaining plate and snap ring. If not
within allowable limit, select proper retaining plate (front side).
Refer to “Parts Information” for retaining plate selection.
Specified clearance
Standard and allowable limit:
Refer to AT-477, «LOW & REVERSE BRAKE» .

8.

Check operation of low & reverse brake. Refer to AT-426, «DISASSEMBLY» .
SAT246D

AT-430

REPAIR FOR COMPONENT PARTS
[ALL]

Rear Internal Gear and Forward Clutch Hub

BCS000XM

A

COMPONENTS

B

AT

D

E

F

SCIA5880J

1.

End bearing

2.

Forward clutch hub

4.

Rear internal gear

5.

Forward one-way clutch

3.

G

Thrust washer

H

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

DISASSEMBLY
1.

Remove forward clutch hub from rear internal gear.

I

J

K

SAT251D

2.

L

Remove end bearing (1) from rear internal gear (2).
M

SCIA7028E

AT-431

REPAIR FOR COMPONENT PARTS
[ALL]
3.

Remove thrust washer from rear internal gear.

SCIA3691E

4.

Remove end bearing (2) from forward one-way clutch (3).
(1): Forward clutch hub

SCIA7026E

5.

Remove forward one-way clutch from forward clutch hub.

SAT255D

AT-432

REPAIR FOR COMPONENT PARTS
[ALL]
INSPECTION
Rear Internal Gear and Forward Clutch Hub

A

Check rubbing surfaces for wear or damage. Replace if necessary.
(1): Rear internal gear
(2): Forward clutch hub

B

AT

D
SCIA5881J

End Bearings and Forward One-way Clutch
●

●

E

Check end bearings (1) for deformation and damage. Replace if
necessary.
Check forward one-way clutch (2) for wear and damage.
Replace if necessary.

F

G

H
SCIA7027E

ASSEMBLY
1.

I

Install forward one-way clutch on forward clutch hub.
CAUTION:
Be careful with the direction of forward one-way clutch.

J

K

L
SAT976H

2.

Install end bearing (2) on forward one-way clutch (3).
(1): Forward clutch hub

M

SCIA7026E

AT-433

REPAIR FOR COMPONENT PARTS
[ALL]
3.

Install thrust washer on rear internal gear.
CAUTION:
Align pawls of thrust washer with holes of rear internal
gear.

SCIA3690E

4.

Install end bearing (1) on rear internal gear (2).

SCIA7028E

5.

Install forward clutch hub on rear internal gear.
CAUTION:
● Check operation of forward one-way clutch.
Hold rear internal gear and turn forward clutch hub.
Check forward clutch hub for correct locking and unlocking directions.
● If not as shown in figure, check the installation direction
of forward one-way clutch.

AAT426

AT-434

REPAIR FOR COMPONENT PARTS
[ALL]

Output Shaft, Output Gear, Idler Gear, Reduction Pinion Gear and Bearing
Retainer

BCS000XN

A

COMPONENTS
B

AT

D

E

F

G

H

I

J

SCIA5883J

1.

Idler gear

2.

Idler gear bearing

4.

Reduction pinion gear bearing

5.

Reduction pinion gear

6.

Output shaft bearing

7.

Seal ring

8.

Bearing retainer

9.

Output shaft

10. Seal ring

11. Output gear adjusting spacer

13. Output gear

14. Lock nut

3.

L

12. Output gear bearing

M

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

DISASSEMBLY
1.

K

Reduction pinion gear adjusting
shim

Remove seal rings from output shaft and bearing retainer.

SAT666D

AT-435

REPAIR FOR COMPONENT PARTS
[ALL]
2.
a.

Remove output shaft bearing according to the following procedures.
Set output shaft bearing inner race (1) on a drift A [commercial
service tool: inner diameter of 31 mm (1.22 in)], and set a suitable drift B on output shaft (2), and press output shaft (2) to
remove output shaft bearing inner race (1).
CAUTION:
Set a drift A on output shaft bearing inner race (1).

SCIA7041E

b.

Set SST on output shaft bearing outer race, and remove output
shaft bearing outer race from bearing retainer.

SAT168K

3.
a.

b.

Remove output gear bearing according to the following procedures.
Insert a flat-bladed screwdriver A between the mating surfaces
of output gear (1) and output gear bearing inner race (2), and
enlarge the gap.
CAUTION:
Be careful not to damage output gear (1).
Set a drift B [commercial service tool: 33 mm (1.30 in) dia.] on
output gear (1), and remove output gear bearing inner race (2)
using a puller C (commercial service tool).
SCIA7042E

c.

Set Tool A on output gear bearing outer race (1), and remove
output gear bearing outer race (1) from bearing retainer (2).
Tool number:

KV381054S0

SCIA7043E

4.
a.

b.

Remove idler gear bearing according to the following procedures.
Insert a flat-bladed screwdriver A between the mating surfaces
of idler gear (1) and idler gear bearing inner race (2), and
enlarge the gap.
CAUTION:
Be careful not to damage idler gear (1).
Set a drift B [commercial service tool: 34 mm (1.34 in) dia.] on
idler gear (1), and remove idler gear bearing inner race (2) using
a puller C (commercial service tool).
SCIA7044E

AT-436

REPAIR FOR COMPONENT PARTS
[ALL]
c.

Set SST on idler gear bearing outer race, and remove idler gear
bearing outer race from transaxle case.

A

B

AT
SAT859DD

D

5.
a.

Remove reduction pinion gear bearing according to the following
procedures.
Set SST on reduction pinion gear bearing inner race, and press
reduction pinion gear to remove reduction pinion gear bearing
inner race.
CAUTION:
Set SST on reduction pinion gear bearing inner race.

E

F

G
NAT048

b.

Remove reduction pinion gear bearing outer race from transaxle
case.

H

I

J

SAT651D

K

L

M

AT-437

REPAIR FOR COMPONENT PARTS
[ALL]
INSPECTION
Output Shaft, Output Gear, Idler Gear and Reduction Pinion Gear
Check for wear, damage or crack. Replace if necessary.

Bearings
Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
●
When replacing taper roller bearing, replace outer and inner race as a set.
Check for damage or deformation. Replace if necessary.
●

Seal Ring Clearance
●
●

Install new seal rings (1) on output shaft (2).
Measure clearance “A” between each seal ring and groove.
Standard clearance and allowable limit:
Refer to AT-478, «Output Shaft» .

●

●
●

Replace output shaft (2) if the measurements exceed the allowable limit.
Install new seal rings (1) on bearing retainer (3).
Measure clearance “A” between each seal ring and groove.
Standard clearance and allowable limit:
Refer to AT-479, «Bearing Retainer» .

●

SCIA7045E

Replace bearing retainer (3) if the measurements exceed the allowable limit.

ASSEMBLY
1.
a.

Install reduction pinion gear bearing according to the following
procedures.
Set SST on reduction pinion gear bearing inner race, and press
reduction pinion gear to reduction pinion gear bearing inner
race.
CAUTION:
Set SST on reduction pinion gear bearing inner race.

NAT049

b.
c.

Install reduction pinion gear bearing outer race to transaxle
case.
Tighten reduction pinion gear bearing outer race fitting bolts to
the specified torque. Refer to AT-435, «COMPONENTS» .

SAT651D

2.

Checking reduction pinion gear bearing preload. Refer to AT-453, «REDUCTION PINION GEAR BEARING PRELOAD» .

AT-438

REPAIR FOR COMPONENT PARTS
[ALL]
3.

a.

Install idler gear bearing according to the following procedures.
CAUTION:
Do not reuse idler gear bearing.
Set Tool A and a suitable drift B on idler gear bearing inner race
(1), and press idler gear bearing inner race (1) to idler gear (2).
Tool number:

A

B

KV35272000

CAUTION:
Set Tool A on idler gear bearing inner race (1).

AT
SCIA7046E

D

b.

Set SST on idler gear bearing outer race, and drive idler gear
bearing outer race into transaxle case.
E

F

G
NAT051

4.
a.

Install output shaft bearing according to the following procedures.
Set a drift A [commercial service tool: inner diameter of 31 mm
(1.22 in)] and a suitable drift B on output shaft bearing inner race
(1), and press output shaft (2) to output shaft bearing inner race
(1).
CAUTION:
Set a drift on output shaft bearing inner race (1).

H

I

J

SCIA7048E

b.

K

Set SST on output shaft bearing outer race, and drive output
shaft bearing outer race to bearing retainer.
L

M

SCIA0270E

5.

Checking output shaft bearing preload. Refer to AT-455, «OUTPUT SHAFT BEARING PRELOAD» .

AT-439

REPAIR FOR COMPONENT PARTS
[ALL]
6.
a.

Install seal rings according to the following procedures.
Install seal rings (1) evenly to the grooves on output shaft (2)
and bearing retainer (3), and fully close the opening.

SCIA7049E

CAUTION:
Roll paper around seal rings to prevent seal rings from
spreading.

SCIA2190E

7.

a.

Install output gear bearing according to the following procedures.
CAUTION:
Do not reuse output gear bearing.
Set Tool A and a suitable drift B on output gear bearing inner
race (1), and press output gear bearing inner race (1) to output
gear (2).
Tool number:

KV35272000

CAUTION:
Set Tool A on output gear bearing inner race (1).
b.

SCIA7047E

Set SST on output gear bearing outer race, and drive output
gear bearing outer race to bearing retainer.

SCIA0268E

AT-440

REPAIR FOR COMPONENT PARTS
[ALL]

Band Servo Piston Assembly

BCS000XO

A

COMPONENTS

B

AT

D

E

F

SCIA5891J

1.

Lock nut

2.

Anchor end pin

3.

4.

Servo piston retainer

5.

D-ring

6.

OD servo piston

7.

O-ring

8.

Snap ring

9.

OD servo piston retainer

G

O-ring

10. E-ring

11. Spring retainer

12. OD servo return spring

13. D-ring

14. Band servo piston

15. Band servo thrust washer

16. Band servo piston stem

17. 2nd servo return spring

H

I

Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

DISASSEMBLY
1.

J

Push in OD servo piston assembly using a puller A (commercial
service tool) and a suitable drift B, and then remove snap ring
(1) from transaxle case using a flat-bladed screwdriver C.

K

L

M
SCIA7050E

2.

3.

Apply compressed air into the oil hole as shown in the figure to
remove OD servo piston assembly and band servo piston
assembly.
CAUTION:
Do not blow air in too quickly, or OD servo piston assembly,
band servo piston assembly and ATF could jump out. Carefully blow air little by little while protecting with lint-free
cloth A.
Remove 2nd servo return spring from transaxle case.
SCIA7051E

AT-441

REPAIR FOR COMPONENT PARTS
[ALL]
4.

Wrap OD servo piston retainer (1) using lint-free cloth A, and
then apply compressed air into the band servo piston stem hole
on OD servo piston (2) to remove OD servo piston (2) from OD
servo piston retainer (1).
CAUTION:
Do not blow air in too quickly, or OD servo piston (2) and
ATF could jump out. Carefully blow air little by little while
protecting with lint-free cloth A.

SCIA7052E

5.

Remove D-ring (1) from OD servo piston (2).

SCIA7053E

6.

Remove O-rings (1), (2) and (3) from OD servo piston retainer
(4).
(1): O-ring (small diameter)
(2): O-ring (medium diameter)
(3): O-ring (large diameter)

SCIA6492J

7.

Press in band servo piston assembly to remove from servo piston retainer.

SAT293D

8.

Place band servo piston stem on a wooden block, and remove
E-ring from band servo piston stem using a flat-bladed screwdriver while pressing spring retainer downward.

SCIA4336E

AT-442

REPAIR FOR COMPONENT PARTS
[ALL]
9.

Remove spring retainer (1), OD servo return spring (2), band
servo piston (3) and band servo thrust washer (4) from band
servo piston stem (5).

A

B

AT

SCIA7054E

D

10. Remove O-rings from servo piston retainer.
E

F

G
SCIA3671E

11. Remove D-rings from band servo piston.

H

I

J

SCIA3688E

INSPECTION
Pistons, Retainers and Piston Stem

K

L

Check the sliding surfaces for damage or excessive wear. Replace if necessary.

Return Springs
●

●

Check each return spring for damage or deformation. Also measure free length. Refer to AT-478, «Band Servo» .
Replace springs if deformed or fatigued.

M

SAT138D

AT-443

REPAIR FOR COMPONENT PARTS
[ALL]
ASSEMBLY
1.

Install D-rings to band servo piston.

SCIA3688E

2.

Install band servo thrust washer (4), band servo piston (3), OD
servo return spring (2) and spring retainer (1) to band servo piston stem (5).

SCIA7054E

3.

Place band servo piston stem (1) on a wooden block, and install
E-ring (2) to band servo piston stem (1) while pressing spring
retainer (3) downward.

SCIA7056E

4.

Install O-rings to servo piston retainer

SCIA3671E

AT-444

REPAIR FOR COMPONENT PARTS
[ALL]
5.

Install band servo piston assembly to servo piston retainer by
pushing it inward.

A

B

AT
SAT303D

D

6.

Install D-ring (1) to OD servo piston (2).
E

F

G
SCIA7053E

7.

Install O-rings (1), (2) and (3) to OD servo piston retainer (4).
(1): O-ring (small diameter)
(2): O-ring (medium diameter)
(3): O-ring (large diameter)

H

I

J

SCIA6492J

8.

K

Install OD servo piston (1) to OD servo piston retainer (2) fitting
the figure direction on it.
L

M

SCIA7057E

9.

Install 2nd servo return spring (2) and band servo piston assembly (3) to transaxle case (1).

SCIA6310J

AT-445

REPAIR FOR COMPONENT PARTS
[ALL]
10. Install OD servo piston assembly (2) to transaxle case (1).

SCIA6010J

11. Push in OD servo piston assembly using a puller A (commercial
service tool) and a suitable drift B, and install snap ring (1) to
transaxle case using a flat-bladed screwdriver C.

SCIA7050E

AT-446

REPAIR FOR COMPONENT PARTS
[ALL]

Final Drive

BCS000XP

A

COMPONENTS

B

AT

D

E

F

SCIA7184E

1.

Pinion mate gear thrust washer

2.

Pinion mate gear

3.

Pinion mate shaft

4.

Side gear

5.

Side gear thrust washer

6.

Lock pin

7.

Differential side bearing

8.

Differential case

9.

Final gear

G

H

10. Differential side bearing adjusting
shim
Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, «Components» .

I

DISASSEMBLY
1.

Remove final gear from differential case.

J

K

L

SCIA0286J

2.
a.

Remove differential side bearings according to the following procedures.
Set a drift A [commercial service tool: 38 mm (1.50 in) dia.] on
differential case (1), and remove differential side bearing (RH
side) (2) from differential case (1) using a puller B (commercial
service tool) and another puller C (commercial service tool).

SCIA7059E

AT-447

M

REPAIR FOR COMPONENT PARTS
[ALL]
b.

Set a drift A [commercial service tool: 38 mm (1.50 in) dia.] on
differential case (1), and remove differential side bearing (LH
side) (2) from differential case (1) using a puller B (commercial
service tool).

SCIA7060E

3.
a.

Remove pinion mate gear and side gear according to the following procedures.
Drive out lock pin from differential case (1) using Tool A.
Tool number:

KV32101000

SCIA7034E

b.
c.
d.

Remove pinion mate shaft from differential case.
Rotate pinion mate gears and pinion mate gear thrust washers
to remove.
Remove side gears and side gear thrust washers from differential case.

SAT316D

INSPECTION
Gears, Washers, Pinion Mate Shaft and Differential Case
Check the sliding surfaces for wear, seizure, crack or damage.
Replace if necessary.

MTK0135D

AT-448

REPAIR FOR COMPONENT PARTS
[ALL]
Bearings
A

Make sure bearings roll freely and are free from noise, cracks, pitting
or wear. Replace if necessary.

B

AT

SPD715

D

ASSEMBLY
1.
a.

b.

2.
a.

b.

Install pinion mate gears and side gears according to the following procedures.
Attach side gear thrust washers to side gears, then install pinion
mate gear thrust washers and pinion mate gears in place.
CAUTION:
Apply plenty of ATF to each sliding / rotating surface before
assembly.
Set 2 pinion mate gears and thrust washers on the same axis,
and while rotating them simultaneously, align them with the
insert hole of pinion mate shaft on differential case to insert pinion mate shaft.
CAUTION:
After aligning 2 pinion mate gears with side gear teeth and
centering with pinion mate shaft, take pinion mate shaft out
and move pinion mate gears in place while rotating the them simultaneously.

E

F

G

H
SAT318D

I

Select side gear thrust washers according to the following procedures.
Place differential case in the upright position so that the side
gear to be measured is at the top.
(A): Location for inserting feeler gauge
(B): Side gear tooth
(C): The center line of differential case
In order to maximize the back clearance, rotate side gears so
that a tooth on side gears at the top and bottom will align at the
same position as shown in the figure.

J

K

L

SCIA7064E

AT-449

M

REPAIR FOR COMPONENT PARTS
[ALL]
c.
i.

ii.

Adjust the back clearance of side gear according to the following
procedures.
Insert feeler gauges A of the same thickness to the back of side
gear from both sides, preventing side gear from falling, to measure the clearance.
● Measure clearance 3 times by rotating side gears and take
the average.
CAUTION:
In all 3 measurements, maximize the clearance by aligning
teeth on side gears at the top and bottom at the same position.
Select side gear thrust washer so that the clearance will fall
within the standard.
Differential side gear clearance:
Refer to AT-478, «Final Drive» .

iii. Turn differential case upside down, and measure the back clearance of the other side gear in the same manner.
NOTE:
Adjust the clearance to approx. 0.1 mm (0.004 in) for used differential [driven approx. 3,000 km (1864 mile) or more].
●
Refer to “Parts Information” for side gear thrust washers selection.
3.

SCIA7061E

Install lock pin (1) to pinion mate shaft using the pin punch A.
Tool number:

KV32101000

CAUTION:
Make sure that lock pin (1) flush with differential case.

SCIA7228E

4.

Set Tool A on differential side bearing (RH side) (1), and press
differential side bearing (RH side) (1) to differential case (2).
Tool number:

ST33200000

CAUTION:
Set Tool A on differential side bearing inner race.

SCIA7062E

AT-450

REPAIR FOR COMPONENT PARTS
[ALL]
5.

Set Tool A on differential side bearing (LH side) (1), and press
differential side bearing (LH side) (1) to differential case (2).
Tool number:

A

ST33200000

CAUTION:
Set Tool A on differential side bearing inner race.

B

AT
SCIA7063E

D

6.

Install final gear on differential case, and tighten fitting bolts to
the specified torque in the numerical order as shown in the figure. Refer to AT-447, «COMPONENTS» .

E

F

G
SCIA0294J

H

I

J

K

L

M

AT-451

ASSEMBLY
[ALL]

ASSEMBLY
Assembly (1)
1.

PFP:00000
BCS000XQ

Drive each differential side oil seal evenly using a drift (SST and
commercial service tool) so that differential side oil seal protrudes by the dimension “C” or “D” respectively.
(1): LH differential side oil seal
(2): RH differential side oil seal
(A): Transaxle case side
(B): Converter housing side
Unit: mm (in)
Dimension “C”

0 ± 0.5 (0 ± 0.020)

Dimension “D”

1.1 ± 0.5 (0.043 ± 0.020)
SCIA7226E

NOTE:
Differential side oil seal pulling direction is used as the reference.
Drift to be used:

2.

3.
4.
5.

6.

Location

Tool number

Transaxle case side (A)

ST35325000
KV31103000

Converter housing side (B)

Commercial service tool [Inner diameter: 47 mm (1.85 in), outer
diameter: 54 mm (2.13 in)]

Install O-ring on governor cap.
CAUTION:
● Do not reuse O-ring.
● Apply ATF to O-ring.
Install governor cap in transaxle case.
Install snap ring in transaxle case.
Install parking actuator support (1) on transaxle case.
(A): Inside
(B): Outside
CAUTION:
Be careful with the direction of parking actuator support (1).
Tighten parking actuator support fitting bolts to the specified
torque. Refer to AT-360, «Components» .

SCIA5910J

7.

Install parking pawl (2) on transaxle case, and fix it with parking
shaft (1).

SCIA6997E

AT-452

ASSEMBLY
[ALL]
8.

Install return spring (2) on parking shaft (3) and parking pawl (1)
using a flat-bladed screwdriver.

A

B

AT
SCIA6996E

D

Adjustment (1)

BCS000XR

REDUCTION PINION GEAR BEARING PRELOAD
1.
a.
b.

Select proper thickness of reduction pinion gear adjusting shim using the following procedures.
Place reduction pinion gear on transaxle case as shown in the
figure.
Install idler gear bearing outer race on transaxle case. Refer to
AT-435, «COMPONENTS» .

E

F

G

H
SCIA3623E

c.
d.

Place idler gear bearing inner race on outer race.
Measure dimensions “B”, “C” and “D”, and calculate dimension
“A”.

I

“A”:

Distance between the surface of idler gear
bearing inner race and the adjusting shim mating surface of reduction pinion gear.
A = D − (B + C)

J

K

SCIA3624E

●

●

Measure dimension “B” between the end of reduction pinion
gear and the surface of transaxle case.
Measure dimension “B” in at least two places, and take
the average.

M

SCIA3625E

AT-453

L

ASSEMBLY
[ALL]
●

●

Measure dimension “C” between the surface of idler gear
bearing inner race and the surface of transaxle case.
Measure dimension “C” in at least two places, and take
the average.

SCIA3626E

●
●

●

●

Remove reduction pinion gear from transaxle case.
Measure dimension “D” between the end of reduction pinion
gear and the adjusting shim mating surface of reduction pinion gear.
Measure dimension “D” in at least two places, and take
the average.
Calculate dimension “A”.
A = D − (B + C)
SAT336DA

e.

f.

Measure dimension “E” between the end of idler gear and idler
gear bearing inner race mating surface of idler gear.
● Measure dimension “E” in at least two places, and take
the average.
Select proper thickness of reduction pinion gear adjusting shim.
Refer to “Parts Information” for reduction pinion gear adjusting
shim selection.
Proper shim thickness = A − E − 0.05 mm (0.0020 in)*
(*: Bearing preload)
SAT337D

2.

3.
4.

Install reduction pinion gear (1) and reduction pinion gear adjusting shim (2) selected in step 2-e on transaxle case.
CAUTION:
Apply ATF to reduction pinion gear bearing.
Press idler gear bearing inner race on idler gear (3). Refer to AT435, «COMPONENTS» .
Set Tool A on idler gear (3), and press idler gear (3) on reduction
pinion gear (1).
CAUTION:
● Apply ATF to idler gear bearing.
● Press idler gear (3) until idler gear (3) fully contacts
reduction pinion gear bearing adjusting shim (2).
Tool number:

5.
6.

ST35271000

Set manual shaft in “P” position to fix idler gear (3).
Tighten lock nut of idler gear to the specified torque. Refer to AT-360, «Components» .
CAUTION:
Lock idler gear with parking pawl when tightening lock nut.

AT-454

SCIA7110E

ASSEMBLY
[ALL]
7.

Measure turning torque of reduction pinion gear.
A

Turning torque of reduction pinion gear:
Refer to AT-478, «Reduction Pinion Gear» .
●

●

When measuring turning torque, turn reduction pinion
gear in both directions several times to seat bearing rollers correctly.
If turning torque is out of specification, decrease or
increase thickness of reduction pinion gear adjusting
shim.

B

AT
SAT190FB

D

OUTPUT SHAFT BEARING PRELOAD
1.
a.
b.
c.

Select proper thickness of output gear adjusting spacer using the following procedures.
Remove paper rolled around output shaft.
Install output gear bearing outer race on bearing retainer. Refer
to AT-435, «COMPONENTS» .
Place bearing retainer on output shaft.

E

F

G

SAT682D

d.
e.

Place output gear bearing inner race on bearing retainer.
Measure dimensions “G” and “H”, and calculate dimension “F”.

H

I

“F”:

Distance between the surface of output gear
bearing inner race and adjusting spacer mating surface of output shaft.
F=H−G

J

K
SAT683D

●

●

L

Measure dimension “G” between end of output shaft and surface of output gear bearing inner race.
Measure dimension “G” in at least two places, and take
the average.

M

SAT684D

AT-455

ASSEMBLY
[ALL]
●

●

●

Measure dimension “H” between end of output shaft and
adjusting spacer mating surface of output shaft.
Measure dimension “H” in at least two places, and take
the average.
Calculate dimension “F”.
F=H−G

SAT685D

f.

g.

Measure dimension “I” between end of output gear (adjusting
spacer mating surface) and output gear bearing inner race fitting
surface.
● Measure dimension “I” in at least two places, and take
the average.
Select proper thickness of output gear adjusting spacer. Refer to
“Parts Information” for output gear adjusting spacer selection.
Proper spacer thickness
= F − I − [0.03 − 0.08 mm (0.0012 − 0.0031 in)]*
(*: Bearing preload)

2.
3.

SAT686D

Install bearing retainer (1) in transaxle case.
Tighten bearing retainer fitting bolts to the specified torque.
Refer to AT-360, «Components» .

SCIA5909J

4.

5.
6.

Install output shaft (1) and output gear adjusting spacer (2)
selected in step 1-f on transaxle case.
CAUTION:
● Apply ATF to output shaft bearing.
● Do not force output shaft to install or seal ring may be
damaged.
Press output gear bearing inner race on output gear (3). Refer to
AT-435, «COMPONENTS» .
Set Tool A on output gear (3), and press output gear (3) on output shaft (1).
CAUTION:
● Apply ATF to output gear bearing.
● Do not pinch seal ring when output shaft is pressed in.
● Press output gear (3) until output gear (3) fully contacts output gear adjusting space (2).
Tool number:

7.
8.

ST35271000

Set manual shaft in “P” position to fix idler gear.
Tighten lock nut of output gear to the specified torque. Refer to AT-360, «Components» .
CAUTION:
● Do not reuse lock nut.
● Lock idler gear with parking pawl when tightening lock nut.

AT-456

SCIA7080E

ASSEMBLY
[ALL]
9.

Remove idler gear (1) using Tool A to measure output shaft
bearing preload.
Tool number:

A

ST27180001
B

AT
SCIA5921J

D

10. Measure turning torque of output shaft.
Turning torque of output shaft:
Refer to AT-478, «Output Shaft» .

E

When measuring turning torque, turn output shaft in both
directions several times to seat bearing rollers correctly.
● If turning torque is out of specification, decrease or
increase thickness of output gear adjusting spacer.
11. Press idler gear on reduction pinion gear. Refer to AT-453,
«REDUCTION PINION GEAR BEARING PRELOAD» .
●

F

G
SAT190FB

12. Tighten lock nut (1) of idler gear to the specified torque. Refer to
AT-360, «Components» .
13. After properly adjusting turning torque, clinch lock nuts (1) of
idler gear and output gear as shown in the figure.

H

I

L1 : 3 mm (0.12 in) or more
L2 : 1 mm (0.04 in) or more

J

SCIA5922J

14. Install side cover gasket and side cover on transaxle case.
CAUTION:
● Do not reuse side cover gasket.
● Completely remove all moisture, oil and old gasket, etc.
from the transaxle case and side cover mating surfaces.
15. Tighten side cover fitting bolts (1) to the specified torque. Refer
to AT-360, «Components» .

L

M

SCIA6039J

Assembly (2)
1.
2.

BCS000XS

Remove paper rolled around bearing retainer.
Install thrust washer on bearing retainer.
CAUTION:
Align pawls of thrust washer with holes of bearing retainer.

SAT354D

AT-457

K

ASSEMBLY
[ALL]
3.

Install forward clutch assembly and overrun clutch assembly (1)
into transaxle case.
CAUTION:
● Align teeth of low & reverse brake drive plates before
installing.
● Make sure that bearing retainer seal rings are not spread.

SCIA5900J

4.

Install needle bearing (1) on bearing retainer.
CAUTION:
Be careful with the direction of needle bearing.

SCIA5926J

5.

Install thrust washer (1) on overrun clutch hub (2).
CAUTION:
Align pawls of thrust washer (1) with holes of overrun
clutch hub (2).

SCIA5899J

6.

Install overrun clutch hub (1) into forward clutch drum.
CAUTION:
Align teeth of overrun clutch drive plates before installing.

SCIA5898J

7.

Hold forward clutch hub, and check that rear internal gear locks
when tried to rotate counterclockwise.
CAUTION:
If rear internal gear rotates counterclockwise, check installation direction of forward one-way clutch.

SCIA7078E

AT-458

ASSEMBLY
[ALL]
8.

Install needle bearing (1) on rear internal gear (2).
CAUTION:
Be careful with the direction of needle bearing (1).

A

B

AT

SCIA6041J

9.

Install rear internal gear (1) and forward clutch hub (2) as a set
into forward clutch drum.
CAUTION:
Align teeth of forward clutch drive plates before installing.

D

E

F

G
SCIA5897J

10. Install needle bearing (1) on rear planetary carrier (2).
CAUTION:
Be careful with the direction of needle bearing (1).

H

I

J

SCIA5927J

11. Install rear sun gear on rear planetary carrier.
CAUTION:
Be careful with the direction of rear sun gear.

K

L

M

SAT052D

12. Install rear planetary carrier in transaxle case.

SAT051D

AT-459

ASSEMBLY
[ALL]
13. Install needle bearing (1) on front planetary carrier (2).
CAUTION:
Be careful with the direction of needle bearing (1).

SCIA6047J

14. Install low one-way clutch to front planetary carrier by turning it
in the direction of unlock.
15. Check that low one-way clutch rotates counterclockwise around
front planetary carrier. Then try to turn it clockwise and check
that it is locked.

SAT048D

16. Install front planetary carrier (2) and low one-way clutch (1) as a
set into transaxle case.

SCIA5896J

17. Install snap ring into transaxle case using a flat-bladed screwdriver.

SCIA3633E

18. Install needle bearing (1) on front sun gear (2).
CAUTION:
Be careful with the direction of needle bearing (1).

SCIA6960E

AT-460

ASSEMBLY
[ALL]
19. Install front sun gear on front planetary carrier.
A

B

AT

SAT368D

20. Install needle bearing on front sun gear.
CAUTION:
Be careful with the direction of needle bearing.

D

E

F

G
SAT369D

21. Install high clutch hub on front sun gear.

H

I

J

SAT370D

22. Install needle bearing on high clutch hub.
CAUTION:
Be careful with the direction of needle bearing.
23. Remove paper rolled around input shaft assembly (high clutch
drum).

L

M

SAT371D

24. Install input shaft assembly (high clutch assembly) (1).
CAUTION:
Align teeth of high clutch drive plates before installing.

SCIA7079E

AT-461

K

ASSEMBLY
[ALL]
25. Install reverse clutch assembly.
CAUTION:
Align teeth of reverse clutch drive plates before installing.

SAT373D

Adjustment (2)

BCS000XT

When any parts listed below are replaced, adjust total end play and reverse clutch end play.
Part name

Total end play

Reverse clutch end play

Transaxle case

●

●

Overrun clutch hub

●

●

Rear internal gear

●

●

Rear planetary carrier

●

●

Rear sun gear

●

●

Front planetary carrier

●

●

Front sun gear

●

●

High clutch hub

●

●

Input shaft assembly (high clutch drum)

●

●

Oil pump cover

●

●

Reverse clutch drum

—

●

TOTAL END PLAY
●

●

Measure clearance between reverse clutch drum and needle
bearing for oil pump cover.
Select proper thickness of bearing race so that end play is within
specifications.

SCIA3661E

1.

Measure dimensions “K” and “L”, and then calculate dimension
“J”.

SCIA3662E

AT-462

ASSEMBLY
[ALL]
a.

Measure dimension “K”.
A

B

AT
SCIA3663E

D

b.
c.

Measure dimension “L”.
Calculate dimension “J”.
E

“J”:

Distance between oil pump fitting surface of
transaxle case and needle bearing mating surface of input shaft assembly (high clutch
drum).
J=K–L

F

G
SCIA3664E

2.
a.

Measure dimension “M”.
Place bearing race and needle bearing on oil pump assembly.

H

I

J

SAT378D

b.

Measure dimension “M”.
“M”:

“M1 ”:

Distance between transaxle case fitting surface of oil pump cover and needle bearing on
oil pump cover.
Indication of gauge

L

M

SAT379D

c.

Measure thickness of straightedge “t”.
M = M1 – t

3.

K

Adjust total end play “T1 ”.
T1 = J – M
Total end play “T1 ”:
Refer to AT-479, «Total End Play» .
●

Select proper thickness of bearing race so that total end play
is within specifications. Refer to “Parts Information” for bearing race selection.

AT-463

SAT443D

ASSEMBLY
[ALL]
REVERSE CLUTCH END PLAY
●

●

Measure clearance between oil pump cover and thrust washer
for reverse clutch drum.
Select proper thickness of thrust washer so that end play is
within specification.

SCIA3665E

1.

Measure dimensions “O” and “P”, and then calculate dimension
“N”.

SCIA3666E

a.
b.

Place thrust washer on reverse clutch drum.
Measure dimension “O”.

SCIA3667E

c.
d.

Measure dimension “P”.
Calculate dimension “N”.
“N”:

Distance between oil pump fitting surface of
transaxle case and thrust washer on reverse
clutch drum.
N=O–P

SCIA3668E

AT-464

ASSEMBLY
[ALL]
2.

Measure dimensions “R” and “S”, and then calculate dimension
“Q”.

A

B

AT
SAT384D

D

a.

Measure dimension “R”.
E

F

G
SAT385D

b.
c.

Measure dimension “S”.
Calculate dimension “Q”.

H

“Q”:

Distance between transaxle case fitting surface and thrust washer mating surface.
Q=R–S

I

J

SAT386D

3.

Adjust reverse clutch end play “T2 ”.
T2 = N – Q
Reverse clutch end play:
Refer to AT-479, «Reverse Clutch End Play» .
●

3.

L

Select proper thickness of thrust washer so that reverse clutch end play is within specifications. Refer
to “Parts Information” for thrust washer selection.

Assembly (3)
1.
2.

K

BCS000XU

Remove reverse clutch assembly.
Install needle bearing on input shaft assembly (high clutch
drum).
CAUTION:
Be careful with the direction of needle bearing.
Install reverse clutch assembly.
CAUTION:
Align teeth of reverse clutch drive plates before installing.
SAT387D

AT-465

M

ASSEMBLY
[ALL]
4.

Install anchor end pin (2) and lock nut (1) on transaxle case.

SCIA6037J

5.
6.

Place brake band on outside of reverse clutch drum.
Tighten anchor end pin just enough so that brake band is evenly
fitted on reverse clutch drum.

SAT038D

7.
8.
9.

Install bearing race selected in total end play adjustment step on
oil pump cover.
Install thrust washer selected in reverse clutch end play adjustment step on oil pump cover.
Install O-ring to oil pump assembly.
CAUTION:
● Do not reuse O-ring.
● Apply ATF to O-ring.
SCIA3629E

10. Install oil pump assembly (1) on transaxle case.
11. Tighten oil pump fitting bolts to the specified torque. Refer to AT360, «Components» .

SCIA6036J

12. Install O-ring to input shaft assembly (high clutch drum).

SCIA4928E

AT-466

ASSEMBLY
[ALL]
13. Adjust brake band.
a. Tighten anchor end pin to the specified torque.
:

A

4.9 N·m (0.50 kg-m, 43 in-lb)
B

AT

SAT394D

b.

D

Back off anchor end pin two and a half turns.
E

F

G
SAT395D

c.

Tighten lock nut while holding anchor end pin. Refer to AT-360,
«Components» .

H

I

J

SAT396D

K

14. Apply compressed air into oil holes of transaxle case and check
operation of brake band.
L

M

SAT397D

15. Select proper thickness of differential side bearing adjusting shim using the following procedures.
● Measure differential side bearing end play, and calculate the adjusting shim thickness so that the end
play is within the specifications.
Differential side bearing end play:
Refer to AT-478, «Final Drive» .

AT-467

ASSEMBLY
[ALL]
a.

Place a straightedge A onto transaxle case (1), and measure the
depth “T” of transaxle case (1) to the mating surface for differential side bearing using depth gauge B.
T = (Measurement) — (Straightedge thickness)
●

Measure the depth “T” in at least two places, and take the
average.

SCIA7114E

b.
c.

Install final drive assembly onto converter housing (1).
Place a straightedge A onto differential case (2), and measure
the height “U” to the end of converter housing (1) using depth
gauge B.
● Measure the height “U” in at least two places, and take
the average.

SCIA7115E

d.

e.

Place a straightedge A onto differential case (1), and measure
the height “V” to the end of differential side bearing outer race
using depth gauge B.
● Measure the height “V” in at least two places, and take
the average.
Select proper thickness of differential side bearing adjusting
shim. Refer to “Parts Information” for differential side bearing
adjusting shim selection.
Proper shim thickness
= T — U + V + [0 — 0.15 mm (0 — 0.0059 in)]*
(* : differential side bearing end play)

SCIA7116E

16. Install differential side bearing adjusting shim selected in differential side bearing end play adjustment step on transaxle case.

SCIA4938E

AT-468

ASSEMBLY
[ALL]
17. Install final drive assembly (1) on transaxle case.
A

B

AT
SCIA6034J

D

18. Install differential lubricant tube and clips on converter housing.
19. Tighten differential lubricant tube fitting bolts to the specified
torque. Refer to AT-360, «Components» .

E

F

G
SCIA3284E

20. Install O-ring (1) on differential oil port of transaxle case as
shown in the figure.

H

I

J

SCIA5918J

21. Apply locking sealant (loctite #518) to transaxle case as shown
in the figure.
: Inside of transaxle case
“A”
“B”
“C”
“D”

K

L

: 3 — 5 mm (0.12 — 0.20 in)
: 8 mm (0.31 in) R
: 1.5 mm (0.059 in) dia.
: 4 mm (0.16 in)

M

CAUTION:
Completely remove all moisture, oil and old sealant, etc.
from the transaxle case and converter housing mating surfaces.

AT-469

SCIA7089E

ASSEMBLY
[ALL]
22. Install converter housing on transaxle case.
23. Install bracket on converter housing.
24. Tighten converter housing fitting bolts (1), (2) and (3) to the
specified torque. Refer to AT-360, «Components» .
Bolt

1

Bolt length
[mm (in)]

30 (1.18)

Number of bolts
*:

2

10

3*
40 (1.57)

9

1

Tighten with bracket.

SCIA6956E

25. Install O-ring to plug.
CAUTION:
● Do not reuse O-ring.
● Apply ATF to O-ring.
26. Install plug to converter housing.
27. Tighten plug fitting bolt to the specified torque. Refer to AT-360, «Components» .
28. Install accumulator pistons.
a. Install O-rings (1) on servo release accumulator piston (2) and
N-D accumulator piston (3). Refer to AT-476, «Accumulator» .

SCIA6033J

b.

Install return springs (1), servo release accumulator piston (2)
and N-D accumulator piston (3) into transaxle case (4). Refer to
AT-476, «Accumulator» .

SCIA6042J

29. Install lip seals (1) for band servo oil holes on transaxle case.

SCIA5895J

AT-470

ASSEMBLY
[ALL]
30. Install control valve assembly on transaxle case.
a. Install O-ring on terminal body.
CAUTION:
● Do not reuse O-ring.
● Apply ATF to O-ring.
b. Insert manual valve into control valve assembly.
CAUTION:
Be careful not to drop manual valve.

A

B

AT
SCIA3999E

D

c.
d.

Set manual shaft in “N” position.
Install control valve assembly on transaxle case while aligning
manual valve (2) with manual plate (1).

E

F

G
SCIA7090E

e.
f.

Install terminal body (2) into transaxle case by pushing it.
Install snap ring (1) to terminal body (2).

H

I

J

SCIA6030J

g.

K

Tighten bolts A , B and C to the specified torque. Refer to AT-360, «Components» .
Bolt length, number and location:

Bolt symbol
Bolt length “

” [mm (in)]

L

A

B

C

40.0 mm
(1.575 in)

33.0 mm
(1.299 in)

43.5 mm
(1.713 in)

5

6

2

Number of bolts

M

SCIA5911J

31. Install oil pan.
a. Attach magnets on oil pan.

AT-471

ASSEMBLY
[ALL]
b.

c.

d.

e.

f.
32.
a.
b.
c.
d.
i.
ii.
e.
f.
33.
34.

35.

Install oil pan gasket on transaxle case.
CAUTION:
● Completely remove all moisture, oil and old gasket, etc.
from the oil pan gasket mounting surface of transaxle
case.
● Do not reuse oil pan gasket.
Install oil pan on transaxle case.
CAUTION:
Completely remove all moisture, oil and old gasket, etc.
from the oil pan gasket mounting surface of oil pan.
Tighten oil pan fitting bolts (1) to the specified torque. Refer to
AT-360, «Components» .
CAUTION:
● Always replace oil pan fitting bolts (1) as they are self-sealing bolts.
● Tighten four bolts in a criss-cross pattern to prevent dislocation of gasket.
Install drain plug gasket and drain plug (2) to oil pan.
CAUTION:
Do not reuse drain plug gasket.
Tighten drain plug to the specified torque. Refer to AT-360, «Components» .
Install PNP switch (2) on transaxle case.
: Bolt (3)
Set manual shaft (1) in “P” position.
Temporarily install PNP switch (2) on manual shaft (1).
Set manual shaft (1) in “N” position.
Use a 4 mm (0.16 in) dia. pin for this adjustment.
Insert the pin straight into the manual shaft (1) adjustment hole.
Rotate PNP switch (2) until the pin can also be inserted straight
into hole in PNP switch (2).
Tighten PNP switch fitting bolts to the specified torque. Refer to
AT-360, «Components» .
Remove pin from adjustment hole after adjusting PNP switch (2).
Install O-ring (3) to turbine revolution sensor (power train revolution sensor) (1).
Install turbine revolution sensor (power train revolution sensor)
(1) to transaxle case (2).
: Bolt (1)
Tighten turbine revolution sensor (power train revolution sensor)
fitting bolt to the specified torque. Refer to AT-360, «Components» .

SCIA6050J

SCIA5904J

SCIA7004J

36. Install revolution sensor (1) to transaxle case (2).
37. Tighten revolution sensor fitting bolts to the specified torque.
Refer to AT-360, «Components» .
: Bolt (2)

SCIA7170J

AT-472

ASSEMBLY
[ALL]
CAUTION:
Ensure revolution sensor harness is firmly secured with
bolt.
(1): Revolution sensor
: Bolt (1)

A

B

AT

SCIA6518J

38. Install torque converter.
a. Pour ATF into torque converter.
● Approximately 1 liter (7/8 Imp pt) of fluid is required for a
new torque converter.
● When reusing old torque converter, add the same amount
of ATF as was drained.

D

E

F

G
SAT428DA

b.

H

Install torque converter while aligning notches of torque converter with notches of oil pump.

I

J

K
SAT429D

c.

Measure distance “A” to make sure that torque converter is in
proper position.
Distance “A”:

L

16.2 mm (0.638 in) or more
M

SAT430D

AT-473

SERVICE DATA AND SPECIFICATIONS (SDS)
[ALL]

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications

PFP:00030
BCS000YM

Engine

HR16DE

Automatic transaxle model

RE4F03B

Automatic transaxle assembly

Transaxle gear ratio

Model code number

3CX02

1st

2.861

2nd

1.562

3rd

1.000

4th

0.697

Reverse

2.310

Final drive

4.072

Recommended fluid
Fluid capacity [

Nissan Genuine ATF Matic D or equivalent*
7.7 (6-3/4)

(Imp qt)]

*: Refer to MA-24, «RECOMMENDED FLUIDS AND LUBRICANTS» .

Vehicle Speed at Which Gear Shifting Occurs
Throttle position

●

BCS000YN

Vehicle speed [km/h (MPH)]
D1 → D2

D2 → D3

D3 → D4

D4 → D3

D3 → D2

D2 → D1

Full throttle

51 — 59
(32 — 37)

97 — 105
(60 — 65)

154 — 162
(96 — 101)

150 — 158
(93 — 98)

87 — 95
(54 — 59)

41 — 49
(25 — 30)

Half throttle

31 — 39
(19 — 24)

60 — 68
(37 — 42)

122 — 130
(76 — 81)

63 — 71
(39 — 44)

36 — 44
(22 — 27)

5 — 13
(3 —

At half throttle, the accelerator opening is 4/8 of the full opening.

Vehicle Speed at When Lock-up Occurs/Releases

BCS000YO

Vehicle speed [km/h (MPH)]
Throttle position

2.0/8

Selector lever position

Lock-up “ON”

Lock-up “OFF”

D position

76 — 84 (47 — 52)

56 — 64 (35 — 40)

D position (OD OFF)

96 — 104 (60 — 65)

93 — 101 (58 — 63)

Stall Speed

BCS000YP

Stall revolution (rpm)

2,250 — 2,700

Line Pressure
Engine speed

BCS000YQ

Line pressure [kPa (bar, kg/cm2 , psi)]
D, 2nd and 1st positions

R position

Idle speed

500 (5.0, 5.1, 73)

778 (7.8, 7.9, 113)

Stall speed

1,159 (11.6, 11.8, 168)

1,803 (18.0, 18.4, 262)

AT-474

SERVICE DATA AND SPECIFICATIONS (SDS)
[ALL]

Adjusting shims, Needle Bearings, Thrust Washers and Snap Rings

BCS000YR

NOTE:
Refer to AT-367, «Locations of Adjusting Shims, Needle Bearings and Thrust Washers» or AT-368, «Locations
of Snap Rings» .

A

B

OUTER DIAMETER AND INNER DIAMETER OF NEEDLE BEARINGS
Unit: mm (in)
Location

Outer diameter

Inner diameter

A

47.0 (1.850)

32.0 (1.260)

B

35.0 (1.378)

20.1 (0.791)

C

60.0 (2.362)

42.0 (1.654)

D

60.0 (2.362)

45.0 (1.772)

E

47.0 (1.850)

30.0 (1.181)

F

42.6 (1.677)

26.1 (1.028)

G

48.0 (1.890)

33.5 (1.319)

H

58.99 (2.3224)

42.1 (1.657)

AT

D

E

F

OUTER DIAMETER AND INNER DIAMETER OF THRUST WASHERS
Unit: mm (in)
Location

Outer diameter

Inner diameter

I

72.0 (2.835)

55.5 (2.185)

J, K

82.0 (3.228)

59.0 (2.323)

L

78.5 (3.091)

62.4 (2.457)

G

H

OUTER DIAMETER AND INNER DIAMETER OF BEARING RACES AND ADJUSTING SHIMS
Unit: mm (in)
Location

Outer diameter

Inner diameter

M

48.0 (1.890)

33.0 (1.299)

N

29.0 (1.142)

25.0 (0.984)

O

34.3 (1.350)

26.1 (1.028)

P

79.5 (3.130)

72.0 (2.835)

I

J

K

OUTER DIAMETER OF SNAP RINGS
Unit: mm (in)
Location

L

Outer diameter

1
142.0 (5.59)

2

M

3
4

162.3 (6.39)

5
7

113.0 (4.45)

8

135.4 (5.33)

9

126.0 (4.96)

INNER DIAMETER OF SNAP RINGS
Unit: mm (in)
Location

Inner diameter

6

32.0 (1.260)

10

63.5 (2.500)

AT-475

SERVICE DATA AND SPECIFICATIONS (SDS)
[ALL]

Control Valves

BCS000YS

CONTROL VALVE SPRINGS
Unit: mm (in)
Location

spring designation
L14

Pilot valve spring

L15

Upper body

Lower body

Free length (l)

Outer diameter (D)

38.98 (1.5346)

8.9 (0.350)

1–2 accumulator valve spring

20.5 (0.807)

6.95 (0.2737)

1–2 accumulator piston spring

55.66 (2.1913)

19.5 (0.768)

L16

1st reducing valve spring

27.0 (1.063)

7.0 (0.276)

L17

3–2 timing valve spring

23.0 (0.906)

6.65 (0.2618)

L18

Overrun clutch reducing valve spring

37.5 (1.476)

7.0 (0.276)

L19

Torque converter relief valve spring

33.3 (1.311)

9.0 (0.354)

L20

Torque converter clutch control valve spring

53.01 (2.0870)

6.5 (0.256)

L21

Cooler check valve spring

28.04 (1.1039)

7.15 (0.2815)

L3

Pressure regulator valve spring

45.0 (1.772)

15.0 (0.591)

L4

Overrun clutch control valve spring

21.7 (0.854)

7.0 (0.276)

L5

Accumulator control valve spring

22.0 (0.866)

6.5 (0.256)

L6

Shift valve A spring

21.7 (0.854)

7.0 (0.276)

L7

Shuttle valve spring

51.0 (2.008)

5.65 (0.2224)

L12

Shift valve B spring

21.7 (0.854)

7.0 (0.276)

Pressure modifier valve spring

32.0 (1.260)

6.9 (0.272)

L13

Pressure modifier piston spring

30.5 (1.201)

9.8 (0.386)

—

Line pressure relief valve spring

17.02 (0.6701)

8.0 (0.315)

—

Torque converter pressure holding spring

9.0 (0.354)

7.3 (0.287)

Accumulator

BCS000YT

RETURN SPRINGS
Unit: mm (in)
Location

Free length (L1 )

Servo release accumulator

62.8 (2.472)
Unit: mm (in)
Location

Length (L2 )

N-D accumulator

46.5 (1.831)

O-RINGS
Unit: mm (in)
Location

Inner diameter (Small)

Inner diameter (Large)

Servo release accumulator

26.9 (1.059)

44.2 (1.740)

N-D accumulator

34.6 (1.362)

39.4 (1.551)

Clutches and Brakes

BCS000YU

REVERSE CLUTCH
Number of drive plates

2

Number of driven plates

2

Drive plate thickness [mm (in)]
Driven plate thickness [mm (in)]
Clearance [mm (in)]

Standard

2.0 (0.079)

Allowable limit

1.8 (0.070)

Standard

2.0 (0.079)

Standard

0.5 — 0.8 (0.020 — 0.031)

Allowable limit

1.2 (0.047)

AT-476

SERVICE DATA AND SPECIFICATIONS (SDS)
[ALL]
HIGH CLUTCH
Number of drive plates

3

Number of driven plates

6 (1*1 + 5*2 )

Drive plate thickness [mm (in)]

Driven plate thickness [mm (in)]

Standard

1.6 (0.063)

Allowable limit

1.4 (0.055)

Standard
Standard

Clearance [mm (in)]

A

B

*1

*2

1.5 (0.059)

2.0 (0.079)

AT

1.4 — 1.8 (0.055 — 0.070)

Allowable limit

2.4 (0.094)

D

FORWARD CLUTCH
Number of drive plates

5

Number of driven plates

5

Drive plate thickness [mm (in)]
Driven plate thickness [mm (in)]
Clearance [mm (in)]

Standard

1.8 (0.070)

Allowable limit

1.6 (0.063)

Standard

2.0 (0.079)

Standard

0.45 — 0.85 (0.0177 — 0.0335)

E

F

1.85 (0.0728)

G

Number of drive plates

3

H

Number of driven plates

4

Allowable limit

OVERRUN CLUTCH

Drive plate thickness [mm (in)]
Driven plate thickness [mm (in)]
Clearance [mm (in)]

Standard

1.6 (0.063)

Allowable limit

1.4 (0.055)

Standard

2.0 (0.079)

Standard

1.0 — 1.4 (0.039 — 0.055)

Allowable limit

K

Number of drive plates

4

Number of driven plates

4

Driven plate thickness [mm (in)]
Clearance [mm (in)]

J

2.0 (0.079)

LOW & REVERSE BRAKE

Drive plate thickness [mm (in)]

I

Standard

2.0 (0.079)

Allowable limit

1.8 (0.070)

Standard

2.0 (0.079)

Standard

1.4 — 1.8 (0.055 — 0.070)

Allowable limit

2.6 (0.102)

BRAKE BAND
Anchor end pin tightening torque [N·m (kg-m, in-lb)]

4.9 (0.50, 43)

Number of returning revolutions for anchor end pin

2.5

Lock nut tightening torque [N·m (kg-m, ft-lb)]

33.9 (3.5, 25)

AT-477

L

M

SERVICE DATA AND SPECIFICATIONS (SDS)
[ALL]

Final Drive

BCS000YV

DIFFERENTIAL SIDE GEAR CLEARANCE
Clearance between side gear and differential case with washer [mm (in)]

0.1 — 0.2 (0.004 — 0.008)

DIFFERENTIAL SIDE BEARING END PLAY
Differential side bearing end play [mm (in)]

0 — 0.15 (0 — 0.0059)

Planetary Carrier

BCS000YW

Clearance between planetary carrier and pinion washer [mm (in)]

Standard
Allowable limit

0.15 — 0.70 (0.0059 — 0.0276)
0.80 (0.0315)

Oil Pump

BCS000YX

Oil pump side clearance

0.02 — 0.04 (0.0008 — 0.0016)

Clearance between oil pump housing and outer gear [mm (in]

Standard
Allowable limit

Oil pump cover seal ring clearance [mm (in)]

Standard
Allowable limit

0.08 — 0.15 (0.0031 — 0.0059)
0.15 (0.0059)
0.10 — 0.25 (0.0039 — 0.0098)
0.25 (0.0098)

Input Shaft

BCS000YY

SEAL RING CLEARANCE
Standard
Input shaft seal ring clearance [mm (in)]

Allowable limit

0.10 — 0.25 (0.0039 — 0.0098)
0.25 (0.098)

SEAL RING
Unit: mm (in)
Outer diameter

Inner diameter

Width

24 (0.94)

20.4 (0.803)

1.97 (0.0776)

Reduction Pinion Gear

BCS000YZ

TURNING TORQUE
Turning torque of reduction pinion gear [N·m (kg-m, in-lb)]

0.11 — 0.69 (0.02 — 0.07, 1 — 6)

Band Servo

BCS000Z0

RETURN SPRINGS
Unit: mm (in)
Return spring

Free length

2nd servo return spring

32.5 (1.280)

OD servo return spring

38.52 (1.5165)

Output Shaft

BCS000Z1

SEAL RING CLEARANCE
Standard
Output shaft seal ring clearance [mm (in)]

Allowable limit

0.10 — 0.25 (0.0039 — 0.0098)
0.25 (0.0098)

SEAL RING
Unit: mm (in)
Outer diameter

Inner diameter

Width

29.5 (1.161)

26.2 (1.031)

1.95 (0.0768)

TURNING TORQUE
Turning torque of output shaft [N·m (kg-m, in-lb)]

0.25 — 0.88 (0.03 — 0.08, 3 — 7)

AT-478

SERVICE DATA AND SPECIFICATIONS (SDS)
[ALL]

Bearing Retainer

BCS000Z2

A

SEAL RING CLEARANCE
Bearing retainer seal ring clearance [mm (in)]

Standard

0.10 — 0.25 (0.0039 — 0.0098)

Allowable limit

0.25 (0.0098)

B

Total End Play

BCS000Z3

Total end play [mm (in)]

0.25 — 0.55 (0.0098 — 0.0217)

AT

Reverse Clutch End Play

BCS000Z4

Reverse clutch end play [mm (in)]

0.65 — 1.0 (0.0256 — 0.039)

D

Removal and Installation

BCS000Z5

Distance between end of converter housing and torque converter [mm (in)]

16.2 (0.638)

E

Shift Solenoid Valves

BCS000Z6

Gear position

1

2

3

4

Shift solenoid valve A

ON (Closed)

OFF (Open)

OFF (Open)

ON (Closed)

Shift solenoid valve B

ON (Closed)

ON (Closed)

OFF (Open)

OFF (Open)

F

G

Solenoid Valves

BCS000Z7

Solenoid valve designation

Resistance (Approx.)

Terminal

20 — 30 Ω

2

Shift solenoid valve B

5 — 20 Ω

1

Overrun clutch solenoid valve

20 — 30 Ω

3

Line pressure solenoid valve

2.5 — 5.0 Ω

4

5 — 20 Ω

5

Shift solenoid valve A

Torque converter clutch solenoid valve

A/T Fluid Temperature Sensor

I

BCS000Z8

Remarks: Specification data are reference values.
Condition
Cold [20°C (68°F)]
↓
Hot [80°C (176°F)]

H

J

Specification (Approx.)
1.5V
↓
0.5V

K

2.5 kΩ
↓
0.3 kΩ

L

Revolution Sensor

BCS000Z9

Condition

Judgement standard

When driving at 20 km/h (12 MPH)

M

150 Hz (Approx.)

Dropping Resistor

BCS000ZA

Resistance

12Ω (Approx.)

Turbine Revolution Sensor (Power Train Revolution Sensor)
Condition

Judgement standard

When driving at 20 km/h (12 MPH)

360 Hz (Approx.)

AT-479

BCS000ZB

SERVICE DATA AND SPECIFICATIONS (SDS)
[ALL]

AT-480

BODY CONTROL SYSTEM

K ELECTRICAL

SECTION

BCS

BODY CONTROL SYSTEM

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 2
Maintenance Information …………………………………… 2
RHD MODELS ……………………………………………… 2
LHD MODELS ………………………………………………. 2
BCM (BODY CONTROL MODULE) ……………………… 3
System Description ………………………………………….. 3
BCM FUNCTION …………………………………………… 3
COMBINATIONSWITCHREADING FUNCTION….. 3
SYSTEMS CONTROLLED BY BCM ………………… 3
SYSTEMS CONTROLLED BY BCM AND IPDM
E/R ……………………………………………………………… 3
SYSTEMS CONTROLLED BY BCM AND INTELLIGENT KEY UNIT ………………………………………… 3
INPUT/OUTPUT ……………………………………………. 4
CAN COMMUNICATION CONTROL ……………….. 5

BCM STATUS CONTROL ………………………………. 5
CAN Communication ………………………………………… 6
SYSTEM DESCRIPTION ……………………………….. 6
CAN Communication Unit ………………………………….. 6
Schematic ……………………………………………………….. 7
CONSULT-II Function (BCM) …………………………….. 9
CONSULT–II INSPECTION PROCEDURE ……….. 9
ITEMS OF EACH PART …………………………………. 9
Configuration …………………………………………………. 10
DESCRIPTION ……………………………………………. 10
READ CONFIGURATION PROCEDURE ………… 10
WRITE CONFIGURATION PROCEDURE ………. 13
CAN Communication Inspection With CONSULTII (Self-Diagnosis) …………………………………………… 17
Removal and Installation of BCM ……………………… 17
REMOVAL ………………………………………………….. 17
INSTALLATION …………………………………………… 18

E

F

G

H

I

J

BCS

L

M

BCS-1

PRECAUTIONS
PFP:00011
PRECAUTIONS
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

BKS0026F

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Maintenance Information

BKS0026G

If any of following part is replaced, always replace with new* one.
If it’s not (or fail to do so), the electrical system may not be operated properly.
*: New one means a virgin control unit that has never been energized on-board.

RHD MODELS
●
●
●
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM
IPDM E/R
Combination meter
EPS control unit

LHD MODELS
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM

BCS-2

BCM (BODY CONTROL MODULE)
BCM (BODY CONTROL MODULE)
System Description

PFP:284B2

A
BKS0026R

BCM (Body Control Module) controls the operation of various electrical units installed on the vehicle.

BCM FUNCTION

B

BCM has a combination switch reading function for reading the operation of combination switches (light, wiper
washer, turn signal) in addition to the function for controlling the operation of various electrical components.
Also, it functions as an interface that receives signals from the A/C auto amplifier, and sends signals to ECM
using CAN communication.

C

COMBINATION SWITCH READING FUNCTION
BCM reads combination switch (headlamp, wiper and washer, turn signal) status, and controls various electrical components according to the results.
BCM reads information of 20 switches and 5 diagnostic results by combining five output terminals (Output 1 5) and five input terminals (Input 1 — 5).
Refer to LT-114, «COMBINATION SWITCH» .

SYSTEMS CONTROLLED BY BCM
●
●
●
●
●
●
●

●
●

Power door lock system. Refer to BL-16, «POWER DOOR LOCK SYSTEM» .
Super lock system. Refer to BL-59, «POWER DOOR LOCK — SUPER LOCK —» .
Multi-remote control system. Refer toBL-111, «MULTI-REMOTE CONTROL SYSTEM» .
Power window system. Refer to GW-32, «POWER WINDOW SYSTEM» .
Interior room lamp timer. Refer to LT-150, «INTERIOR ROOM LAMP» .
Warning chime. Refer to DI-52, «WARNING CHIME» .
Turn signal and hazard warning lamps. Refer to LT-98, «TURN SIGNAL AND HAZARD WARNING
LAMPS» .
Rear wiper. Refer to WW-49, «REAR WIPER AND WASHER SYSTEM» .
Rear fog lamp. Refer to LT-88, «REAR FOG LAMP» .

SYSTEMS CONTROLLED BY BCM AND IPDM E/R
●
●
●
●
●
●

NATS (Nissan Anti-Theft System). Refer to BL-215, «NATS (Nissan Anti-Theft System)» .
Front wiper. Refer to WW-4, «FRONT WIPER AND WASHER SYSTEM» .
Front washer. Refer toWW-4, «FRONT WIPER AND WASHER SYSTEM» .
Rear window defogger. Refer to GW-12, «REAR WINDOW DEFOGGER» .
Front fog lamp. Refer to LT-73, «FRONT FOG LAMP» .
Headlamp washer. Refer to WW-73, «HEADLAMP WASHER» .

D

E

F

G

H

I

J

BCS

L

SYSTEMS CONTROLLED BY BCM AND INTELLIGENT KEY UNIT
●

Intelligent Key system. Refer toBL-130, «INTELLIGENT KEY SYSTEM» .

BCS-3

M

BCM (BODY CONTROL MODULE)
INPUT/OUTPUT
System

Multi-remote control system

Intelligent Key system

Power door lock system/ Super lock system

Input

Remote controller

Output
●

Door lock actuator

●

Back door release actuator

●

Turn signal lamp (LH, RH)

●

Door lock actuator

●

Back door release actuator

●

Turn signal lamp

●

Combination meter

●

Door lock actuator

●

Back door release actuator

●

Power window main switch

●

Front power window switch
(passenger side)

Intelligent Key unit

●

Key switch

●

Door lock/unlock switch

●

Door switches

Power supply (IGN) to power window system

Ignition power supply

●

Power window main switch

Power supply (BAT) to power window system

Battery power supply

●

Front power window switch
(passenger side)

Headlamp

Combination switch

IPDM E/R (headlamp relay)

Tail lamp

Combination switch

IPDM E/R (tail lamp relay)

Rear fog lamp

Combination switch

Rear combination lamp (Refer fog)

Turn signal lamp

Combination switch

Hazard warning lamp

●

Key switch

●

Intelligent Key unit (key switch signal)

●

Remote controller

●

Door lock/unlock switch

●

Front door switch (driver side)

●

Door switches

●

Key switch

●

Intelligent Key unit (key switch signal)

●

Front door switch (driver side)

●

Combination switch

●

Key switch

●

Intelligent Key unit (key switch signal)

●

Front door switch (driver side)

●

Combination switch

●

Combination meter

●

Rain sensor

Light warning chime

Front wiper with rain sensor

Turn signal lamps

●

Combination meter

●

Turn signal lamps

●

Combination meter

Hazard switch

Interior room lamp timer

Ignition key warning chime

●

Interior room lamp

Combination meter (warning buzzer)

Combination meter (warning buzzer)

IPDM E/R (front wiper relays)

Front washer

Combination switch

Washer motor

Rear wiper

Combination switch

Rear wiper motor

Rear washer

Combination switch

Washer motor

Headlamp washer

Headlamp washer switch

Headlamp washer relay (via IPDM E/R)

●

A/C auto amp. (Rear window defogger
switch) (with auto amp).

●

Heater control panel (Rear window
defogger switch) (with manual A/C).

Rear window defogger

BCS-4

IPDM E/R (rear window defogger relay)

BCM (BODY CONTROL MODULE)
System

Input

Output

A/C switch signal

A/C auto amp.

ECM

Blower fan switch signal

A/C auto amp.

ECM

A

CAN COMMUNICATION CONTROL

B

CAN communication is capable of dealing with a lot of information through the two communication lines (CAN
L line, CAN H line) connecting control units in the system. Also each control unit functions to transmit and
receive data, and reads necessary information only.

C

BCM STATUS CONTROL
BCM changes its status depending on the operation status in order to save power consumption.
D
1. CAN communication status
● With ignition switch ON, CAN communicates with other control units normally.
● Control by BCM is being operated properly.
E
● When ignition switch is OFF, switching to sleep mode is possible.
● Even when ignition switch is OFF, if CAN communication with IPDM E/R and combination meter is
active, CAN communication status is active.
F
2. Pre-sleep status
● This is the status to stop CAN communication when ignition switch is turned OFF.
● It transmits sleep request signal to IPDM E/R and combination meter.
G
● Two seconds after CAN communication with another control unit stops, it switches to CAN communication inactive status.
H
3. CAN communication inactive status
● With ignition switch OFF, CAN communication is not active.
● With ignition switch OFF, control performed only by BCM is active.
I
● Two seconds after CAN communication with another control unit stops, it switches to CAN communication inactive status.
4. Sleep status
J
● BCM is activated with low-current-consumption mode.
● CAN communication is not active.
● When CAN communication operation is detected, it switches to CAN communication status.
BCS
● When control performed only by BCM is required by switch, it shifts to CAN communication inactive
mode.
● It changes combination switch reading function.
L

M

BCS-5

BCM (BODY CONTROL MODULE)
CAN Communication

BKS0026S

SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

CAN Communication Unit

BKS0026T

Refer to LAN-21, «CAN COMMUNICATION» .

BCS-6

BCM (BODY CONTROL MODULE)
Schematic

BKS0026U

A

B

C

D

E

F

G

H

I

J

BCS

L

M

MKWA4378E

BCS-7

BCM (BODY CONTROL MODULE)

MKWA4379E

BCS-8

BCM (BODY CONTROL MODULE)
CONSULT-II Function (BCM)

BKS0026V

CONSULT-II can display each diagnostic item using the diagnostic modes shown following. Data is received
and transmitted via the control module communication line.
BCM diagnostic test item

Check item, diagnostic test mode

Inspection by part

Content

A

B

WORK SUPPORT

Setting of each function can be changed.

SELF-DIAGNOSTIC RESULTS

BCM performs self-diagnosis of CAN communication.

DATA MONITOR

Displays the input data of BCM in real time.

CAN DIAG SUPPORT MNTR

The results of transmit/receive diagnosis of
CAN communication can be read.

ACTIVE TEST

Gives a drive signal to a load to check the
operation.

ECU PART NUMBER

Displays BCM parts number

CONFIGURATION

Performs BCM configuration read/write functions.

C

D

E

F

CONSULT–II INSPECTION PROCEDURE
Refer to GI-36, «CONSULT-II Start Procedure» .
G

ITEMS OF EACH PART

×:Applicable
Diagnostic test mode (Inspection by part)

System and item

“TEST ITEM” screen

WORK
SUPPORT

SELFDIAG
RESULT
S

ACTIVE
TEST

×

×

×

×

KEY WARN
ALM

×

×

LIGHT WARN
ALM

×

×

Back door warning chime

BACK DR
OPEN WARN

×

×

Door warning indicator

DOOR WARNING IND

×

×

INT LAMP

×

×

MULTI REMOTE ENT

×

Power door lock system

DOOR LOCK

Rear window defogger

REAR DEFOGGER

Ignition key warning chime
Light warning chime
BUZZER

Interior room lamp timer
Multi-remote control system
Headlamp
Wiper
Turn signal lamp
Hazard warning lamp

×

DATA
MONITOR

CAN
DIAG
SUPPORT
MNTR

HEAD LAMP

×

×

×

WIPER

×

×

×

FLASHER

×

×

×
×

A/C switch signal
Blower fan switch signal

AIR CONDITIONER

×

Intelligent Key system

INTELLIGENT KEY

×

COMB SW

×

Combination switch
Theft warning system
(Dealer option)
BCM

THEFT ALM

H
ECU
PARTS
NUMBER

J

BCS

L

M

×
×

BCM

BCS-9

×

×

I

×

BCM (BODY CONTROL MODULE)
Configuration

BKS0026W

DESCRIPTION
There are two CONFIGURATION functions, as follows.
READ CONFIGURATION is a function for confirming vehicle configuration written on BCM.
WRITE CONFIGURATION is a function for writing a vehicle configuration to BCM.
CAUTION:
●
When replacing BCM, completely perform WRITE CONFIGURATION with CONSULT-II.
●
Orderly complete the procedure of WRITE CONFIGURATION.
●
If you set incorrect WRITE CONFIGURATION, vehicle operation will not be correct.
●
Configuration is different by each vehicle model, confirm configuration in each case.

READ CONFIGURATION PROCEDURE
CAUTION:
If CONSULT-II is used with no connection of CONSULT CONVERTER, malfunctions might be detected
in self-diagnosis depending on control unit which carry out CAN communication.
1. With the ignition switch OFF, connect CONSULT-II and CONSULT-II CONVERTER to the data link connector, then turn the
ignition switch ON.

PAIA0070E

2.

Touch “START(NISSAN BASED VHCL)”.

BCIA0029E

3.

Touch “BCM” on “SELECT SYSTEM” screen.
If “BCM” is not indicated, go to GI-38, «CONSULT-II Data Link
Connector (DLC) Circuit» .

BCIA0030E

BCS-10

BCM (BODY CONTROL MODULE)
4.

Touch “BCM” on “SELECT TEST SYSTEM” screen.
A

B

C
MKIB0394E

D

5.

Touch “CONFIGURATION” on “SELECT DIAG MODE” screen.
E

F

G
MKIB2357E

6.

Touch “E11”, and “OK” on “VEHICLE SELECT” screen.
For canceling, touch “CANCEL” on “VEHICLE SELECT” screen.
NOTE:
Confirm vehicle model on GI-47, «IDENTIFICATION PLATE» .

H

I

J

MKIB2358E

7.

BCS

Touch “READ CONFIGURATION” on “SELECT CINFIG ITEM”
screen.
L

M

MKIB2362E

BCS-11

BCM (BODY CONTROL MODULE)
8.

Configuration of brand-new BCM are printed out automatically.
Configuration of brand-new BCM before executing “WRITE
CONFIGURATION” is as follows.
MANUAL SET ITEM
ITEM

SET VAL

HANDLE

LHD

DTRL

OFF

I-KEY

WITHOUT

RAIN SENSOR

WITHOUT

AIR COND

HEATER

PTC HEATER

WITHOUT

THEFT ALARM

WITHOUT

RETRACT H/TOP

WITHOUT

AUTO SET ITEM
RR DEF SET

YET

H/L WASH FREQ

5

DONGLE

OFF

SUPER LOCK

WITH

DOOR LCK SET 1

5

DOOR LCK SET 2

7

LIT OFF TIMER

ON

AUTO LT BEEP

WITH

AUTO LT TIMER

—

MKIB2359E

9.

TURN SIG TIME

WITHOUT

DTRL SW LBEAM

WITHOUT

DTRL SW RELAY

WITH

RR ADD WIPE

WITHOUT

Touch “BACK” on “ READ CONFIGURATION“screen.

MKIB0775E

BCS-12

BCM (BODY CONTROL MODULE)
WRITE CONFIGURATION PROCEDURE
CAUTION:
If CONSULT-II is used with no connection of CONSULT CONVERTER, malfunctions might be detected
in self-diagnosis depending on control unit which carry out CAN communication.
1. With the ignition switch OFF, connect CONSULT-II and CONSULT-II CONVERTER to the data link connector, then turn the
ignition switch ON.

A

B

C

D

PAIA0070E

2.

E

Touch “START(NISSAN BASED VHCL)”.
F

G

H
BCIA0029E

3.

I

Touch “BCM” on “SELECT SYSTEM” screen.
If “BCM” is not indicated, go to GI-38, «CONSULT-II Data Link
Connector (DLC) Circuit» .

J

BCS

L
BCIA0030E

4.

Touch “BCM” on “SELECT TEST SYSTEM” screen.

M

MKIB0394E

BCS-13

BCM (BODY CONTROL MODULE)
5.

Touch “CONFIGURATION” on “SELECT DIAG MODE” screen.

MKIB2357E

6.

Touch “E11”, and “OK” on “VEHICLE SELECT” screen.
For canceling, touch “CANCEL” on “VEHICLE SELECT” screen.
NOTE:
Confirm vehicle model on GI-47, «IDENTIFICATION PLATE» .

MKIB2358E

7.

Touch “WRITE CONFIGURATION” on “SELECT CONFIG
ITEM” screen.

MKIB2362E

8.

Touch “YES”.
For canceling, touch “NO”.

MKIB0762E

BCS-14

BCM (BODY CONTROL MODULE)
9.

Select the configuration for the vehicle on “WRITE CONFIGURATION”screen based on the following ITEM LIST.
< ITEM LIST>
ITEM

SET VAL

NOTE

LHD

For LHD models

RHD

For RHD models

ON

With day time light system*1

OFF

Without day time light system*1

WITH

With Intelligent Key system

WITHOUT

Without Intelligent Key system

WITH

With rain sensor*1

WITHOUT

Without rain sensor*1

AUTO A/C

With auto A/C*1

MANUAL A/C

With manual A/C*1

HEATER

Heater*1

WITH

With PTC heater*2

WITHOUT

Without PTC heater*2

WITH

With theft warning system*3

WITHOUT

Without theft warning system*3

RETRACT H/

WITH

With retractable hard top

TOP*4

WITHOUT

Without retractable hard top

HANDLE
DTRL (Day time
Running Light)
I-KEY (Intelligent
Key system)

A

B

C
MKIB0769E

D

RAIN SENSOR

AIR COND

E

F

G

PTC HEATER

THEFT ALARM

H

I

*1: Refer to bottom illustration to specify the items for “SET VAL”.
*2: Models with PTC heater have PTC heater relays. Refer to Harness Layout, PG-59, «ENGINE ROOM HARNESS/K9K ENGINE
MODELS» , to confirm whether PTC heater relays are equipped or not.
*3: Confirm with the customer if the vehicle is equipped with the optional parts.
*4: Always select “WITHOUT”, because retractable hard top is not equipped to E11.

J

BCS

L

M

MKIB2315E

1.

Daytime light relay

4.

A/C button

2.

Light and rain sensor

For canceling, touch “CANCEL”.
10. Touch “CONFIG” on “WRITE CONFIGURATION“screen.

BCS-15

3.

In-vehicle sensor (for Auto A/C)

BCM (BODY CONTROL MODULE)
CAUTION:
Make sure to touch “CONFIG” even if the indicated configuration of brand new BCM is same as
the desirable configuration.
If not, configuration which is set automatically by selecting vehicle model can not be memorized.
11. Touch “OK” on “WRITE CONFIGURATION”screen.
When touched “CANCEL”, go to previous screen.

MKIB0770E

12. Wait until the next screen during setting.

MKIB0771E

13. WRITE CONFIGURATION results are printed out automatically.
Check “WRITE CONFIGURATION” is correctly executed by
comparing sheet automatically printed out with desirable configuration.

MKIB2360E

BCS-16

BCM (BODY CONTROL MODULE)
14. Touch “OK” on “WRITE CONFIGURATION“screen.
WRITE CONFIGURATION is completed.

A

B

C
MKIB0773E

D

CAN Communication Inspection With CONSULT-II (Self-Diagnosis)

BKS0026X

1. CHECK SELF-DIAGNOSTIC RESULT

E

CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carry out CAN communication.
1. Connect to CONSULT-II, and select “BCM” on “SELECT SYSTEM” screen.
2. Select “BCM” on “SELECT TEST ITEM” screen.
3. Touch “SELF-DIAG RESULTS”, on “SELECT DIAG MODE” screen.
4. Check display content in self-diagnostic results.
CONSULT-II display code

Diagnosis item

F

G

H

TRANSMIT DIAG
ECM

I

IPDM E/R
U1000

METER / M&A
I-KEY

J

VDC / TCS / ABS

Contents displayed
BCS
No malfunction>>INSPECTION END
Malfunction in CAN communication system>>After printing the monitor items, go to “CAN System”. Refer to
LAN-3, «Precautions When Using CONSULT-II» .

Removal and Installation of BCM

BKS0026Y

CAUTION:
Always replace with new* BCM when the BCM replacement is required.
*: New one means virgin control unit that has never been energized on-board.

M

REMOVAL
NOTE:
If possible, before removing BCM, retrieve current BCM configuration to use for reference when configuring
brand-new BCM after installation. Refer to BCS-10, «Configuration» .
1. Remove instrument upper panel. Refer to IP-4, «INSTRUMENT
PANEL ASSEMBLY» .
2. Disconnect BCM connector.
3. Remove BCM.

MKIB2365E

BCS-17

L

BCM (BODY CONTROL MODULE)
INSTALLATION
●

Install in the reverse order of removal.

BCS-18

BODY, LOCK & SECURITY SYSTEM

I BODY

SECTION

BL

BODY, LOCK & SECURITY SYSTEM

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 5
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 5
Maintenance Information …………………………………… 5
RHD MODELS ……………………………………………… 5
LHD MODELS ………………………………………………. 5
Precautions …………………………………………………….. 5
CLIP AND FASTENER ……………………………………….. 6
List of Table …………………………………………………….. 6
HOOD ………………………………………………………………. 7
Fitting Adjustment ……………………………………………. 7
FRONT END HEIGHT ADJUSTMENT AND LATERAL/LONGITUDINAL CLEARANCE ADJUSTMENT ………………………………………………………….. 7
SURFACE MISMATCH ADJUSTMENT ……………. 7
Removal and Installation …………………………………… 8
REMOVAL ……………………………………………………. 8
INSTALLATION …………………………………………….. 9
Removal and Installation of Hood Lock Control ……. 9
REMOVAL ……………………………………………………. 9
INSTALLATION …………………………………………… 10
Hood Lock Control Inspection ……………………………11
RADIATOR CORE SUPPORT ……………………………. 13
Removal and Installation …………………………………. 13
REMOVAL ………………………………………………….. 13
INSTALLATION …………………………………………… 14
FRONT FENDER ……………………………………………… 15
Removal and Installation …………………………………. 15
REMOVAL ………………………………………………….. 15
INSTALLATION …………………………………………… 15
POWER DOOR LOCK SYSTEM ………………………… 16
Component Parts and Harness Connector Location… 16
System Description ………………………………………… 17
OPERATION ………………………………………………. 17
DOOR LOCK AND UNLOCK SWITCH OPERATION ………………………………………………………….. 18
BACK DOOR SWITCH OPERATION …………….. 18
BACK DOOR RELEASE ACTUATOR OPERATION ………………………………………………………….. 18

BL-1

BACK DOOR SWITCH OPERATION ……………… 18
KEY REMINDER SYSTEM …………………………… 18
UNLOCK LINK FUNCTION …………………………… 18
BACK DOOR OPENER OPERTION ………………. 19
AUTO RE-LOCK FUNCTION ………………………… 19
ANTI-HIJACK FUNCTION …………………………….. 19
CAN Communication ………………………………………. 19
SYSTEM DESCRIPTION ……………………………… 19
CAN Communication Unit ………………………………… 19
Schematic (Without Intelligent Key System) ……….. 20
Wiring Diagram — D/LOCK — (Without Intelligent
Key System) ………………………………………………….. 21
Schematic (With Intelligent Key System) ……………. 26
Wiring Diagram — D/LOCK — (With Intelligent Key
System) ………………………………………………………… 27
Terminal and Reference Value for BCM …………….. 33
CONSULT- II Inspection Procedure …………………… 34
CONSULT- II Application Items ………………………… 34
WORK SUPPORT ……………………………………….. 34
DATA MONITOR …………………………………………. 34
ACTIVE TEST …………………………………………….. 34
Work Flow ……………………………………………………… 35
TROUBLE DIAGNOSES CHART BY SYMPTOM/WITHOUT INTELLIGENT KEY SYSTEM… 35
TROUBLE DIAGNOSES CHART BY SYMPTOM/WITH INTELLIGENT KEY SYSTEM ………. 36
Check Power Supply and Ground Circuit of BCM… 37
Check Door Lock / Unlock Switch …………………….. 38
Check Key Switch /Without Intelligent Key System… 39
Check Key Switch and Ignition Knob Switch/With
Intelligent Key System …………………………………….. 40
Check Door Lock Actuator Circuit …………………….. 41
Check Door Lock Actuator ……………………………….. 42
DRIVER SIDE …………………………………………….. 42
PASSENGER SIDE ……………………………………… 43
REAR LH SIDE …………………………………………… 44
REAR RH SIDE …………………………………………… 45
Check Door Switch …………………………………………. 46
DRIVER SIDE …………………………………………….. 46
PASSENGER SIDE ……………………………………… 48

E

F

G

H

BL

J

K

L

M

REAR LH SIDE ……………………………………………. 50
REAR RH SIDE …………………………………………… 52
BACK DOOR SWITCH …………………………………. 53
Check Back Door Switch …………………………………. 55
Check Back Door Release Actuator ………………….. 57
Check Door Lock/Unlock Switch Indicator ………….. 58
POWER DOOR LOCK — SUPER LOCK — ………… 59
ComponentParts and Harness Connector Location… 59
System Description …………………………………………. 60
OPERATION ……………………………………………….. 60
DOOR LOCK AND UNLOCK SWITCH OPERATION ………………………………………………………….. 61
BACK DOOR SWITCH OPERATION ……………… 61
BACK DOOR RELEASE ACTUATOR OPERATION ………………………………………………………….. 61
BACK DOOR SWITCH OPERATION ……………… 61
KEY REMINDER SYSTEM …………………………… 61
UNLOCK LINK FUNCTION …………………………… 61
BACK DOOR OPENER OPERTION ………………. 61
AUTO RE-LOCK FUNCTION ………………………… 62
ANTI-HIJACK FUNCTION …………………………….. 62
SUPER LOCK OPERATION …………………………. 62
OUTLINE ……………………………………………………. 62
OPERATION ……………………………………………….. 62
CAN Communication ………………………………………. 63
SYSTEM DESCRIPTION ……………………………… 63
CAN Communication Unit ………………………………… 63
Schematic –S/LOCK – (Without Intelligent Key System) ……………………………………………………………… 64
Wiring Diagram — S/LOCK — (Without Intelligent
Key System) ………………………………………………….. 65
Schematic – S/LOCK – (With Intelligent Key System) ……………………………………………………………… 71
Wiring Diagram — S/LOCK — (With Intelligent Key
System) ………………………………………………………… 72
Terminal and Reference Value for BCM …………….. 78
CONSULT- II Inspection Procedure …………………… 79
CONSULT- II Application Items ………………………… 79
WORK SUPPORT ……………………………………….. 79
DATA MONITOR ………………………………………….. 79
ACTIVE TEST …………………………………………….. 79
Work Flow ……………………………………………………… 79
Trouble Diagnoses ………………………………………….. 81
PRELIMINARY CHECK/WITHOUT INTELLIGENT KEY SYSTEM ……………………………………. 81
SYMPTOM CHART/WITHOUT INTELLIGENT
KEY SYSTEM ……………………………………………… 82
PRELIMINARY CHECK/WITH INTELLIGENT
KEY SYSTEM ……………………………………………… 83
SYMPTOM CHART/WITH INTELLIGENT KEY
SYSTEM …………………………………………………….. 84
Check Power Supply and Ground Circuit …………… 85
Check Door Lock / Unlock Switch …………………….. 86
Check Key Switch /Without Intelligent Key System… 87
Check Key Switch And Ignition Knob Switch/With
Intelligent Key System …………………………………….. 88
Check Power Door Lock / Unlock Output Signal … 89
Check Super Lock Output Signal ……………………… 90
Check Door Lock Actuator ……………………………….. 91

DRIVER SIDE ………………………………………………91
PASSENGER SIDE ………………………………………92
REAR LH SIDE …………………………………………….93
REAR RH SIDE ……………………………………………94
Check Super Lock Actuator ………………………………95
DRIVER SIDE ………………………………………………95
PASSENGER SIDE ………………………………………96
REAR LH SIDE …………………………………………….97
REAR RH SIDE ……………………………………………98
Check Door Switch ………………………………………….99
DRIVER SIDE ………………………………………………99
PASSENGER SIDE ……………………………………. 101
REAR LH SIDE ………………………………………….. 103
REAR RH SIDE …………………………………………. 105
Check Back Door Switch ……………………………….. 107
Check Back Door Release Actuator ………………… 109
MULTI-REMOTE CONTROL SYSTEM ………………. 111
ComponentParts and Harness Connector Location. 111
System Description ……………………………………….. 112
INPUTS …………………………………………………….. 112
OUTLINE ………………………………………………….. 112
Schematic ……………………………………………………. 114
Wiring Diagram — MULTI — ………………………….. 115
Terminal and Reference Value for BCM ……………. 119
CONSULT- II Inspection Procedure …………………. 120
CONSULT- II Application Items ……………………….. 120
DATA MONITOR ………………………………………… 120
Work Flow ……………………………………………………. 120
Trouble Diagnosis Chart by Symptom ……………… 121
Check Remote controller ……………………………….. 122
Check Door Switch ……………………………………….. 122
DOOR SWITCH DRIVER SIDE ……………………. 122
DOOR SWITCH PASSENGER SIDE …………….123
DOOR SWITCH REAR LH ………………………….. 124
DOOR SWITCH REAR RH ………………………….. 125
BACK DOOR RELEASE ACTUATOR (BACK
DOOR SWITCH) ………………………………………… 126
Key Switch Check …………………………………………. 127
Hazard Reminder Check ………………………………… 128
Remote Controller Battery Replacement ………….. 129
INTELLIGENT KEY SYSTEM …………………………… 130
ComponentParts and Harness Connector Location.130
System Description ……………………………………….. 132
DOOR LOCK FUNCTION ……………………………. 132
REMOTE CONTROL ENTRY FUNCTIONS …… 133
ENGINE STARTUP FUNCTION …………………… 134
WARNING AND ALARM FUNCTION ……………. 135
CHANGE SETTINGS FUNCTION ………………… 137
INTELLIGENT KEY REGISTRATION ……………. 137
STEERING LOCK UNIT REGISTRATION ……… 137
Schematic —I/KEY— …………………………………….. 138
Wiring Diagram — I/KEY— …………………………….. 139
Terminals and Reference Value for INTELLIGENT
KEY UNIT ……………………………………………………. 149
Terminals and Reference Value for Steering Lock
unit ……………………………………………………………… 151
Terminal and Reference Value for BCM ……………. 151
Trouble Diagnosis Procedure ………………………….. 153
PRELIMINALY CHECK ……………………………….. 153

BL-2

WORK FLOW ……………………………………………. 154
CONSULT-II Function (INTELLIGENT KEY) …….. 155
CONSULT-II Inspection Procedure …………………. 155
BASIC OPERATION ………………………………….. 155
CONSULT-II Application Items ……………………….. 155
SELF-DIAGNOSTIC RESULTS …………………… 155
DATA MONITOR ……………………………………….. 155
ACTIVE TEST …………………………………………… 156
WORK SUPPORT ……………………………………… 156
Trouble Diagnosis Symptom Chart …………………. 157
KEY WARNING LAMP (GREEN) ILLUMINATES. 157
KEY WARNING LAMP (RED) ILLUMINATES … 157
KEY WARNING LAMP DOES NOT ILLUMINATE. 158
SELF-DIAGNOSIS RESULTS ARE NOT DISPLAYED …………………………………………………… 158
ENGINE START CONDITION CHECK …………. 158
DOOR LOCK/UNLOCK FUNCTION MALFUNCTION ………………………………………………………… 159
REMOTE KEYLESS ENTRY FUNCTION MALFUNCTION ……………………………………………….. 159
HAZARD AND BUZZER REMINDER FUNCTION MALFUNCTION ………………………………… 161
WARNING CHIME FUNCTION MALFUNCTION. 161
WARNING LAMP FUNCTION MALFUNCTION. 163
Check CAN Communication System ………………. 163
Check Power Supply and Ground Circuit …………. 164
Check Ignition Switch Signal Circuit ………………… 164
Check Key Switch (Intelligent Key Unit Input) …… 165
Check Key Switch (BCM Input) ………………………. 167
Check Ignition Knob Switch …………………………… 168
Check Door Request Switch ………………………….. 170
Check Back Door Request Switch ………………….. 172
Check Door Switch ……………………………………….. 174
DRIVER SIDE …………………………………………… 174
PASSENGER SIDE ……………………………………. 176
REAR LH SIDE …………………………………………. 178
REAR RH SIDE …………………………………………. 180
BACK DOOR SWITCH ………………………………. 181
Check Intelligent Key Warning Buzzer Circuit …… 183
Check Outside Key Antenna (Driver Side and Passenger Side) ………………………………………………… 184
Check Outside Key Antenna (Back Door) ………… 185
Check Inside Key Antenna …………………………….. 187
Check Steering Lock Unit ………………………………. 188
Check Warning Lamp ……………………………………. 191
Check Warning Buzzer in Combination Meter ….. 191
Check Hazard Function …………………………………. 191
Check Headlamp Function …………………………….. 191
Check Stop Lamp Switch ………………………………. 192
Removal and Installation of Intelligent key unit …. 193
REMOVAL ………………………………………………… 193
INSTALLATION …………………………………………. 193
Intelligent Key Inspection ………………………………. 193
INTELLIGENT KEY DISASSEMBLY AND
ASSEMBLY ………………………………………………. 193
REMOTE CONTROLLER BATTERY INSPECTION ………………………………………………………… 194
DOOR …………………………………………………………… 195
Fitting Adjustment ………………………………………… 195

FRONT DOOR ………………………………………….. 195
REAR DOOR …………………………………………….. 196
STRIKER ADJUSTMENT ……………………………. 196
Removal and Installation ……………………………….. 196
REMOVAL OF FRONT DOOR …………………….. 196
INSTALLATION …………………………………………. 196
REMOVAL OF REAR DOOR ………………………. 197
INSTALLATION …………………………………………. 197
Front Door Weatherstrip ………………………………… 198
REMOVAL ………………………………………………… 198
INSTALLATION …………………………………………. 198
Front Door Weatherstrip ………………………………… 199
REMOVAL ………………………………………………… 199
INSTALLATION …………………………………………. 199
FRONT DOOR LOCK ……………………………………… 200
Component Parts Location …………………………….. 200
Removal and Installation ……………………………….. 200
REMOVAL ………………………………………………… 200
Disassembly and Assembly ……………………………. 203
DOOR KEY CYLINDER ASSEMBLY ……………. 203
OUTSIDE HANDLE ……………………………………. 203
REAR DOOR LOCK ……………………………………….. 204
Component Parts Location …………………………….. 204
Removal and Installation ……………………………….. 204
REMOVAL ………………………………………………… 204
BACK DOOR …………………………………………………. 207
Fitting Adjustment …………………………………………. 207
VERTICAL/LATERAL CLEARANCE (SURFACE
DIFFERENCE) ADJUSTMENT ……………………. 207
Back Door Assembly …………………………………….. 208
REMOVAL ………………………………………………… 208
INSTALLATION …………………………………………. 208
INSPECTION ……………………………………………. 208
Back Door Striker ………………………………………….. 208
REMOVAL ………………………………………………… 208
INSTALLATION …………………………………………. 209
Back Door Stay Assembly ……………………………… 209
REMOVAL ………………………………………………… 209
INSTALLATION …………………………………………. 209
RemovalandInstallationofBackDoorWeatherstrip. 210
REMOVAL ………………………………………………… 210
INSTALLATION …………………………………………. 210
BACK DOOR LOCK ……………………………………….. 211
Removal and Installation ……………………………….. 211
BACK DOOR LOCK ASSEMBLY …………………. 211
BACK DOOR HANDLE ASSEMBLY …………….. 211
FUEL FILLER LID OPENER …………………………….. 212
Removal and Installation of Fuel Filler Lid Opener. 212
REMOVAL ………………………………………………… 212
INSTALLATION …………………………………………. 213
THEFT WARNING SYSTEM …………………………….. 214
Wiring Diagram — THEFT — / PRWIRE ………….. 214
NATS (NISSAN ANTI-THEFT SYSTEM) ……………. 215
Component Parts and Harness Connector Location
(Hatchback) …………………………………………………. 215
System Description ……………………………………….. 217
OPERATING DESCRIPTION ………………………. 217
SECURITY INDICATOR ……………………………… 217
System Composition ……………………………………… 218

BL-3

A

B

C

D

E

F

G

H

BL

J

K

L

M

ECM Re-communicating Function …………………… 218
Wiring Diagram —NATS— …………………………….. 219
WITHOUT INTELLIGENT KEY SYSTEM ………. 219
WITH INTELLIGENT KEY SYSTEM …………….. 220
Terminals and Reference Value for Steering Lock
Unit/With Intelligent Key System …………………….. 222
Terminals and Reference Value for Intelligent Key
Unit/With Intelligent Key System …………………….. 222
Terminals and Reference Value for BCM/Without
Intelligent Key System …………………………………… 223
CONSULT-II …………………………………………………. 224
CONSULT-II INSPECTION PROCEDURE …….. 224
CONSULT-II DIAGNOSTIC TEST MODE FUNCTION ………………………………………………………… 224
CHECK RESULT ITEM CHART FOR NATS
IMMU FUNCTION ……………………………………… 225
Diagnosis Procedure …………………………………….. 226
WORK FLOW ……………………………………………. 226

BL-4

Trouble Diagnosis Symptom Chart ………………….. 227
MODELS WITHOUT INTELLIGENT KEY SYSTEM …………………………………………………………. 227
MODELS WITH INTELLIGENT KEY SYSTEM .228
Security Indicator Inspection …………………………… 228
Diagnostic Procedure 1 ………………………………….. 229
Diagnostic Procedure 2 ………………………………….. 229
MODELS WITHOUT INTELLIGENT KEY SYSTEM …………………………………………………………. 229
MODELS WITH INTELLIGENT KEY SYSTEM .231
Diagnostic Procedure 3 ………………………………….. 233
Diagnostic Procedure 4 ………………………………….. 233
Diagnostic Procedure 5 ………………………………….. 234
Diagnostic Procedure 6 ………………………………….. 234
Diagnostic Procedure 7 ………………………………….. 236
Removal and Installation NATS Antenna Amp. ….. 237
REMOVAL …………………………………………………. 237
INSTALLATION ………………………………………….. 237

PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

A

BIS000HV

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Maintenance Information

B

C

D

E

F

BIS000HW

If any of following part is replaced, always replace with new* one.
If it’s not (or fail to do so), the electrical system may not be operated properly.
*: New one means a virgin control unit that has never been energized on-board.

G

RHD MODELS

H

●
●
●
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM
IPDM E/R
Combination meter
EPS control unit

BL

J

LHD MODELS
●
●
●

BCM (Models without Intelligent Key system)
Intelligent Key unit (Models with Intelligent Key system)
ECM

L

Precautions
●

●

K

BIS000HX

After installing removed lids or doors, be sure to adjust hinges and mount points so that lids or doors can
open and close properly.
Confirm parts for proper lubrication, damage or wear. Lubricate, repair or replace as necessary.

BL-5

M

CLIP AND FASTENER
CLIP AND FASTENER
List of Table
Symbol No.

PFP:76906
BIS000HY

Shape

Removal and installation

PIIA1350J

PIIA1354J

MIIB0153E

BL-6

HOOD
HOOD
Fitting Adjustment

PFP:F5100

A
BIS000HZ

B

C

D

E

F

G

H

BL

J

K

L

PIIB5563J

FRONT END HEIGHT ADJUSTMENT AND LATERAL/LONGITUDINAL CLEARANCE ADJUSTMENT
1.

Remove hood lock. Rotate bumper rubber to adjust height until
hood becomes 1 to 1.5 mm lower than the fender.
2. Position hood lock and engage striker. Check hood lock and
striker for looseness. Tighten lock bolts to the specified torque.
CAUTION:
Adjust the clearance between hood and other parts so that the
dimensional difference left and right is as follows.
Hood (B) — Headlamp (B)
Hood (C) — Headlamp (C)

: 1.5 mm or less
: 1.0 mm or less
PIIB5564J

SURFACE MISMATCH ADJUSTMENT
1.

Release hood lock, and adjust surface level difference of hood, fender, and headlamp according to the fitting standard dimension, using RH and LH bumper rubbers.

BL-7

M

HOOD
Hood (C) — Fender (C)
2.
3.

4.
5.

: -1.0 — 1.0 mm

Install hood lock, and move hood lock laterally until the centers of striker and lock become vertical when
viewed from the front.
Make sure the secondary latch is securely engaged with the secondary striker from either the dead weight
of the hood (free-fall from approx. 200 mm height), or by applying light pressure (approx. 3 kg).
CAUTION:
Do not drop hood from a height of 300 mm or more.
Move hood lock-up and down until striker smoothly engages the lock when the hood is closed.
After adjustment, tighten lock bolts to the specified torque.

Removal and Installation

BIS000I0

PIIB5565J

1. Hood hinge

2. Hood stay

3. Radiator core seal rubber

4. Hood assembly

5. Hood lock

6. Hood stay holder

REMOVAL
Hood Assembly
1.
2.

Disconnect washer hose at the connecting point.
Remove hinge nuts on hood and remove hood assembly.

PIIB2529J

Hood Hinge
1.
2.
3.

Remove front fender. Refer to BL-15, «Removal and Installation» .
Remove cowl top cover.
Remove hood assembly.

BL-8

HOOD
4.

Remove bolts and then remove hood hinge.
A

B

C
PIIB2530J

D

INSTALLATION
●

●

●

Perform installation in the reverse order of removal while being careful of the following items while performing the work.
Apply Anti-Corrosion Wax M-97 Super or comparable product to the hood hinge, hood ledge, and hood
assembly.
After installing, perform hood fitting adjustment. Refer to BL-7, «Fitting Adjustment» .

Removal and Installation of Hood Lock Control

E

F

BIS000I1

G

H

BL

J

K

L

M

PIIB5566J

1. Hood lock cable

2. Clip

3. Clip

4. Radiator core support upper

5. Washer hose

6. Hood legge reinforcement

REMOVAL
Hood Lock
1.

Remove front bumper. Refer to EI-10, «Removal and Installation» .

BL-9

HOOD
2.

Remove hood lock bolts.

PIIB2532J

3.

Remove hood lock cable from hood lock.

Hood Lock Mounting Reinforcement
1.
2.
3.

Remove front bumper. Refer to EI-4, «Removal and Installation» .
Remove crash zone censor.
Remove bolts, and then remove hood lock mounting reinforcement.

PIIB5569J

Hood Lock Cable
1.
2.
3.
4.
5.
6.

Remove front bumper. Refer to EI-10, «Removal and Installation» .
Remove fender protector. Refer to EI-14, «Removal and Installation» .
Remove hood lock, and remove hood lock cable from hood lock.
Remove radiator core upper support and hood ledge clips, and then remove hood lock cable.
Remove hood opener on bottom right or left of instrument panel,
and then remove hood lock cable.
Remove grommet on lower dashboard, and pull out hood lock
cable from passenger room side.
CAUTION:
While pulling the cable, be careful not to damage (peel)
hood opener cable outer surface on edges of body through
hole.

PIIB2534J

INSTALLATION
●

●

Perform installation in the reverse order of removal while being careful of the following items while performing the work.
After installing, perform hood fitting adjustment. Refer to BL-7, «Fitting Adjustment» .

Hood Lock Mounting Reinforcement
●

When installing hood lock mounting reinforcement, loosen hood bolts, and then tighten bolts in the order
shown in the figure.

BL-10

HOOD
Bolt No. 1 to 5.

Tightening torque (N·m, (kgm))
: 20.6 — 26.5 (2.1 — 2.7)

A

B

C
PIIB5568J

D

Hood Lock Cable
1.
2.
3.

Pass hood lock cable through the opening while keeping the
winding radius 100 mm or larger.
After confirming grommet is properly positioned, push it securely
into the hole.
Apply sealant (POS seal) to area on the grommet indicated with
the * mark.

E

F

G
PIIA0173E

4.
5.

H

Install cable securely to lock.
After installing, check hood lock adjustment and hood opener
operation.

BL

J

K
PIIB5570J

Hood Lock Control Inspection

BIS000I2

CAUTION:
If hood lock cable is bent or deformed, replace it.
1. Confirm hood lock secondary latch securely engages secondary striker by releasing it from a height of
approximately 200 mm.

PIIB6101J

2.

While operating the hood opener carefully, make sure the front end of the hood is lifted by approximately
20 mm. Also, make sure the hood opener returns to the original position.

BL-11

L

M

HOOD
3.

Inspect hood lock grease, and if insufficient, apply grease to the
area shown in the figure.

PIIB5571J

BL-12

RADIATOR CORE SUPPORT
RADIATOR CORE SUPPORT
Removal and Installation

PFP:62500

A
BIS000I3

B

C

D

E

F

G
PIIB5572J

1. Radiator core support upper

2. Air guide (LH)

3. Air guide (RH)

4. bamper reinforcement

5. Food lock mounting reinforcement

6. Radiator core support upper

H

REMOVAL
Radiator Core Upper Support
1.
2.
3.
4.
5.
6.
7.
8.
9.

BL

Remove crash zone sensor.
Remove air duct.
Remove bumper reinforcement.
Remove food lock assembly.
Remove air guide.
Remove clip from washer tunk inlet, and then remove washer tunk inlet.
Remove ambient sencor.
Riemove horn.
Remove bolts, and then remove radiator core upper support.

J

K

L

Radiator Core Lower Support
1.
2.
3.
4.

5.

Remove front bamper reinforcement. Refer to EI-10, «Removal and Installation» .
Remove under cover.
Remove front bumper lower clip. Refer to EI-4, «Removal and Installation» .
Tie cord to all radiator core upper supports of the radiator and
condenser.
NOTE:
To prevent the compressor and radiator from being dropped
when the radiator core lower support is removed.
Remove bolts, and then remove radiator core lower supports.

M

PIIB5573J

6.

Remove air guide (RH) bottom clips, and remove radiator core lower supports from passenger room.

BL-13

RADIATOR CORE SUPPORT
INSTALLATION
Install in the reverse order of removal.

BL-14

FRONT FENDER
FRONT FENDER
Removal and Installation

PFP:63100

A
BIS000I4

B

C

D

E

F

G
PIIB5574J

1. Front fender

H

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

Remove side turn signal lamp. Refer to LT-111, «Removal and Installation of Side Turn Signal Lamp» .
Remove front bumper. Refer to LT-32, «Removal and Installation» .
Remove headlamps. Refer to LT-32, «Removal and Installation» .
Remove front fender finisher.
Remove fender protector front front side clip.
Remove bolts and then front fender.

BL

J

INSTALLATION
K

Install in the reverse order of removal.

L

M

BL-15

POWER DOOR LOCK SYSTEM
POWER DOOR LOCK SYSTEM
Component Parts and Harness Connector Location

PFP:24814
BIS000I5

MIIB1367E

BL-16

POWER DOOR LOCK SYSTEM
1.

BCM (Body Control Module)
M57, M58, M59

2.

Front door lock actuator
Driver side: D11
Passenger side: D28

3.

Rear door lock actuator
RH: D65
LH: D45

A

4.

Front door switch
RH: B29
LH: B14

5.

Rear door switch
RH: B42
LH: B19

6.

Key switch and ignition knob switch
connector M34
(With Intelligent Key system)

B

Key switch connector M33
(Without Intelligent Key system)

8.

Intelligent Key unit M60
(With Intelligent Key system)

9.

7.

10. Back door switch D104

11. Back door release actuator B46

System Description

Door lock/unlock switch M54

C

12. Door lock relay M20
(With Intelligent Key system)
BIS000I7

OPERATION

D

Power is supplied (Without Intelligent Key System)
●
through to 40A fusible link (letter J , located in the fusible link box)
E
●
to BCM terminal 74 and 79.
●
through 10A fuse [No.9, located in the fuse box (J/B)]
F
●
to key switch terminal 2.
Power is supplied (With Intelligent Key System)
●
through to 40A fusible link (letter J , located in the fusible link box)
G
●
to BCM terminal 74 and 79.
●
through 10A fuse [No.13, located in the fuse box (J/B)]
●
to key switch and ignition knob switch terminal 1 and 3.
H
When the key switch is ON (Ignition key is inserted in ignition key cylinder), power is supplied (Without Intelligent Key system)
●
through key switch terminal 1
BL
●
to BCM terminal 3.
When the key switch is ON (Ignition key is inserted in ignition key cylinder), power is supplied. (With Intelligent
Key system)
J
●
through key switch and ignition knob switch terminal 4
●
to BCM terminal 3.
●
to Intelligent Key unit terminal 7.
K
When the ignition switch is ON or START, power is supplied
●
through 10A fuse [No. 5, located in the fuse block (J/B)]
L
●
to BCM terminal 24.
Ground is supplied
●
through BCM terminals 2 and 70
M
●
to body ground M21 and M66.
When the front door switch LH (LHD Models) or RH (RHD Models) is ON (door is open), ground is supplied
●
through BCM terminal 29
●
through front door switch LH (LHD Models) or RH (RHD Models) terminal 1
●
to front door switch LH (LHD Models) or RH (RHD Models) case ground.
When the front door switch RH (LHD Models) or LH (RHD Models) is ON (door is open), ground is supplied
●
through BCM terminal 30
●
through front door switch RH (LHD Models) or LH (RHD Models) terminal 1
●
to front door switch RH (LHD Models) or LH (RHD Models) case ground.
When the rear door switch LH is ON (door is open), ground is supplied
●
through BCM terminal 59
●
through rear door switch LH terminal 1
●
to rear door switch LH case ground.

BL-17

POWER DOOR LOCK SYSTEM
When the rear door switch RH is ON (door is open), ground is supplied
●
through BCM terminal 60
●
through rear door switch RH terminal 1
●
to rear door switch RH case ground.

DOOR LOCK AND UNLOCK SWITCH OPERATION
When door lock/unlock switch is in LOCK position, ground is supplied
●
through BCM terminal 6.
●
through door lock/unlock switch terminal 1 and 3
●
to body grounds M21 and M66
With power and ground supplied, doors are locked.
When door lock/unlock switch is in UNLOCK position, ground is supplied
●
through BCM terminal 25
●
through door lock/unlock switch terminal 2 and 3
●
to body grounds M21 and M66
With power and ground supplied, all doors are unlocked.
Lock/unlock switch indicated by LED when key in switch is on or on with timer.

BACK DOOR SWITCH OPERATION
When the back door switch is turn on, back door is opened
Ground is supplied
●
through BCM terminal 5
●
through back door switch terminal 1 and 2
●
to body ground B13, B28, B38 and B48.

BACK DOOR RELEASE ACTUATOR OPERATION
When the back door release actuator receives a release signal from BCM
Ground is supplied
●
through BCM terminal 68
●
through back door release actuator terminal 4 and 3
●
to body ground B13, B28, B38 and B48.

BACK DOOR SWITCH OPERATION
When the back door switch is opened, ground is supplied
●
through BCM terminal 10
●
through back door switch terminal 2 and 1
●
to body ground B13, B28, B38 and B48.

KEY REMINDER SYSTEM
If the ignition key is in the ignition key cylinder and driver door is open, setting door lock/unlock switch, key or
remote controller to “LOCK” locks the door once but then immediately unlocks all doors.

UNLOCK LINK FUNCTION
When this function is activated, if the car is locked by door lock/unlock switch, opening the driver or passenger
side door from the inside handle will override the lock state and unlock the whole car.
(This function will be deactivate if anti-hijack function is activated.)

Selectable Function
Door Lock/unlock switch
How to change setting

Press unlock for more than 4 seconds

Contents

Unlock link activate/deactivate

How to confirm

Buzzer should sound for 0.2 seconds

BL-18

POWER DOOR LOCK SYSTEM
BACK DOOR OPENER OPERTION
Back door can be opened with back door switch: When all door are unlocked, or When back door request
switch is pushed (With Intelligent Key system).

AUTO RE-LOCK FUNCTION
The BCM is equipped with an auto re-lock function, when no further user action occurs after an full or partial
unlock, the doors will automatically re-lock after 2 minutes (default value). The 2 minutes timer of auto re-lock
will be reset if unlock button from the key fob is pressed. The auto re-lock function will not be activated under
the following states.
●
Key switch is ON
●
Mechanical key is inserted
●
Any door is opened
NOTE:
For the Intelligent Key system models, this function will be deactivated.

A

B

C

D

E

ANTI-HIJACK FUNCTION
With the anti-hijack function enabled, the first unlock request send from key fob will partially unlock only the
driver side door (released super lock if equipped). Then if a second unlock signal is send, then all remaining
doors will be unlocked.

CAN Communication

F

BIS000I8

SYSTEM DESCRIPTION

G

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

H

CAN Communication Unit

BL

BIS000I9

Refer to LAN-27, «CAN Communication Unit» .
J

K

L

M

BL-19

POWER DOOR LOCK SYSTEM
Schematic (Without Intelligent Key System)

BIS000IA

MIWA0688E

BL-20

POWER DOOR LOCK SYSTEM
Wiring Diagram — D/LOCK — (Without Intelligent Key System)

BIS000IB

A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0689E

BL-21

POWER DOOR LOCK SYSTEM

MIWA0690E

BL-22

POWER DOOR LOCK SYSTEM
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0691E

BL-23

POWER DOOR LOCK SYSTEM

MIWA0692E

BL-24

POWER DOOR LOCK SYSTEM
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0693E

BL-25

POWER DOOR LOCK SYSTEM
Schematic (With Intelligent Key System)

BIS000IC

MIWA0694E

BL-26

POWER DOOR LOCK SYSTEM
Wiring Diagram — D/LOCK — (With Intelligent Key System)

BIS000ID

A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0695E

BL-27

POWER DOOR LOCK SYSTEM

MIWA0696E

BL-28

POWER DOOR LOCK SYSTEM
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0697E

BL-29

POWER DOOR LOCK SYSTEM

MIWA0698E

BL-30

POWER DOOR LOCK SYSTEM
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0699E

BL-31

POWER DOOR LOCK SYSTEM

MIWA0700E

BL-32

POWER DOOR LOCK SYSTEM
Terminal and Reference Value for BCM

BIS000IE

A
Terminal

Wire
color

2

B

3

O
GR*

5

Y

6

LG

10

P

Signal
Input/
Output

Condition

Voltage (V)
(Approx.)

—

—

0

Key switch

Input

Key inserted (ON) → key removed from
Ignition key cylinder (OFF)

Battery voltage → 0

Back door switch

Input

Back door switch open operation

Door lock / unlock switch
(Lock signal)

Input

Item
Ground

Back door switch

Input

Lock operation (ON)

0

Other than above (OFF)

5

Open (ON) → Close (OFF)

Input/
Output

19*

L

CAN-H

24

O

Ignition power supply

Input

25

BR

Door lock/unlock switch
(Unlock signal)

Input

5→0

—

B

C

D

0→5
—

Ignition switch
(ON or START position)

Battery voltage

Unlock operation (ON)

0

Other than above (OFF)

5

29

LG

Front door switch LH

Input

Door open (ON) → close (OFF)

0 → Battery voltage

30

BR

Front door switch RH

Input

Door open (ON) → close (OFF)

0 → Battery voltage

32

V

Door lock status indicator

Output

Goes OFF→ Illuminates (Ignition switch
ON and all door closed)

0 → Battery voltage

Input/
Output

—

—

E

F

G

H

39*

R

CAN-L

59

G

Rear door switch LH

Input

Door open (ON) → close (OFF)

0 → Battery voltage

60

L

Rear door switch RH

Input

Door open (ON) → close (OFF)

0 → Battery voltage

67

Y

Door lock actuator unlock
(Passenger and rear LH, RH
doors)

Output

Door lock / unlock switch Unlock operation

0 → Battery voltage

J

68

O

Back door release actuator

Output

Door lock/unlock switch
(Back door release switch) Open operation

Battery voltage → 0

K

70

B

Ground (Power)

—

—

0

74

Y

Battery power supply (BCM)

Input

—

Battery voltage

76

BR

Door lock actuator unlock (DR
side door)

Output

Door lock / unlock switch Unlock operation

0 → Battery voltage

77

SB

Door lock actuator lock signal
(All doors)

Output

Door lock/unlock switch & remote controller lock operation

0 → Battery voltage

79

Y

Battery power supply (Power)

Input

—

*: With Intelligent Key system

BL-33

Battery voltage

BL

L

M

POWER DOOR LOCK SYSTEM
CONSULT- II Inspection Procedure

BIS000IF

Refer to GI-36, «CONSULT-II Start Procedure» .

CONSULT- II Application Items

BIS000IG

WORK SUPPORT
Supported Item

Description

SECURITY DOOR LOCK SET

Anti-hijack function mode can be changed in this mode.

AUTO LOCK SET

Auto locking function mode can be changed in this mode.

Security Door Lock Set
Anti hijack function

ON

OFF

Activation

Deactivation

Auto Lock Set
Auto locking function

MODE1

MODE2

MODE3

MODE4

MODE5

MODE6*

MODE7*

MODE8*

1 minute

2 minutes

3 minutes

4 minutes

5 minutes

–

–

–

*: These mode are not supported.

DATA MONITOR
Monitored Item

Description

IGN ON SW

Indicates [ON/OFF] condition of ignition switch.

PUSH SW (*1)

Indicates [ON/OFF] condition of ignition knob switch.

KEY IN SW (*2)

Indicates [ON/OFF] condition of key switch.

CDL LOCK SW

Indicates [ON/OFF] condition of lock signal from door lock/ unlock switch.

CDL UNLOCK SW

Indicates [ON/OFF] condition of unlock signal from door lock/ unlock switch.

DOOR SW-DR

Indicates [ON/OFF] condition of front door switch (driver side).

DOOR SW-AS

Indicates [ON/OFF] condition of front door switch (passenger side).

DOOR SW-RR

Indicates [ON/OFF] condition of rear door switch LH.

DOOR SW-RL

Indicates [ON/OFF] condition of rear door switch RH.

BACK DOOR SW

Indicates [ON/OFF] condition of back door switch.

TRNK OPNR SW

Indicates [ON/OFF] condition of back door switch.

*1: Models with Intelligent Key System.
*2: Models without Intelligent Key System.

ACTIVE TEST
Monitored Item

Description

DOOR LOCK

This test is able to check all door lock actuator (except for back door) lock / unlock operation.
These actuator lock / unlock when “LOCK” or “UNLOCK” on CONSULT-II screen is touched.

DOOR LOCK IND

This test is able to check door lock / unlock switch’s indicator illumination.

TRUNK / BACK DOOR

This test is able to check back door release actuator open operation.
These actuator open when “OPEN” on CONSUT-II screen is touched.

BL-34

POWER DOOR LOCK SYSTEM
Work Flow
1.
2.
3.

4.

5.

BIS000IH

Check the symptom and customer’s requests.
Understand the outline of system. Refer to BL-17, «System Description» .
According to the trouble diagnosis, repair or replace the cause of the malfunction. Refer to BL-35, «TROUBLE DIAGNOSES CHART BY SYMPTOM/WITHOUT INTELLIGENT KEY SYSTEM» or BL-36, «TROUBLE DIAGNOSES CHART BY SYMPTOM/WITH INTELLIGENT KEY SYSTEM» .
Does power door lock system operate normally?
YES: GO TO 5.
NO: GO TO 2.
INSPECTION END.

TROUBLE DIAGNOSES CHART BY SYMPTOM/WITHOUT INTELLIGENT KEY SYSTEM
NOTE:
Always check the “Work Flow” before troubleshooting. Refer to BL-35, «Work Flow» .
Symptom
Power door lock does not operate with door lock /
unlock switch.

Malfunctioning system

BL-37

2. Check door lock / unlock switch.

BL-38

3. Check front door lock actuator (driver side).

BL-42
BCS-17

1. Check door lock actuator.

BL-42

Front door lock actuator (driver side) does not operate.
(All other door lock actuators operate properly)

1. Check front door lock actuator (driver side).

BL-42

1. Check door lock actuator circuit.

BL-41

2. Replace BCM.

2. Check door switch.
3. Replace BCM.

Back door does not open.
But power door lock operates properly.

F

G

BCS-17
BL-39

BL-55

2. Check back door release actuator.

BL-57

1. Check door lock/unlock switch indicator.
2. Replace BCM.

BL

BL-46
BCS-17

1. Check back door switch.

3. Replace BCM.
Door lock/unlock switch indicator does not illuminate.
(All other door lock system is “OK”)

D

H

1. Check key switch.
Key reminder system does not operate.

C

E

Specific door lock actuator does not operate.

All door lock actuator (except driver side) does not
operate.

B

Refer to page

1. Check power supply and ground circuit of BCM.

4. Replace BCM.

A

BCS-17

J

K

BL-58
BCS-17

L

M

BL-35

POWER DOOR LOCK SYSTEM
TROUBLE DIAGNOSES CHART BY SYMPTOM/WITH INTELLIGENT KEY SYSTEM
NOTE:
Always check the “Work Flow” before troubleshooting. Refer to BL-35, «Work Flow» .
Symptom
Power door lock does not operate with door lock /
unlock switch.

Malfunctioning system

Refer to page

1. Check power supply and ground circuit of BCM.

BL-37

2. Check door lock / unlock switch.

BL-38

3. Check door lock actuator (driver side).

BL-42

4. Replace BCM.

BCS-17

Specific door lock actuator does not operate.

1. Check door lock actuator.

BL-42

Front door lock actuator (driver side) does not operate.
(All other door lock actuators operate properly)

1. Check front door lock actuator (driver side).

BL-42

1. Check door lock actuator circuit.

BL-41

All door lock actuator (except driver side) does not
operate.

Key reminder system does not operate.

2. Replace BCM.
1. Check key switch.

BL-40

2. Check door switch.

BL-46

3. Replace BCM.
Back door does not open.
But power door lock operates properly.

BCS-17

1. Check back door switch.

BL-55

2. Check back door release actuator.

BL-57

3. Replace BCM.
Door lock/unlock switch indicator does not illuminate.
(All other door lock system is “OK”)

BCS-17

1. Check door lock/unlock switch indicator.
2. Replace BCM.

BL-36

BCS-17
BL-58
BCS-17

POWER DOOR LOCK SYSTEM
Check Power Supply and Ground Circuit of BCM

BIS000II

First perform the “SELF-DIAG RESULTS” in “BCM” with CONSULT-II, then perform the each trouble diagnosis of malfunction system indicated “SELF-DIAG RESULTS” of “BCM”, Refer toBCS-9,
«CONSULT-II Function (BCM)».

1. FUSE INSPECTION
Check 10A fuse [No.5, located in fuse block (J/B)]
●
Check 40A fusible link (letter J located in the fuse and fusible link box).
●
Check 10A fuse [No.9, located in fuse block (J/B)] (Without Intelligent Key system)
●
Check 10A fuse [No.13, located in fuse block (J/B)] (With Intelligent Key system)
NOTE:
Refer to BL-16, «Component Parts and Harness Connector Location» .
OK or NG
OK
>> GO TO 2.
NG
>> PG-4, «POWER SUPPLY ROUTING CIRCUIT»If fuse is blown out, be sure to eliminate cause of
malfunction before installing new fuse. Refer to.

A

B

●

2. CHECK POWER SUPPLY CIRCUIT
1.
2.

Turn ignition switch ON.
Check voltage between BCM connector M57, M59 terminals 24, 74, 79 and ground.
24 – Ground
74 – Ground
79 – Ground

C

D

E

F

G

: Battery voltage
: Battery voltage
: Battery voltage

H

BL

OK or NG
OK
>> GO TO 3.
NG
>> Check BCM power supply circuit for open or short.

J
MIIB1111E

K

3. CHECK GROUND CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector.
Check continuity between BCM connector M57, M59 terminals 2, 70 and ground.
2 – Ground
70 – Ground

L

:Continuity should exist.
:Continuity should exist.

M

OK or NG
OK
>> Power supply and ground circuit is OK.
NG
>> Check BCM ground circuit for open or short.

MIIB0093E

BL-37

POWER DOOR LOCK SYSTEM
Check Door Lock / Unlock Switch

BIS000IJ

1. CHECK DOOR LOCK / UNLOCK SWITCH SIGNAL
With CONSULT- II
Check door lock / unlock switch input signal (“CDL LOCK SW” “CDL UNLOCK SW”) in “DATA MONITOR”
mode with CONSULT- II.
When door lock/unlock switch is turned to LOCK:
CDL LOCK SW Þ ON
When door lock/unlock switch is turned to UNLOCK:
CDL UNLOCK SW Þ ON

SIIA1566E

Without CONSULT- II
Operate door lock / unlock switch, check voltage between BCM connector M57 terminal 6, 25 and ground.
Terminals (Wire color)
Connector

(+)

(-)

6
M57

Ground
25

Condition

Voltage (V)
(Approx.)

Lock

0

Neutral / Unlock

5

Unlock

0

Neutral / Lock

5

OK or NG
OK
>> Door lock / unlock switch is OK.
NG
>> GO TO 2.

MIIB0317E

2. CHECK DOOR LOCK/UNLOCK SWITCH
1.
2.
3.

Turn ignition switch OFF.
Disconnect door lock / unlock switch connector.
Check continuity between door lock / unlock switch terminals.
Terminals
Door lock/
unlock switch

2
3
1

Condition

Continuity

Unlock

Yes

Neutral / Lock

No

Lock

Yes

Neutral / Unlock

No

OK or NG
OK
>> Check the following.
● Ground circuit for door lock / unlock switch
● Harness for open or short between BCM and door
lock / unlock switch.
NG
>> Replace door lock / unlock switch.

BL-38

MIIB1369E

POWER DOOR LOCK SYSTEM
Check Key Switch /Without Intelligent Key System

BIS000IK

1. CHECK KEY SWITCH INPUT SIGNAL

A

With CONSULT-II
Check key switch input signal “KEY IN SW” in “DATA MONITOR” mode with CONSULT- II.

B

When key is inserted in ignition key cylinder:
KEY IN SW Þ ON
When key is removed from ignition key cylinder:
KEY IN SW Þ OFF

C

D

Without CONSULT- II
Check voltage between BCM connector and ground.
Connector

M57

Terminal (Wire color)
(+)

(-)

3

Ground

Condition

Voltage (V)
(Approx.)

Key is inserted

Battery voltage

Key is removed

0

E

F

OK or NG
OK
>> Key switch is OK.
NG
>> GO TO 2.

G
MIIB0499E

H

2. CHECK KEY SWITCH
1.
2.
3.

Turn ignition switch OFF.
Disconnect key switch connector.
Check continuity between key switch terminals.
Terminals

Key switch
1

2

BL

Condition

Continuity

Key is inserted

YES

Key is removed

NO

OK or NG?
OK
>> Check the following.
● 10A fuse [No. 9, located in fuse block (J/B)].
● Harness for open or short between key switch and
fuse.
● Harness for open or short between BCM and key
switch.
NG
>> Replace key switch.

BL-39

J

K

L

MIIB1370E

M

POWER DOOR LOCK SYSTEM
Check Key Switch and Ignition Knob Switch/With Intelligent Key System

BIS000IL

1. KEY SWITCH AND IGNITION KNOB SWITCH INSPECTION
With CONSULT-II
Display “PUSH SW” on DATA MONITOR screen, and check if ONOFF display is linked to ignition knob switch operation.
When ignition knob is pushed
When ignition knob is released

: PUSH SW ON
: PUSH SW OFF

PIIB1360E

Without CONSULT- II
Check voltage between BCM connector and ground.
Connector

Terminal (Wire color)

M57

(+)

(-)

3

Ground

Condition

Voltage (V)
(Approx.)

Key is inserted

Battery voltage

Key is removed

0

OK or NG
OK
>> Key switch is OK.
NG
>> GO TO 2.
MIIB0499E

2. KEY SWITCH POWER SUPPLY CIRCUIT INSPECTION
1.
2.
3.

Remove mechanical key from ignition knob.
Disconnect key switch and ignition knob switch connector.
Check voltage between key switch and ignition knob switch connector and ground.
Key switch and
ignition knob
switch connector

Terminal

M34

2

Ground

Voltage (V)
(Approx.)
Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace key switch power supply circuit.

PIIB6598E

BL-40

POWER DOOR LOCK SYSTEM

3. KEY SWITCH OPERATION INSPECTION
1.
2.

A

Insert mechanical key into ignition knob.
Check continuity between key switch and ignition knob switch connector M34 terminal.
B
Terminal

Key switch
and ignition
knob switch

3

Condition

Continuity

Key is inserted

Yes

Key is removed

No

4

C

OK or NG
OK
>> GO TO 4.
NG
>> Replace key switch.

D

MIIB1372E

E

4. KEY SWITCH CIRCUIT INSPECTION
1.
2.

Disconnect Intelligent Key unit connector.
Check continuity between Intelligent Key unit connector and key switch and ignition knob switch connector.
A

Intelligent Key
unit connector
M60

3.

Terminal

Key switch
and ignition
knob switch
connector

Terminal

7

M34

4

Continuity

H

Yes

BL

Check continuity between key switch connector and ground.
J

Key switch and
ignition knob
switch connector

Terminal

M34

4

Continuity

MIIB1373E

Ground

K

No

OK or NG
OK
>> Key switch is OK.
NG
>> Repair or replace harness between Intelligent Key unit and key switch and ignition knob switch.

Check Door Lock Actuator Circuit

M

Disconnect BCM connector.
Check continuity between BCM connector M59 terminal 67 and front door lock actuator (passenger side)
connector D28 terminal 2.
67 – 2

: Continuity should exist.

Check continuity between BCM connector M59 terminal 67 and
ground.
67 – Ground

L

BIS000IM

1. CHECK HARNESS CONTINUITY

3.

G

B

B

1.
2.

F

: Continuity should not exist.

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Repair or replace harness.
MIIB0412E

BL-41

POWER DOOR LOCK SYSTEM
Check Door Lock Actuator

BIS000IN

DRIVER SIDE

1. CHECK DOOR LOCK ACTUATOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect front door lock actuator (driver side) connector.
Operate door lock / unlock switch, check voltage between front door lock actuator (driver side) connector
D11 terminal 4, 5 and ground.
Terminals (Wire color)

Connector

(+)

(-)

5
D11

4

Ground

Condition

Voltage (V)
(Approx.)

Unlock

0 → Battery voltage → 0

Lock

0 → Battery voltage → 0

MIIB0396E

OK or NG
OK
>> Replace front door lock actuator (driver side).
NG
>> GO TO 2.

2. CHECK HARNESS CONTINUITY
1.
2.

Disconnect BCM connector.
Check continuity between BCM connector M59 terminals 76, 77 and front door lock actuator (driver side)
connector D11 terminals 4, 5.
76 – 5
77 – 4

3.

: Continuity should exist.
: Continuity should exist.

Check continuity between BCM connector M59 terminals 76, 77
and ground.
76 – Ground
77 – Ground

: Continuity should not exist.
: Continuity should not exist.

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Repair or replace harness.

BL-42

MIIB0397E

POWER DOOR LOCK SYSTEM
PASSENGER SIDE
A

1. CHECK DOOR LOCK ACTUATOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect front door lock actuator (passenger side) connector.
Operate door lock / unlock switch, check voltage between front door lock actuator (passenger side) connector D28 terminal 2, 3 and ground.

Connector

Terminals (Wire color)
(+)
3

D28

2

C
Condition

Voltage (V)
(Approx.)

Lock

0 → Battery voltage → 0

Unlock

0 → Battery voltage → 0

(-)
Ground

B

D

E

MIIB0398E

OK or NG
OK
>> Replace front door lock actuator (passenger side).
NG
>> GO TO 2.

G

2. CHECK HARNESS CONTINUITY
1.
2.

H

Disconnect BCM connector.
Check continuity between BCM connector M59 terminals 67, 77 and front door lock actuator (passenger
side) connector D28 terminals 2, 3.
BL
67 – 2
77 – 3

3.

F

: Continuity should exist.
: Continuity should exist.

J

Check continuity between BCM connector M59 terminals 67, 77
and ground.
67 – Ground
77 – Ground

: Continuity should not exist.
: Continuity should not exist.

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Repair or replace harness.

K

L
MIIB0399E

M

BL-43

POWER DOOR LOCK SYSTEM
REAR LH SIDE

1. CHECK DOOR LOCK ACTUATOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect rear door lock actuator LH connector.
Operate door lock / unlock switch, check voltage between rear door lock actuator LH connector D45 terminal 4, 5 and ground.

Connector

Terminals (Wire color)
(+)
4

D45

5

Condition

Voltage (V)
(Approx.)

Lock

0 → Battery voltage → 0

Unlock

0 → Battery voltage → 0

(-)
Ground

MIIB0324E

OK or NG
OK
>> Replace rear door lock actuator LH.
NG
>> GO TO 2.

2. CHECK HARNESS CONTINUITY
1.
2.

Disconnect BCM connector.
Check continuity between BCM connector M59 terminals 67, 77 and rear door lock actuator LH connector
D45 terminals 4, 5.
67– 5
77– 4

3.

: Continuity should exist.
: Continuity should exist.

Check continuity between BCM connector M59 terminals 67, 77
and ground.
67 – Ground
77 – Ground

: Continuity should not exist.
: Continuity should not exist.

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Repair or replace harness.

BL-44

MIIB0325E

POWER DOOR LOCK SYSTEM
REAR RH SIDE
A

1. CHECK DOOR LOCK ACTUATOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect rear door lock actuator RH connector.
Operate door lock / unlock switch, check voltage between rear door lock actuator RH connector D65 terminal 2, 3 and ground.

Connector

Terminals (Wire color)
(+)
2

D65

3

C
Condition

Voltage (V)
(Approx.)

Unlock

0 → Battery voltage → 0

Lock

0 → Battery voltage → 0

(-)
Ground

B

D

E

MIIB0326E

OK or NG
OK
>> Replace rear door lock actuator RH.
NG
>> GO TO 2.

G

2. CHECK HARNESS CONTINUITY
1.
2.

H

Disconnect BCM connector.
Check continuity between BCM connector M59 terminals 67, 77 and rear door lock actuator RH connector
D65 terminals 2, 3.
BL
67 – 2
77 – 3

3.

F

: Continuity should exist.
: Continuity should exist.

J

Check continuity between BCM connector M59 terminals 67, 77
and ground.
67 – Ground
77 – Ground

: Continuity should not exist.
: Continuity should not exist.

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Repair or replace harness.

K

L
MIIB0327E

M

BL-45

POWER DOOR LOCK SYSTEM
Check Door Switch

BIS000IO

DRIVER SIDE

1. CHECK DOOR SWITCH INPUT SIGNAL
With CONSULT- II
Check door switch “DOOR SW-DR” in “DATA MONITOR” mode with CONSULT- II.
When front door (driver side) is opened:
DOOR SW-DR Þ ON
When front door (driver side) is close:
DOOR SW-DR Þ OFF

MIIB1050E

Without CONSULT- II
Check voltage between BCM connector and ground.
Connector

M57

Terminals (Wire color)
(+)

(-)

29

Ground

Condition

Voltage (V)
(Approx.)

Open

0

Close

Battery voltage

OK or NG
OK
>> Front door switch LH is OK.
NG
>> GO TO 2.
MIIB0342E

2. CHECK HARNESS CONTINUITY
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM and front door switch LH connector.
Check continuity between BCM connector M57 terminal 29 and front door switch LH connector B14 terminal 1.
29 – 1

4.

: Continuity should exist.

Check continuity between BCM connector M57 terminal 29 and
ground.
29 – Ground

: Continuity should not exist.

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.
MKIB0849E

BL-46

POWER DOOR LOCK SYSTEM

3. CHECK DOOR SWITCH

A

Check continuity between door switch terminal 1 and body ground part of door switch.
Terminal
1

Body ground part of door switch

Condition

Continuity

Pushed

No

Released

Yes

B

OK or NG
OK
>> GO TO 4.
NG
>> Replace door switch.

C

D
PIIA3351E

E

4. CHECK BCM OUTPUT SIGNAL
1.
2.

Connect BCM connector.
Check voltage between BCM connector M57 terminal 29 and ground.
29 – Ground

F

: Battery voltage

OK or NG
OK
>> Check door switch ground condition.
NG
>> Replace BCM.

G

H

BL
MIIB0342E

J

K

L

M

BL-47

POWER DOOR LOCK SYSTEM
PASSENGER SIDE

1. CHECK DOOR SWITCH INPUT SIGNAL
With CONSULT- II
Check door switch “DOOR SW-AS” in “DATA MONITOR” mode with CONSULT- II.
When front door (passenger side) is opened:
DOOR SW-AS Þ ON
When front door (passenger side) is close:
DOOR SW-AS Þ OFF

MIIB1051E

Without CONSULT- II
Check voltage between BCM connector M57 terminal 30 and ground.
Terminal (Wire color)
Connector

M48

(+)

(-)

30

Ground

Condition

Voltage (V)
(Approx.)

Open

0

Close

Battery voltage

OK or NG
OK
>> Front door switch RH is OK.
NG
>> GO TO 2.
MIIB0344E

2. CHECK HARNESS CONTINUITY
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM and front door switch RH connector.
Check continuity between BCM connector M57 terminal 30 and front door switch RH connector B29 terminal 1.
30 – 1

4.

: Continuity should exist.

Check continuity between BCM connector M57 terminal 30 and
ground.
30 – Ground

: Continuity should not exist.

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.
MKIB0850E

BL-48

POWER DOOR LOCK SYSTEM

3. CHECK DOOR SWITCH

A

Check continuity between door switch terminal 1 and body ground of door switch.
Terminal
1

Ground

Condition

Continuity

Pushed

No

Released

Yes

B

OK or NG
OK
>> GO TO 4.
NG
>> Replace door switch.

C

D
PIIA3351E

E

4. CHECK BCM OUTPUT SIGNAL
1.
2.

Connect BCM connector.
Check voltage between BCM connector M57 terminal 30 and ground.
30 – Ground

F

: Battery voltage

OK or NG
OK
>> Check door switch ground condition.
NG
>> Replace BCM.

G

H

BL
MIIB0344E

J

K

L

M

BL-49

POWER DOOR LOCK SYSTEM
REAR LH SIDE

1. CHECK DOOR SWITCH INPUT SIGNAL
With CONSULT- II
Check door switch “DOOR SW-RL” in “DATA MONITOR” mode with CONSULT- II.
When rear door (LH side) is opened:
DOOR SW-RL Þ ON
When rear door (LH side) is close:
DOOR SW-RL Þ OFF

MIIB1052E

Without CONSULT- II
Check voltage between BCM connector M58 terminal 59 and ground.
Terminal (Wire color)
Connector

M58

(+)

(-)

59

Ground

Condition

Voltage (V)
(Approx.)

Open

0

Close

Battery voltage

OK or NG
OK
>> Rear door switch LH is OK.
NG
>> GO TO 2.
MIIB0346E

2. CHECK HARNESS CONTINUITY
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM and rear door switch LH connector.
Check continuity between BCM connector and rear door switch LH connector.
A

4.

B
Continuity

BCM
connector

Terminal

Rear door
switch LH

Terminal

M58

59

B19

1

Yes

Check continuity between BCM connector and ground.
A

Continuity

BCM connector

Terminal

M58

59

Ground
No

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.

BL-50

MIIB1374E

POWER DOOR LOCK SYSTEM

3. CHECK DOOR SWITCH

A

Check continuity between door switch terminal 1 and body ground of door switch.
Terminals
1

Ground

Condition

Continuity

Pushed

NO

Released

YES

B

C

OK or NG
OK
>> GO TO 4.
NG
>> Replace door switch.

D
PIIA3351E

E

4. CHECK BCM OUTPUT SIGNAL
1.
2.

Connect BCM connector.
Check voltage between BCM connector M58 terminal 59 and ground.
59 – Ground

F

: Battery voltage

OK or NG
OK
>> Check door switch ground condition.
NG
>> Replace BCM.

G

H

BL
MIIB0346E

J

K

L

M

BL-51

POWER DOOR LOCK SYSTEM
REAR RH SIDE

1. CHECK DOOR SWITCH INPUT SIGNAL
With CONSULT- II
Check door switch “DOOR SW-RR” in “DATA MONITOR” mode with CONSULT- II.
When rear door (RH side) is opened:
DOOR SW-RR Þ ON
When rear door (RH side) is close:
DOOR SW-RR Þ OFF

MIIB1053E

Without CONSULT- II
Check voltage between BCM connector and ground.
Terminal (Wire color)
Connector

M58

(+)

(-)

60

Ground

Condition

Voltage (V)
(Approx.)

Open

0

Close

Battery voltage

OK or NG
OK
>> Rear door switch RH is OK.
NG
>> GO TO 2.
MIIB0348E

2. CHECK HARNESS CONTINUITY
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM and rear door switch RH connector.
Check continuity between BCM connector and rear door switch RH connector.
A

4.

B
Continuity

BCM
connector

Terminal

Rear door
switch RH

Terminal

M58

60

B42

1

Yes

Check continuity between BCM connector and ground.
A

Continuity

BCM connector

Terminal

M58

60

Ground
No

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.

BL-52

MIIB1375E

POWER DOOR LOCK SYSTEM

3. CHECK DOOR SWITCH

A

Check continuity between door switch terminal 1 and body ground of door switch.
Terminal
1

Ground

Condition

Continuity

Pushed

NO

Released

YES

B

OK or NG
OK
>> GO TO 4.
NG
>> Replace door switch.

C

D
PIIA3351E

E

4. CHECK BCM OUTPUT SIGNAL
1.
2.

Connect BCM connector.
Check voltage between BCM connector M58 terminal 60 and ground.
60 – Ground

F

: Battery voltage

OK or NG
OK
>> Check door switch ground condition.
NG
>> Replace BCM.

G

H

BL
MIIB0348E

BACK DOOR SWITCH

J

1. CHECK BACK DOOR SWITCH INPUT SIGNAL
1.
2.

Turn ignition switch OFF.
Check voltage between BCM connector M57 terminal 10 and ground.
Terminal
(+)

(–)

10

Ground

Back door condition

Voltage (V)
Approx.

Closed

5

Open

0

K

L

M

OK or NG
OK
>> Back door switch circuit is OK.
NG
>> GO TO 2
MIIB0314E

BL-53

POWER DOOR LOCK SYSTEM

2. CHECK BACK DOOR SWITCH HARNESS
1.
2.

Disconnect back door switch connector.
Check voltage between back door switch connector and ground.
(Check harness for open.)
Back door switch
connector

Terminal

B46

2

Voltage (V)
(Approx.)

Ground

Battery voltage

MIIB1376E

3.
4.

Disconnect BCM connector.
Check continuity between back door switch connector and
ground. (Check harness for short.)
Back door switch
connector

Terminal

B46

2

Continuity
Ground
No

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.
MIIB1377E

3. CHECK BACK DOOR SWITCH
Check continuity between back door switch terminal.
Terminal
Back door
switch
1

2

Rear door condition

Continuity

Closed

No

Opened

Yes

OK or NG
OK
>> GO TO 4.
NG
>> Replace back door release actuator (back door switch).
MIIB1378E

4. CHECK BACK DOOR SWITCH GROUND HARNESS
Check continuity between back door switch connector and ground.
Back door switch
connector

Terminal

B46

1

Continuity
Ground
Yes

OK or NG
OK
>> Check harness connection.
NG
>> Replace back door switch.
MIIB1379E

BL-54

POWER DOOR LOCK SYSTEM
Check Back Door Switch

BIS000IP

1. CHECK BACK DOOR SWITCH INPUT SIGNAL

A

With CONSULT- II
Check back door switch “TRNK OPNR SW” in “DATA MONITOR” mode with CONSULT- II.

B

Back door switch is pushed
TRNK OPNR SW
: ON
Back door switch is released
TRNK OPNR SW
: OFF

C

D

E
MIIB0350E

Without CONSULT- II
Check voltage between BCM connector and ground.
Terminal (Wire color)
Connector

(+)

(-)

5

Ground

M57

F

Condition

Voltage (V)
(Approx.)

Pushed

0

Released

5

G

H

OK or NG
OK
>> Back door switch is OK.
NG
>> GO TO 2.

BL
MIIB0719E

2. CHECK HARNESS CONTINUITY

J

1.
2.
3.

K

Turn ignition switch OFF.
Disconnect BCM and back door switch connector.
Check continuity between BCM connector and back door switch connector.
A

4.

BCM
connector
M57

B

L
Continuity

Terminal

Back door
switch connector

Terminal

5

D104

1

M

Yes

Check continuity between BCM connector and ground.
A

Continuity

BCM connector

Terminal

M57

5

Ground
No

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.

BL-55

MIIB1380E

POWER DOOR LOCK SYSTEM

3. CHECK BACK DOOR SWITCH
Check continuity between back door switch terminals.
Terminals
Back door
switch

1

2

Condition

Continuity

Pushed

Yes

Released

No

OK or NG
OK
>> GO TO 4.
NG
>> Replace back door switch.

MIIB1381E

4. CHECK BCM OUTPUT SIGNAL
1.
2.

Connect BCM connector.
Check voltage between BCM connector M57 terminal 5 and ground.
5 – Ground

: Approx. 5V

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Replace BCM.

MIIB0351E

BL-56

POWER DOOR LOCK SYSTEM
Check Back Door Release Actuator

BIS000IQ

1. CHECK BCM OUTPUT SIGNAL

A

Check back door release output signal
Perform (“TRUNK/BACK DOOR”) in “ACTIVE TEST” mode with CONSULT-II.

B

When “ACTIVE TEST” is executed, does the back door
open?
C

OK or NG
OK
>> Back door release output is OK.
NG
>> GO TO 2.

D

E
MIIB0354E

2. CHECK BACK DOOR RELEASE ACTUATOR
1.
2.
3.

F

Turn ignition switch OFF.
Disconnect back door release actuator connector.
Operate back door switch, check voltage between back door release actuator connector B46 terminal 4
and ground.
Terminal

Connector

back door
switch
connector

B46

(+)

(-)

4

Ground

Condition

Voltage (V)
(Approx.)

Pushed

0 → Battery voltage
→0

G

H

BL

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

J
MIIB1382E

K

3. CHECK HARNESS CONTINUITY
1.
2.

Disconnect BCM connector.
Check continuity between BCM connector and back door release actuator connector.
A

3.

BCM
connector
M59

L

B
Terminal

Back door
release actuator
connector

Terminal

68

B46

4

M

Continuity

Yes

Check continuity between BCM connector and ground.
A
BCM connector

Terminal

M59

68

Ground

Continuity
MIIB1383E

No

OK or NG
OK
>> Replace BCM.
NG
>> Repair or replace harness.

BL-57

POWER DOOR LOCK SYSTEM

4. CHECK GROUND CIRCUIT
Check continuity between back door release actuator connector and ground.
Back door release
actuator connector

Terminal

B46

3

Ground

Continuity
Yes

OK or NG
OK
>> Replace back door release actuator.
NG
>> Repair or replace harness.

MIIB1384E

Check Door Lock/Unlock Switch Indicator

BIS00160

1. CHECK DOOR LOCK/UNLOCK SWITCH INDICATOR
Check continuity between door lock/unlock switch indicator harness
connector terminals 3 and 5.
Terminals

Continuity

(+)

(-)

5

3

Yes

3

5

No

OK or NG
OK
>> Check harness for open or short between BCM and
door lock/unlock switch.
NG
>> replace door lock/unlock switch.

BL-58

MIIB1442E

POWER DOOR LOCK — SUPER LOCK —
POWER DOOR LOCK — SUPER LOCK —
Component Parts and Harness Connector Location

PFP:24814

A
BIS000IW

B

C

D

E

F

G

H

BL

J

K

L

M

MIIB1367E

BL-59

POWER DOOR LOCK — SUPER LOCK —
1.

BCM (Body control Module)
M57,M58, M59

2.

Front door lock actuator
Driver side: D11
Passenger side: D28

3.

Rear door lock actuator
RH: D65
LH: D45

4.

Front door switch
RH: B29
LH: B14

5.

Rear door switch
RH: B42
LH: B19

6.

Key switch and ignition knob
switch connector M34
(With Intelligent Key system)

7.

Key switch connector M33
(without Intelligent Key system)

8.

Intelligent Key unit M60
(With Intelligent Key system)

9.

Door lock/unlock switch M54

10. back door switch D104

11. Back door release actuator B46

System Description

12. Door lock relay M20
(With Intelligent Key system)
BIS000IY

OPERATION
Power is supplied (Without Intelligent Key System)
●
through to 40A fusible link (letter J , located in the fusible link box)
●
to BCM terminal 74 and 79.
●
through 10A fuse [No.9, located in the fuse box (J/B)]
●
to key switch terminal 2.
Power is supplied (With Intelligent Key System)
●
through to 40A fusible link (letter J , located in the fusible link box)
●
to BCM terminal 74 and 79.
●
through 10A fuse [No.13, located in the fuse box (J/B)]
●
to key switch and ignition knob switch terminal 1 and 3.
When the key switch is ON (Ignition key is inserted in ignition key cylinder), power is supplied (Without Intelligent Key system)
●
through key switch terminal 1
●
to BCM terminal 3.
When the key switch is ON (Ignition key inserted key cylinder), power is supplied (With Intelligent Key system)
●
through key switch and ignition knob switch terminal 4
●
to BCM terminal 3.
●
to Intelligent Key unit terminal 7.
When the ignition switch is ON or START, power is supplied
●
through 10A fuse [No. 5, located in the fuse block (J/B)]
●
to BCM terminal 24.
Ground is supplied
●
through BCM terminals 2 and 70
●
to body ground M21 and M66.
When the front door switch LH (LHD Models) or RH (RHD Models) is ON (door is open), ground is supplied
●
through BCM terminal 29
●
through front door switch LH (LHD Models) or RH (RHD Models) terminal 1
●
to front door switch LH (LHD Models) or RH (RHD Models) case ground.
When the front door switch RH (LHD Models) or LH (RHD Models) is ON (door is open), ground is supplied
●
through BCM terminal 30
●
through front door switch RH (LHD Models) or LH (RHD Models) terminal 1
●
to front door switch RH (LHD Models) or LH (RHD Models) case ground.
When the rear door switch LH is ON (door is open), ground is supplied
●
through BCM terminal 59
●
through rear door switch LH terminal 1
●
to rear door switch LH case ground.
When the rear door switch RH is ON (door is open), ground is supplied
●
through BCM terminal 60

BL-60

POWER DOOR LOCK — SUPER LOCK —
●
●

through rear door switch RH terminal 1
to rear door switch RH case ground.

A

DOOR LOCK AND UNLOCK SWITCH OPERATION
When door lock/unlock switch is in LOCK position, ground is supplied
●
through BCM terminal 6.
●
through door lock/unlock switch terminal 2 and 3
●
to body grounds M21 and M66
With power and ground supplied, doors are locked.
When door lock/unlock switch is in UNLOCK position, ground is supplied
●
through BCM terminal 25
●
through door lock/unlock switch terminal 2 and 3
●
to body grounds M21and M66
With power and ground supplied, all doors are unlocked.
Lock/unlock switch indicated by LED when key in switch is on or on with timer.

BACK DOOR SWITCH OPERATION

B

C

D

E

F

When the back door switch is turn on, back door is opened
Ground is supplied
●
through BCM terminal 5
●
through back door switch terminal 1 and 2
●
to body ground B13, B28, B38 and B48.

G

BACK DOOR RELEASE ACTUATOR OPERATION

H

When the back door release actuator receives a release signal from BCM
Ground is supplied
●
through BCM terminal 68
●
through back door release actuator terminal 4 and 3
●
to body ground B13, B28, B38 and B48.

BL

J

BACK DOOR SWITCH OPERATION
When the back door switch is opened, ground is supplied
●
through BCM terminal 10
●
through back door switch terminal 2 and 1
●
to body ground B13, B28, B38 and B48.

K

L

KEY REMINDER SYSTEM
●

If the ignition key is in the ignition key cylinder and driver door is open, setting door lock/unlock switch, key
or remote controller to “LOCK” locks the door once but then immediately unlocks all doors.

UNLOCK LINK FUNCTION
When this function is activated, if the car is locked by door lock/unlock switch, opening the driver or passenger
side door from the inside handle will override the lock state and unlock the whole car.
(This function will be deactivate if anti-hijack function is activated.)

Selectable Function
Door Lock/unlock switch
How to change setting

Press unlock for more than 4 seconds

Contents

Unlock link activate/deactivate

How to confirm

Buzzer should sound for 0.2 seconds

BACK DOOR OPENER OPERTION
Back door can be opened with back door switch: When all door are unlocked, or When back door request
switch is pushed (With Intelligent Key system).

BL-61

M

POWER DOOR LOCK — SUPER LOCK —
AUTO RE-LOCK FUNCTION
The BCM is equipped with an auto re-lock function, when no further user action occurs after an full or partial
unlock, the doors will automatically re-lock after 2 minutes (default value). The 2 minutes timer of auto re-lock
will be reset if unlock button from the key fob is pressed. The auto re-lock function will not be activated under
the following states.
●
Key switch is ON
●
Mechanical key is inserted
●
Any door is opened
NOTE:
For the Intelligent Key system models, this function will be deactivated.

ANTI-HIJACK FUNCTION
With the anti-hijack function enabled, the first unlock request send from key fob will partially unlock only the
driver side door (released super lock if equipped). Then if a second unlock signal is send, then all remaining
doors will be unlocked.

SUPER LOCK OPERATION
When super lock is set, ground is supplied
●
through BCM terminals 75
●
through each super lock actuators terminals 1 and 2
●
to BCM terminal 76
When super lock is released, ground is supplied
●
through BCM terminal 76
●
through each super lock actuators terminals 2 and 1
●
to BCM terminals 75
Door lock and unlock switch operation
When door lock/unlock switch is in LOCK position, ground is supplied

OUTLINE
Power door lock system with super lock and key reminder is controlled by BCM (Body Control Module). Super
lock has a higher anti-theft performance than conventional power door lock systems.
When super lock is in released condition, lock/unlock switch operation locks or unlocks door.
When super lock is in set condition, door operation cannot lock nor unlock door.

OPERATION
Power Door Lock / Unlock and Super Lock Set / Release Operation by Remote Controller or
Intelligent Key
●

●

Pressing remote controller LOCK button will lock all doors and set super lock. (Super lock will not be set
while key is inserted in the ignition key cylinder.)
Pressing remote controller UNLOCK button once will unlock driver door and release super lock. Then, if
an unlock signal is sent from the remote controller again, all other doors will be unlocked.

Power Door Lock / Unlock and Super Lock Release Operation by Door Key Cylinder
With the key inserted into driver door key cylinder, turning it to UNLOCK will unlock the door and release super
lock.

Power Door Lock and Super Lock Release Operation
When the super lock is set, turning the ignition key switch to ON will release the super lock. All doors will
unlock once, but then immediately lock again.

BL-62

POWER DOOR LOCK — SUPER LOCK —
CAN Communication

BIS000IZ

SYSTEM DESCRIPTION

A

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.

B

CAN Communication Unit

C

BIS000J0

Refer to LAN-27, «CAN Communication Unit» .

D

E

F

G

H

BL

J

K

L

M

BL-63

POWER DOOR LOCK — SUPER LOCK —
Schematic – S/LOCK – (Without Intelligent Key System)

BIS000J1

MIWA0701E

BL-64

POWER DOOR LOCK — SUPER LOCK —
Wiring Diagram — S/LOCK — (Without Intelligent Key System)

BIS000J2

A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0702E

BL-65

POWER DOOR LOCK — SUPER LOCK —

MIWA0703E

BL-66

POWER DOOR LOCK — SUPER LOCK —
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0704E

BL-67

POWER DOOR LOCK — SUPER LOCK —

MIWA0705E

BL-68

POWER DOOR LOCK — SUPER LOCK —
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0706E

BL-69

POWER DOOR LOCK — SUPER LOCK —

MIWA0707E

BL-70

POWER DOOR LOCK — SUPER LOCK —
Schematic – S/LOCK – (With Intelligent Key System)

BIS000J3

A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0708E

BL-71

POWER DOOR LOCK — SUPER LOCK —
Wiring Diagram — S/LOCK — (With Intelligent Key System)

BIS000J4

MIWA0709E

BL-72

POWER DOOR LOCK — SUPER LOCK —
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0710E

BL-73

POWER DOOR LOCK — SUPER LOCK —

MIWA0711E

BL-74

POWER DOOR LOCK — SUPER LOCK —
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0712E

BL-75

POWER DOOR LOCK — SUPER LOCK —

MIWA0713E

BL-76

POWER DOOR LOCK — SUPER LOCK —
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0714E

BL-77

POWER DOOR LOCK — SUPER LOCK —
Terminal and Reference Value for BCM
Terminal

Wire
color

2

B

3

O
(GR)

5

Y

6

LG

10

Item
Ground

BIS000J5

Signal
Input/
Output

Condition

Voltage (V)
(Approx.)

—

—

0

Key switch

Input

Key inserted (ON) → key removed
from IGN key cylinder (OFF)

Back door switch

Input

Release switch open operation

Door lock / unlock switch
(Lock signal)

Input

P

Back door switch

Input

(19)

L

CAN-H

24

O

IGN power supply

Input

25

BR

Door lock/unlock switch
(Unlock signal)

Input

Battery voltage → 0
5→0

Lock operation (ON)

0

Other than above (OFF)

5

Open (ON) → Close (OFF)

Input/
Output

—

0→5
—

Ignition switch
(ON or START position)

Battery voltage

Unlock operation (ON)

0

Other than above (OFF)

5

29

BR

Front door switch RH

Input

Door open (ON) → close (OFF)

0 → Battery voltage

30

LG

Front door switch LH

Input

Door open (ON) → close (OFF)

0 → Battery voltage

32

V

Door lock status indicator

Output

Goes OFF→ Illuminates (Ignition
switch ON and all door closed)

0 → Battery voltage

(39)

Y

CAN-L

Input/
Output

59

G

Rear door switch LH

Input

Door open (ON) → close (OFF)

0 → Battery voltage

60

L

Rear door switch RH

Input

Door open (ON) → close (OFF)

0 → Battery voltage

67

Y

Door lock actuator & super lock
actuator unlock signal
(Passenger and rear LH, RH
doors)

Output

Door lock / unlock switch & remote
controller unlock operation *

0 → Battery voltage

68

O

Back door release actuator

Output

Door lock/unlock switch
(Back door release switch) Open
operation

Battery voltage → 0

70

B

Ground (Power)

74

Y

BAT power supply (BCM)

75

O

Super lock actuator lock signal
(All doors)

Output

Remote controller
lock operation

0 → Battery voltage

76

BR

Door lock actuator & super lock
actuator unlock signal (Driver
side)

Output

Door lock / unlock switch & remote
controller unlock operation *

0 → Battery voltage

77

SB

Door lock actuator lock signal
(All doors)

Output

Door lock/unlock switch & remote
controller lock operation

0 → Battery voltage

79

Y

BAT power supply (PW)

—

—

—

—

0

Input

—

Battery voltage

Input

(): With Intelligent Key system models
*: Door lock actuator operation activated by door lock/unlock switch.

BL-78

—

Battery voltage

POWER DOOR LOCK — SUPER LOCK —
CONSULT- II Inspection Procedure

BIS000J6

A

Refer to GI-36, «CONSULT-II Start Procedure» .

CONSULT- II Application Items

BIS000J7

WORK SUPPORT

B

Supported Item

Description

SECURITY DOOR LOCK SET

Anti-hijack function mode can be changed in this mode.

AUTO LOCK SET

Auto re-locking function mode can be changed in this mode.

C

Security Door Lock Set

D

Anti hijack function

ON

OFF

Activation

Deactivation

E

Auto Lock Set
Auto locking function

MODE1

MODE2

MODE3

MODE4

MODE5

MODE6*

MODE7*

MODE8*

1 minute

2 minutes

3 minutes

4 minutes

5 minutes

–

–

–

F

*: These mode are not supported.

DATA MONITOR

G

Monitored Item

Description

IGN ON SW

Indicates [ON/OFF] condition of ignition switch.

PUSH SW (*1)

Indicates [ON/OFF] condition ignition knob switch.

KEY IN SW (*2)

Indicates [ON/OFF] condition of key switch.

CDL LOCK SW

Indicates [ON/OFF] condition of lock signal from door lock/ unlock switch.

CDL UNLOCK SW

Indicates [ON/OFF] condition of unlock signal from door lock/ unlock switch.

DOOR SW-DR

Indicates [ON/OFF] condition of front door switch (driver side).

DOOR SW-AS

Indicates [ON/OFF] condition of front door switch (passenger side).

DOOR SW-RR

Indicates [ON/OFF] condition of rear door switch (RH).

DOOR SW-RL

Indicates [ON/OFF] condition of rear door switch (LH).

BACK DOOR SW

Indicates [ON/OFF] condition of back door switch.

TRNK OPNR SW

Indicates [ON/OFF] condition of back door switch.

H

BL

J

K

L

*1: Models with Intelligent Key system.
*2: Models without Intelligent Key system.

ACTIVE TEST

M

Monitored Item

Description

DOOR LOCK

This test is able to check all door lock actuator (except for back door) lock / unlock operation.
Actuators lock / unlock when “LOCK” or “UNLOCK” on CONSULT-II screen is touched.

SUPER LOCK

This test is able to check super lock actuator lock / unlock operation.
Actuators lock / unlock when “LOCK” or “UNLOCK” on CONSULT-II screen is touched.

DOOR LOCK IND

This test is able to check door lock / unlock switch’s illumination.

TRUNK / BACK DOOR

This test is able to check back door release actuator open operation.
These actuator open when “OPEN” on CONSUT-II screen is touched.

Work Flow
1.
2.
3.

4.

BIS000J8

Check the symptom and customer’s requests.
Understand the outline of system. Refer to BL-17, «System Description» .
According to the trouble diagnosis, repair or replace the cause of the malfunction. Refer to BL-35, «TROUBLE DIAGNOSES CHART BY SYMPTOM/WITHOUT INTELLIGENT KEY SYSTEM» or BL-36, «TROUBLE DIAGNOSES CHART BY SYMPTOM/WITH INTELLIGENT KEY SYSTEM» .
Does power door lock system operate normally?

BL-79

POWER DOOR LOCK — SUPER LOCK —

5.

YES: GO TO 5.
NO: GO TO 2.
INSPECTION END.

BL-80

POWER DOOR LOCK — SUPER LOCK —
Trouble Diagnoses

BIS000J9

A

PRELIMINARY CHECK/WITHOUT INTELLIGENT KEY SYSTEM

B

C

D

E

F

G

H

BL

J

K

L

M

MIIB1440E

BL-81

POWER DOOR LOCK — SUPER LOCK —
SYMPTOM CHART/WITHOUT INTELLIGENT KEY SYSTEM
NOTE:
Before starting trouble diagnosis below, perform Preliminary Check BL-81, «PRELIMINARY CHECK/
WITHOUT INTELLIGENT KEY SYSTEM» .
Symptom numbers in the symptom chart correspond with those of Preliminary check.
Symptom

Diagnosis/service procedure

Reference page

1. Check power supply and ground circuit

BL-85

2. Check door lock/unlock switch

BL-86

3. Check door switch (except back door switch)

BL-99

4. Check front door lock actuator (driver side)

BL-91

1. Check front door lock actuator (driver side)

BL-92

1. Check front door lock actuator (driver side)

BL-91

2. Check front door lock actuator (passenger side)

BL-92

3. Check rear door lock actuator LH

BL-93

4. Check rear door lock actuator RH

BL-94

1. Check key switch

BL-87

2. Check super lock actuator (driver side)

BL-95

1. Check super lock actuator (driver side)

BL-95

2. Check super lock actuator (passenger side)

BL-96

3. Check super lock actuator (rear LH)

BL-97

4. Check super lock actuator (rear RH)

BL-98

1.Check ignition switch ON circuit

BL-85

SYMPTOM 7
Key reminder system does not operate.

1. Check key switch

BL-87

SYMPTOM 8
Door lock indicator does not illuminate.

1. Check door lock/unlock switch indicator lamp

SYMPTOM 1
Power door lock does not operate by using door lock/
unlock switch.
SYMPTOM 2
All door lock actuators except driver side does not operate using door lock/unlock switch.
SYMPTOM 3
Specific door lock actuator does not operate using door
lock/unlock switch.

SYMPTOM 4
Super lock does not operate by using Key fob.

SYMPTOM 5
Specific super lock actuator does not operate.

SYMPTOM 6
Super lock cannot be released by ignition switch.

2. If above systems are OK, replace BCM.

2. If above systems are OK, replace BCM.

BL-82

BCS-17
BL-58
BCS-17

POWER DOOR LOCK — SUPER LOCK —
PRELIMINARY CHECK/WITH INTELLIGENT KEY SYSTEM
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIIB1441E

BL-83

POWER DOOR LOCK — SUPER LOCK —
SYMPTOM CHART/WITH INTELLIGENT KEY SYSTEM
NOTE:
Before starting trouble diagnosis below, perform Preliminary Check BL-83, «PRELIMINARY CHECK/
WITH INTELLIGENT KEY SYSTEM» .
Symptom numbers in the symptom chart correspond with those of Preliminary check.
Symptom

Diagnosis/service procedure

Reference page

1. Check power supply and ground circuit

BL-85

2. Check door lock/unlock switch

BL-86

3. Check door switch (except back door switch)

BL-99

4. Check front door lock actuator (driver side)

BL-95

1. Check front door lock actuator (driver side)

BL-96

1. Check front door lock actuator (driver side)

BL-95

2. Check front door lock actuator (passenger side)

BL-96

3. Check rear door lock actuator LH

BL-97

4. Check rear door lock actuator RH

BL-98

1. Check key switch and ignition knob switch

BL-88

2. Check super lock actuator (driver side)

BL-95

1. Check super lock actuator (driver side)

BL-95

2. Check super lock actuator (passenger side)

BL-96

3. Check super lock actuator (rear LH)

BL-97

4. Check super lock actuator (rear RH)

BL-98

1. Check ignition switch ON circuit

BL-85

SYMPTOM 7
Key reminder system does not operate.

1. Check key switch and ignition switch

BL-88

SYMPTOM 8
Door lock indicator does not illuminate.

1. Check door lock/unlock switch indicator lamp

SYMPTOM 1
Power door lock does not operate by using door lock/
unlock switch.
SYMPTOM 2
All door lock actuators except driver side does not operate using door lock/unlock switch.
SYMPTOM 3
Specific door lock actuator does not operate using door
lock/unlock switch.

SYMPTOM 4
Super lock does not operate by using Intelligent Key.

SYMPTOM 5
Specific super lock actuator does not operate.

SYMPTOM 6
Super lock cannot be released by ignition switch.

2. If above systems are OK, replace BCM.

2. If above systems are OK, replace BCM.

BL-84

BCS-17
BL-58
BCS-17

POWER DOOR LOCK — SUPER LOCK —
Check Power Supply and Ground Circuit

BIS000JA

First perform the “SELF-DIAG RESULTS” in “BCM” with CONSULT-II, then perform the each trouble diagnosis of malfunction system indicated “SELF-DIAG RESULTS” of “BCM”, Refer to BCS-9,
«CONSULT-II Function (BCM)» .

1. FUSE INSPECTION
Check 10A fuse [No.5, located in fuse block (J/B)]
●
Check 40A fusible link (letter J located in the fuse and fusible link box).
●
Check 10A fuse [No.9, located in fuse block (J/B)] (Without Intelligent Key system)
●
Check 10A fuse [No.13, located in fuse block (J/B)] (With Intelligent Key system)
NOTE:
Refer to BL-59, «Component Parts and Harness Connector Location» .
OK or NG
OK
>> GO TO 2
NG
>> If fuse is blown out, be sure to eliminate cause of malfunction before installing new fuse. Refer to
PG-4, «POWER SUPPLY ROUTING CIRCUIT» .

A

B

●

2. CHECK POWER SUPPLY CIRCUIT
1.
2.

Turn ignition switch ON.
Check voltage between BCM connector M57, M59 terminals 24, 79 and ground.
24 – Ground
74 – Ground
79 – Ground

C

D

E

F

G

:Battery voltage.
:Battery voltage.
:Battery voltage.

H

BL

OK or NG
OK
>> GO TO 3
NG
>> Check BCM power supply circuit for open or short.

J
MIIB1111E

K

3. CHECK GROUND CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM connector.
Check continuity between BCM connector M57, M59 terminals 2, 70 and ground.
2 – Ground
70 – Ground

L

:Continuity should exist.
:Continuity should exist.

M

OK or NG
OK
>> Power supply and ground circuit is OK.
NG
>> Check BCM ground circuit for open or short.

MIIB0093E

BL-85

POWER DOOR LOCK — SUPER LOCK —
Check Door Lock / Unlock Switch

BIS000JB

1. CHECK DOOR LOCK / UNLOCK SWITCH SIGNAL
With CONSULT- II
Check door lock / unlock switch input signal (“CDL LOCK SW” “CDL UNLOCK SW”) in “DATA MONITOR”
mode with CONSULT- II.
When door lock/unlock switch is turned to LOCK:
CDL LOCK SW Þ ON
When door lock/unlock switch is turned to UNLOCK:
CDL UNLOCK SW Þ ON

SIIA1566E

Without CONSULT- II
Operate door lock / unlock switch, check voltage between BCM connector and ground.
Terminals (Wire color)
Connector

(+)

(-)

6
M57

Ground
25

Condition

Voltage (V)
(Approx.)

Lock

0

Neutral / Unlock

5

Unlock

0

Neutral / Lock

5

OK or NG
OK
>> Door lock / unlock switch is OK.
NG
>> GO TO 2.

MIIB0721E

2. CHECK DOOR LOCK/UNLOCK SWITCH
1.
2.
3.

Turn ignition switch OFF.
Disconnect door lock / unlock switch connector.
Check continuity between door lock / unlock switch terminals.
Terminals

Door lock/
unlock switch

2
3
1

Condition

Continuity

Unlock

YES

Neutral / Lock

NO

Lock

YES

Neutral / Unlock

NO

OK or NG
OK
>> Check the following.
● Ground circuit for door lock / unlock switch
● Harness for open or short between BCM and door
lock / unlock switch.
NG
>> Replace door lock / unlock switch.

BL-86

MIIB1369E

POWER DOOR LOCK — SUPER LOCK —
Check Key Switch /Without Intelligent Key System

BIS000JC

1. CHECK KEY SWITCH INPUT SIGNAL

A

With CONSULT-II
Check key switch input signal “KEY ON SW” in “DATA MONITOR” mode with CONSULT- II.

B

When key is inserted in ignition key cylinder:
KEY IN SW Þ ON
When key is removed from ignition key cylinder:
KEY IN SW Þ OFF

C

D

Without CONSULT- II
Check voltage between BCM connector and ground.
Connector

M57

Terminal (Wire color)
(+)

(-)

3

Ground

Condition

Voltage (V)
(Approx.)

Key is inserted

Battery voltage

Key is removed

0

E

F

OK or NG
OK
>> Key switch is OK.
NG
>> GO TO 2.

G
MIIB0499E

H

2. CHECK KEY SWITCH (INSERT)
1.
2.
3.

Turn ignition switch OFF.
Disconnect key switch connector.
Check continuity between key switch terminals.
Terminals
Key switch
1

2

BL

Condition

Continuity

Key is inserted

YES

Key is removed

NO

OK or NG?
OK
>> Check the following.
● 10A fuse [No. 9, located in fuse block (J/B)].
● Harness for open or short between key switch and
fuse.
● Harness for open or short between BCM and key
switch.
NG
>> Replace key switch.

BL-87

J

K

L

MIIB1370E

M

POWER DOOR LOCK — SUPER LOCK —
Check Key Switch And Ignition Knob Switch/With Intelligent Key System

BIS000JD

1. KEY SWITCH AND IGNITION KNOB SWITCH INSPECTION
With CONSULT-II
Display “PUSH SW” on DATA MONITOR screen, and check if ONOFF display is linked to ignition knob switch operation.
When ignition knob is pushed
When ignition knob is released

: PUSH SW ON
: PUSH SW OFF

PIIB1360E

Without CONSULT- II
Check voltage between BCM connector and ground.
Connector

Terminal (Wire color)

M57

(+)

(-)

3

Ground

Condition

Voltage (V)
(Approx.)

Key is inserted

Battery voltage

Key is removed

0

OK or NG
OK
>> Key switch is OK.
NG
>> GO TO 2.
MIIB0499E

2. KEY SWITCH POWER SUPPLY CIRCUIT INSPECTION
1.
2.
3.

Remove mechanical key from ignition knob.
Disconnect key switch and ignition knob switch connector.
Check voltage between key switch and ignition knob switch connector and ground.
Key switch and
ignition knob
switch connector

Terminal

M34

2

Ground

Voltage (V)
(Approx.)
Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace key switch power supply circuit.

PIIB6598E

BL-88

POWER DOOR LOCK — SUPER LOCK —

3. KEY SWITCH OPERATION INSPECTION
1.
2.

A

Insert mechanical key into ignition knob.
Check continuity between key switch and ignition knob switch connector M34 terminal.
B
Terminal

Key switch
and ignition
knob switch

3

4

Condition

Continuity

Key is inserted

Yes

Key is removed

No

C

OK or NG
OK
>> GO TO 4.
NG
>> Replace key switch.

D

MIIB1372E

E

4. KEY SWITCH CIRCUIT INSPECTION
1.
2.

Disconnect Intelligent Key unit connector.
Check continuity between Intelligent Key unit connector and key switch and ignition knob switch connector.
A

Intelligent Key
unit connector
M60

3.

F

G

B

Terminal

Key switch
and ignition
knob switch
connector

Terminal

7

M34

4

Continuity

H

Yes

BL

Check continuity between key switch connector and ground.
B

J

Key switch and
ignition knob
switch connector

Terminal

M34

4

Continuity

MIIB1373E

Ground

K

No

OK or NG
OK
>> Key switch is OK.
NG
>> Repair or replace harness between Intelligent Key unit and key switch and ignition knob switch.

Check Power Door Lock / Unlock Output Signal

BIS000JE

1. CHECK POWER DOOR LOCK OUTPUT SIGNAL

M

Operate door lock / unlock switch, check voltage between BCM connector and ground.
Connector

Terminals (Wire color)
(+)
67

M59

76
77

Condition

Voltage (V)
(Approx.)

Unlock

0 → Battery voltage→ 0

Unlock

0 → Battery voltage→ 0

Lock

0 → Battery voltage→ 0

(-)

Ground

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Replace BCM.
MIIB0319E

BL-89

L

POWER DOOR LOCK — SUPER LOCK —
Check Super Lock Output Signal

BIS000JF

1. CHECK SUPER LOCK OUTPUT SIGNAL
Operate remote controller, check voltage between BCM connector and ground.
Terminals (Wire color)
Connector
M59

(+)

(-)

75

Ground

Condition
Lock button is
pressed.

Voltage (V)
(Approx.)
0 → Battery voltage→ 0

OK or NG
OK
>> Check the condition of the harness and connector.
NG
>> Replace BCM.
MIIB0722E

BL-90

POWER DOOR LOCK — SUPER LOCK —
Check Door Lock Actuator

BIS000JG

A

DRIVER SIDE

1. CHECK DOOR LOCK ACTUATOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect front door lock actuator (driver side) connector.
Operate door lock / unlock switch, check voltage between front door lock actuator (driver side) connector
and ground.
Terminals (Wire color)

Connector

(+)

(-)

2
D11

3

Ground

Condition

Voltage (V)
(Approx.)

Unlock

0 → Battery voltage → 0

Lock

0 → Battery voltage → 0

B

C

D

E

F
MIIB0320E

OK or NG
OK
>> Replace front door lock actuator (driver side).
NG
>> GO TO 2.

G

2. CHECK HARNESS CONTINUITY
1.
2.

Disconnect BCM connector.
Check continuity between BCM connector M59 terminals 76, 77 and front door lock actuator (driver side) BL
connector D11 terminals 2, 3.
76 – 2
77 – 3

3.

H

: Continuity should exist.
: Continuity should exist.

J

Check continuity between BCM connector M59 terminals 76, 77
and ground.
76 – Ground
77 – Ground

K

: Continuity should not exist.
: Continuity should not exist.

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Repair or replace harness.

BL-91

L
MIIB0321E

M

POWER DOOR LOCK — SUPER LOCK —
PASSENGER SIDE

1. CHECK DOOR LOCK ACTUATOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect front door lock actuator (passenger side) connector.
Operate door lock / unlock switch, check voltage between front door lock actuator (passenger side) connector and ground.

Connector

Terminals (Wire color)
(+)
4

D28

5

Condition

Voltage (V)
(Approx.)

Lock

0 → Battery voltage → 0

Unlock

0 → Battery voltage → 0

(-)
Ground

MIIB0322E

OK or NG
OK
>> Replace front door lock actuator (passenger side).
NG
>> GO TO 2.

2. CHECK HARNESS CONTINUITY
1.
2.

Disconnect BCM connector.
Check continuity between BCM connector M59 terminals 67, 77 and front door lock actuator (passenger
side) connector D28 terminals 4, 5.
67 – 5
77 – 4

3.

: Continuity should exist.
: Continuity should exist.

Check continuity between BCM connector M59 terminal 67, 77
and ground.
67 – Ground
77 – Ground

: Continuity should not exist.
: Continuity should not exist.

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Repair or replace harness.

BL-92

MIIB0323E

POWER DOOR LOCK — SUPER LOCK —
REAR LH SIDE
A

1. CHECK DOOR LOCK ACTUATOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect rear door lock actuator LH connector.
Operate door lock / unlock switch, check voltage between rear door lock actuator LH connector and
ground.

Connector

Terminals (Wire color)
(+)
4

D45

5

C
Condition

Voltage (V)
(Approx.)

Lock

0 → Battery voltage → 0

Unlock

0 → Battery voltage → 0

(-)
Ground

B

D

E

MIIB0324E

OK or NG
OK
>> Replace rear door lock actuator LH.
NG
>> GO TO 2.

G

2. CHECK HARNESS CONTINUITY
1.
2.

H

Disconnect BCM connector.
Check continuity between BCM connector M59 terminals 67, 77 and rear door lock actuator LH connector
D45 terminals 4, 5.
BL
67 – 5
77 – 4

3.

F

: Continuity should exist.
: Continuity should exist.

J

Check continuity between BCM connector M59 terminals 67, 77
and ground.
67 – Ground
77 – Ground

: Continuity should not exist.
: Continuity should not exist.

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Repair or replace harness.

K

L
MIIB0325E

M

BL-93

POWER DOOR LOCK — SUPER LOCK —
REAR RH SIDE

1. CHECK DOOR LOCK ACTUATOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect rear door lock actuator RH connector.
Operate door lock / unlock switch, check voltage between rear door lock actuator RH connector and
ground.

Connector

Terminals (Wire color)
(+)
2

D65

3

Condition

Voltage (V)
(Approx.)

Unlock

0 → Battery voltage → 0

Lock

0 → Battery voltage → 0

(-)
Ground

MIIB0326E

OK or NG
OK
>> Replace rear door lock actuator RH.
NG
>> GO TO 2.

2. CHECK HARNESS CONTINUITY
1.
2.

Disconnect BCM connector.
Check continuity between BCM connector M59 terminals 67, 77 and rear door lock actuator RH connector
D65 terminals 2, 3.
67 – 2
77 – 3

3.

: Continuity should exist.
: Continuity should exist.

Check continuity between BCM connector M59 terminals 67, 77
and ground.
67 – Ground
77 – Ground

: Continuity should not exist.
: Continuity should not exist.

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Repair or replace harness.

BL-94

MIIB0327E

POWER DOOR LOCK — SUPER LOCK —
Check Super Lock Actuator

BIS000JH

A

DRIVER SIDE

1. CHECK SUPER LOCK ACTUATOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect front door lock actuator (driver side) connector.
Operate door lock / unlock switch, check voltage between front door lock actuator (driver side) connector
and ground.
Terminal (Wire color)

Connector
D11

(+)
1

(-)
Ground

Condition
Lock button is
pressed.

Voltage (V)
(Approx.)

B

C

D

0 → Battery voltage → 0

E

F
MIIB0333E

OK or NG
OK
>> Replace front door lock actuator (driver side).
NG
>> GO TO 2.

G

2. CHECK HARNESS CONTINUITY
1.
2.

Disconnect BCM connector.
Check continuity between BCM connector M59 terminal 75 and front door lock actuator (driver side) con- BL
nector D11 terminal 1.
75 – 1

3.

H

: Continuity should exist.
J

Check continuity between BCM connector M59 terminal 75 and
ground.
75 – Ground

: Continuity should not exist.

K

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Repair or replace harness.

L
MIIB0334E

M

BL-95

POWER DOOR LOCK — SUPER LOCK —
PASSENGER SIDE

1. CHECK DOOR LOCK ACTUATOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect front door lock actuator (passenger side) connector.
Operate remote controller, check voltage between front door lock actuator (passenger side) connector
and ground.

Connector

Terminal (Wire color)

D28

(+)

(-)

6

Ground

Condition
Lock button is
pressed.

Voltage (V)
(Approx.)
0 → Battery voltage → 0

MIIB0335E

OK or NG
OK
>> Replace front door lock actuator (passenger side).
NG
>> GO TO 2.

2. CHECK HARNESS CONTINUITY
1.
2.

Disconnect BCM connector.
Check continuity between BCM connector M59 terminal 75 and front door lock actuator (passenger side)
connector D45 terminal 6.
75 – 6

3.

: Continuity should exist.

Check continuity between BCM connector M59 terminal 75 and
ground.
75 – Ground

: Continuity should not exist.

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Repair or replace harness.
MIIB0336E

BL-96

POWER DOOR LOCK — SUPER LOCK —
REAR LH SIDE
A

1. CHECK DOOR LOCK ACTUATOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect rear door lock actuator LH connector.
Operate remote controller, check voltage between rear door lock actuator LH connector and ground.

Connector

Terminal (Wire color)

D45

(+)

(-)

6

Ground

Voltage (V)
(Approx.)

Condition
Lock button is
pressed.

B

C

0 → Battery voltage → 0

D

E

MIIB0337E

F

OK or NG
OK
>> Replace rear door lock actuator LH.
NG
>> GO TO 2.

G

2. CHECK HARNESS CONTINUITY
1.
2.

Disconnect BCM connector.
Check continuity between BCM connector M59 terminal 75 and rear door lock actuator LH connector D45
terminal 6.
75 – 6

3.

BL

: Continuity should exist.

Check continuity between BCM connector M59 terminal 75 and
ground.
75 – Ground

H

J

: Continuity should not exist.

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Repair or replace harness.

K

MIIB0338E

L

M

BL-97

POWER DOOR LOCK — SUPER LOCK —
REAR RH SIDE

1. CHECK DOOR LOCK ACTUATOR
1.
2.
3.

Turn ignition switch OFF.
Disconnect rear door lock actuator RH connector.
Operate remote controller, check voltage between rear door lock actuator RH connector and ground.

Connector

Terminal (Wire color)

D65

(+)

(-)

1

Ground

Voltage (V)
(Approx.)

Condition
Lock button is
pressed.

0 → Battery voltage → 0

MIIB0339E

OK or NG
OK
>> Replace rear door lock actuator RH.
NG
>> GO TO 2.

2. CHECK HARNESS CONTINUITY
1.
2.

Disconnect BCM connector.
Check continuity between BCM connector M59 terminal 75 and rear door lock actuator RH connector D65
terminal 1.
75 – 1

3.

: Continuity should exist.

Check continuity between BCM connector M59 terminal 75 and
ground.
75 – Ground

: Continuity should not exist.

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Repair or replace harness.
MIIB0340E

BL-98

POWER DOOR LOCK — SUPER LOCK —
Check Door Switch

BIS000JI

A

DRIVER SIDE

1. CHECK DOOR SWITCH INPUT SIGNAL
B

With CONSULT- II
Check door switch “DOOR SW-DR” in “DATA MONITOR” mode with CONSULT- II.
Monitor item

Condition

DOOR SW-DR

C

OPEN

: ON

CLOSE

:OFF

D

E
MIIB1050E

F

Without CONSULT- II
Check voltage between BCM connector and ground.
Connector

M57

Terminal (Wire color)
(+)

(-)

29

Ground

Condition

Voltage (V)
(Approx.)

OPEN

0

CLOSE

Battery voltage

G

H

OK or NG
OK
>> Front door switch RH is OK.
NG
>> GO TO 2.

BL

MIIB0342E

J

2. CHECK HARNESS CONTINUITY
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM and front door switch RH connector.
Check continuity between BCM connector M57 terminal 29 and front door switch RH connector B29 terminal 1.
29 – 1

4.

L

: Continuity should exist.

Check continuity between BCM connector M57 terminal 29 and
ground.
29 – Ground

K

M

: Continuity should not exist.

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.
MIIB0343E

BL-99

POWER DOOR LOCK — SUPER LOCK —

3. CHECK DOOR SWITCH
Check continuity between door switch terminal 1 and body ground part of door switch.
Connector
B29

Terminal
1

Body ground part
of door switch

Condition

Continuity

Pushed

NO

Released

YES

OK or NG
OK
>> GO TO 4.
NG
>> Replace door switch.

PIIA3351E

4. CHECK BCM OUTPUT SIGNAL
1.
2.

Connect BCM connector.
Check voltage between BCM connector M57 terminal 29 and ground.
29 – Ground

: Battery voltage

OK or NG
OK
>> Check door switch ground condition.
NG
>> Replace BCM.

MIIB0342E

BL-100

POWER DOOR LOCK — SUPER LOCK —
PASSENGER SIDE
A

1. CHECK DOOR SWITCH INPUT SIGNAL
With CONSULT- II
Check door switch “DOOR SW-AS” in “DATA MONITOR” mode with CONSULT- II.
Monitor item

B

Condition

DOOR SW-AS

OPEN

: ON

CLOSE

: OFF

C

D

E
MIIB1051E

F

Without CONSULT- II
Check voltage between BCM connector and ground.
Terminal (Wire color)
Connector

M57

(+)

(-)

30

Ground

Condition

Voltage (V)
(Approx.)

OPEN

0

CLOSE

Battery voltage

G

H

OK or NG
OK
>> Front door switch LH is OK.
NG
>> GO TO 2.

BL
MIIB0344E

J

2. CHECK HARNESS CONTINUITY
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM and front door switch LH connector.
Check continuity between BCM connector M57 terminal 30 and front door switch LH connector B14 terminal 1.
30 – 1

4.

: Continuity should exist.

Check continuity between BCM connector M57 terminal 30 and
ground.
30 – Ground

L

M

: Continuity should not exist.

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.
MIIB0345E

BL-101

K

POWER DOOR LOCK — SUPER LOCK —

3. CHECK DOOR SWITCH
Check continuity between door switch terminal 1 and body ground part of door switch.
Connector
B14

Terminal
1

Body ground
part of door
switch

Condition

Continuity

Pushed

NO

Released

YES

OK or NG
OK
>> GO TO 4.
NG
>> Replace door switch.

PIIA3351E

4. CHECK BCM OUTPUT SIGNAL
1.
2.

Connect BCM connector.
Check voltage between BCM connector M57 terminal 30 and ground.
30 – Ground

: Battery voltage

OK or NG
OK
>> Check door switch ground condition.
NG
>> Replace BCM.

MIIB0344E

BL-102

POWER DOOR LOCK — SUPER LOCK —
REAR LH SIDE
A

1. CHECK DOOR SWITCH INPUT SIGNAL
With CONSULT- II
Check door switch “DOOR SW-RL” in “DATA MONITOR” mode with CONSULT- II.
Monitor item

B

Condition

DOOR SW-RL

OPEN

ON

CLOSE

OFF

C

D

E
MIIB1052E

F

Without CONSULT- II
Check voltage between BCM connector and ground.
Terminal (Wire color)
Connector

M58

(+)

(-)

59

Ground

Condition

Voltage (V)
(Approx.)

OPEN

0

CLOSE

Battery voltage

G

H

OK or NG
OK
>> Rear door switch LH is OK.
NG
>> GO TO 2.

BL
MIIB0346E

J

2. CHECK HARNESS CONTINUITY
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM and rear door switch LH connector.
Check continuity between BCM connector and rear door switch LH connector.
A

4.

K

L

B
Continuity

BCM
connector

Terminal

Rear door
switch LH

Terminal

M58

59

B19

1

M

Yes

Check continuity between BCM connector and ground.
A

Continuity

BCM connector

Terminal

M58

59

Ground
No

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.

BL-103

MIIB1374E

POWER DOOR LOCK — SUPER LOCK —

3. CHECK DOOR SWITCH
Check continuity between door switch terminal 1 and body ground of door switch.
Connector
B19

Terminal
1

Body ground
part of door
switch

Condition

Continuity

Pushed

NO

Released

YES

OK or NG
OK
>> GO TO 4.
NG
>> Replace door switch.

PIIA3351E

4. CHECK BCM OUTPUT SIGNAL
1.
2.

Connect BCM connector.
Check voltage between BCM connector M58 terminal 59 and ground.
59 – Ground

: Battery voltage

OK or NG
OK
>> Check door switch ground condition.
NG
>> Replace BCM.

MIIB0346E

BL-104

POWER DOOR LOCK — SUPER LOCK —
REAR RH SIDE
A

1. CHECK DOOR SWITCH INPUT SIGNAL
With CONSULT- II
Check door switch “DOOR SW-RR” in “DATA MONITOR” mode with CONSULT- II.
Monitor item

B

Condition

DOOR SW-RR

OPEN

ON

CLOSE

OFF

C

D

E
MIIB1053E

F

Without CONSULT- II
Check voltage between BCM connector and ground.
Terminal (Wire color)
Connector

M58

(+)

(-)

60

Ground

Condition

Voltage (V)
(Approx.)

OPEN

0

CLOSE

Battery voltage

G

H

OK or NG
OK
>> Rear door switch RH is OK.
NG
>> GO TO 2.

BL
MIIB0348E

J

2. CHECK HARNESS CONTINUITY
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM and rear door switch RH connector.
Check continuity between BCM connector and rear door switch RH connector.
A

4.

K

L

B
Continuity

BCM
connector

Terminal

Rear door
switch RH

Terminal

M58

60

B42

1

M

Yes

Check continuity between BCM connector and ground.
A

Continuity

BCM connector

Terminal

M58

60

Ground
No

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.

BL-105

MIIB1375E

POWER DOOR LOCK — SUPER LOCK —

3. CHECK DOOR SWITCH
Check continuity between door switch terminal 1 and body ground of door switch.
Connector
B42

Terminal
1

Body ground part
of door switch

Condition

Continuity

Pushed

NO

Released

YES

OK or NG
OK
>> GO TO 4.
NG
>> Replace door switch.

PIIA3351E

4. CHECK BCM OUTPUT SIGNAL
1.
2.

Connect BCM connector.
Check voltage between BCM connector M58 terminal 60 and ground.
60 – Ground

: Battery voltage

OK or NG
OK
>> Check door switch ground condition.
NG
>> Replace BCM.

MIIB0348E

BL-106

POWER DOOR LOCK — SUPER LOCK —
Check Back Door Switch

BIS000JJ

1. CHECK BACK DOOR SWITCH INPUT SIGNAL

A

With CONSULT- II
Check back door switch “TRNK OPNR SW” in “DATA MONITOR” mode with CONSULT- II.

B

Back door switch is pushed
TRNK OPNR SW
: ON
Back door switch is released
TRNK OPNR SW
: OFF

C

D

E
MIIB0350E

Without CONSULT- II
Check voltage between BCM connector and ground.
Terminal (Wire color)
Connector

(+)

(-)

5

Ground

M57

F

Condition

Voltage (V)
(Approx.)

Pushed

0

Released

5

G

H

OK or NG
OK
>> Back door switch is OK.
NG
>> GO TO 2.

BL
MIIB0719E

2. CHECK HARNESS CONTINUITY

J

1.
2.
3.

K

Turn ignition switch OFF.
Disconnect BCM and back door switch connector.
Check continuity between BCM connector and back door switch connector.
A

4.

BCM
connector
M57

B

L
Continuity

Terminal

Back door
switch connector

Terminal

5

D104

1

M

Yes

Check continuity between BCM connector and ground.
A

Continuity

BCM connector

Terminal

M57

5

Ground
No

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.

BL-107

MIIB1380E

POWER DOOR LOCK — SUPER LOCK —

3. CHECK BACK DOOR SWITCH
Check continuity between back door switch terminals.
Terminals
Back door switch

1

2

Condition

Continuity

Pushed

YES

Released

NO

OK or NG
OK
>> GO TO 4.
NG
>> Replace back door switch.

MIIB1381E

4. CHECK BCM OUTPUT SIGNAL
1.
2.

Connect BCM connector.
Check voltage between BCM connector M57 terminal 5 and ground.
5 – Ground

: Approx. 5V

OK or NG
OK
>> Check the condition of the harness and the connector.
NG
>> Replace BCM.

MIIB0351E

BL-108

POWER DOOR LOCK — SUPER LOCK —
Check Back Door Release Actuator

BIS000JK

1. CHECK BCM OUTPUT SIGNAL

A

Check back door release output signal
Perform (“TRUNK/BACK DOOR”) in “ACTIVE TEST” mode with CONSULT-II.

B

When “ACTIVE TEST” is executed, does the back door
open?
C

OK or NG
OK
>> Back door release output is OK.
NG
>> GO TO 2.

D

E
MIIB0354E

2. CHECK BACK DOOR RELEASE ACTUATOR
1.
2.
3.

F

Turn ignition switch OFF.
Disconnect back door release actuator connector.
Operate back door switch, check voltage between back door release actuator connector and ground.
Terminal

Back door switch
connector

(+)

(-)

B46

4

Ground

Condition

Voltage (V)
(Approx.)

Pushed

0 → Battery voltage → 0

G

H

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 3.

BL

J
MIIB1382E

3. CHECK HARNESS CONTINUITY

K

1.
2.

L

Disconnect BCM connector.
Check continuity between BCM connector and back door release actuator connector.
A

3.

B

BCM
connector

Terminal

Back door
release actuator
connector

Terminal

M59

68

B46

4

Continuity

M

Yes

Check continuity between BCM connector and ground.
A
BCM connector

Terminal

M59

68

Ground

Continuity
MIIB1383E

No

OK or NG
OK
>> Replace BCM.
NG
>> Repair or replace harness.

BL-109

POWER DOOR LOCK — SUPER LOCK —

4. CHECK GROUND CIRCUIT
Check continuity between back door release actuator connector and ground.
Back door release
actuator connector

Terminal

B46

3

Ground

Continuity
Yes

OK or NG
OK
>> Replace back door release actuator.
NG
>> Repair or replace harness.

MIIB1384E

BL-110

MULTI-REMOTE CONTROL SYSTEM
MULTI-REMOTE CONTROL SYSTEM
Component Parts and Harness Connector Location

PFP:28596

A
BIS000JP

B

C

D

E

F

G

H

BL
MIIB1368E

1.

BCM (Body Control Module)
M57, M58, M59

2.

Front door switch
RH: B29 (RHD/LHD models)
LH: B14 (RHD/LHD models)

4.

Back door release actuator B46

5.

Key switch connector M33
(Without Intelligent Key system)

3.

Rear door switch
RH: B42
LH: B19

J

K

L

M

BL-111

MULTI-REMOTE CONTROL SYSTEM
System Description

BIS000JR

INPUTS
Power is supplied at all times
●
through 40A fusible link (letter J , located in the fusible link box)
●
to BCM terminals 74 and 79.
●
through 10A fuse [No. 9, located in the fuse block (J/B)]
●
to key switch terminal 2.
When the key switch is ON (Ignition key is inserted in ignition key cylinder), power is supplied
●
through key switch terminal 1
●
to BCM terminal 3.
When the ignition switch is ON or START, power is supplied
●
through 10A fuse [No. 5, located in the fuse block (J/B)]
●
to BCM terminal 24.
Ground is supplied
●
through BCM terminals 2 and 70
●
to body grounds M21 and M66.
When the front door switch LH (LHD Models) or RH (RHD Models) is ON (door is open), ground supplied
●
through BCM terminal 29
●
through front door switch LH (LHD Models) or RH (RHD Models) terminal 1
●
to front door switch LH (LHD Models) or RH (RHD Models) case ground.
When the front door switch RH (LHD Models) or LH (RHD Models) is ON (door is open), ground supplied
●
through BCM terminal 30
●
through front door switch RH (LHD Models) or LH (RHD Models) terminal 1
●
to front door switch RH (LHD Models) or LH (RHD Models) case ground.
When the rear door switch LH is ON (door is open), ground is supplied
●
through BCM terminal 59
●
through rear door switch LH terminal 1
●
to rear door switch LH case ground.
When the rear door switch RH is ON (door is open), ground is supplied
●
through BCM terminal 60
●
through rear door switch RH terminal 1
●
to rear door switch RH case ground.
When the back door release actuator (back door switch) is ON (back door is open), ground is supplied
●
through BCM terminal 10
●
through back door release actuator (back door switch) terminals 2 and 1
●
to body grounds B13, B28, B38 and B48.
Remote controller signal is inputted to BCM (The antenna of the system is combined with BCM).

OUTLINE
Power Door Lock Operation
UNLOCK LINK FUNCTION
When this function is activated, if the car is locked by door lock/unlock switch, opening the driver or passenger
side door from the inside handle will override the lock state and unlock the whole car.
(This function will be deactivate if anti-hijack function is activated.)
Selectable Function
Door Lock/unlock switch
How to change setting

Press unlock for more than 4 seconds

Contents

Unlock link activate/deactivate

How to confirm

Buzzer should sound for 0.2 seconds

BL-112

MULTI-REMOTE CONTROL SYSTEM
AUTO RE-LOCK FUNCTION
The BCM is equipped with an auto re-lock function, when no further user action occurs after an full or partial
unlock, the doors will automatically re-lock after 2 minutes (default value). The auto re-lock function will not be
activated under the following states.
●
Key switch is ON
●
Mechanical key is inserted
●
Any door is opened
NOTE:
the 2 minutes timer of auto re-lock will be reset if unlock button from the key fob is pressed.
ANTI-HIJACK FUNCTION
With the anti-hijack function enabled, the first unlock request send from key fob will partially unlock only the
driver side door (released super lock if equipped). Then if a second unlock signal is send from the first, then all
remaining doors will be unlocked.
HOW TO CHANGE DOOR LOCK FUNCTION MODE
With CONSULT-II
Door lock function can be changed using “SECURITY DOOR LOCK SET” mode in “WORK SUPPORT” of
“DOOR LOCK”.
Refer to BL-34, «WORK SUPPORT» .
Without CONSULT-II
Press and hold the UNLOCK and LOCK button on remote controller for more than 4 second will switch the
Anti-Hijack mode to ON or OFF.

A

B

C

D

E

F

G

Answer Back
When the doors are locked or unlocked by remote controller, supply power to hazard warning lamp flashes as
follows
H
●
LOCK operation: Flash once
●
UNLOCK operation: Flash twice
Answer back mode can be changed using “HAZARD LAMP SET” mode in “WORK SUPPORT” of “FLASHER”. BL
Refer to LT-106, «WORK SUPPORT» .

Remote Controller ID Code Entry
A maximum of four remote controller can be entered.
Dedicated remote controller ID registration procedure is not required.
Remote controller ID registration must be completed in conjunction with immobilizer transponder ID registration.

J

K

L

M

BL-113

MULTI-REMOTE CONTROL SYSTEM
Schematic

BIS000JS

MIWA0715E

BL-114

MULTI-REMOTE CONTROL SYSTEM
Wiring Diagram — MULTI —

BIS000JT

A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0716E

BL-115

MULTI-REMOTE CONTROL SYSTEM

MIWA0717E

BL-116

MULTI-REMOTE CONTROL SYSTEM
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0718E

BL-117

MULTI-REMOTE CONTROL SYSTEM

MIWA0719E

BL-118

MULTI-REMOTE CONTROL SYSTEM
Terminal and Reference Value for BCM

BIS000JU

A
Signal
Input/
Output

Condition

Voltage [V]
(Approx.)

—

—

0

Key switch

Input

Key is removed from IGN key cylinder (OFF)
→ Key is inserted in IGN key cylinder (ON)

0 → Battery voltage

P

Back door actuator
switch

Input

Back door or trunk lid open (ON) → Back
door or trunk lid close (OFF)

0 → Battery voltage

O

IGN power supply

Input

Terminal

Wire
color

2

B

Ground

3

O

10
24

29

30

LG
(BR)

BR
(LG)

Item

Front door switch LH
(LHD models)
Front door switch RH
(RHD models)
Front door switch RH
(LHD models)

Input

Ignition switch is in ON or START position

Door open (ON) → Door close (OFF)

B

C
Battery voltage

D

0 → Battery voltage

E

Input

Door open (ON) → Door close (OFF)

0 → Battery voltage

Front door switch LH
(RHD models)

59

G

Rear door switch LH

Input

Door open (ON) → Door close (OFF)

0 → Battery voltage

60

L

Rear door switch RH

Input

Door open (ON) → Door close (OFF)

0 → Battery voltage

F

G

H
When door lock operated using remote controller*1

BL
65

LG

Answer back
(Turn signal lamp LH)

PIIA2486J

Output

J
When door unlock operated using remote
controller*1

K
PIIA2487J

L

When door lock operated using remote con-

M

troller*1

66

W

Answer back
(Turn signal lamp RH)

PIIA2486J

Output

When door unlock operated using remote
controller*1

PIIA2487J

67

Y

All door lock actuator
unlock
(Except driver side)

Output

Door lock/unlock switch
UNLOCK operation

0 → Battery voltage

68

O

Back door or trunk lid
opener actuator

Output

Power window main switch
(Back door or trunk lid release switch)
OPEN operation

Battery voltage → 0

BL-119

MULTI-REMOTE CONTROL SYSTEM
Signal
Input/
Output

Condition

Voltage [V]
(Approx.)

—

—

0

Input

—

Battery voltage

Terminal

Wire
color

70

B

Ground

74

Y

BAT power supply
(fusible link) (BCM)

75*2

O

Super lock set output
(All door)

Output

Super lock operation (Set)

0 → Battery voltage

76

BR

Door lock actuator
unlock (Driver side)

Output

Door lock/unlock switch
Unlock operation

0 → Battery voltage

77

SB

Door lock actuator lock
(ALL Door)

Output

Door lock/unlock switch
LOCK operation

0 → Battery voltage

79

Y

Item

BAT power supply
(fusible link)
(Power window)

Input

—

Battery voltage

*1 : In the state that answer back operates
*2 : Only the model equipped with super lock system (RHD Models)
(): RHD models

CONSULT- II Inspection Procedure

BIS000JV

Refer to GI-36, «CONSULT-II Start Procedure» .

CONSULT- II Application Items

BIS000JW

DATA MONITOR
Monitored Item

Description

MEMORY 1

Indicates [ON/OFF] condition of remote controller ID code registration.

MEMORY 2

Indicates [ON/OFF] condition of remote controller ID code registration.

MEMORY 3

Indicates [ON/OFF] condition of remote controller ID code registration.

MEMORY 4

Indicates [ON/OFF] condition of remote controller ID code registration.

Work Flow
1.
2.
3.
4.
5.

BIS000JX

Check the trouble symptom and customer’s requests.
Understand outline of system. Refer to BL-112, «System Description» .
Confirm that power door lock system operates normally.
Refer to BL-16, «POWER DOOR LOCK SYSTEM» .
Refer to trouble diagnosis chart by symptom, repair or replace any malfunctioning parts.
INSPECTION END

BL-120

MULTI-REMOTE CONTROL SYSTEM
Trouble Diagnosis Chart by Symptom

BIS000JY

First perform the “SELF-DIAG RESULTS” in “BCM” with CONSULT-II, when perform the each trouble diagnosis. Refer to BCS-9, «CONSULT-II Function (BCM)» .
NOTE:
●
Always check “Work Flow” before troubleshooting. Refer to BL-120, «Work Flow» .
●
Always check remote controller battery before replacing remote controller.
Diagnoses/service procedure

Reference
page

1. Check remote controller
(Reproduce the malfunction using a specific remote controller.)

BL-122

2. Replace remote controller.

BL-113

3. Replace BCM.

BCS-17

1. Check remote controller

BL-122

2. Check key switch

BL-127

Symptom

All function of multi-remote control system do not
operate.

Door lock or unlock does not function with remote
controller.
(Power door lock system is “OK”)

Answer back does not activate properly when
pressing lock or unlock button of remote controller.

Auto door lock operation does not activate properly.
(All other remote keyless entry system function is
“OK”.)

A

B

C

D

3. Replace remote controller.

E

F

NOTE:
If the result of remote controller function check with CONSULT-II
is OK, remote controller is not malfunctioning.

BL-113

4. Replace BCM.

BCS-17

1. Check answer back mode.*
*: Answer back mode can be changed.
First check the hazard reminder setting.

LT-106

2. Check hazard reminder

BL-128

3. Replace BCM.

BCS-17

G

H

1. Check auto door lock operation mode.*
*: Auto door lock operation can be changed.
First check the auto door lock operation setting.

BL-34

2. Check door switch

BL-122

3. Replace BCM.

BCS-17

BL

J

K

L

M

BL-121

MULTI-REMOTE CONTROL SYSTEM
Check Remote controller

BIS000JZ

1. CHECK REMOTE CONTROLLER BATTERY
Remove battery and measure voltage across battery positive and negative terminals, (+) and (−).
Battery voltage

: 2.5V – 3.0V

NOTE:
Remote controller does not function if battery is not set correctly.

SEL237W

OK or NG
OK
>> Replace remote controller.
NG
>> Replace battery. Refer to BL-129, «Remote Controller Battery Replacement» .

Check Door Switch

BIS000K0

DOOR SWITCH DRIVER SIDE

1. CHECK DOOR SWITCH INPUT SIGNAL
1.
2.

Turn ignition switch OFF.
Check voltage between BCM connector M57 terminal 29 and ground.
Terminal
(+)

(–)

Driver door condition

Voltage (V)
Approx.

Closed

5

Open

0

LHD Models
RHD Models

29

Ground

OK or NG
OK
>> Door switch circuit is OK.
NG
>> GO TO 2.
MIIB0342E

2. CHECK DOOR SWITCH HARNESS
1.

Check continuity between BCM connector M57 terminal 29 and
driver door switch connector B14 (LHD Models) or B29 (RHD
Models) terminal 1.
Terminal
LHD Models

Continuity
Yes

29 — 1

RHD Models

2.

Yes

Check continuity between BCM connector M57 terminal 29 and
ground.
Terminal
LHD Models

29

Continuity
Ground

Continuity should not exist.

RHD Models

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.

BL-122

MKIB0851E

MULTI-REMOTE CONTROL SYSTEM

3. CHECK DOOR SWITCH

A

Check continuity between driver door switch terminal 1 and ground
part of door switch.
Terminal

Driver door switch condition

Continuity

Pushed

No

Released

Yes

1 — Ground part of door switch

B

C

OK or NG
OK
>> Check driver door switch ground condition.
NG
>> Replace driver door switch.

D
SIIA1589E

DOOR SWITCH PASSENGER SIDE

E

1. CHECK DOOR SWITCH INPUT SIGNAL
1.
2.

Turn ignition switch OFF.
Check voltage between BCM connector M57 terminal 30 and ground.
Terminal
(+)

(–)

Passenger door
condition

Voltage (V)
Approx.

Closed

5

Open

0

LHD Models
RHD Models

30

Ground

F

G

H

OK or NG
OK
>> Door switch circuit is OK.
NG
>> GO TO 2

BL
MIIB0344E

2. CHECK DOOR SWITCH HARNESS
1.

Check continuity between BCM connector M57 terminal 30 and
passenger door switch connector B29 (LHD Models) or B14
(RHD Models) terminal 1.
Terminal

K

Continuity

LHD Models

L

Yes

30 — 1

RHD Models

2.

J

Yes

Check continuity between BCM connector M57 terminal 30 and
ground.
Terminal
LHD Models

30

Continuity
Ground

Continuity should not exist.

RHD Models

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.

BL-123

M
MKIB0852E

MULTI-REMOTE CONTROL SYSTEM

3. CHECK DOOR SWITCH
Check continuity between passenger door switch terminal 1 and
ground part of door switch.
Terminal

Passenger door switch condition

Continuity

Pushed

No

Released

Yes

1 — Ground part of door switch

OK or NG
OK
>> Check passenger door switch ground condition.
NG
>> Replace passenger door switch.
SIIA1589E

DOOR SWITCH REAR LH

1. CHECK DOOR SWITCH INPUT SIGNAL
1.
2.

Turn ignition switch OFF.
Check voltage between BCM connector M58 terminal 59 and ground.
Terminal
(+)

(–)

59

Ground

Rear door LH condition

Voltage (V)
Approx.

Closed

5

Open

0

OK or NG
OK
>> Door switch circuit is OK.
NG
>> GO TO 2
MIIB0346E

2. CHECK DOOR SWITCH HARNESS
1.

Check continuity between BCM connector M58 terminal 59 and
rear door switch LH connector B19 terminal 1.
59 – 1

2.

: Continuity should exist.

Check continuity between BCM connector M58 terminal 59 and
ground
59 – Ground

: Continuity should not exist.

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.

MIIB0347E

3. CHECK DOOR SWITCH
Check continuity between rear door switch LH terminal 1 and ground
part of door switch.
Terminal
1 — Ground part of door switch

Rear door switch LH condition

Continuity

Pushed

No

Released

Yes

OK or NG
OK
>> Check rear door switch LH ground condition.
NG
>> Replace rear door switch LH.
PIIA3351E

BL-124

MULTI-REMOTE CONTROL SYSTEM
DOOR SWITCH REAR RH
A

1. CHECK DOOR SWITCH INPUT SIGNAL
1.
2.

Turn ignition switch OFF.
Check voltage between BCM connector M58 terminal 60 and ground.
Terminal
(+)

(–)

60

Rear door RH condition

Voltage (V)
Approx.

Closed

5

Open

0

Ground

B

C

D

OK or NG
OK
>> Door switch circuit is OK.
NG
>> GO TO 2

E
MIIB0348E

2. CHECK DOOR SWITCH HARNESS
1.

Check continuity between BCM connector and rear door switch
RH connector.
A

2.

F

BCM
connector
M58

G

B
Continuity

Terminal

Rear door
switch RH

Terminal

60

B42

1

H
Yes

Check continuity between BCM connector and ground

BL

A
BCM connector

Terminal

M58

60

Continuity

Ground

MIIB1375E

J

No

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.

K

3. CHECK DOOR SWITCH

L

Check continuity between rear door switch RH terminal 1 and
ground part of door switch.
Terminal
1 — Ground part of door switch

Rear door switch RH condition

Continuity

Pushed

No

Released

Yes

M

OK or NG
OK
>> Check rear door switch RH ground condition.
NG
>> Replace rear door switch RH.
PIIA3351E

BL-125

MULTI-REMOTE CONTROL SYSTEM
BACK DOOR RELEASE ACTUATOR (BACK DOOR SWITCH)

1. CHECK BACK DOOR RELEASE ACTUATOR (BACK DOOR SWITCH) INPUT SIGNAL
1.
2.

Turn ignition switch OFF.
Check voltage between BCM connector M57 terminal 10 and ground.
Terminal
(+)

(–)

10

Ground

Back door condition

Voltage (V)
Approx.

Closed

5

Open

0

OK or NG
OK
>> Back door switch circuit is OK.
NG
>> GO TO 2
MIIB0314E

2. CHECK BACK DOOR RELEASE ACTUATOR (BACK DOOR SWITCH) HARNESS
1.
2.

Disconnect back door release actuator (back door switch) connector.
Check voltage between back door release actuator (back door
switch) connector and ground. (Check harness for open.)
Back door switch
connector

Terminal

B46

2

Voltage (V)
(Approx.)

Ground

Battery voltage

MIIB1376E

3.
4.

Disconnect BCM connector.
Check continuity between back door release actuator (back door
switch) connector and ground. (Check harness for short.)
Back door switch
connector

Terminal

B46

2

Continuity

Ground

No

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.
MIIB1377E

3. CHECK BACK DOOR SWITCH
Check continuity between back door release actuator (back door
switch) terminal 1 and 2.
Terminal
Back door
switch

1

2

Rear door condition

Continuity

Closed

No

Opened

Yes

OK or NG
OK
>> GO TO 4.
NG
>> Replace back door release actuator (back door switch).
MIIB1378E

BL-126

MULTI-REMOTE CONTROL SYSTEM

4. CHECK BACK DOOR SWITCH GROUND HARNESS

A

Check continuity between back door release actuator (back door
switch) connector and ground.
B

Back door switch
connector

Terminal

B46

1

Continuity
Ground
Yes

C

OK or NG
OK
>> Check harness connection.
NG
>> Replace back door switch.

D
MIIB1379E

Key Switch Check

BIS000K1

1. CHECK KEY SWITCH INPUT SIGNAL
Check voltage between BCM connector M57 terminal 3 and ground.
Terminals
(+)

3

Key switch condition

Voltage (V)
Approx.

Key is inserted in IGN key cylinder
(key switch is “ON”.)

Battery voltage

Key is removed from IGN key cylinder
(Key switch is “OFF”.)

0

(–)

Ground

E

F

G

OK or NG
OK
>> Key switch circuit is OK.
NG
>> GO TO 2

H

BL
MIIB0499E

2. CHECK KEY SWITCH (INSERT)
J

1.
2.

Disconnect key switch connector.
Check continuity between key switch terminals.
Terminals

Key switch
1

2

Condition

Continuity

Key is inserted

YES

Key is removed

NO

OK or NG
OK
>> Check the following.
● 10A fuse [No. 9, located in fuse block (J/B)]
● Harness for open or short between key switch and
fuse
● Harness for open or short between BCM and key
switch
NG
>> Replace key switch.

BL-127

K

L

M

MIIB1370E

MULTI-REMOTE CONTROL SYSTEM
Hazard Reminder Check

BIS000K2

1. CHECK HAZARD WARNING LAMP
Check if hazard warning lamp flashes with hazard switch.
Does hazard warning lamp operate?
Yes
>> GO TO 2
No
>> Check hazard warning lamp circuit. Refer to LT-98, «TURN SIGNAL AND HAZARD WARNING
LAMPS» .

2. CHECK HAZARD REMINDER OPERATION
Check the following at when push the remote controller switch.
Check voltage between BCM harness connector M59 terminal 65,
66 and ground.
Remote controller

Voltage (V)
Approx.

Pushing LOCK button

MIIB0312E
PIIA2486J

Pushing UNLOCK button

PIIA2487J

OK or NG
OK
>> Check harness for open between BCM and hazard switch.
NG
>> Check harness for short between BCM and hazard switch. If check result is “OK”, replace BCM. If
check result is “NG”, repair or replace harness.

BL-128

MULTI-REMOTE CONTROL SYSTEM
Remote Controller Battery Replacement
1.
2.

3.

4.

A

Remove installation screw on the rear of remote controller.
Place the key with the lower case facing up. Set a screwdriver
wrapped with tape into section A of the lower case and separate
the lower case from the upper case.
When replacing the circuit board assembly, remove circuit board
assembly from the upper case.
(Circuit board assembly: Switch rubber + Board surface)
CAUTION:
Be careful not to touch the printed circuits directly.
When replacing the battery
Remove battery from the lower case and replace it.
Battery
replacement

5.

BIS000K3

B

C

D

: Coin-type lithium battery (CR1620)

CAUTION:
When replacing battery, be sure to keep dirt, grease and
other foreign materials off the electrode contact area.
After replacement, fit the lower and upper cases together, part
and tighten with the screw.
CAUTION:
After replacing the battery, be sure to check that door locking operates normally using the remote controller.

E

F

G
MIIB0308E

H

BL

J

K

L

M

BL-129

INTELLIGENT KEY SYSTEM
INTELLIGENT KEY SYSTEM
Component Parts and Harness Connector Location

PFP:285e2
BIS000K4

MIIB1436E

1.

BCM M57, M58, M59

2.

Intelligent Key unit M60

3.

IPDM E/R E6, E10, E11, E12

4.

Combination meter M27

5.

Steering lock unit M37

6.

Key switch and ignition knob switch
M34

7.

Door lock relay M20

8.

Stop lamp switch
E38: LHD CR engine and HR
engine M/T models
E60: LHD HR engine A/T models
and K9K engine models
M203: RHD CR engine and HR
engine M/T models
M204: RHD HR engine A/T models
and K9K engine models

BL-130

INTELLIGENT KEY SYSTEM
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIIB1437E

BL-131

INTELLIGENT KEY SYSTEM

PIIB5851J

1.

Inside key antenna (dash board)
M47

2.

Intelligent key warning buzzer D10

3.

a: Door request switch (driver side)
D12
Door request switch (passenger
side) D29
b: Outside antenna (driver side) D13
Outside antenna (passenger side)
D30

4.

Inside key antenna (center console)
B20

5.

Inside key antenna (luggage room)
B32

6.

Outside antenna (back door) B43

7.

Door request switch (back door)
D102

System Description
●

●

●

●

●

●

BIS000K6

The Intelligent Key system is a system that makes it possible to lock and unlock the door locks (door lock
function) and start the engine (engine start function) by carrying the Intelligent Key, which operates based
on the results of electrical key-ID verification using two-way communications between the Intelligent Key
and the vehicle.
Operation of the remote control buttons on the Intelligent Key also provides the same functions as the
remote control entry system. (Remote control entry functions)
As an ignition key warning function, when a door lock is locked or unlocked with door request switch or
Intelligent Key button operation, the hazard lamps flashes and sound the Intelligent Key buzzer.
Even if the vehicle or Intelligent Key battery runs out, the door locks can be locked and unlocked and the
engine can be initiated by the mechanical key built-in the Intelligent Key.
If Intelligent Key is lost, a new Intelligent Key can be registered. A maximum of 4 Intelligent Keys can be
registered.
It has been made possible to diagnose the system, change the function setting and register Intelligent Key
with the CONSULT-II.

DOOR LOCK FUNCTION
Operation Description
When the driver door, passenger door, or back door request switch is pressed, Intelligent Key unit sends a
request signal from the transmission antenna corresponding to the pressed door request switch, key-ID
verification is performed using two-way communication with Intelligent Key, and if ID is successfully verified, a door lock/unlock request signal is sent to BCM (Body Control Module) through CAN communication
to lock/unlock the door lock.
●
With the locking operation of door request switch, door lock actuators of all doors will be locked.
Driver side door request switch operation
●
When door request switch (driver side) is pressed, driver side door lock actuator will be unlocked.
●
When door request switch (driver side) is pressed for the second time, within 5 seconds after the first the
remaining doors will be unlock.
●

BL-132

INTELLIGENT KEY SYSTEM
Unlock mode can be changed using “WORK SUPPORT” mode in “LOCK/UNLOCK BY I-KEY”. Refer to
BL-155, «CONSULT-II Function (INTELLIGENT KEY)» .
Passenger side door request switch operation
●
When door request switch (passenger side) is pressed, passenger side door will be unlocked.
●
When door request switch (passenger side) is pressed for the second time, with in 5 seconds after the first
operation, the remaining doors will be unlock.
●
Unlock mode can be changed using “WORK SUPPORT” mode in “LOCK/UNLOCK BY I-KEY”. Refer to
BL-155, «CONSULT-II Function (INTELLIGENT KEY)» .
●

A

B

C

Operation Condition
Request switch operation

Operating conditions (When all the conditions below are met)

Door request switch (driver side)

●

All doors closed (door switch: OFF)

Door request switch (passenger side)

●

Key switch OFF (key removed)

●

Ignition knob switch: OFF (ignition knob switch not pressed)

●

The Intelligent Key is in the antenna detection area for the door for which the door
request switch was operated.

Door request switch (back door)

D

E

F

Operation Range
The antenna detection area for each door is about 80 cm (31.50 in) from the handle of each door (driver door,
passenger door and back door). However, this operating range may differed by the ambient conditions.

G

Auto Door Lock Function

When the door request switches are pressed and doors are locked or unlocked once, during this state, door
lock will re-lock automatically unless the following conditions are met.
H
●
Mechanical key is inserted into ignition knob.
●
Ignition knob is pressed.
●
Any of the doors is opened.
BL
●
Intelligent Key button is operated within 30 seconds.

Key Reminder Function
As an operation confirmation, when the doors are lock or unlock by using door request switch or Intelligent
Key, hazard lamps flashes and Intelligent Key warning buzzer sounds.
Vehicle operation

Hazard lamp

Intelligent Key warning buzzer

Door unlock operation

Twice

Twice

Door lock operation

Once

Once

Intelligent Key Lock-in Prevention Function
When Intelligent Key is within the vehicle, a door is open or doors are locked using door lock and unlock
switch, driver door lock knob or door request switch, Intelligent Key unit sends door unlock request signal to
BCM via CAN communication to unlock all doors to prevent Intelligent Key from being locking in vehicle.
CAUTION:
The functions mentioned above are operable when the Intelligent Key is inside the vehicle. However,
there may be times that the Intelligent Key cannot be detected in some blind spot of the inside key
antennas. Thus engine start function system might not response when the Intelligent Key is placed on
the instrument panel, rear parcel shelf or in the glove box. Furthermore, by placing the Intelligent Key
in the door pocket and opening the door may interrupt the communication between the Intelligent Key
and the antennas.

REMOTE CONTROL ENTRY FUNCTIONS
Door Lock Function
●

●

Operating the button on the Intelligent Key sends the Intelligent Key-ID signals to the Intelligent Key unit.
Intelligent Key unit conducts a verification of the received key-ID, and if the verification is accepted, a door
lock or door unlock request signal is sent to BCM via CAN communication to lock/unlock the door lock.
When door lock/unlock is performed using Intelligent Key button operation, confirmation is conducted by
making hazard lamps flashes and Intelligent Key warning buzzer sounds.

BL-133

J

K

L

M

INTELLIGENT KEY SYSTEM
OPERATION CONDITION
Intelligent Key operation

Door lock operation

Operation condition
●

All doors closed

●

Key switch OFF (key removed)

●

Ignition knob switch: OFF (ignition knob not pressed)

●

Key switch OFF (key removed)

●

Ignition knob switch: OFF (ignition knob not pressed)

Door unlock operation

MT vehicle Key Interlock function
In case of a MT vehicle is in motion and ignition knob is turned into lock position, steering lock unit pose a risk
by activating the steering lock actuator. The key interlock function is designed to override the steering lock
system and prevent situation mention above to occur.

LOCK condition
When the following condition had been fulfilled and then key interlock solenoid will be locked. (Steering lock
inactive)
●
When ignition switch is in ON position and engine revolution speed went above 500rpm. (1 second delay)

UNLOCK condition
When any of the following conditions had been fulfilled and then key interlock solenoid will be unlocked (Steering lock active)
●
When vehicle speed is below 4 km/h and the ignition switch is turned from ON to OFF (1 second delay)
●
When vehicle speed is over 4 km/h but less than 10 km/h and ignition switch is turned from ON to OFF. (3
seconds delay)

Map Lamp Function
When the following conditions is met:
●
Condition of map lamp switch is DOOR position
●
Door switch OFF (when all the doors are closed)
Remote keyless entry system turns on interior lamp (for 30 seconds) once input of UNLOCK signal from Intelligent Key is received.
For detailed description. Refer to LT-152, «INTERIOR ROOM LAMP TIMER OPERATION» .

ENGINE STARTUP FUNCTION
Operation Description
●

●

●

When ignition knob is pressed, Intelligent Key unit sends request signal from inside key antenna, key-ID
verification is conducted with Intelligent Key using two-way communication, and if verification is successful, an ignition rotation prohibition latch release signal is sent to steering lock unit and releases ignition
knob rotation prohibition latch. (Ignition knob can now be turned)
NOTE:
When it becomes impossible to rotate the ignition knob, “KEY” warning lamp in combination meter lights
up red.
When key-ID verification is successful and ignition knob switch is in the ON state, Intelligent Key unit uses
CAN communication to send engine start permission signal to BCM.
When BCM receives engine start permission signal, it uses CAN communication to sent starter request
signal to IPDM E/R so that the engine will start when ignition knob is rotated to START position.

Operation Range
Engine can be started when Intelligent Key is in side the vehicle. However, sometimes engine might not start
when Intelligent Key is on instrument panel, rear parcel shelf, or in glove box.
NOTE:
Luggage room is not within the operation range, but sometimes it is possible to start the engine from there.

Active Check Function
Confirm whether or not ignition knob can be rotated by checking the color of warning lamp in combination
meter.

BL-134

INTELLIGENT KEY SYSTEM
Condition

Operation

Ignition knob rotation possible

“KEY” warning lamp in combination meter is lit up green.

Ignition knob rotation not possible

“KEY” warning lamp in combination meter is lit up red.

A

B

WARNING AND ALARM FUNCTION
Operation Description
Warnings and alarms shown as follows and are given to the user as warning notice when using the combinations of Intelligent Key warning buzzer (driver door), inside vehicle buzzer (in combination meter), and warning
lamps “KEY” and “LOCK.”
●
Ignition switch return forgotten warning
With the ignition in OFF or ACC position, if the driver door is opened, this warning is issued.
●
Key left in ignition warning (when mechanical key is used)
While the mechanical key in the ignition knob and the ignition switch is in the OFF, ACC, or LOCK position, if the driver door is opened, this warning is issued.
●
Ignition switch OFF position warning (combination buzzer: when door closed)
This warning is issued when the user forgets to return the ignition knob to the LOCK position.
●
Ignition switch OFF position warning [Intelligent key warning buzzer (driver door): when door opened/
closed]
This warning is issued when the user leaving the car without returning the ignition knob to the LOCK position.
●
This warning is issued if the Intelligent Key is taken outside the car while the engine is running. (when
door open → closed)
●
This warning is issued if the Intelligent Key is taken outside the car through a window while the engine is
running. (from window)
●
Intelligent Key low battery warning
This warning is issued when it detects that the battery in the Intelligent Key is running low.

C

D

E

F

G

H

BL

Operation Condition
Warning and alarm names
Ignition knob return forgotten warning
Ignition key warning
(When mechanical key used)

Ignition knob OFF position warning
(driver side door buzzer: when door
closed)

Ignition knob OFF position warning
(E/G room buzzer: when door
opened/closed)

Operating conditions (when all the conditions below are met)
●

The ignition switch is in the ACC, OFF, or LOCK position (knob pressed)

●

The driver door is opened.

●

The mechanical key is inserted in the ignition knob (key switch: ON)

●

The ignition switch is in the ACC, OFF, or LOCK position.

●

The driver door opened.

●

The ignition switch is in the OFF or LOCK position (knob pressed)

●

In the above state, when the ACC switch is switched from ON to OFF and 1 second
passes. (However, this warning is not issued if the mechanical key is inserted in the ignition knob.)

●

The ignition switch is in the OFF or LOCK position (knob pressed)

●

In the above state, when the ACC switch is changed from ON to OFF and 1 second
passes. (However, this warning is not issued if the mechanical key is inserted in the ignition knob.)

●

Driver door open → closed

When Any of the Following Conditions Are Met

Warning for Intelligent Key taken
outside the car (when door open →
closed)

●

When the ignition knob is pressed in so that it can be rotated (or has been rotated), if any
of the doors has been opened, when all the doors are closed, the Intelligent Key unit
compares the key-ID with the Intelligent Key using the inside key antenna (center console), if the results of the comparison are NG (the Intelligent Key is not found)

●

When the ignition knob is pressed and rotated (or has been rotated), if any of the doors is
open, the Intelligent Key unit compares the key-ID with that of the Intelligent Key every 5
seconds using the inside key antenna (center console), if the results of the comparison
are NG (the Intelligent Key is not found)
NOTE:
However, this warning is not issued if the mechanical key is inserted in the ignition knob.

BL-135

J

K

L

M

INTELLIGENT KEY SYSTEM
Warning and alarm names

Warning for Intelligent Key taken
out from the window

Operating conditions (when all the conditions below are met)
When the ignition knob is pressed in so that it can be rotated (or has been rotated), if the
vehicle speed is no greater than 5 km per hour, the Intelligent Key unit compares the key-ID
with that of the Intelligent Key every 30 seconds using the inside key antenna (center console), if the results of the comparison are NG (the Intelligent Key is not found)
Note: The default setting for this function is OFF.
When any of the following conditions are met

Intelligent Key Lock-in Prevention Warning
●

When the Intelligent Key is inside the car and the ignition knob is not pressed, when an
attempt is made to lock a door lock with a door request switch.
NOTE:
This warning is issued even if the Intelligent Key is not in the door antenna detection area
corresponding to the door request switch was operated.

Knob Return Forgotten Warning
●

Door lock non-operation warning

When the ignition knob is pressed, when an attempt is made to lock a door lock with a
door request switch.
NOTE:
This warning is only issued if the Intelligent Key is in the door antenna detection area corresponding to the door request switch was operated.

Door Ajar Alarm
●

When any of the doors is open, when an attempt is made to lock a door with a door
request switch.
NOTE:
This warning is only issued if the Intelligent Key is in the door antenna detection area corresponding to the specific door request switch was operated.

Intelligent Key low battery prewarning

This warning is issued when the battery of the Intelligent Key is running low.

Warning Procedure
Buzzer

Warning and alarm names

Warning lamp

Inside car

Outside car

“KEY”

“LOCK”

Ignition switch return forgotten
warning

Buzzer: Continuous

—

—

—

Ignition key warning
(When mechanical key is
used)

Buzzer: Continuous

—

—

—

Ignition switch OFF position
warning (for inside car: when
door closed)

Buzzer (twice)

—

—

Illuminate

Ignition switch OFF position
warning (for outside car: when
door opened → closed)

—

Buzzer
(3 seconds)

—

Illuminate

Warning for removal of Intelligent Key to outside the car
(when door open → closed)

—

Buzzer
(3 seconds)

Red illuminate

—

Warning for removal of Intelligent Key to outside the car
(from window)

Buzzer (3 seconds)

—

Red illuminate

—

Door lock non-operation warning

—

Buzzer
(2 seconds)

—

—

Intelligent Key low battery prewarning

—

—

Green illuminate
(30 seconds after ignition switch comes ON)

—

BL-136

INTELLIGENT KEY SYSTEM
CHANGE SETTINGS FUNCTION
The settings for each function can be changed with the CONSULT-II or Intelligent Key.

A

Changing Anti-Hijack Function Settings With the Intelligent Key
Intelligent Key remote controller button and door request switch operations change the Anti-hijack function
settings (enabled/disabled).
Settings Change Procedure
1. Hold down both the LOCK and UNLOCK remote control buttons on the Intelligent Key at the same time for
at least 10 seconds (The yardstick is that the Intelligent Key LED flashes 20 times.)
2. Within 3 seconds of releasing the Intelligent Key remote controller buttons, press the driver door request
switch for once.
3. The KEY indicator in combination meter lights up for 3 seconds (Anti-hijack: enabled → disabled: lights up
red, Anti-hijack: disabled → enabled: flashes green). This completes the setting procedure.

B

C

D

Changing Settings Using CONSULT-II

E

The settings for the Intelligent Key system functions can be changed using CONSULT-II (WORK SUPPORT).
NOTE:
Once a function setting is changed, it will remain effective even if the battery is disconnected.

F

INTELLIGENT KEY REGISTRATION
Intelligent Key-ID registration is executed using the CONSULT-II. Up to 4 Intelligent Key can be registered.
CAUTION:
●
After a new Intelligent Key-ID is registered, be sure to check the function.
●
When registering an additional Intelligent Key-ID, remove any registered Intelligent Keys out of the
vehicle before starting.
CONSULT-II can be used to check and delete Intelligent Key-IDs.
For future information, see the CONSULT-II Operation Manual NATS.

STEERING LOCK UNIT REGISTRATION
Steering Lock Unit ID Registration
CAUTION:
The method for registering a steering lock unit ID depends on the status of the steering lock unit and
Intelligent Key unit (new or old unit).
After the registration procedures are completed
●
Press and rotate the ignition knob while the registered Intelligent Key is within the vehicle to confirm the registration procedure.
●
Press and rotate the ignition knob while the registered Intelligent Key is removed from the vehicle
to confirm the registration procedure.
For future information, see the CONSULT-II Operation Manual NATS.

G

H

BL

J

K

L

M

BL-137

INTELLIGENT KEY SYSTEM
Schematic —I/KEY—

BIS000K9

MIWA0720E

BL-138

INTELLIGENT KEY SYSTEM
Wiring Diagram — I/KEY—

BIS000KA

A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0721E

BL-139

INTELLIGENT KEY SYSTEM

MIWA0722E

BL-140

INTELLIGENT KEY SYSTEM
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0723E

BL-141

INTELLIGENT KEY SYSTEM

MIWA0724E

BL-142

INTELLIGENT KEY SYSTEM
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0725E

BL-143

INTELLIGENT KEY SYSTEM

MIWA0726E

BL-144

INTELLIGENT KEY SYSTEM
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0727E

BL-145

INTELLIGENT KEY SYSTEM

MIWA0728E

BL-146

INTELLIGENT KEY SYSTEM
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0729E

BL-147

INTELLIGENT KEY SYSTEM

MIWA0730E

BL-148

INTELLIGENT KEY SYSTEM
Terminals and Reference Value for INTELLIGENT KEY UNIT

BIS000KB

A
Measuring condition
Operation or conditions

Voltage (V)
(Approx.)

Output

LOCK

—

5

CAN-H

Input/
Output

—

—

—

Y

CAN-L

Input/
Output

—

—

—

P

Intelligent Key warning buzzer

Output

Door request switch
(driver side)

Input

Wire
color

1

P

Steering lock unit
power supply

2

L

3

4

5
6

7

Signal
Input/
Output

Ignition
knob
position

Terminal

O
O

GR

Item

Ignition power supply

Key switch

Input

Input

C

LOCK

—

Operate remote controller button or door
request switch.

8

Door request switch operation:
Press (ON).

0

Other than the above (OFF)

5

—
Insert mechanical key into ignition
key cylinder.

Battery voltage

Remove mechanical key from ignition key cylinder.

0

F

G

H

ACC power supply

Input

ACC

—

Battery voltage

11

Y

Battery power supply

Input

—

—

Battery voltage

12

B

GND

—

—

—

0

13

Y

Inside key antenna (+)
(Luggage room)

BL

Output

LOCK
Inside key antenna (-)
(Luggage room)

E

Battery voltage

L

BR

D

Battery voltage

Sound
buzzer

ON

LOCK

Buzzer OFF

10

14

B

Output

J

Any door open → all doors shut
(Door switch: ON → OFF)

K
SIIA1910J

15

V

Inside key antenna (+)
(Center console)

Output

Inside key antenna (-)
(Center console)

Output

LOCK
16

LG

L

Any door open → Close (Door
switch: ON → OFF)
Ignition knob switch: ON (press ignition knob.)

M
SIIA1910J

17

B

Out side antenna (+)

Output

18

W

Back door or trunk lid
antenna (-)

Output

LOCK

Back door request switch operation
(Switch: ON)

SIIA1910J

19

20

R

Outside antenna
(driver side) (+)

W

Outside antenna
(driver side) (-)

Output

LOCK

Driver door request signal operation (Switch: ON)

Output
SIIA1910J

BL-149

INTELLIGENT KEY SYSTEM
Measuring condition
Terminal

25

26

Wire
color

LG

R

Item

Signal
Input/
Output

Door request switch
(passenger side)

Input

Stop lamp switch

Input

Ignition
knob
position
—

—

Operation or conditions
Door request switch operation:
Press (ON)

0

Other than the above (OFF)

5

Brake pedal depressed (ON)

Battery voltage

Brake pedal not depressed (OFF)
Press ignition knob.

27

29

31

32

O

R

Ignition knob switch

Door request switch
(back door)

G

Steering lock unit
ground

V

Steering lock unit communication signal

Input

Input

—

Input/
Output

—

—

0
Battery voltage

Return ignition knob to LOCK position.

0

Back door request switch operation: Press (ON)

0

Other than the above (OFF)

5

—

LOCK

Voltage (V)
(Approx.)

—

0

Press ignition knob with Intelligent
Key inside vehicle.

SIIA1911J

Other than the above
35

P

Inside key antenna (+)
(Dashboard)

Output

Inside key antenna (-)
(Dashboard)

Output

LOCK
36

L

5

Any door open → Close
(Door switch: ON → OFF)
Ignition knob switch: ON
(Press ignition knob)
SIIA1910J

37

BR

Outside antenna (passenger side) (+)

Output

LOCK
38

Y

Outside antenna (passenger side) (-)

Passenger door request switch
operation (Switch: ON)

Output
SIIA1910J

40

L

Door lock relay

Output

—

Press unlock button once (in all
doors locked condition)

BL-150

Battery voltage → 0 → Battery
voltage

INTELLIGENT KEY SYSTEM
Terminals and Reference Value for Steering Lock unit

BIS000KC

A
Measuring condition
Terminal

Wire
color

Item

1

Y

Battery power supply

2

P

Steering lock unit
power supply

Signal
Input/
Output

Ignition
knob
position

Operation or conditions

Voltage (V)
(Approx.)

Input

LOCK

—

Battery voltage

Input

LOCK

—

5

LOCK

Press ignition knob with Intelligent
Key inside vehicle.

B

C

D
3

V

Steering lock unit
communication signal

Input/
Output

E
SIIA1911J

Other than the above
4

G

Steering lock unit
ground

—

—

—

5

Terminal and Reference Value for BCM
Terminal

Wire
color

2

B

3

GR

10

P

Measuring condition

—

—

0

Key switch

Input

Mechanical key is removed from ignition
knob (OFF) → Mechanical key is inserted
in ignition knob (ON)

0 → Battery voltage

Back door or trunk lid
switch

Input

Back door or trunk lid open (ON) →
Back door or trunk lid close (OFF)

0 → Battery voltage

Ground

19

L

CAN-H

24

O

IGN power supply

LG

Front door switch LH
(LHD models)

BR

Front door switch RH
(RHD models)

BR

Front door switch RH
(LHD models)

LG

Front door switch LH
(RHD models)

29

30

BIS000KD

Signal
Input/
Output

Item

F

0

Voltage (V)
(Approx.)

Input/
Output

—

—

Input

Ignition knob ON or START position

Battery voltage

Input

Door open (ON) → Door close (OFF)

0 → Battery voltage

Input

Door open (ON) → Door close (OFF)

0 → Battery voltage

Input/
Output

—

—

39

R

CAN-L

59

G

Rear door switch LH

Input

Door open (ON) → Door close (OFF)

0 → Battery voltage

60

L

Rear door switch RH

Input

Door open (ON) → Door close (OFF)

0 → Battery voltage

BL-151

G

H

BL

J

K

L

M

INTELLIGENT KEY SYSTEM
Terminal

Wire
color

Item

Signal
Input/
Output

Measuring condition

Voltage (V)
(Approx.)

When door lock operated using remote
controller*1

65

LG

Answer back
(Turn signal lamp LH)

PIIA2486J

Output

When door unlock operated using remote
controller*1

PIIA2487J

When door lock operated using remote
controller*1

66

W

Answer back
(Turn signal lamp RH)

PIIA2486J

Output

When door unlock operated using remote
controller*1

PIIA2487J

67

Y

Door lock actuator unlock
(ALL Door) (Except driver
side)

Output

Door lock/unlock switch
UNLOCK operation

0 → Battery voltage

68

O

Back door opener actuator

Output

Power window main switch
(Back door release switch) OPEN operation

Battery voltage → 0

70

B

Ground

74

Y

75*2

—

—

0

BAT power supply (fusible
link) (BCM)

Input

—

Battery voltage

O

Super lock set output (All
door)

Output

Super lock operation (Set)

0 → Battery voltage

76

BR

Door lock actuator unlock
(Driver side)

Output

Door lock/unlock switch
Unlock operation

0 → Battery voltage

77

SB

Door lock actuator lock
(ALL Door)

Output

Door lock/unlock switch
LOCK operation

0 → Battery voltage

79

Y

BAT power supply (fusible
link) (Power window)

Input

—

*1 : In the state that answer back operates
*2 : Only the model equipped with super lock system (RHD Models)

BL-152

Battery voltage

INTELLIGENT KEY SYSTEM
Trouble Diagnosis Procedure

BIS0015E

A

PRELIMINALY CHECK

B

C

D

E

F

G

H

BL

J

K

L

M

MIIB0940E

*1:

BL-193

*2:

BL-157

*3:

BL-158

*4:

BL-157

*5:

BL-155

*6:

BL-158

*7:

BL-158

*8:

BL-154

*9:

BL-226

BL-153

INTELLIGENT KEY SYSTEM
WORK FLOW

MIIB0941E

*1:

BL-16

*2:

BL-59

*3:

BL-159

*4:

BL-159

*5:

BL-161

*6:

BL-135

*7:

BL-161

*8:

BL-163

BL-154

INTELLIGENT KEY SYSTEM
CONSULT-II Function (INTELLIGENT KEY)

BIS000KF

A

CONSULT-II can display each diagnostic item using the diagnostic test modes as shown below.
Part to be diagnosed

Test item, Diagnosis mode

Intelligent Key

Description

B

WORK SUPPORT

Changes settings for each function.

SELF-DIAG RESULTS

Intelligent Key unit performs CAN communication diagnosis.

DATA MONITOR

Displays Intelligent Key unit input data in real time.

CAN DIAGNOSTIC SUPPORT
MONITOR

The results of transmit/receive diagnosis of CAN Communication can
be read.

ACTIVE TEST

Operation of electrical loads can be checked by sending driving signal
to then.

ECU PART NUMBER

Displays Intelligent Key unit part No.

C

CONSULT-II Inspection Procedure

BIS000KG

CAUTION:
If CONSULT-II is used with no connection CONSULT-II CONVERTER, malfunctions might be detected
in self-diagnosis depending on control unit which performs CAN Communication.

D

E

F

BASIC OPERATION
Refer to GI-36, «CONSULT-II Start Procedure» .

G

CONSULT-II Application Items

BIS000KH

SELF-DIAGNOSTIC RESULTS
Self-diag results

Description

Diagnosis procedure

Reference page

CAN COMM

Malfunction is detected in CAN communication.

Check CAN communication system.

BL-163

CAN COMM2

Intelligent Key unit internal malfunction

Check CAN communication system.

BL-163

STRG COMM

Malfunction is detected in communication of Intelligent Key unit and steering lock unit.

Check steering lock unit.

BL-188

I-KEY C/U

Intelligent Key unit internal malfunction

Replace Intelligent Key unit.

BL-193

IMMU

NATS malfunction

Check NATS.

BL-215

DATA MONITOR

H

BL

J

K

Monitor item

Content

PUSH SW

Indicates [ON/OFF] condition of ignition knob switch.

KEY SW

Indicates [ON/OFF] condition of key switch.

DR REQ SW

Indicates [ON/OFF] condition of door request switch (driver side).

AS REQ SW

Indicates [ON/OFF] condition of door request switch (passenger side).

BD/TR REQ SW

Indicates [ON/OFF] condition of trunk opener request switch.

IGN SW

Indicates [ON/OFF] condition of ignition switch in ON position.

ACC SW

Indicates [ON/OFF] condition of ignition switch in ACC position.

STOP LAMP SW

Indicates [ON/OFF] condition of door unlock sensor.

DOOR LOCK SIG*

Indicates [ON/OFF] condition of door lock signal from Intelligent Key remote controller button.

DOOR UNLOCK SIG*

Indicates [ON/OFF] condition of door unlock signal from Intelligent Key remote controller button.

DOOR SW DR*

Indicates [OPEN/CLOSE] condition of front door switch driver side from BCM via CAN communication line.

DOOR SW AS*

Indicates [OPEN/CLOSE] condition of front door switch passenger side from BCM via CAN communication line.

DOOR SW RR*

Indicates [OPEN/CLOSE] condition of rear door switch LH from BCM via CAN communication line.

DOOR SW RL*

Indicates [OPEN/CLOSE] condition of rear door switch RH from BCM via CAN communication line.

DOOR BK SW*

Indicates [OPEN/CLOSE] condition of back door switch from BCM via CAN communication line.

VEHICLE SPEED*

Indicates [km/h] condition of vehicle speed.

BL-155

L

M

INTELLIGENT KEY SYSTEM
*: Select “SELECTION FROM MENU”.

ACTIVE TEST
Monitor item

Description

DOOR LOCK/UNLOCK

This test is able to check all door lock actuators lock operation. These actuators
lock when “LOCK” on CONSULT-II screen is touched.

OUTSIDE BUZZER

This test is able to check Intelligent Key warning buzzer operation. The buzzer will
be activated on when “ON” on CONSULT-II screen is touched.

INSIDE BUZZER

This test is able to check buzzer (built in combination meter) operation. The
buzzer will be activated on when either “TAKE OUT”, “KNOB” or “KEY” on CONSULT-II screen is touched.

INDICATOR

This test is able to check warning lamp operation. The lamp will be turned on
when either “BLUE ON”, “BLUE IND”, “RED ON”, “RED IND”, “KNOB ON” or
“KNOB IND” on CONSULT-II screen is touched.

KEY LOCK SOLENOID

This test is able to LOCK/UNLOCK the key lock solenoid.

WORK SUPPORT
Monitor item

Description

CONFIRM KEY FOB ID

It can be checked whether Intelligent Key ID code is registered or not in this mode.

LOW BAT OF KEY FOB WARN

Intelligent Key low battery warning mode can be changed to operate (ON) or not operate (OFF)
with this mode.

SELECTIVE UNLOCK FUNCTION

Selective unlock function mode can be changed to operate (ON) or not operate (OFF) with this
mode.

INTELLIGENT KEY FUNCTION

All of the Intelligent Key functions can be changed to operate (ON) or not operate (OFF) with this
mode.

ANSWER BACK WITH I-KEY
LOCK

Answer back buzzer (external buzzer) function can be changed to operate (ON) or not operate
(OFF) with this mode.

ANSWER BACK WITH I-KEY
UNLOCK

Answer back buzzer (external buzzer) function (unlock operation) can be changed to operate
(ON) or not operate (OFF) with this mode.

AUTO RELOCK TIMER

Auto door lock timer mode can select with this mode.

ENGINE START BY I-KEY

Engine start function mode can be changed to operate (ON) or not operate (OFF) with this mode.

LOCK/UNLOCK BY I-KEY

Door lock/unlock function by door request switch (driver side, passenger side and back door)
mode can be changed to operate (ON) or not operate (OFF) with this mode.

BL-156

INTELLIGENT KEY SYSTEM
Trouble Diagnosis Symptom Chart

BIS0015F

A

KEY WARNING LAMP (GREEN) ILLUMINATES
NOTE:
●
Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, «Trouble Diagnosis Procedure»
●
Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis,
and check each symptom.
●
If the following “symptoms” are detected, check systems shown in the “Diagnoses/service procedure” column in this order.

B

C

Conditions of Vehicle (Operating Conditions)
●
●
●

D

Intelligent Key is registered.
Key is not inserted in ignition switch.
One or more registered Intelligent Keys are in the vehicle.
Symptom

Ignition switch does not turn on with Intelligent Key.
[KEY warning lamp (green) illuminates.]

Diagnosis/service procedure

E
Reference page

1. Check steering lock unit.

BL-188

2. Replace Intelligent Key unit.

BL-193

F

KEY WARNING LAMP (RED) ILLUMINATES
G
NOTE:
●
Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, «Trouble Diagnosis Procedure» .
●
Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis, H
and check each symptom.
●
If the following “symptoms” are detected, check systems shown in the “Diagnoses/service procedure” column in this order.
BL

Conditions of Vehicle (Operating Conditions)
●
●
●

Intelligent Key is registered.
Key is not inserted in ignition switch.
One or more registered Intelligent Keys are in the vehicle.
Symptom
Ignition switch does not turn on with Intelligent
Key. [KEY warning lamp (red) illuminates.]

Diagnosis/service procedure

J

Reference page

1. Check inside key antenna.

BL-187

2. Replace Intelligent Key unit.

BL-193

K

L

M

BL-157

INTELLIGENT KEY SYSTEM
KEY WARNING LAMP DOES NOT ILLUMINATE
NOTE:
●
Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, «Trouble Diagnosis Procedure» .
●
Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis,
and check each symptom.
●
If the following “symptoms” are detected, check systems shown in the “Diagnoses/service procedure” column in this order.
●
Check if ignition switch turns using mechanical key. If it turns, check if “ENGINE START BY I-KEY” in
“WORK SUPPORT” mode is ON.

Conditions of Vehicle (Operating Conditions)
●
●
●

Intelligent Key is registered.
Key is not inserted in ignition switch.
One or more registered Intelligent Keys are in the vehicle.
Symptom

Diagnosis/service procedure

Ignition switch does not turn on with Intelligent Key.
(KEY warning lamp does not illuminate.)

Reference page

1.

Check Intelligent Key unit power supply and ground
circuit.

BL-164

2.

Check ignition knob switch.

BL-168

3.

Check key switch.

BL-165

4.

Replace Intelligent Key unit.

BL-193

SELF-DIAGNOSIS RESULTS ARE NOT DISPLAYED
NOTE:
●
Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, «Trouble Diagnosis Procedure» .
●
Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis,
and check each symptom.
●
If the following “symptoms” are detected, check systems shown in the “Diagnoses/service procedure” column in this order.

Conditions of Vehicle (Operating Conditions)
●
●

Intelligent Key is registered.
Multiple mechanical keys are not set in a keyfob.
(If mechanical keys are near the ignition switch, the operation may not work properly.)
Symptom
Ignition switch does not turn on with mechanical key.

Diagnosis/service procedure

Reference page

1.

Check key switch.

BL-165

2.

Check NATS antenna amp.

BL-233

ENGINE START CONDITION CHECK
NOTE:
●
Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, «Trouble Diagnosis Procedure» .
●
If the following “symptoms” are detected, check systems shown in the ”Diagnoses/service procedure” column in this order.
Symptom
Engine start condition check

Diagnosis/service procedure
1.

Check stop lamp switch.

BL-158

Reference page
BL-192

INTELLIGENT KEY SYSTEM
DOOR LOCK/UNLOCK FUNCTION MALFUNCTION
NOTE:
●
Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, «Trouble Diagnosis Procedure» .
●
Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis,
and check each symptom.
●
If the following “symptoms” are detected, check systems shown in the “Diagnosis/procedure” column in
this order.

A

B

C

Conditions of Vehicle (Operating Conditions)
●
●
●

“LOCK/UNLOCK BY I-KEY” is ON when setting on CONSULT-II.
Ignition switch is not depressed.
All doors are closed.
Symptom

Door lock/unlock do not operate by all request
switch.

Door lock/unlock does not operate by request
switch (driver side).

Door lock/unlock does not operate by request
switch (passenger side).

Door lock/unlock does not operate by back door
request switch.
Anti-hijack function does not operate by door
request switch (driver side) (other door lock
function operate).
Anti-hijack function does not operate by back
door request switch (other door lock function
operate).

Auto lock function does not operate.

Key reminder function does not operate.

Diagnosis/service procedure

D

Reference page

1.

Check door switch.

BL-174

2.

Check key switch.

BL-165

3.

Check ignition knob switch.

BL-168

4.

Replace Intelligent Key unit.

BL-193

1.

Check door request switch (driver side).

BL-170

2.

Check outside key antenna (driver side).

BL-184

3.

Replace Intelligent Key unit.

BL-193

1.

Check door request switch (passenger side).

BL-170

2.

Check outside key antenna (passenger side).

BL-184

3.

Replace Intelligent Key unit.

BL-193

1.

Check back door request switch.

BL-172

2.

Check outside key antenna (back door).

BL-185

3.

Replace Intelligent Key unit.

BL-193

1.

Check “SELECTIVE UNLOCK FUNCTION” setting in
“WORK SUPPORT”.

BL-156

2.

Replace BCM.

BCS-17

1.

Check “SELECTIVE UNLOCK FUNCTION” setting in
“WORK SUPPORT”.

BL-156

2.

Replace BCM.

BCS-17

1.

Check “AUTO RELOCK TIMER” setting in “WORK
SUPPORT”.

BL-156

2.

Check key switch.

BL-165

3.

Check ignition knob switch.

BL-168

4.

Check door switch.

BL-174

5.

Replace Intelligent Key unit.

BL-193

1.

Check door switch.

BL-174

2.

Check inside key antenna.

BL-187

3.

Check Intelligent Key battery inspection.

BL-193

4.

Replace Intelligent Key unit.

BL-193

REMOTE KEYLESS ENTRY FUNCTION MALFUNCTION
NOTE:
●
Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, «Trouble Diagnosis Procedure» .
●
Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis,
and check each symptom.

BL-159

E

F

G

H

BL

J

K

L

M

INTELLIGENT KEY SYSTEM
●

If the following “symptoms” are detected, check systems shown in the “Diagnosis/service procedure” column in this order.

Conditions of Vehicle (Operating Conditions)
●
●

Ignition switch is not depressed.
All doors are closed.
Symptom
All of the remote keyless entry functions
do not operate.

Anti-hijack function does not operate by
Intelligent Key button.

Auto lock function does not operate.

Key reminder function does not operate.

Diagnosis/service procedure

Reference
page

1.

Check Intelligent Key battery inspection.

BL-193

2.

Replace Intelligent Key unit.

BL-193

1.

Check “SELECTIVE UNLOCK FUNCTION” setting in “WORK
SUPPORT”.

BL-156

2.

Check Intelligent Key battery inspection.

BL-193

3.

Replace Intelligent Key unit.

BL-193

1.

Check “AUTO RELOCK TIMER” setting in “WORK SUPPORT”.

BL-156

2.

Check key switch.

BL-165

3.

Check ignition knob switch.

BL-168

4.

Check door switch.

BL-174

5.

Replace Intelligent Key unit.

BL-193

1.

Check door switch.

BL-174

2.

Check inside key antenna.

BL-187

3.

Check Intelligent Key battery inspection.

BL-193

4.

Replace Intelligent Key unit.

BL-193

BL-160

INTELLIGENT KEY SYSTEM
HAZARD AND BUZZER REMINDER FUNCTION MALFUNCTION
NOTE:
●
Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, «Trouble Diagnosis Procedure» .
●
Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis,
and check each symptom.
●
If the following “symptoms” are detected, check systems shown in the “Diagnosis/service procedure” column in this order.

A

B

C

Conditions of Vehicle (Operating Conditions)
●
●

Ignition switch is not depressed.
All doors are closed.

D

Symptom

Diagnosis/service procedure

Reference page

Hazard reminder does not operate by
request switch.
(Buzzer reminder is operated.)

1.

Check hazard function with hazard switch.

2.

Replace Intelligent Key unit

Hazard reminder does not operate by Intelligent Key button.
(Buzzer reminder is operated.)

1.

Check hazard function with hazard switch.

2.

Replace Intelligent Key

BL-193

1.

Check “ANSWER BACK WITH I-KEY LOCK” or
“ANSWER BACK WITH I-KEY UNLOCK” setting in
“WORK SUPPORT”.

BL-156

2.

Check Intelligent Key warning buzzer.

BL-183

3.

Replace Intelligent Key unit.

BL-193

Buzzer reminder does not operate properly
by request switch.
(Hazard reminder is operated.)

LT-98

E

BL-193
LT-98

F

G

H

WARNING CHIME FUNCTION MALFUNCTION
BL
NOTE:
●
Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, «Trouble Diagnosis Procedure» .
●
Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis, J
and check each symptom.
●
If the following “symptoms” are detected, check systems shown in the “Diagnosis/service procedure” column in this order.
K
Conditions of Vehicle (Operating Conditions)
Each warning chime function is ON when setting on CONSULT-II.
Symptom

Ignition switch warning chime does not
operate.

Ignition key warning chime does not
operate.
(When mechanical key used)

OFF position warning chime (For internal) does not operate.

Diagnosis/service procedure

Reference page

1.

Check ignition knob switch.

BL-168

2.

Check door switch

BL-174

3.

Check key switch

BL-165

4.

Check warning buzzer in combination meter.

BL-191

5.

Replace Intelligent Key unit.

BL-193

1.

Check key switch (Intelligent Key unit input).

BL-165

2.

Check key switch (BCM input).

BL-167

3.

Check door switch.

BL-174

4.

Check warning buzzer in combination meter.

BL-191

5.

Replace Intelligent Key unit.

BL-193

1.

Check ignition switch signal circuit

BL-164

2.

Check ignition knob switch.

BL-168

3.

Check key switch

BL-165

4.

Check warning buzzer in combination meter.

BL-191

5.

Replace Intelligent Key unit.

BL-193

BL-161

L

M

INTELLIGENT KEY SYSTEM
Symptom

OFF position warning chime (For external) does not operate.

Take away warning chime does not operate.

Take away warning chime (Take away
from window) does not operate.

Door lock operation warning chime does
not operate.

Diagnosis/service procedure

Reference page

1.

Check ignition switch signal circuit

BL-164

2.

Check ignition knob switch.

BL-168

3.

Check Intelligent Key warning buzzer.

BL-183

4.

Replace Intelligent Key unit.

BL-193

1.

Check door switch.

BL-174

2.

Check ignition switch signal circuit

BL-164

3.

Check Intelligent Key battery inspection

BL-193

4.

Check inside key antenna.

BL-187

5.

Check Intelligent Key warning buzzer.

BL-191

6.

Replace Intelligent Key unit.

BL-193

1.

Check “TAKE OUT FROM WINDOW WARN” setting in
“WORK SUPPORT”.

BL-156

2.

Check inside key antenna.

BL-187

3.

Check key switch.

BL-165

4.

Check Intelligent Key battery inspection

BL-193

5.

Check warning buzzer in combination meter.

BL-191

6.

Replace Intelligent Key unit.

BL-193

1.

Check door switch

BL-174

2.

Check ignition knob switch

BL-168

3.

Check door request switch

BL-170

4.

Check back door request switch

BL-172

4.

Check outside key antenna

BL-184

5.

Check inside key antenna

BL-187

6.

Check Intelligent Key warning buzzer.

BL-183

7.

Replace Intelligent Key unit.

BL-193

BL-162

INTELLIGENT KEY SYSTEM
WARNING LAMP FUNCTION MALFUNCTION
NOTE:
●
Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, «Trouble Diagnosis Procedure» .
●
If the following “symptoms” are detected, check systems shown in the “Diagnosis/service procedure” column in this order.
Symptom

Intelligent Key low battery warning does not operate.

Diagnosis/service procedure

Reference page

1.

Check “LOW BAT OF KEY FOB WARN” setting in “WORK SUPPORT”.

BL-156

2.

Check Intelligent Key battery inspection.

BL-193

3.

Check warning lamp.

BL-191

4.

Replace Intelligent Key unit.

BL-193

Take away warning lamp does not illuminate. (Take away
warning chime is operated.)

1.

Check warning lamp.

BL-191

2.

Replace Intelligent Key unit.

BL-193

Ignition switch warning lamp does not illuminate. (Ignition switch warning chime is operated)

1.

Check warning lamp.

BL-191

2.

Replace Intelligent Key unit.

BL-193

Check CAN Communication System

A

B

C

D

E

F
BIS0015G

1. CHECK SELF-DIAGNOSTIC RESULTS

G

CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which performs CAN communication.

H

●
●
●
●

With CONSULT-II
Connect CONSULT-II, and turn ignition switch ON.
Touch “INTELLIGENT KEY” on “SELECT SYSTEM” screen.
Touch “SELF-DIAG RESULTS” on “SELECT DIAG MODE” screen.
Check display content in self-diagnostic results.

BL

J

CONSULT-II display item

DTC code

NO DTC IS DETECTED

—

CAN COMM

U1000

CAN COMM2

U1010

OK or NG
NO DTC IS DETECTED>> INSPECTION END
CAN COMM [U1000]>> After printing “SELF-DIAGNOSIS RESULTS”, go to “CAN SYSTEM”, Refer to LAN3, «Precautions When Using CONSULT-II» .
CAN COMM2 [U1010]>> Replace Intelligent Key unit.

BL-163

K

L

M

INTELLIGENT KEY SYSTEM
Check Power Supply and Ground Circuit

BIS00162

1. CHECK POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect Intelligent Key unit connector.
Check voltage between Intelligent Key unit harness connector and ground.
Terminals
(+)

Intelligent Key unit
connector

Terminal

M60

11

(–)

Voltage (V)
(Approx.)

Ground

Battery voltage

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace Intelligent Key power supply circuit.
PIIB6595E

2. CHECK GROUND CIRCUIT
Check continuity between Intelligent Key unit harness connector and ground.
Intelligent Key unit connector
M60

Terminal

Continuity
Ground

12

Yes

OK or NG
OK
>> Power supply and ground circuits are OK.
NG
>> Repair or replace the Intelligent Key unit ground circuit.

PIIB6596E

Check Ignition Switch Signal Circuit

BIS0016K

1. CHECK IGNITION SWITCH SIGNAL
1.
2.
3.

Turn ignition switch OFF.
Disconnect Intelligent Key unit connector.
Check voltage between Intelligent Key unit harness connector and ground.

Intelligent
Key unit
connector

Terminal

Ignition switch position

(+)

(–)

OFF

ACC

ON

M60

6

Ground

0V

0V

Battery voltage

OK or NG
OK
>> Ignition switch signal circuit is OK.
NG
>> Check the following.
● 10A fuse [No. 5, located in fuse and fusible link box
(J/B)]
● Between Intelligent Key unit and fuse.

BL-164

PIIB6884E

INTELLIGENT KEY SYSTEM
Check Key Switch (Intelligent Key Unit Input)

BIS00163

1. CHECK KEY SWITCH INPUT SIGNAL

A

With CONSULT-II
Check key switch (“KEY SW”) in “DATA MONITOR” mode with CONSULT-II.

B

Monitor item

Condition
Insert mechanical key into ignition switch: ON

KEY SW

C

Remove mechanical key from ignition switch: OFF

D

E
PIIB1359E

Without CONSULT-II
1. Turn ignition switch OFF.
2. Disconnect Intelligent Key unit connector.
3. Check voltage between Intelligent Key unit and ground.

F

G

Terminals
(+)
Intelligent Key
unit connector

(–)

Terminal

Insert mechanical key
into ignition switch
M60

7

Ground

H

Voltage (V)
(Approx.)

Condition of key switch

BL

Battery voltage

Remove mechanical
key from ignition switch

0

OK or NG
OK
>> Key switch circuit is OK.
NG
>> GO TO 2.

J
PIIB6597E

K

2. CHECK KEY SWITCH POWER SUPPLY CIRCUIT
1.
2.
3.

L

Remove mechanical key from ignition switch.
Disconnect key switch and ignition knob switch connector.
Check voltage between key switch and ignition knob switch and ground.

M

Terminals
(+)
Key switch and
ignition knob
switch connector

Terminal

M34

2

(–)

Voltage (V)
(Approx.)

Ground

Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace key switch and ignition knob switch
power supply circuit.

BL-165

PIIB6598E

INTELLIGENT KEY SYSTEM

3. CHECK KEY SWITCH
Check continuity key switch and ignition knob switch.
Terminal

Condition of key switch

Continuity

Insert mechanical key into
ignition switch

Yes

Remove mechanical key
from ignition switch

No

Key switch and ignition knob switch

1

2

OK or NG
OK
>> GO TO 4.
NG
>> Replace key cylinder assembly (built-in key switch).

PIIB6599E

4. CHECK KEY SWITCH CIRCUIT
1.
2.

Disconnect Intelligent Key unit connector.
Check continuity between Intelligent Key unit and key switch and ignition knob switch.
A

3.

B

Intelligent Key
unit connector

Terminal

Key switch and
ignition knob
switch connector

Terminal

M60

7

M34

1

Continuity

Yes

Check continuity between Intelligent Key unit and ground.
A
Intelligent Key unit connector

Terminal

M60

7

Ground

Continuity
PIIB6600E

No

OK or NG
OK
>> Check the condition of harness and harness connector.
NG
>> Repair or replace harness between Intelligent Key unit and key switch and ignition knob switch.

BL-166

INTELLIGENT KEY SYSTEM
Check Key Switch (BCM Input)

BIS00164

1. CHECK KEY SWITCH POWER SUPPLY CIRCUIT

A

1.
2.
3.

B

Remove mechanical key from ignition switch.
Disconnect key switch and ignition knob switch connector.
Check voltage between key switch and ignition knob switch and ground.

C

Terminals
(+)
Key switch and
ignition knob
switch connector

Terminal

M34

2

(–)

Voltage (V)
(Approx.)

Ground

Battery voltage

OK or NG
OK
>> GO TO 2.
NG
>> Check harness between key switch and ignition knob
switch and fuse.

D

E

PIIB6598E

F

2. CHECK KEY SWITCH OPERATION
G

Check continuity key switch and ignition knob switch.
Terminal
Key switch and ignition knob switch

1

2

Condition of key switch

Continuity

Insert mechanical key into
ignition switch

Yes

Remove mechanical key
from ignition switch

No

H

BL

OK or NG
OK
>> GO TO 3.
NG
>> Replace key cylinder assembly (built-in key switch).

J
PIIB6599E

3. CHECK KEY SWITCH CIRCUIT

K

1.
2.

L

Disconnect BCM connector.
Check continuity between BCM and key switch and ignition knob switch.
A

3.

B

BCM connector

Terminal

Key switch and
ignition knob
switch connector

Terminal

M57

3

M34

1

Continuity

M

Yes

Check continuity between BCM and ground.
A

Continuity

BCM connector

Terminal

M57

3

Ground
MIIB1443E

No

OK or NG
OK
>> Key switch (BCM input) circuit is OK.
NG
>> Repair or replace harness between key switch and ignition knob switch and BCM.

BL-167

INTELLIGENT KEY SYSTEM
Check Ignition Knob Switch

BIS00165

1. CHECK IGNITION KNOB SWITCH INPUT SIGNAL
With CONSULT-II
Display “PUSH SW” on DATA MONITOR screen, and check if ON/OFF display is linked to ignition switch operation.
Monitor item

Condition
Ignition switch is pressed: ON

PUSH SW

Ignition switch is released: OFF

PIIB1360E

Without CONSULT-II
1. Turn ignition switch OFF.
2. Disconnect Intelligent Key unit connector.
3. Check voltage between Intelligent Key unit and ground.
Terminals
(+)
Intelligent Key unit
connector

M60

Terminal

27

(–)

Ground

Condition of key
switch

Voltage (V)
(Approx.)

Ignition switch is
pressed

Battery voltage

Ignition switch is
released

0

OK or NG
OK
>> Ignition knob switch circuit is OK.
NG
>> GO TO 2.

PIIB6602E

2. CHECK IGNITION KNOB SWITCH POWER SUPPLY CIRCUIT
1.
2.
3.

Turn ignition switch OFF.
Disconnect key switch and ignition knob switch connector.
Check voltage between key switch and ignition knob switch and ground.
Terminals
(+)
Key switch and
ignition knob
switch connector

Terminal

M34

4

(–)

Voltage (V)
(Approx.)

Ground

Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace key switch and ignition knob switch
power supply circuit.

BL-168

PIIB6603E

INTELLIGENT KEY SYSTEM

3. CHECK IGNITION KNOB SWITCH

A

Check continuity ignition knob switch.
Terminal

Condition of key
switch

Continuity

Ignition switch is
pressed

Yes

Ignition switch is
released

No

Key switch and ignition knob switch

3

4

B

C

OK or NG
OK
>> GO TO 4.
NG
>> Replace key switch and ignition knob switch.

D
PIIB6604E

E

4. CHECK IGNITION KNOB SWITCH CIRCUIT
1.
2.

Disconnect Intelligent Key unit connector.
Check continuity between Intelligent Key unit and key switch and ignition knob switch.
A

3.

F

B

Intelligent Key
unit connector

Terminal

Key switch and
ignition knob
switch connector

Terminal

M60

27

M34

3

Continuity

G

Yes

H

Check continuity between Intelligent Key unit and ground.
A
Intelligent Key unit connector

Terminal

M60

27

Ground

BL

Continuity
PIIB6605E

No

OK or NG
OK
>> Check the condition of harness and harness connector.
NG
>> Repair or replace harness between Intelligent Key unit and key switch and ignition knob switch.

J

K

L

M

BL-169

INTELLIGENT KEY SYSTEM
Check Door Request Switch

BIS00166

1. CHECK DOOR REQUEST SWITCH
With CONSULT-II
Check door request switch (“DR REQ SW” or “AS REQ SW”) in “DATA MONITOR” mode.
Monitor item

Condition
Door request switch is pressed: ON

DR REQ SW
AS REQ SW

Door request switch is released: OFF

PIIB4260E

Without CONSULT-II
1. Turn ignition switch OFF.
2. Check voltage between Intelligent Key unit harness connector and ground.
Terminals
(+)
Intelligent Key unit
connector

M60

Terminal

Door request
switch
(driver side)

5

Door request
switch
(passenger side)

25

(–)

Door
request
switch
Condition

Voltage (V)
(Approx.)

Pressed

0

Released

5

Pressed

0

Released

5

Ground

OK or NG
OK
>> Door request switch circuit is OK.
NG
>> GO TO 2.

BL-170

PIIB6613E

INTELLIGENT KEY SYSTEM

2. CHECK DOOR REQUEST SWITCH CIRCUIT
1.
2.

A

Disconnect Intelligent Key unit and front door request switch connector.
Check continuity between Intelligent Key unit connector and front door request switch connector.
B
A
Intelligent Key
unit connector

B
Front door request
switch connector

Terminal
5

Driver side

D12

25

Passenger
side

D29

M60

3.

Continuity

Terminal

C
1

Yes

D

Check continuity between Intelligent Key unit connector and
ground.
PIIB6614E

A
Intelligent Key unit
connector

Continuity

Terminal
Ground

F

5

M60

E

No

25

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness between Intelligent Key unit and front door request switch.

G

3. CHECK DOOR REQUEST SWITCH OPERATION

H

Check front door request switch.
Terminal
Front outside handle
1

2

BL
Door request
switch condition

Continuity

Pressed

Yes

Released

No

J

OK or NG
OK
>> GO TO 4.
NG
>> Replace malfunction front door request switch.

K

PIIB6615E

L

4. CHECK DOOR REQUEST SWITCH GROUND CIRCUIT
M

Check continuity between front door request switch connector and ground.
Front outside
handle
connector
Driver side

D12

Passenger
side

D29

Terminal

Continuity
Ground

2

Yes

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace front door request switch ground circuit.

BL-171

PIIB6616E

INTELLIGENT KEY SYSTEM

5. CHECK INTELLIGENT KEY UNIT OUTPUT SIGNAL
1.
2.

Connect Intelligent Key unit connector.
Check voltage between Intelligent Key unit connector and ground.
Terminals
(+)

Intelligent Key unit
connector

Terminal

(–)

Voltage (V)
(Approx.)

Ground

5

5
M60

25

OK or NG
OK
>> Check the condition of harness and connector.
NG
>> Replace Intelligent Key unit.

PIIB6613E

Check Back Door Request Switch

BIS00167

1. CHECK BACK DOOR REQUEST SWITCH
With CONSULT-II
Check back door request switch (“BD/TR REQ SW”) in “DATA MONITOR” mode.
Monitor item

Condition
Back door request switch is pressed: ON

BD/TR REQ SW

Back door request switch is released: OFF

PIIB4266E

1.
2.

Without CONSULT-II
Turn ignition switch OFF.
Check voltage between Intelligent Key unit connector and ground.
Terminals
(+)

Intelligent Key
unit connector

Terminal

M60

29

(–)

Ground

Back door
request switch
condition

Voltage (V)
(Approx.)

Pressed

0

Released

5

OK or NG
OK
>> Trunk lid request switch circuit is OK.
NG
>> GO TO 2.

PIIB6617E

BL-172

INTELLIGENT KEY SYSTEM

2. CHECK BACK DOOR REQUEST SWITCH CIRCUIT
1.
2.

A

Disconnect Intelligent Key unit and back door request switch connector.
Check continuity between Intelligent Key unit connector and back door request switch connector.
B
A

B

Intelligent Key
unit connector

Terminal

Back door switch
connector

Terminal

M60

29

D102

1

3.

Continuity

C
Yes

Check continuity between Intelligent Key unit connector and
ground.

D

A
Continuity

Intelligent Key unit
connector

Terminal

M60

29

Ground

MIIB1444E

E

No

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness between Intelligent Key unit and back door request switch.

F

3. CHECK BACK DOOR REQUEST SWITCH OPERATION

G

Check back door request switch.
H
Terminal
Back door request switch
1

2

Back door request
switch condition

Continuity

Pressed

Yes

Released

No

BL

OK or NG
OK
>> GO TO 4.
NG
>> Replace trunk lid request switch.

J

MIIB1445E

K

4. CHECK BACK DOOR REQUEST SWITCH GROUND CIRCUIT
L

Check continuity between back door request switch connector and ground.
Back door request switch
connector

Terminal

D102

2

Continuity

M

Ground
Yes

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace back door request switch ground circuit.
MIIB1446E

BL-173

INTELLIGENT KEY SYSTEM

5. CHECK INTELLIGENT KEY UNIT OUTPUT SIGNAL
1.
2.

Connect Intelligent Key unit connector.
Check voltage between Intelligent Key unit connector and ground.
Terminals
(+)

Intelligent Key unit
connector

Terminal

M60

29

(–)

Voltage (V)
(Approx.)

Ground

5

OK or NG
OK
>> Check the condition of harness and connector.
NG
>> Replace Intelligent Key unit.
PIIB6617E

Check Door Switch

BIS0016J

DRIVER SIDE

1. CHECK DOOR SWITCH INPUT SIGNAL
With CONSULT- II
Check door switch “DOOR SW-DR” in “DATA MONITOR” mode with CONSULT- II.
When front door (driver side) is opened:
DOOR SW-DR Þ ON
When front door (driver side) is close:
DOOR SW-DR Þ OFF

MIIB1050E

Without CONSULT- II
Check voltage between BCM connector and ground.
Connector

M57

Terminals (Wire color)
(+)

(-)

29

Ground

Condition

Voltage (V)
(Approx.)

Open

0

Close

Battery voltage

OK or NG
OK
>> Front door switch LH is OK.
NG
>> GO TO 2.
MIIB0342E

BL-174

INTELLIGENT KEY SYSTEM

2. CHECK HARNESS CONTINUITY
1.
2.
3.

29 – 1
4.

A

Turn ignition switch OFF.
Disconnect BCM and front door switch LH connector.
Check continuity between BCM connector M57 terminal 29 and
front door switch LH connector B14 terminal 1.

B

: Continuity should exist.

C

Check continuity between BCM connector M57 terminal 29 and
ground.
29 – Ground

D

: Continuity should not exist.

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.

MKIB0849E

3. CHECK DOOR SWITCH

E

F

Check continuity between door switch terminal 1 and body ground part of door switch.
Terminal
1

Body ground part
of door switch

Condition

Continuity

Pushed

No

Released

Yes

G

OK or NG
OK
>> GO TO 4.
NG
>> Replace door switch.

H

BL
PIIA3351E

J

4. CHECK BCM OUTPUT SIGNAL
1.
2.

Connect BCM connector.
Check voltage between BCM connector M57 terminal 29 and
ground.
29 – Ground

K

: Battery voltage

L

OK or NG
OK
>> Check door switch ground condition.
NG
>> Replace BCM.

M

MIIB0342E

BL-175

INTELLIGENT KEY SYSTEM
PASSENGER SIDE

1. CHECK DOOR SWITCH INPUT SIGNAL
With CONSULT- II
Check door switch “DOOR SW-AS” in “DATA MONITOR” mode with CONSULT- II.
When front door (passenger side) is opened:
DOOR SW-AS Þ ON
When front door (passenger side) is close:
DOOR SW-AS Þ OFF

MIIB1051E

Without CONSULT- II
Check voltage between BCM connector M57 terminal 30 and ground.
Terminal (Wire color)
Connector

M57

(+)

(-)

30

Ground

Condition

Voltage (V)
(Approx.)

Open

0

Close

Battery voltage

OK or NG
OK
>> Front door switch RH is OK.
NG
>> GO TO 2.
MIIB0344E

2. CHECK HARNESS CONTINUITY
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM and front door switch RH connector.
Check continuity between BCM connector M57 terminal 30 and
front door switch RH connector B29 terminal 1.
30 – 1

4.

: Continuity should exist.

Check continuity between BCM connector M57 terminal 30 and
ground.
30 – Ground

: Continuity should not exist.

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.

MKIB0850E

BL-176

INTELLIGENT KEY SYSTEM

3. CHECK DOOR SWITCH

A

Check continuity between door switch terminal 1 and body ground of door switch.
Terminal
1

Ground

Condition

Continuity

Pushed

No

Released

Yes

B

OK or NG
OK
>> GO TO 4.
NG
>> Replace door switch.

C

D
PIIA3351E

E

4. CHECK BCM OUTPUT SIGNAL
1.
2.

Connect BCM connector.
Check voltage between BCM connector M57 terminal 30 and
ground.
30 – Ground

F

: Battery voltage

G

OK or NG
OK
>> Check door switch ground condition.
NG
>> Replace BCM.

H

BL
MIIB0344E

J

K

L

M

BL-177

INTELLIGENT KEY SYSTEM
REAR LH SIDE

1. CHECK DOOR SWITCH INPUT SIGNAL
With CONSULT- II
Check door switch “DOOR SW-RL” in “DATA MONITOR” mode with CONSULT- II.
When rear door (LH side) is opened:
DOOR SW-RL Þ ON
When rear door (LH side) is close:
DOOR SW-RL Þ OFF

MIIB1052E

Without CONSULT- II
Check voltage between BCM connector M58 terminal 59 and ground.
Terminal (Wire color)
Connector

M58

Voltage (V)
(Approx.)

Condition

(+)

(-)

59

Ground

Open

0

Close

Battery voltage

OK or NG
OK
>> Rear door switch LH is OK.
NG
>> GO TO 2.
MIIB0346E

2. CHECK HARNESS CONTINUITY
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM and rear door switch LH connector.
Check continuity between BCM connector and rear door switch LH connector.
A

4.

B
Continuity

BCM
connector

Terminal

Rear door
switch LH

Terminal

M58

59

B19

1

Yes

Check continuity between BCM connector and ground.
A

Continuity

BCM connector

Terminal

M58

59

Ground
No

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.

BL-178

MIIB1374E

INTELLIGENT KEY SYSTEM

3. CHECK DOOR SWITCH

A

Check continuity between door switch terminal 1 and body ground of door switch.
Terminals
1

Condition
Ground

Continuity

Pushed

NO

Released

YES

B

C

OK or NG
OK
>> GO TO 4.
NG
>> Replace door switch.

D
PIIA3351E

E

4. CHECK BCM OUTPUT SIGNAL
1.
2.

Connect BCM connector.
Check voltage between BCM connector M58 terminal 58 and ground.
59 – Ground

F

: Battery voltage

OK or NG
OK
>> Check door switch ground condition.
NG
>> Replace BCM.

G

H

BL
MIIB0346E

J

K

L

M

BL-179

INTELLIGENT KEY SYSTEM
REAR RH SIDE

1. CHECK DOOR SWITCH INPUT SIGNAL
With CONSULT- II
Check door switch “DOOR SW-RR” in “DATA MONITOR” mode with CONSULT- II.
When rear door (RH side) is opened:
DOOR SW-RR Þ ON
When rear door (RH side) is close:
DOOR SW-RR Þ OFF

MIIB1053E

Without CONSULT- II
Check voltage between BCM connector and ground.
Terminal (Wire color)
Connector

M58

Voltage (V)
(Approx.)

Condition

(+)

(-)

60 (L)

Ground

Open

0

Close

Battery voltage

OK or NG
OK
>> Rear door switch RH is OK.
NG
>> GO TO 2.
MIIB0348E

2. CHECK HARNESS CONTINUITY
1.
2.
3.

Turn ignition switch OFF.
Disconnect BCM and rear door switch RH connector.
Check continuity between BCM connector and rear door switch RH connector.
A

4.

B
Continuity

BCM
connector

Terminal

Rear door
switch RH

Terminal

M58

60

B42

1

Yes

Check continuity between BCM connector and ground.
A

Continuity

BCM connector

Terminal

M58

60

Ground
No

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.

BL-180

MIIB1375E

INTELLIGENT KEY SYSTEM

3. CHECK DOOR SWITCH

A

Check continuity between door switch terminal 1 and body ground of door switch.
Terminal
1

Ground

Condition

Continuity

Pushed

NO

Released

YES

B

OK or NG
OK
>> GO TO 4.
NG
>> Replace door switch.

C

D
PIIA3351E

E

4. CHECK BCM OUTPUT SIGNAL
1.
2.

Connect BCM connector.
Check voltage between BCM connector M58 terminal 60 and
ground.
60 – Ground

F

: Battery voltage

G

OK or NG
OK
>> Check door switch ground condition.
NG
>> Replace BCM.

H

BL
MIIB0348E

BACK DOOR SWITCH

1. CHECK BACK DOOR SWITCH INPUT SIGNAL
1.
2.

J

Turn ignition switch OFF.
Check voltage between BCM connector M57 terminal 10 and ground.
Terminal
(+)
10 (P)

Back door condition

Voltage (V)
Approx.

Closed

5

Open

0

(–)
Ground

K

L

M

OK or NG
OK
>> Back door switch circuit is OK.
NG
>> GO TO 2
MIIB0314E

BL-181

INTELLIGENT KEY SYSTEM

2. CHECK BACK DOOR SWITCH HARNESS
1.
2.

Disconnect back door switch connector.
Check voltage between back door switch connector and ground. (Check harness for open.)
Back door switch
connector

Terminal

B46

2

Voltage (V)
(Approx.)

Ground

Battery voltage

MIIB1376E

3.
4.

Disconnect BCM connector.
Check continuity between back door switch connector and ground. (Check harness for short.)
Back door switch
connector

Terminal

B46

2

Continuity
Ground
No

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness.

MIIB1377E

3. CHECK BACK DOOR SWITCH
Check continuity between back door switch terminal.
Terminal
Back door
switch

1

2

Rear door condition

Continuity

Closed

No

Opened

Yes

OK or NG
OK
>> GO TO 4.
NG
>> Replace back door release actuator (back door switch).
MIIB1378E

4. CHECK BACK DOOR SWITCH GROUND HARNESS
Check continuity between back door switch connector and ground.
Back door switch
connector

Terminal

B46

1

Ground

Continuity
Yes

OK or NG
OK
>> Check harness connection.
NG
>> Replace back door switch.

MIIB1379E

BL-182

INTELLIGENT KEY SYSTEM
Check Intelligent Key Warning Buzzer Circuit

BIS00168

1. CHECK INTELLIGENT KEY WARNING BUZZER POWER SUPPLY CIRCUIT

A

1.
2.
3.

B

Turn ignition switch OFF.
Disconnect Intelligent Key warning buzzer connector.
Check voltage between Intelligent Key warning buzzer connector and ground.
Terminals

C

(+)
Intelligent Key
warning buzzer
connector

Terminal

D10

1

(–)

Voltage (V)
(Approx.)

Ground

Battery voltage

D

OK or NG
OK
>> GO TO 2.
NG
>> Check the following.
● 10A fuse [No. 7, located in the fuse block (J/B)]
● Continuity between Intelligent Key warning buzzer and fuse

E
PIIB6622E

F

2. CHECK INTELLIGENT KEY WARNING BUZZER CIRCUIT

G

1.
2.

H

Disconnect Intelligent Key unit connector.
Check continuity between Intelligent Key unit connector and Intelligent Key warning buzzer connector.
A

3.

B

Intelligent Key
unit connector

Terminal

Intelligent Key
warning buzzer
connector

M60

4

D10

Terminal
2

Continuity

BL

Yes

J

Check continuity between Intelligent Key unit connector and
ground.
A

K

Intelligent Key unit
connector

Terminal

M60

4

Ground

Continuity

PIIB6623E

L

No

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness between Intelligent Key unit and Intelligent Key warning buzzer.

3. CHECK INTELLIGENT KEY WARNING BUZZER OPERATION
Connect battery power supply to Intelligent Key warning buzzer terminals 1 and 2, and check the operation.
1 (BAT+) — 2 (BAT-)

: the buzzer sounds

OK or NG
OK
>> Intelligent Key warning buzzer is OK.
NG
>> Replace Intelligent Key warning buzzer.

PIIB6624E

BL-183

M

INTELLIGENT KEY SYSTEM
Check Outside Key Antenna (Driver Side and Passenger Side)

BIS00169

1. CHECK OUTSIDE KEY ANTENNA INPUT SIGNAL 1
1.
2.

Turn ignition switch OFF.
Check signal between Intelligent Key unit connector and ground with oscilloscope.
Terminals
(+)
Intelligent Key
unit connector
Driver
side

Terminal
19

M60

Door
request
switch is
pushed

Ground
Passenger side

Signal
(Reference value.)

Condition
(–)

37

PIIB6626E

SIIA1910J

OK or NG
OK
>> Outside key antenna is OK.
NG
>> GO TO 2.

2. CHECK OUTSIDE KEY ANTENNA CIRCUIT
1.
2.

Disconnect Intelligent Key unit and outside key antenna connector.
Check continuity between Intelligent Key unit connector and outside key antenna connector.
A

Intelligent Key
unit connector

B
Terminal
19

Outside key antenna connector
D13

37

2
D30

38

Continuity

1

Driver side

20

M60

3.

Terminal

Yes

1

Passenger
side

2

Check continuity between Intelligent Key unit connector and
ground.
A
Intelligent Key unit
connector

Continuity

Terminal
19

Ground

20
M60

No

37
38

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness between Intelligent Key unit and outside key antenna.

BL-184

PIIB6627E

INTELLIGENT KEY SYSTEM

3. CHECK OUTSIDE KEY ANTENNA INPUT SIGNAL 2
1.
2.
3.

A

Replace outside key antenna. (New antenna or other antenna)
Connect Intelligent Key unit and outside key antenna connector.
Check signal between Intelligent Key unit connector and ground with oscilloscope.

B

Terminals
(+)
Intelligent Key
unit connector

Condition

Driver
side
M60

(–)

Terminal

C

Signal
(Reference value.)

D

19

Ground

Passenger side

37

Door
request
switch is
pushed

E
PIIB6626E

SIIA1910J

F

OK or NG
OK
>> Replace malfunction outside key antenna.
NG
>> Replace Intelligent Key unit.

G

Check Outside Key Antenna (Back Door)

BIS0016A

1. CHECK OUTSIDE KEY ANTENNA INPUT SIGNAL 1
1.
2.

H

Turn ignition switch OFF.
Check signal between Intelligent Key unit connector and ground with oscilloscope.

BL

Terminals
(+)
Intelligent
Key unit
connector

(–)

Condition

Signal
(Reference value.)

J

Terminal

K

M60

17

Ground

Back door
request
switch is
pushed

PIIB6628E

SIIA1910J

OK or NG
OK
>> Outside key antenna (back door) is OK.
NG
>> GO TO 2.

BL-185

L

M

INTELLIGENT KEY SYSTEM

2. CHECK OUTSIDE KEY ANTENNA CIRCUIT
1.
2.

Disconnect Intelligent Key unit and outside key antenna (back door) connector.
Check continuity between Intelligent Key unit connector and outside key antenna (back door) connector.
A
Intelligent Key
unit connector

B
Terminal

Outside key
antenna (back
door) connector

17
M60

3.

Continuity

Terminal
1

B43

18

Yes

2

Check continuity between Intelligent Key unit connector and
ground.
PIIB6629E

A
Intelligent Key unit
connector

Continuity

Terminal
Ground
17

M60

No

18

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness between Intelligent Key unit and outside key antenna (back door).

3. CHECK OUTSIDE KEY ANTENNA INPUT SIGNAL 2
1.
2.
3.

Replace outside key antenna. (New antenna or other antenna)
Connect Intelligent Key unit and outside key antenna (back door) connector.
Check signal between Intelligent Key unit connector and ground with oscilloscope.
Terminals
(+)

Intelligent
Key unit
connector

M60

Condition
Terminal

17

(–)

Ground

Signal
(Reference value.)

Trunk lid
request
switch is
pushed

PIIB6628E

SIIA1910J

OK or NG
OK
>> Replace outside key antenna (back door).
NG
>> Replace Intelligent Key unit.

BL-186

INTELLIGENT KEY SYSTEM
Check Inside Key Antenna

BIS0016B

1. CHECK INSIDE KEY ANTENNA INPUT SIGNAL 1
1.
2.

A

Turn ignition switch OFF.
Check signal between Intelligent Key unit connector and ground with oscilloscope.

B

Terminals
(+)
Intelligent Key
unit connector

M60

Signal
(Reference value.)

Condition
(–)

Terminal

Dash
board

35

Center
console

15

Back
door

13

C

D
Any door
is open →
close

Ground

E
PIIB6630E

SIIA1910J

F

OK or NG
OK
>> Check the condition of harness and connector.
NG
>> GO TO 2.

G

2. CHECK INSIDE KEY ANTENNA CIRCUIT
1.
2.

A
Intelligent Key
unit connector

B
Terminal
35

BL

Inside key antenna
connector
M47

Terminal

M60

15

J

2
B20

1

Center console

16
13

Continuity

1

Dash board

36

Yes

K

2
B32

1

Back door

14

3.

H

Disconnect Intelligent Key unit and inside key antenna connector.
Check continuity between Intelligent Key unit connector and inside key antenna connector.

MIIB1447E

2

L

Check continuity between Intelligent Key unit connector and ground.
A
Intelligent Key unit
connector

Continuity
Terminal
35

Dash board

36

Ground

15
M60

Center console

No

16
13

Back door

14

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness between Intelligent Key unit and inside key antenna.

BL-187

M

INTELLIGENT KEY SYSTEM

3. CHECK INSIDE KEY ANTENNA INPUT SIGNAL 2
1.
2.
3.

Replace inside key antenna. (New antenna or other antenna)
Connect Intelligent Key unit and inside key antenna connector.
Check signal between Intelligent Key unit connector and ground with oscilloscope.
Terminals
(+)

M60

Signal
(Reference value.)

Condition

Intelligent Key
unit connector

(–)

Terminal

Dash
board

35

Center
console

15

Back
door

13

Ground

Any door
is open →
close
PIIB6630E

SIIA1910J

OK or NG
OK
>> Replace malfunction inside key antenna.
NG
>> Replace Intelligent Key unit.

Check Steering Lock Unit

BIS0016C

1. CHECK STEERING LOCK UNIT POWER SUPPLY
1.
2.
3.

Turn ignition switch OFF.
Disconnect steering lock unit connector.
Check voltage between steering lock unit and ground.
Terminals
(–)

Voltage (V)
(Approx.)

Ground

Battery voltage

(+)
Steering lock unit

Terminal

M37

1

OK or NG
OK
>> GO TO 2.
NG
>> Repair or replace steering lock unit power supply circuit.
PIIB6632E

2. CHECK STEERING LOCK UNIT GROUND CIRCUIT
Check continuity between steering lock unit and ground.
Steering lock unit connector

Terminal

M37

4

Ground

Continuity
Yes

OK or NG
OK
>> GO TO 3.
NG
>> GO TO 6.

PIIB6633E

BL-188

INTELLIGENT KEY SYSTEM

3. CHECK INTELLIGENT KEY UNIT OUTPUT SIGNAL
1.
2.

A

Connect steering lock unit connector.
Check voltage between Intelligent Key unit and ground.
B
Terminals
(+)

Intelligent Key unit
connector

Terminal

M37

1

(–)

Voltage (V)
(Approx.)

Ground

5

C

D

OK or NG
OK
>> GO TO 4.
NG
>> Replace Intelligent Key unit.
PIIB6634E

E

4. CHECK STEERING LOCK COMMUNICATION SIGNAL
F

Check signal between Intelligent Key unit and ground with oscilloscope.
Terminals
(+)
Intelligent
Key unit
connector

M37

(–)

Condition of
key switch

G

Voltage (V)
(Approx.)

Terminal

H

32

Ground

Ignition
switch is
pressed,
when Intelligent Key is
into the vehicle.
Other than
above

BL
PIIB6635E

J
SIIA1911J

5

K

OK or NG
OK
>> GO TO 5.
NG
>> Replace Intelligent Key unit.

L

M

BL-189

INTELLIGENT KEY SYSTEM

5. CHECK STEERING LOCK UNIT COMMUNICATION CIRCUIT
1.
2.

Disconnect Intelligent Key unit and steering lock unit connectors.
Check continuity between Intelligent Key unit and steering lock unit.
A
Intelligent Key
unit connector

B
Terminal

Steering lock unit
connector

Terminal

1
M60

2

31

M37

4

32

3.

Continuity

Yes

3

Check continuity between steering lock unit and ground.
A
Intelligent Key unit connector

Continuity

Terminal
1

M60

PIIB6636E

Ground

31

No

32

OK or NG
OK
>> Replace steering lock unit.
● After replacing steering lock unit, perform registration procedure. Refer to “CONSULT-II Operation Manual NATS”.
NG
>> Repair or replace harness between steering lock unit and Intelligent Key unit.

6. CHECK STEERING LOCK UNIT COMMUNICATION CIRCUIT
1.
2.

Disconnect Intelligent Key unit connector.
Check continuity between Intelligent Key unit and steering lock unit.
A

3.

Intelligent Key
unit connector
M60

B
Continuity

Terminal

Steering lock unit
connector

Terminal

31

M37

4

Yes

Check continuity between steering lock unit and ground.
A

Continuity

Intelligent Key unit connector

Terminal

M60

31

Ground
No

OK or NG
OK
>> Check the following.
● Intelligent Key unit ground circuit.
● Intelligent Key unit.
NG
>> Repair or replace harness between steering lock unit and Intelligent Key unit.

BL-190

PIIB6637E

INTELLIGENT KEY SYSTEM
Check Warning Lamp

BIS0016E

1. CHECK WARNING LAMP OPERATION
●

●

A

With CONSULT-II
Check “INDICATOR” in “ACTIVE TEST” mode with CONSULTII.
Select “BLUE ON”, “RED ON” or “KNOB ON”

B

C

Does each warning lamp illuminate?
OK or NG
OK
>> INSPECTION END
NG
>> GO TO DI-32, «WARNING LAMPS» .

D

E
PIIB4356E

Check Warning Buzzer in Combination Meter

BIS0016F

1. CHECK WARNING BUZZER OPERATION
●

●

F

With CONSULT-II
Check “INSIDE BUZZER” in “ACTIVE TEST” mode with CONSULT-II.
Touch “TAKE OUT”, “KNOB” or “KEY” on “ACTIVE TEST”
screen.

G

H

Does each warning buzzer sound?
OK or NG
OK
>> INSPECTION END
NG
>> GO TO 2.

BL

PIIB6619E

J

2. CHECK OTHER WARNING BUZZER OPERATION
K

Check other warning buzzer operation using combination meter.
Does warning buzzer in combination meter sound?
OK or NG
OK
>> INSPECTION END
NG
>> GO TO DI-52, «WARNING CHIME» .

L

Check Hazard Function

BIS0016G

1. CHECK HAZARD WARNING LAMP
Does hazard warning lamp flash with hazard switch?
YES or NO
YES >> Hazard warning lamp circuit is OK.
NO
>> Check hazard circuit. Refer to LT-98, «TURN SIGNAL AND HAZARD WARNING LAMPS» .

Check Headlamp Function

BIS0016H

1. CHECK HEADLAMP OPERATION
Check if headlamp operate by lighting switch.
Does headlamp come on when turning lighting switch “ON”?
YES >> Headlamp circuit is OK.
NO
>> Check headlamp system. Refer to LT-7, «HEADLAMP -CONVENTIONAL TYPE-»
«HEADLAMP — DAYTIME LIGHT SYSTEM -» .

BL-191

or LT-35,

M

INTELLIGENT KEY SYSTEM
Check Stop Lamp Switch

BIS0015U

1. CHECK STOP LAMP SWITCH INPUT SIGNAL
1.
2.
3.

Turn ignition switch OFF.
Disconnect Intelligent Key unit connector.
Check voltage between Intelligent Key unit harness connector and ground.
Terminal
Connector

M60

(+)

(–)

26

Ground

Condition

Voltage (V)
(Approx.)

Brake pedal depressed

Battery voltage

Brake pedal released

0

OK or NG
OK
>> Stop lamp switch is OK.
NG
>> GO TO 2.
PIIB4346E

2. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT
Check voltage between stop lamp switch harness connector and
ground.
1 – Ground

: Battery voltage

OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace harness between stop lamp switch
power supply circuit and fuse.

MIIB0817E

3. CHECK STOP LAMP SWITCH OPERATION
Check continuity between stop lamp switch connector.
Connector
E38 (LHD with M/T)
E60 (LHD with A/T)
E203 (RHD with M/T)
E204 (RHD with A/T)

Terminal

1

2

Condition

Continuity

Brake pedal depressed

Yes

Brake pedal not
depressed

No

OK or NG
OK
>> GO TO 4.
NG
>> Replace stop lamp switch.
MIIB0818E

BL-192

INTELLIGENT KEY SYSTEM

4. CHECK STOP LAMP SWITCH CIRCUIT
1.

26 – 2
2.

A

Check continuity between Intelligent Key unit harness connector
and stop lamp switch harness connector.
B

: Continuity should exist.

Check continuity between Intelligent Key unit harness connector
and ground.
26 – Ground

C

: Continuity should not exist.

OK or NG
OK
>> Check condition of harness and connector.
NG
>> Repair or replace harness.

Removal and Installation of Intelligent key unit

D
MIIB0819E

BIS000KU

REMOVAL
1.
2.

Remove the instrument lower driver panel. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Disconnect the Intelligent Key unit connector, remove the screw
and Intelligent Key unit.

E

F

G

H

MIIB0305E

BL

INSTALLATION
Install in the reverse order of removal.

J

Intelligent Key Inspection

BIS000KV

INTELLIGENT KEY DISASSEMBLY AND ASSEMBLY
1.
2.

Remove Intelligent Key cover.
Insert a thin screwdriver wrapped with tape into Area A and then
separate lower and upper cases while twisting screwdriver.

K

L

M

MIIB0303E

BL-193

INTELLIGENT KEY SYSTEM
3.

4.

When replacing the circuit board or rubber
● Remove the circuit board assembly from the upper case.
(Substrate assembly: circuit board + rubber)
● Gently press the rubber and remove the circuit board.
CAUTION:
Be careful not to touch the printed circuits directly.
When replacing the battery
● Remove the battery from the lower case and replace it.
Battery replacement

5.

: Coin-shaped lithium battery 3V (CR2032)

CAUTION:
When replacing battery, be sure to keep dirt, grease, and
other foreign materials off the electrode contact area.
After replacement, assemble the upper and lower cases by
engaging the hooks on their circumference while being careful
not to pinch the rubber, etc.
CAUTION:
After replacing the battery, check to make sure all Intelligent Key functions work normally.
MIIB0304E

REMOTE CONTROLLER BATTERY INSPECTION
Check by connecting a resistance (approximately 300Ω) so that the
current value becomes about 10 mA.
Standard

: Approx. 2.5V — 3.0V

OCC0607D

BL-194

DOOR
DOOR
Fitting Adjustment

PFP:80100

A
BIS000KW

B

C

D

E

F

G

H

BL

J

K

L

M

PIIB5575J

1. Front fender

2. Front door

3. Rear door

4. Body side outor panel

FRONT DOOR
Longitudinal Gap and Front End Height Difference Adjustment
1.
2.

Remove front fender. Refer to BL-15, «Removal and Installation» .
Loosen the hinge bolts on body, then lift the rear end of front door to adjust the clearance and surface difference properly.

BL-195

DOOR
REAR DOOR
Longitudinal Gap and Front End Height Difference Adjustment
1.
2.

Remove center pillar upper garnish and center pillar lower garnish. Refer to EI-26, «Removal and Installation» .
Working from inside and outside vehicle, loosen bolts and nuts, and then open rear door, and adjust while
raising rear door by rear edge.

STRIKER ADJUSTMENT
Adjust the striker so that it becomes parallel with the lock inserting
direction.

PIIB2804J

Removal and Installation

BIS000KZ

CAUTION:
●
During removal and installation of the door assembly, use a jack to support the door. Place a shop
cloth or other suitable material onto the jack plate to protect the door and body from damage.
●
After removal and installation of the door assembly, always adjust the fit.
●
Check hinge rotating part for poor lubrication. If necessary, apply “Body Grease”.

REMOVAL OF FRONT DOOR
1.
2.
3.
4.
5.

Remove dash side finisher. Refer to EI-20, «Removal and Installation» .
Dissconnect front door harness connectors.
Remove harness gromet, and then remove front door harness conectors.
Remove connectors and harness clamps in front door, and then pull out harness from front door.
Remove check link bolts.

PIIB2865J

6.

Remove hinge nuts on the door and then the door assembly.

PIIB2866J

INSTALLATION
Install in the reverse order of removal.

BL-196

DOOR
REMOVAL OF REAR DOOR
1.
2.
3.
4.

A

Remove rear door finisher. Refer to EI-20, «Removal and Installation» .
Remove door window. Refer to GW-93, «Removal and Installation» .
Remove connectors and harness clamps from rear door and then pull out harness from rear door.
Remove check link bolts.

B

C

D

E
MIIB0120E

5.

Remove hinge nuts on the door and then the door assembly.
F

G

H
MIIB0122E

BL

INSTALLATION
Install in the reverse order of removal.

J

K

L

M

BL-197

DOOR
Front Door Weatherstrip

BIS000L0

PIIB5586J

1. Front door weatherstrip

2. Front door

CAUTION:
During removal, if peeling off the double-sided tape is difficult, apply remover (product equivalent to
Sumitomo 3M Cleaner 30) and then remove the double-sided tape. When using remover, keep it way
from open flame and work in a sufficiently ventilated area.

REMOVAL
1.
2.

Remove check link bolts.
Remove door weatherstrip.

INSTALLATION
Install in the reverse order of removal.

BL-198

DOOR
Front Door Weatherstrip

BIS000UG

A

B

C

D

E

F

G

H

BL

J

K

L
PIIB5587J

1. Rear door weatherstrip

2. Rear door

CAUTION:
During removal, if peeling off the double-sided tape is difficult, apply remover (product equivalent to
Sumitomo 3M Cleaner 30) and then remove the double-sided tape. When using remover, keep it way
from open flame and work in a sufficiently ventilated area.

REMOVAL
1.
2.

Removal check link bolts.
Remove door weatherstrip.

INSTALLATION
Install in the reverse oprder of removal.

BL-199

M

FRONT DOOR LOCK
FRONT DOOR LOCK
Component Parts Location

PFP:80502
BIS000L1

PIIB5576J

1.

Front door panel

2.

Inside handle

3.

Inside handle cable

4.

Door lock assembly

5.

Outside handle cable

6.

TOLX bolt (T30)

7.

Key cylinder connecting rod

8.

Grommet

9.

TOLX bolt (T30)

10. Rear gasket

11. *Door key cylinder assembly

12. Outside handle

13. Front gasket

14. Lock knob cable

15. Holder

16. Outside handle bracket
*: Outside handle escutcheon for vehicles with passenger door key cylinders.

Removal and Installation

BIS000L2

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

Remove front door finisher. Refer to EI-20, «Removal and Installation» .
Fully close front door glass.
Remove sealing screen.
Remove front door lower sash (rear). Refer to GW-89, «Removal and Installation» .
Remove inside handle cable and lock knob cable from holder.
Remove inside handle screws, slide handle toward rear of vehicle, disengage handle from door panel, and remove inside handle.

MIIB0126E

BL-200

FRONT DOOR LOCK
7.

Disconnect inside handle cable and lock knob cable from inside
handle.
CAUTION:
During removal and installation, work so as not to bend the
ends of the lock knob cable and inside handle cable.

A

B

C
MIIB0127E

D

8.

Remove door side grommets, and then remove door key cylinder assembly (escutcheon) bolts (Torx T30) from the grommet
holes.
9. Remove key cylinder connecting rod (key cylinder side).: If there
is no door key cylinder, GO TO 9.
10. Disconnect door antenna and door request switch connector
and remove harness clamp. (Vehicle with intelligent key systems
only)

E

F

G
MIIB0128E

11. Remove door cylinder assembly while pulling outside handle forward.

H

BL

J

MIIB0129E

K

12. Pull outside door handle forward and then slide it toward vehicle
rear to remove.
L

M

MIIB0130E

13. Remove front and rear gaskets.

MIIB0131E

BL-201

FRONT DOOR LOCK
14. Remove door lock assembly bolts (Torx T30).

MIIB0132E

15. Slide outside handle bracket toward rear of vehicle, and then
remove outside handle bracket and door lock assembly.
16. Disconnect door lock assembly connector.

MIIB0133E

17. Disconnect outside handle cable from outside handle bracket.

MIIB0134E

Install in the reverse order of removal.
CAUTION:
●
Before installing door lock assembly, apply “anti-corrosion wax M-97 super” onto mounting seat
on the body.
●
Install each rod by rotating the rod holder until it engages with a tactile feel.

BL-202

FRONT DOOR LOCK
Disassembly and Assembly

BIS000L3

A

DOOR KEY CYLINDER ASSEMBLY

B

C

D
MIIB0135E

1.
2.

Remove key cylinder escutcheon engagement (3 locations), and then remove door key cylinder.
Remove hook (2 locations) engagements, and then remove door request switch from key cylinder
escutcheon. (Vehicles with intelligent key systems only)

OUTSIDE HANDLE

E

F

G

H

MIIB0136E

1.
2.

Remove handle cover screws.
Remove handle cover, and then remove door antenna. (Vehicles with intelligent key systems only)

BL

J

K

L

M

BL-203

REAR DOOR LOCK
REAR DOOR LOCK
Component Parts Location

PFP:82502
BIS000L4

PIIB5577J

1.

Rear door panel

2.

Inside handle

3.

Inside handle cable

4.

Door lock assembly

5.

TOLX bolt (T30)

6.

Outside handle cable

7.

Grommet

8.

TOLX bolt (T30)

9.

Rear gasket

10. Outside handle escutcheon

11. Outside handle

13. Lock knob cable

14. Outside handle bracket

12. Front gasket

Removal and Installation

BIS000L5

REMOVAL
1.
2.
3.
4.
5.

Remove rear door finisher. Refer to EI-20, «Removal and Installation» .
Remove sealing screen.
Remove partition sash. Refer to GW-93, «Removal and Installation» .
Support door glass while lifting it up to the door window completely closed position.
Remove inside handle bolts, slide handle toward rear of vehicle,
remove engagement with door panel, and remove inside handle.

PIIB2870J

6.

Disconnect inside handle cable and lock knob cable from inside
handle.
CAUTION:
During removal and installation, work so as not to bend the
ends of the lock knob cable and inside handle cable.

PIIB2871J

BL-204

REAR DOOR LOCK
7.

Remove door side grommets, and then remove outside handle
escutcheon screws (Torx T30) from grommet holes.

A

B

C

PIIB2872J

8.

D

Pull outside handle forward while removing outside handle
escutcheon.
E

F

G
PIIB2873J

9.

Pull outside door handle forward and then slide it toward vehicle
rear to remove.

H

BL

J

PIIB2874J

K

10. Remove front and rear gaskets.
L

M

PIIB2875J

11. Remove door lock assembly screws (Torx T30).

PIIB2876J

BL-205

REAR DOOR LOCK
12. Slide outside handle bracket toward rear of vehicle, and then
remove outside handle bracket and door lock assembly.
13. Disconnect door lock assembly connector.

PIIB2877J

14. Disconnect outside handle cable from outside handle bracket.

PIIB2878J

Install in the reverse order of removal.
CAUTION:
●
Before installing door lock assembly, apply “anti-corrosion wax M-97 super” onto mounting seat
on the body.
●
When installing door lock assembly, be careful when rotating the outside handle cable as shown
in the figure.
–
Place the outside handle bracket cable on the outside of
door lock assembly before installing.

PIIB2879J

BL-206

BACK DOOR
BACK DOOR
Fitting Adjustment

PFP:90100

A
BIS000L6

B

C

D

E

F

G

H

BL

J

K

L

M

PIIB5578J

1.

Back door hingel

4.

Back door panel

2.

Back door striker

3.

Bamper robber

VERTICAL/LATERAL CLEARANCE (SURFACE DIFFERENCE) ADJUSTMENT
1.

Remove luggage rear plate. Refer to EI-32, «Removal and Installation» .

BL-207

BACK DOOR
2.
3.

Loosen back door striker screws.
Use a rubber hammer, etc., to strike back door striker to make the gap on the right and left and with the
rear bumper even, and then tighten striker screws to specified torque.
CAUTION:
Adjust gap between back door and other areas to attain the right and left dimensional difference
shown below.
Back door outer (B) — Body side outer (B)

: 2.0 mm or less

Back Door Assembly

BIS000L7

REMOVAL
1.
2.
3.

Remove back door finisher. Refer to EI-22, «Removal and Installation» .
Disconnect connectors in back door and unclamp harness. Pull out harness from back door.
After supporting the back door lock to keep it from falling, use a
screwdriver, etc., to remove the back door stay (glass stay) door
side hooks, and then pull out back door stay from stud pole.

PIIB2890J

4.

Remove back door hinge bolts, and then remove back door
assembly.

PIIB2886J

INSTALLATION
Install in the order of removal.

INSPECTION
1.

2.

Check hinges for the following:
— Unusual noise or door closing and opening effort
— Component wear or damage
Apply body grease to the rotating part of the hinge.

PIIB2887J

Back Door Striker

BIS000L8

REMOVAL
1.

Remove luggage rear plate. Refer to EI-32, «Removal and Installation» .

BL-208

BACK DOOR
2.

Remove screws and back door striker.
A

B

C
PIIB5580J

D

INSTALLATION
Install in the reverse order of removal.
CAUTION:
●
After finishing work, confirm proper operation.
●
After finishing work, adjust fitting. Refer to BL-207, «Fitting Adjustment» .

Back Door Stay Assembly

E

BIS000L9

F

REMOVAL
1.
2.

Support back door lock to prevent it from falling.
Remove back door stay assembly (gas stay) vehicle side
bracket bolts.

G

H

BL
PIIB2889J

J

3.

Remove back door stud balls, and then remove back door stay
assembly from back door.
K

L

M
PIIB2890J

INSTALLATION
Install in the reverse order of removal.
CAUTION:
●
After finishing work, confirm proper operation.

BL-209

BACK DOOR
Removal and Installation of Back Door Weatherstrip

BIS000LA

PIIB5579J

1.

Back door panel

2.

Back door weatherstrip

3.

Roof panel

REMOVAL
Pull up and remove engagement with body from weatherstrip joint.
CAUTION:
After removal, do not pull strongly on the weatherstrip.

INSTALLATION
Install in the reverse order of removal.
●
Working from the upper section, align weatherstrip mark with vehicle center position mark and install
weatherstrip onto the back door.
●
For the lower section, align the weatherstrip seam with center of the striker.
●
After finishing work, pull weatherstrip lightly to check for looseness.
●
Make sure the weatherstrip is fit tightly at each corner and luggage rear plate.

BL-210

BACK DOOR LOCK
BACK DOOR LOCK
Removal and Installation

PFP:90504

A
BIS000LB

BACK DOOR LOCK ASSEMBLY
Removal
1.
2.
3.

B

Remove back door finisher. Refer to EI-22, «Removal and Installation» .
Disconnect back door lock assembly connector.
Remove bolts to remove back door lock assembly from inside
back door panel.

C

D

E

MIIB0149E

F

Installation
Install in the reverse order of removal.
●
If greasing condition in each sliding section on back door assembly is poor, apply “BODY GREASE”.
●
After finishing work, confirm proper operation.

BACK DOOR HANDLE ASSEMBLY
Removal
1.
2.
3.

G

H

Remove back door finisher. Refer to EI-22, «Removal and Installation» .
Remove back door request switch (vehicles with intelligent key systems) and back door open switch har- BL
ness fastening clips and connectors.
Remove back door handle assembly nuts, and then remove
J
back door handle assembly.

K

L
MIIB0150E

M

Installation
Install in the reverse order of removal.
CAUTION:
After finishing work, confirm proper operation.

Disassembly and Assembly
Remove screws, and then remove back door request switch (vehicles with intelligent key systems) and back door open switch.

MIIB0151E

BL-211

FUEL FILLER LID OPENER
FUEL FILLER LID OPENER
Removal and Installation of Fuel Filler Lid Opener

PFP:78820
BIS0014T

MIIB1433E

1. Fuel filler lid opener cable (RH)

2. Fuel filler lid opener cable (LH)

REMOVAL
1.
2.

Remove fuel filler lid.
Remove trunk side finisher (RH). Refer to EI-32, «Removal and
Installation» .

PIIB3776J

3.
4.
5.

Remove ruggage rear plat.
Remove ruggage side lower finisher.
Remove ruggage floor finisher.(LH models)

BL-212

FUEL FILLER LID OPENER
6.
7.

Remove fuel filler lock.
Remove front kicking plate and rear kicking plate. Refer to EI26, «Removal and Installation» .

A

B

C
PIIB3831J

D

8.

Remove fuel filler lid opener cable mounting clip on vehicle.

9. Remove mounting bolts and remove fuel filler lid opener.
10. Remove fuel filler lid opener cable.

E

F

G

PIIB2534J

H

INSTALLATION
Install in the reverse order of removal.
BL

J

K

L

M

BL-213

THEFT WARNING SYSTEM
THEFT WARNING SYSTEM
Wiring Diagram — THEFT — / PRWIRE

PFP:25362
BIS000LN

MIWA0731E

BL-214

NATS (NISSAN ANTI-THEFT SYSTEM)
NATS (NISSAN ANTI-THEFT SYSTEM)
Component Parts and Harness Connector Location (Hatchback)

PFP:28591

A
BIS000M0

B

C

D

E

F

G

H

BL
MIIB1438E

1.

BCM M57, M58, M59
(Without Intelligent Key system)

2.

Intelligent Key unit M60
(With Intelligent Key system)

4.

Steering lock unit M37
(With Intelligent Key system)

5.

a: NATS antenna AMP.
M35: With Intelligent Key system
M36: Without Intelligent Key system
b: Key switch and ignition knob switch
connector M34 (with Intelligent Key
system)

3.

Combination meter M27

J

K

L

M

BL-215

NATS (NISSAN ANTI-THEFT SYSTEM)

MIIB1439E

1.

Inside key antenna (dash board)
M47

2.

Inside key antenna (center console)
B20

3.

Inside key antenna (luggage room)
B32

NOTE:
If customer reports a “NO START” condition, request ALL ignition key (without Intelligent Key system) or
mechanical key (with Intelligent Key system) to be brought to the dealer to check for a NATS malfunction.

BL-216

NATS (NISSAN ANTI-THEFT SYSTEM)
System Description

BIS000M2

A

OPERATING DESCRIPTION
NATS (Nissan Anti-Theft System) has the following functions:
●
NATS shows a higher anti-theft performance at preventing engine to be initiates by an unregistered key.
(Registered key: Ignition key, mechanical key, Intelligent Key)
●
Only a key with key ID registered in BCM (without Intelligent Key system) or Intelligent Key unit (with Intelligent Key system) and ECM can start engine, it has a higher protection against auto thefts that duplicates
keys.
●
If a malfunction has been detected, security indicator will keep illuminates when ignition switch is in ON
position.
●
Intelligent Key can be registered up to 5 keys (Including the standard key) on request from the owner.
●
During trouble diagnosis or when the following parts have been replaced, and if ignition key or mechanical
key is added, registration* is required.
*: All keys kept by the owner of the vehicle should be registered with ignition key or mechanical key.
–
ECM
–
BCM (without Intelligent Key system)
–
Intelligent Key unit (with Intelligent Key system)
–
Ignition key (without Intelligent Key system)
–
Mechanical key (with Intelligent Key system)
●
NATS trouble diagnoses, system initialization and additional registration of other ignition key or mechanical key IDs must be carried out using CONSULT-II hardware and CONSULT-II NATS software. When
NATS initialization has been completed, the ID of the inserted ignition key or mechanical key is automatically registered. Then, if necessary, additional registration of other ignition key or mechanical key IDs can
be carried out. Regarding the procedures of NATS initialization and ignition key or mechanical key ID registration, refer to CONSULT-II operation manual, NATS.

●

●

C

D

E

F

G

H

BL

SECURITY INDICATOR
●

B

Fore warns that the vehicle is equipped with NATS (Nissan Anti-Theft System).
Vehicles without Intelligent Key system, security indicator will not blink while the ignition knob is in ON or
START state.
Vehicles with Intelligent Key system, security indicator blinks constantly when the mechanical key is
removed from the ignition key cylinder.
NOTE:
Because security indicator is highly efficient, the battery is barely affected.

Condition of Security Indicator (Normal)

J

K

L

WITHOUT INTELLIGENT KEY SYSTEM
Ignition key state
Ignition key

ON position

ACC position

OFF position
(Key inserted.)

OFF position
(Key removed.)

Registered key

OFF

Flashing

Flashing

Flashing

Unregistered key

ON

Flashing

Flashing

Flashing

Security indicator
condition

WITH INTELLIGENT KEY SYSTEM
Key condition
Ignition key
Security indicator
condition

Intelligent key
Mechanical key

Ignition knob
pressed

Ignition knob
released

Key inserted

Key removed

ON

Flashing

×

×

×

×

OFF

Flashing

BL-217

M

NATS (NISSAN ANTI-THEFT SYSTEM)
System Composition

BIS000M3

The function of the NATS consists of the following:
●
Ignition key (without Intelligent Key system)
●
Mechanical key (with Intelligent Key system)
●
NATS antenna amp.
●
Steering lock unit. (with Intelligent Key system)
●
BCM (without Intelligent Key system)
●
Intelligent Key unit (with Intelligent Key system)
●
Engine control module (ECM)
●
Security indicator (built-in combination meter)
NOTE:
The communication between ECM and BCM/Intelligent Key unit uses the CAN communication system.

MIIB0390E

ECM Re-communicating Function

BIS000M4

Performing following procedure can automatically perform re-communication of ECM and BCM or Intelligent
Key unit, but only when the ECM has been replaced with a new one (*1).
*1: New one means a virgin ECM which has never been energized on-board.
(In this step, initialization procedure by CONSULT-II is not necessary)
NOTE:
●
When registering new Key IDs or replacing the ECM other than brand new, refer to CONSULT-II
Operation Manual NATS.
●
If multiple keys are attached to the key holder, separate them before work.
●
Distinguish keys with unregistered key ID from those with registered ID.
1. Install ECM.
2. Using a registered key (*2), turn ignition switch to “ON”.
*2: To perform this step, use the key that has been used before performing ECM replacement.
3. Maintain ignition switch in “ON” position for at least 5 seconds.
4. Turn ignition switch to “OFF”.
5. Start engine.
If engine can be started, procedure is completed.
If engine cannot be started, refer to CONSULT-II Operation Manual NATS and initialize control unit.

BL-218

NATS (NISSAN ANTI-THEFT SYSTEM)
Wiring Diagram —NATS—

BIS000M5

A

WITHOUT INTELLIGENT KEY SYSTEM

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0732E

BL-219

NATS (NISSAN ANTI-THEFT SYSTEM)
WITH INTELLIGENT KEY SYSTEM

MIWA0733E

BL-220

NATS (NISSAN ANTI-THEFT SYSTEM)
A

B

C

D

E

F

G

H

BL

J

K

L

M

MIWA0734E

BL-221

NATS (NISSAN ANTI-THEFT SYSTEM)
Terminals and Reference Value for Steering Lock Unit/With Intelligent Key System

BIS000M6

Ignition knob
position

Operation or conditions

Voltage (V)
(Approx.)

Battery power supply

Input

LOCK

—

Battery voltage

P

Steering wheel lock
unit power supply

Input

LOCK

—

5

V

Steering wheel lock
unit communication
signal

Input/
Output

LOCK

Press ignition knob with
Intelligent Key inside vehicle.

Wire
color

Signal Designation

1

Y

2

3

Measuring condition

Signal
Input/
Output

Terminal

SIIA1911J

Other than the above
4

G

Steering wheel lock
unit ground

—

—

—

5
0

Terminals and Reference Value for Intelligent Key Unit/With Intelligent Key System

BIS000M7

Measuring condition

Signal
Input/
Output

Ignition knob
position

Operation or conditions

Voltage (V)
(Approx.)

Steering wheel lock
unit power supply

Output

LOCK

—

5

L

CAN-H

Input/
Output

—

—

—

3

Y

CAN-L

Input/
Output

—

—

—

6

O

Ignition power supply

Input

ON

—

Battery voltage

7

GR

Ignition knob switch

Input

—

8

W

NATS antenna amp.

Input

—

Ignition knob OFF → ON
position

Right after turning ignition switch
“ON” pointer tester of tester should
move

9

O

NATS antenna amp.

Output

—

Ignition knob OFF → ON
position

Right after turning ignition switch
to ON position pointer of tester
should move

Terminal

Wire
color

1

P

2

Signal designation

Press ignition knob.
Return ignition knob to
LOCK position.

Battery voltage
0

10

L

ACC power supply

Input

ACC

—

Battery voltage

11

Y

Battery power supply

Input

—

—

Battery voltage

12

B

GND

—

—

—

0

13

Y

Inside key antenna
(+) (Luggage room)

LOCK

Any door open → all doors
shut
(Door switch: ON → OFF)

14

BR

Inside key antenna
(-) (Luggage room)

Output

Output

SIIA1910J

BL-222

NATS (NISSAN ANTI-THEFT SYSTEM)
Terminal

Wire
color

15

V

Inside key antenna
(+) signal
(Center console)

LG

Inside key antenna
(-) signal
(Center console)

16

Signal designation

Signal
Input/
Output

Measuring condition
Ignition knob
position

Operation or conditions

LOCK

Any door open → Close
(Door switch: ON → OFF)
Ignition knob switch: ON
(press ignition knob.)

Voltage (V)
(Approx.)

A

B

Output

Output

C
SIIA1910J

27

O

Key switch signal

30

P

Security indicator
lamp

31

G

Steering wheel lock
unit ground

Input

LOCK

Insert mechanical key into
ignition key cylinder.

Battery voltage

Remove mechanical key
from ignition key cylinder.

0

Goes OFF → illuminates
(Every 2.4 seconds)

Battery voltage → 0

Output

LOCK

—

—

—

LOCK

Press ignition knob with
Intelligent Key inside vehicle.

D

E

F

0

G
32

Y

Steering wheel lock
unit communication
signal

Input/
Output

H
SIIA1911J

Other than the above
35

P

Inside key antenna
(+) signal
(Dashboard)

Output

L

Inside key antenna
(-) signal
(Dashboard)

BL

Any door open → Close
(Door switch: ON → OFF)
Ignition knob switch: ON
(press ignition knob.)

LOCK
36

5

Output

J

SIIA1910J

Terminals and Reference Value for BCM/Without Intelligent Key System
Terminal

Wire
color

Signal designation

Signal
Input/
Output

K

BIS000M8

L

Measuring condition
Voltage (V)
(Approx.)

Ignition
switch position

Operation or conditions

—

—

—

0

Input/
Output

—

—

—

—

Battery voltage

M

2

B

GND

19

L

CAN-H

24

O

Ignition power supply

Input

ON

38

V

NATS antenna amp.

Input/
Output

—

39

Y

CAN-L

Input/
Output

—

47

P

Security indicator
lamp

Output

OFF

70

B

GND

—

—

—

0

74

Y

Battery power supply

Input

—

—

Battery voltage

79

Y

Battery power supply

Input

—

—

Battery voltage

Ignition knob OFF → ON
position
—
Goes OFF → illuminates
(Every 2.4 seconds)

BL-223

Right after turning ignition switch
to ON position pointer of tester
should move
—
Battery voltage → 0

NATS (NISSAN ANTI-THEFT SYSTEM)
CONSULT-II

BIS000M9

CONSULT-II INSPECTION PROCEDURE
1.
2.

Turn ignition switch OFF.
Insert NATS program card into CONSULT-II.
Program card

3.

: NATS (AEN06A)

Connect CONSULT-II and “CONSULT-II CONVERTER” to data
link connector.

PAIA0070E

4.
5.

Turn ignition switch ON position.
Touch “START”.

PBR455D

6. Select “E11”
7. Perform each diagnostic test mode according to each service procedure.
For further information, see the CONSULT-II Operation Manual, NATS.

CONSULT-II DIAGNOSTIC TEST MODE FUNCTION
CONSULT- II DIAGNOSTIC TEST MODE

Description

C/U INITIALIZATION

When replacing any of the following components, C/U initialization and re-registration
of all NATS mechanical keys are necessary.
[mechanical key, BCM or Intelligent Key unit]

SELF-DIAG RESULTS

Detected items (screen terms) are as shown in the chart.

NOTE:
●
When any initialization is performed, all ID previously registered will be erased and all NATS mechanical
keys must be registered again. The engine can not be start be started with an unregistered key. The system will show “DIFFERENCE OF KEY” as IMMU FUNCTION CHECK on the CONSULT-II screen.

BL-224

NATS (NISSAN ANTI-THEFT SYSTEM)
CHECK RESULT ITEM CHART FOR NATS IMMU FUNCTION
Detected items (Screen terms)

Description

UNREGISTERED BCM*

ID is not registered in BCM

CHAIN OF IMMU-KEY

NATS IMMU cannot receive the key ID signal.

DIFFERENCE OF KEY

BCM or Intelligent Key unit receive the key ID signal but the result of ID verification between key
ID and BCM or Intelligent Key is NG

CHAIN OF IPDM-IMMU*

The communication with IPDM E/R.

ID DISCORD IPDM-IMMU

BCM or Intelligent Key unit receive from IPDM E/R signal but the result of ID verification is NG.

CHAIN OF METER-IMMU*

The communication with combination meter.

ID DISCORD METER-IMMU

BCM or Intelligent Key unit receive from combination meter ID signal but the result of ID verification is NG.

CHAIN OF EPS-IMMU*

The communication with EPS is malfunction.

ID DISCORD EPS-IMMU

BCM or Intelligent Key unit receive from EPS ID signal but the result of ID verification is NG.

UNREGISTERED ECM

ID is not registered in ECM.

ID DISCORD ECM-IMMU

The result of ID verification between BCM and ECM is NG. System initialization is required.

A

B

C

D

E

F

*: Applied for models without Intelligent Key system.

G

H

BL

J

K

L

M

BL-225

NATS (NISSAN ANTI-THEFT SYSTEM)
Diagnosis Procedure

BIS000MA

WORK FLOW

MIIB0492E

BL-226

NATS (NISSAN ANTI-THEFT SYSTEM)
Trouble Diagnosis Symptom Chart

BIS000MB

MODELS WITHOUT INTELLIGENT KEY SYSTEM

A

NOTE:
Perform “Diagnostic Procedure 7”, when “P1610” is displayed by the “SELF-DIAG RESULTS” of the ENGINE.
Refer to “CONSULT-II Operation Manual NATS”.

B

SYMPTOM

Displayed “IMMU FUNCTION
CHECK” results on CONSULTII screen.
UNREGISTERED BCM

Diagnoses service procedure

DIAGNOSTIC PROCEDURE

C
Replace BCM

Refer to BL-229, «Diagnostic
Procedure 1» .

1. Check the following parts

CHAIN OF IMMU-KEY

●

Open or short circuit
between BCM and NATS
antenna amp.

●

Malfunction of key ID chip

●

NATS antenna amp.

D

Refer to BL-229, «Diagnostic
Procedure 2» .

2. If the above system are
“OK”, replace BCM
Refer to BL-233, «Diagnostic
Procedure 3» .

2. If the above system is “OK”,
replace BCM

Refer to BCS-17, «Removal
and Installation of BCM» .

1. Check CAN communication
system

Refer to BCS-17, «CAN Communication Inspection With
CONSULT-II (Self-Diagnosis)» .

2. If CAN communication is
“OK”, replace IPDM E/R

Refer to PG-37, «Removal and
Installation of IPDM E/R» .

Replace IPDM E/R

Refer to PG-37, «Removal and
Installation of IPDM E/R» .

1. Check CAN communication
system

Refer to BCS-17, «CAN Communication Inspection With
CONSULT-II (Self-Diagnosis)» .

2. If CAN communication is
“OK”, replace combination
meter

Refer to DI-20, «Removal and
Installation for Combination
Meter» .

K

Refer to DI-20, «Removal and
Installation for Combination
Meter» .

L

Replace combination meter

1. Check CAN communication
system

Refer to BCS-17, «CAN Communication Inspection With
CONSULT-II (Self-Diagnosis)» .

M

2. If CAN communication is
“OK”, replace EPS

Refer to BCS-17, «CAN Communication Inspection With
CONSULT-II (Self-Diagnosis)» .

ID DISCORD EPS-IMMU

Replace EPS

Refer to PS-7, «STEERING
COLUMN» .

UNREGISTERED ECM

Replace ECM

Refer to BL-233, «Diagnostic
Procedure 4» .

ID DISCORD ECM-IMMU

Replace ECM

Refer toBL-234, «Diagnostic
Procedure 5» .

CHAIN OF IPDM-IMMU

Security indicator lighting up*

●

Engine hard to start

F

1. Perform registration key
DIFFERENCE OF KEY

●

E

ID DISCORD IPDM-IMMU

CHAIN OF METER-IMMU

ID DISCORD METER-IMMU

CHAIN OF EPS-IMMU

*: When NATS detects trouble, the security indicator lights up while ignition key is in the “ON” position.

BL-227

G

H

BL

J

NATS (NISSAN ANTI-THEFT SYSTEM)
MODELS WITH INTELLIGENT KEY SYSTEM
NOTE:
Perform “Diagnostic Procedure 7”, when “P1610” is displayed by the “SELF-DIAG RESULTS” of the ENGINE.
Refer to “CONSULT-II Operation Manual NATS”.
SYMPTOM

Displayed “IMMU FUNCTION
CHECK” results on CONSULTII screen.

Diagnoses service procedure

DIAGNOSTIC PROCEDURE

1. Check the following parts
●

CHAIN OF IMMU-KEY

Open or short circuit between
BCM and NATS antenna
amp.

●

Malfunction of key ID chip

●

NATS antenna amp.

2. If the above system are
“OK”, replace Intelligent Key
unit

Refer to BL-193, «Removal and
Installation of Intelligent key
unit» .

1. Perform key registration

Refer to BL-233, «Diagnostic
Procedure 3» .

2. If the above system is “OK”,
replace Intelligent Key unit

Refer to BL-193, «Removal and
Installation of Intelligent key
unit» .

1. Check CAN communication
system

Refer to BCS-17, «CAN Communication Inspection With
CONSULT-II (Self-Diagnosis)» .

2. If CAN communication system is “OK”, replace IPDM E/R

Refer to PG-37, «Removal and
Installation of IPDM E/R» .

1. Check CAN communication
system

Refer to BCS-17, «CAN Communication Inspection With
CONSULT-II (Self-Diagnosis)» .

2. If CAN communication system is “OK”, replace combination meter

Refer to DI-20, «Removal and
Installation for Combination
Meter» .

1. Check CAN communication
system

Refer to BCS-17, «CAN Communication Inspection With
CONSULT-II (Self-Diagnosis)» .

2. If CAN communication system is “OK”, replace EPS

Refer to PS-7, «STEERING
COLUMN» .

Replace ECM

Refer to BL-234, «Diagnostic
Procedure 5» .

DIFFERENCE OF KEY

●

Security indicator lighting up*

●

Engine hard to start

ID DISCORD IPDM-IMMU

ID DISCORD METER-IMMU

ID DISCORD EPS-IMMU

ID DISCORD ECM-IMMU

Refer to BL-229, «Diagnostic
Procedure 2» .

*: When NATS detects trouble, the security indicator lights up while mechanical key is inserted.

Security Indicator Inspection
SYMPTOM

BIS000MC

SYSTEM
(Malfunctioning part or mode)

DIAGNOSTIC PROCEDURE

Security indicator
Open circuit between Fuse and NATS IMMU
(BCM or Intelligent Key unit)
Security indicator does not operate*

Continuation of initialization mode

Refer toBL-234, «Diagnostic Procedure 6» .

BCM (without Intelligent Key system)
Intelligent Key unit (with Intelligent Key system)
*: CONSULT-II “IMMU FUNCTION CHECK” results display screen “no malfunction is detected”.

BL-228

NATS (NISSAN ANTI-THEFT SYSTEM)
Diagnostic Procedure 1

BIS000MD

A

IMMU FUNCTION CHECK results:
“UNREGISTERD BCM” displayed on CONSULT-II screen

1. CONFIRM IMMU FUNCTION CHECK

B

Confirm “IMMU FUNCTION CHECK” results “UNREGISTERD BCM” displayed on CONSULT-II screen.
Is CONSULT-II screen displayed as above?
YES >> ● BCM is malfunctioning.
● Replace BCM.
● Perform initialization with CONSULT-II.
– For initialization, refer to “CONSULT-II Operation Manual NATS”.
NO
>> GO TO BL-227, «Trouble Diagnosis Symptom Chart» .

Diagnostic Procedure 2

C

D

BIS000ME

E

MODELS WITHOUT INTELLIGENT KEY SYSTEM
IMMU FUNCTION CHECK results:
“CHAIN OF IMMU-KEY” displayed on CONSULT-II screen

F

1. CONFIRM IMMU FUNCTION CHECK
Confirm “IMMU FUNCTION CHECK” results “CHAIN OF IMMU-KEY” displayed on CONSULT-II screen.
Is CONSULT-II screen displayed as above?
Yes
>> GO TO 2.
No
>> GO TO BL-227, «Trouble Diagnosis Symptom Chart» .

G

H

2. CHECK NATS ANTENNA AMP. INSTALLATION
Check NATS antenna amp. installation. Refer to BL-237, «Removal and Installation NATS Antenna Amp.» .
OK or NG
OK
>> GO TO 3.
NG
>> Reinstall NATS antenna amp. correctly.

3. CHECK IGNITION KEY ID CHIP

L

M

4. CHECK POWER SUPPLY FOR NATS ANTENNA AMP.
Turn ignition switch “ON”.
Check voltage between NATS antenna amp. connector and
ground.
3 — Ground:

J

K

Start engine with another registered ignition key.
Does the engine start?
Yes
>> ● Ignition key ID chip is malfunctioning.
● Replace the ignition key.
● Perform initialization with CONSULT-II.
For initialization, refer to “CONSULT-II Operation Manual NATS”.
No
>> GO TO 4.

1.
2.

BL

Battery voltage

OK or NG
OK
>> GO TO 5.
NG
>> Check harness for open or short between NATS
antenna amp. and fuse.

MIIB0401E

BL-229

NATS (NISSAN ANTI-THEFT SYSTEM)

5. CHECK NATS ANTENNA AMP. SIGNAL LINE
Check voltage between NATS antenna amp. connector and ground
with analogue tester.
Before turning ignition switch “ON”
Voltage: 0V
Just after turning ignition switch “ON”
: Pointer of tester should move.
OK or NG
OK
>> GO TO 6.
NG
>> ● Check harness for open or short between NATS
MIIB0402E
antenna amp. and BCM.
NOTE:
If harness is OK, replace new* BCM, perform initialization with CONSULT-II. For initialization,
refer to “CONSULT-II Operation Manual NATS”.
*: New one means virgin control unit that has never been energized on-board.

6. CHECK NATS ANTENNA AMP. GROUND LINE CIRCUIT
1.
2.

Turn ignition switch “OFF”.
Check continuity between NATS antenna amp. connector and
ground.
2 — Ground:

Continuity should exist.

OK or NG
OK
>> NATS antenna amp. is malfunctioning.
NG
>> ● Check harness for open or short between NATS
antenna amp. and ground.
NOTE:
If harness is OK, replace new* BCM, perform initialization with CONSULT-II. For initialization, refer to
“CONSULT-II Operation Manual NATS”.
*: New one means virgin control unit that has never been energized on-board.

BL-230

MIIB0403E

NATS (NISSAN ANTI-THEFT SYSTEM)
MODELS WITH INTELLIGENT KEY SYSTEM
A

IMMU FUNCTION CHECK results:
“CHAIN OF IMMU-KEY” displayed on CONSULT-II screen

1. CONFIRM IMMU FUNCTION CHECK

B

Confirm “IMMU FUNCTION CHECK” results “CHAIN OF IMMU-KEY” displayed on CONSULT-II screen.
Is CONSULT-II screen displayed as above?
Yes
>> GO TO 2.
No
>> GO TO BL-227, «Trouble Diagnosis Symptom Chart» .

2. CHECK NATS ANTENNA AMP. INSTALLATION

C

D

Check NATS antenna amp. installation. Refer to BL-237, «Removal and Installation NATS Antenna Amp.» .
OK or NG
OK
>> GO TO 3.
NG
>> Reinstall NATS antenna amp. correctly.

E

3. CHECK MECHANICAL KEY ID CHIP

F

Start engine with another registered mechanical key.
Does the engine start?
Yes
>> ● Mechanical key ID chip is malfunctioning.
● Replace the mechanical key.
● Perform initialization with CONSULT-II.
For initialization, refer to “CONSULT-II Operation Manual NATS”.
No
>> GO TO 4.

G

H

BL

4. CHECK POWER SUPPLY FOR NATS ANTENNA AMP.
1.
2.

Turn ignition switch “ON”.
Check voltage between NATS antenna amp. connector and
ground.
4 — Ground:

J

Battery voltage

K

OK or NG
OK
>> GO TO 5.
NG
>> Check harness for open or short between NATS
antenna amp. and fuse.

L

M
MIIB0404E

BL-231

NATS (NISSAN ANTI-THEFT SYSTEM)

5. CHECK NATS ANTENNA AMP. SIGNAL LINE- 1
Check voltage between NATS antenna amp. connector M35 terminal
2 and ground with analogue tester.
Before inserting mechanical key in ignition knob
Voltage: 0V
Just after inserting mechanical key in ignition knob
: Pointer of tester should move.
OK or NG
OK
>> GO TO 6.
NG
>> ● Check harness for open or short between NATS
MIIB0405E
antenna amp. and Intelligent Key unit.
NOTE:
If harness is OK, replace new* Intelligent Key unit, perform initialization with CONSULT-II. For
initialization, refer to “CONSULT-II Operation Manual NATS”.
*: New one means virgin control unit that has never been energized on-board.

6. CHECK NATS ANTENNA AMP. SIGNAL LINE- 2
Check voltage between NATS antenna amp. connector M35 terminal
3 and ground with analogue tester.
Before inserting mechanical key in ignition knob
Voltage: 0V
Just after inserting mechanical key in ignition knob
: Pointer of tester should move.
OK or NG
OK
>> GO TO 7.
NG
>> ● Check harness for open or short between NATS
MIIB0406E
antenna amp. and Intelligent Key unit.
NOTE:
If harness is OK, replace new* Intelligent Key unit, perform initialization with CONSULT-II. For
initialization, refer to “CONSULT-II Operation Manual NATS”.
*: New one means virgin control unit that has never been energized on-board.

7. CHECK NATS ANTENNA AMP. GROUND LINE CIRCUIT
1.
2.

Turn ignition switch “OFF”.
Check continuity between NATS antenna amp. connector M35
terminal 1 and ground.
1 — Ground:

Continuity should exist.

OK or NG
OK
>> NATS antenna amp. is malfunctioning.
NG
>> ● Check harness for open or short between NATS
antenna amp. and ground.
NOTE:
If harness is OK, replace new* Intelligent Key unit,
perform initialization with CONSULT-II. For initialization, refer to “CONSULT-II Operation Manual NATS”.
*: New one means virgin control unit that has never been energized on-board.

BL-232

MIIB0407E

NATS (NISSAN ANTI-THEFT SYSTEM)
Diagnostic Procedure 3

BIS000MF

A

IMMU FUNCTION CHECK results:
“DIFFERENCE OF KEY” displayed on CONSULT-II screen

1. CONFIRM IMMU FUNCTION CHECK

B

Confirm “IMMU FUNCTION CHECK” results “DIFFERENCE OF KEY” displayed on CONSULT-II screen.
Is CONSULT-II screen displayed as above?
Yes
>> GO TO 2.
No
>> GO TO BL-227, «Trouble Diagnosis Symptom Chart» .

C

2. PERFORM INITIALIZATION WITH CONSULT-II

D

Perform initialization with CONSULT-II. Re-register all NATS ignition key IDs.
For initialization and registration of NATS ignition key IDs, refer to “CONSULT-II Operation Manual NATS”.
NOTE:
If the initialization is not completed or malfunctions, CONSULT-II
shows message on the screen.
Can the system be initialized and can the engine be started with reregistered NATS ignition key?
Yes
>> ● Ignition key ID was unregistered.
No
>> ● BCM is malfunctioning. (models without Intelligent
Key system)
● Replace new* BCM.
● Intelligent Key unit is malfunctioning. (models with
Intelligent Key system)
SEL297W
● Replace new* Intelligent Key unit.
● Perform initialization with CONSULT-II.
● For initialization, refer to “CONSULT-II Operation Manual NATS”.
*: New one means virgin control unit that has never been energized on-board.

Diagnostic Procedure 4

E

F

G

H

BL

J

BIS000MG

IMMU FUNCTION CHECK results:
“UNREGISTERD ECM” displayed on CONSULT-II screen

K

1. CONFIRM IMMU FUNCTION CHECK
Confirm “IMMU FUNCTION CHECK” results “UNREGISTERD ECM” displayed on CONSULT-II screen.
Is CONSULT-II screen displayed as above?
YES >> ● ECM is malfunctioning.
● Replace ECM.
● Perform initialization or re-communicating function.
– For initialization, refer to BL-218, «ECM Re-communicating Function» .
NO
>> GO TO BL-227, «Trouble Diagnosis Symptom Chart» .

BL-233

L

M

NATS (NISSAN ANTI-THEFT SYSTEM)
Diagnostic Procedure 5

BIS000MH

IMMU FUNCTION CHECK results:
“ID DISCORD ECM-IMMU” displayed on CONSULT-II screen

1. CONFIRM IMMU FUNCTION CHECK
Confirm “IMMU FUNCTION CHECK” results “UNREGISTERD ECM” displayed on CONSULT-II screen.
Is CONSULT-II screen displayed as above?
YES >> ● ECM is malfunctioning.
● Replace ECM.
● Perform initialization or re-communicating function.
– For initialization, refer to “CONSULT-II Operation Manual NATS”.
NO
>> GO TO BL-227, «Trouble Diagnosis Symptom Chart» .

Diagnostic Procedure 6

BIS000MI

MODELS WITHOUT INTELLIGENT KEY SYSTEM
“Security indicator does not light up”

1. CHECK FUSE
Check 10A fuse [No. 7, located in the fuse block (J/B)]
OK or NG
OK
>> GO TO 2.
NG
>> Replace fuse.

2. CHECK SECURITY INDICATOR LAMP
1.
2.
3.

Install 10A fuse.
Start engine and turn ignition switch OFF.
Check the security indicator lamp lights up.
Security indicator lamp should light up.

OK or NG
OK
>> Inspection END.
NG
>> GO TO 3.

3. CHECK SECURITY INDICATOR LAMP POWER SUPPLY CIRCUIT
1.
2.

Disconnect combination meter (security indicator lamp) connector.
Check voltage between security indicator lamp connector M27
terminal 27 and ground.
27 — Ground:

Battery voltage

OK or NG
OK
>> GO TO 4.
NG
>> Check harness for open or short between fuse and
security indicator lamp.

MIIB0393E

BL-234

NATS (NISSAN ANTI-THEFT SYSTEM)

4. CHECK BCM FUNCTION
1.
2.
3.

A

Connect combination meter (security indicator lamp) connector.
Disconnect BCM connector.
Check voltage between BCM connector M58 terminal 47 and
ground.
47 — Ground:

B

Battery voltage

C

OK or NG
OK
>> BCM is malfunctioning.
● Replace BCM.
● Perform initialization with CONSULT-II.
● For initialization, refer to “CONSULT-II Operation
Manual NATS”.
NG
>> Check the following.
● Harness for open or short between security indicator lamp and BCM.
● Indicator lamp condition
MODELS WITH INTELLIGENT KEY SYSTEM
“Security indicator does not light up”

D

MIIB0394E

F

G

1. CHECK FUSE
Check 10A fuse [No. 7, located in the fuse block (J/B)]
OK or NG
OK
>> GO TO 2.
NG
>> Replace fuse.

H

BL

2. CHECK SECURITY INDICATOR LAMP
1.
2.
3.

Install 10A fuse.
Start engine and turn ignition knob OFF position.
Check the security indicator lamp lights up.

J

K

Security indicator lamp should light up.
OK or NG
OK
>> Inspection END.
NG
>> GO TO 3.

L

3. CHECK SECURITY INDICATOR LAMP POWER SUPPLY CIRCUIT
1.
2.

M

Disconnect combination meter (security indicator lamp) connector.
Check voltage between security indicator lamp connector M27
terminal 27 and ground.
27 — Ground:

E

Battery voltage

OK or NG
OK
>> GO TO 4.
NG
>> Check harness for open or short between fuse and
security indicator lamp.

MIIB0393E

BL-235

NATS (NISSAN ANTI-THEFT SYSTEM)

4. CHECK INTELLIGENT KEY UNIT FUNCTION
1.
2.
3.

Connect combination meter (security indicator lamp) connector.
Disconnect Intelligent Key unit connector.
Check voltage between Intelligent Key unit connector M60 terminal 30 and ground.
30 — Ground:

Battery voltage

OK or NG
OK
>> Intelligent Key is malfunctioning.
● Replace Intelligent Key unit.
● Perform initialization with CONSULT-II.
● For initialization, refer to “CONSULT-II Operation
Manual NATS”.
NG
>> Check the following.
● Harness for open or short between security indicator lamp and Intelligent Key unit.
● Indicator lamp condition

Diagnostic Procedure 7

MIIB1448E

BIS000MJ

IMMU FUNCTION CHECK results:
“P1610” displayed on CONSULT-II screen

1. CONFIRM IMMU FUNCTION CHECK
Confirm “IMMU FUNCTION CHECK” results “P1610” (LOCK MODE) is displayed on CONSULT-II screen.
Is CONSULT-II screen displayed as above?
Yes
>> GO TO 2.
No
>> GO TO BL-226, «WORK FLOW» .

2. ESCAPE FROM LOCK MODE
1. Turn ignition switch OFF.
2. Turn ignition switch ON with registered key. (Do not start engine.) Wait 5 seconds.
3. Return the key to OFF position. Wait 5 seconds.
4. Repeat steps 2 and 3 twice (total of three cycles).
5. Start the engine.
Does engine start?
Yes
>> System is OK (Now system is escaped from “LOCK MODE”).
No
>> Perform “IMMU FUNCTION CHECK”, and repair the diagnosis result on the display.

BL-236

NATS (NISSAN ANTI-THEFT SYSTEM)
Removal and Installation NATS Antenna Amp.

BIS000MK

A

REMOVAL
CAUTION:
Before servicing SRS, turn ignition switch OFF, disconnect both battery cables and wait at least 3 minutes.
1. Remove the spiral cable. Refer to SRS-38, «Removal and Installation» .
2. Disconnect the NATS antenna amp. connect, remove the screw
and NATS antenna amp.

B

C

D

E
PIIB6539E

F

INSTALLATION
Install in the reverse order of removal.

G

H

BL

J

K

L

M

BL-237

NATS (NISSAN ANTI-THEFT SYSTEM)

BL-238

BRAKE CONTROL SYSTEM

F BRAKES

SECTION

BRC

BRAKE CONTROL SYSTEM

A

B

C

D

CONTENTS
ABS
PRECAUTIONS …………………………………………………. 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 3
Precautions for Brake System ……………………………. 3
Precautions for Brake Control ……………………………. 3
Precaution for Harness Repair …………………………… 4
CAN SYSTEM ………………………………………………. 4
PREPARATION ………………………………………………….. 5
Special Service Tools ……………………………………….. 5
SYSTEM DESCRIPTION …………………………………….. 6
System Diagram ………………………………………………. 6
System Components ………………………………………… 6
ABS Function ………………………………………………….. 7
EBD Function ………………………………………………….. 7
Fail-Safe Function ……………………………………………. 7
Hydraulic Circuit Diagram …………………………………. 7
TROUBLE DIAGNOSIS ………………………………………. 8
Diagnosis Procedure ………………………………………… 8
BASIC CONCEPT …………………………………………. 8
DIAGNOSIS FLOW ……………………………………….. 9
QUESTIONNAIRE ………………………………………. 10
EXAMPLE OF DIAGNOSIS SHEET ………………. 10
Component Parts Location ………………………………..11
Schematic …………………………………………………….. 12
Wiring Diagram — ABS — ………………………………. 13
CONSULT-II Functions (ABS) ………………………….. 19
CONSULT-II MAIN FUNCTION ……………………… 19
CONSULT-IIBASICOPERATIONPROCEDURE
… 19
Self-Diagnosis ……………………………………………….. 19
OPERATION PROCEDURE …………………………. 19
ERASE MEMORY ……………………………………….. 19
DISPLAY ITEM LIST ……………………………………. 20
Data Monitor ………………………………………………….. 21
OPERATION PROCEDURE …………………………. 21
DISPLAY ITEM LIST ……………………………………. 21
Active Test …………………………………………………….. 22
OPERATION PROCEDURE …………………………. 22

TEST ITEM —ABS SOLENOID VALVE— ……….. 22
TEST ITEM —ABS MOTOR— ………………………. 23
CAN Communication ………………………………………. 24
SYSTEM DESCRIPTION ……………………………… 24
For Fast and Accurate Diagnosis ……………………… 25
PRECAUTIONS FOR TROUBLE DIAGNOSIS … 25
Basic Inspection …………………………………………….. 26
BASIC INSPECTION 1: BRAKE FLUID LEVEL,
LEAK AND BRAKE PAD INSPECTION ………….. 26
BASIC INSPECTION 2: INSPECTION OF
POWER SUPPLY SYSTEM TERMINAL LOOSENESS AND BATTERY ………………………………….. 26
BASIC INSPECTION 3: ABS WARNING LAMP
AND BRAKE WARNING LAMP INSPECTION … 26
Inspection 1 Wheel Sensor System …………………… 27
Inspection 2 Engine System …………………………….. 29
Inspection 3ABSActuatorandElectricUnit(Control
Unit) System ………………………………………………….. 29
Inspection 4 ABS Actuator and Electric Unit Power
and Ground System ………………………………………… 29
Inspection 5 Stop Lamp Switch System …………….. 31
Inspection 6 CAN Communication Circuit ………….. 33
Symptom 1 ABS Works Frequently. ………………….. 33
Symptom 2 Unexpected Pedal Reaction ……………. 34
Symptom 3 Longer Stopping Distance ………………. 34
Symptom 4 ABS Does Not Work ………………………. 35
Symptom 5 Pedal Vibration and ABS Operation
Noise ……………………………………………………………. 35
WHEEL SENSORS …………………………………………… 36
Removal and Installation …………………………………. 36
REMOVAL ………………………………………………….. 36
INSTALLATION …………………………………………… 36
SENSOR ROTOR …………………………………………….. 37
Removal and Installation …………………………………. 37
FRONT ………………………………………………………. 37
REAR ………………………………………………………… 37
ACTUATOR AND ELECTRIC UNIT (ASSEMBLY)… 38
Removal and Installation …………………………………. 38
REMOVAL ………………………………………………….. 38
INSTALLATION …………………………………………… 38

BRC-1

E

BRC

G

H

I

J

K

L

M

ESP/TCS/ABS
PRECAUTIONS ………………………………………………… 39
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ……………………………………………………….. 39
Precautions for Brake System ………………………….. 39
Precautions for Brake Control ………………………….. 39
Diagnosis Precaution ………………………………………. 40
CAN SYSTEM …………………………………………….. 40
Precaution for Harness Repair …………………………. 40
CAN SYSTEM …………………………………………….. 40
PREPARATION ………………………………………………… 41
Special Service Tools ……………………………………… 41
ON-VEHICLE SERVICE …………………………………….. 42
Adjustment of Steering Angle Sensor Neutral Position ……………………………………………………………….. 42
OPERATION PROCEDURE ………………………….. 42
SYSTEM DESCRIPTION …………………………………… 45
System Diagram …………………………………………….. 45
ESP Function …………………………………………………. 45
TCS Function …………………………………………………. 45
ABS Function …………………………………………………. 45
EBD Function ………………………………………………… 46
Fail-Safe Function ………………………………………….. 46
ESP / TCS SYSTEM ……………………………………. 46
ABS, EBD SYSTEM …………………………………….. 46
Hydraulic Circuit Diagram ………………………………… 47
CAN COMMUNICATION ……………………………………. 48
System Description …………………………………………. 48
TROUBLE DIAGNOSIS …………………………………….. 49
How to Proceed With Diagnosis ……………………….. 49
BASIC CONCEPT ……………………………………….. 49
DIAGNOSIS FLOWCHART …………………………… 50
ASKING COMPLAINTS ………………………………… 51
EXAMPLE OF DIAGNOSIS SHEET ……………….. 51
Component Installation Location ………………………. 52
Schematic ……………………………………………………… 53
Wiring Diagram — ESP — ………………………………. 54
CONSULT-II Functions (ABS) …………………………… 62
CONSULT-II MAIN FUNCTION ……………………… 62
CONSULT-IIBASICOPERATIONPROCEDURE
… 62
Self-Diagnosis ……………………………………………….. 62
OPERATION PROCEDURE ………………………….. 62
ERASE MEMORY ……………………………………….. 62
DISPLAY ITEM LIST ……………………………………. 63
Data Monitor ………………………………………………….. 64
OPERATION PROCEDURE ………………………….. 64
DISPLAY ITEM LIST ……………………………………. 64
Active Test …………………………………………………….. 66
OPERATION PROCEDURE ………………………….. 66
SOLENOID VALVE OPERATION CHART ……….. 67
ABS MONITOR …………………………………………… 67

For Fast and Accurate Diagnosis ……………………….68
PRECAUTIONS FOR DIAGNOSIS …………………68
Basic Inspection ………………………………………………69
BASIC INSPECTION 1: BRAKE FLUID
AMOUNT, LEAKS, AND BRAKE PADS INSPECTION …………………………………………………………..69
BASIC INSPECTION 2: POWER SYSTEM TERMINAL LOOSENESS AND BATTERY INSPECTION …………………………………………………………..69
BASIC INSPECTION 3: ABS WARNING LAMP,
ESP OFF INDICATOR LAMP AND SLIP INDICATOR LAMP INSPECTION ………………………….70
Inspection 1: Wheel Sensor System …………………..70
Inspection 2: Engine System …………………………….73
Inspection 3: ESP/TCS/ABS Control Unit System…73
Inspection 4: Steering Angle Sensor System ……….73
Inspection 5: Yaw Rate/Side G-Sensor System ……75
Inspection 6: ABS Actuator and Electric Unit (Control Unit) Power Supply and Ground System ……….77
Inspection 7: Stop Lamp Switch System ……………..79
Inspection 8: Brake Fluid Level Switch System ……81
Inspection 9: CAN Communication System …………81
Component Inspection ……………………………………..82
ESP OFF SWITCH ……………………………………….82
Symptom 1: Excessive ABS Function Operation
Frequency ………………………………………………………82
Symptom 2: Unexpected Pedal Reaction ……………82
Symptom 3: The Braking Distance Is Long ………….83
Symptom 4: The ABS Function Does Not Operate…83
Symptom 5: Pedal Vibration or ABS Operation
Sound Occurs …………………………………………………83
Symptom 6: Vehicle Jerks During ESP/TCS/ABS
Control …………………………………………………………..84
WHEEL SENSORS ……………………………………………86
Removal and Installation …………………………………..86
REMOVAL ……………………………………………………86
INSTALLATION …………………………………………….86
SENSOR ROTOR ………………………………………………87
Removal and Installation …………………………………..87
FRONT ………………………………………………………..87
REAR ………………………………………………………….87
ACTUATOR AND ELECTRIC UNIT (ASSEMBLY) …88
Removal and Installation …………………………………..88
REMOVAL ……………………………………………………88
INSTALLATION …………………………………………….88
YAW RATE/SIDE G SENSOR ……………………………..89
Removal and Installation …………………………………..89
REMOVAL ……………………………………………………89
INSTALLATION …………………………………………….89
STEERING ANGLE SENSOR ……………………………..90
Removal and Installation …………………………………..90
REMOVAL ……………………………………………………90
INSTALLATION …………………………………………….90

BRC-2

PRECAUTIONS
[ABS]

PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
[ABS]

A

BFS0008Z

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along B
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
C
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be perD
formed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
E
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connecBRC
tors.

Precautions for Brake System
●
●
●

●

●

●

●

●

BFS00090

Recommended fluid is brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)”.
Do not reuse the drained brake fluid.
Be careful not to splash brake fluid on painted areas such as body. If brake fluid is splashed, wipe it off
and flush area with water immediately.
Do not use mineral oils such as gasoline or kerosene to clean. They will ruin rubber parts and cause
improper operation.
Using a flare nut torque wrench, securely tighten brake tube
flare nuts.
Brake system is an important safety part. If a brake fluid leak is
detected, always disassemble malfunctioning parts. If any malfunctioning part is found, replace the part with a new one.
Before working, turn ignition switch OFF and disconnect connectors for ABS actuator and electric unit or battery terminals.
When installing brake piping, be sure to check tightening torque.
SBR820BA

Precautions for Brake Control
●
●

●

●

●

●

●

G

H

I

J

K

L

BFS00091

During ABS operation, brake pedal lightly vibrates and a mechanical noise may be heard. This is normal.
When starting engine, or just after starting vehicle, brake pedal may vibrate or motor operating noise may
be heard from engine compartment. This is a normal status of operation check.
Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel,
or snow-covered (fresh, deep snow) roads.
When an error is indicated by ABS or another warning lamp, collect all necessary information from the
customer (what symptoms are present under what conditions) and check for simple causes before starting diagnostic servicing. Besides the electrical system inspection, check booster operation, brake fluid
level, and oil leaks.
If tyre size and type are used in an improper combination, or brake pads are not Genuine Nissan parts,
stopping distance or steering stability may deteriorate.
If there is a radio, antenna, or antenna lead-in wire (including wiring) near the control unit, ABS system
may malfunction or return an error.
If aftermarket parts (e.g. car stereo equipment, CD player) have been installed, check electrical harnesses
for pinches, open, and improper wiring.

BRC-3

M

PRECAUTIONS
[ABS]

Precaution for Harness Repair

BFS00092

CAN SYSTEM
●

Area to be repaired shall be soldered, and wrapped with a tape
(be sure that fraying of twisted wire shall be within 110 mm 4.33
in)).

PKIA0306E

●

Do not make a bypass connection to repaired area. (If it is done,
branch part will be removed and characteristics of twisted wire
will be lost.)

PKIA0307E

BRC-4

PREPARATION
[ABS]

PREPARATION
Special Service Tools

PFP:00002

A
BFS00093

Tool number
Tool name

Description

GG94310000
Flare nut torque wrench
a: 10 mm (0.39 in)

Removing and installing each brake
piping

B

C

D
NT406

E

BRC

G

H

I

J

K

L

M

BRC-5

SYSTEM DESCRIPTION
[ABS]

SYSTEM DESCRIPTION
System Diagram

PFP:00000
BFS00094

SFIA1173E

System Components

BFS00095

SFIA1174E

BRC-6

SYSTEM DESCRIPTION
[ABS]

ABS Function
●

●

●

BFS00096

Anti-lock Brake System monitors wheel rotation in braking and electronically controls braking force (brake
fluid pressure) to prevent wheel locking. Thus, it improves vehicle stability in abrupt braking and allows
driver to clear obstacles more easily.
In the event of an electric system malfunction, the fail-safe function will operate, the vehicle will enter the
ABS non-operation state, and ABS warning lamp will come on.
CONSULT-II can be used to diagnose the electrical system.

●

●

BFS00097

The electronically controlled braking force distribution unit detects the minute slips that occur in front and
rear wheels during braking and uses electronic control to control rear wheel braking force (brake hydraulic
pressure) to suppress rear wheel slipping as much as possible to improve stability during braking.
In the event an electrical system malfunction occurs, the fail-safe function will operate and EBD and ABS
will enter non-operational states, and ABS warning lamp and brake warning lamp will come on.
CONSULT-II can be used to diagnose the electrical system.

Fail-Safe Function
●
●

B

C

EBD Function
●

A

D

E

BFS00098

BRC

If a malfunction occurs in ABS system, “ABS warning lamp” turns ON.
If a malfunction occurs in EBD, brake warning lamp and ABS warning lamp turn ON.

Hydraulic Circuit Diagram

BFS00099

G

H

I

J

K

L

M

SBR984D

1.

Inlet solenoid valve

2.

Outlet solenoid valve

3.

Reservoir

4.

Pump

5.

Motor

6.

Inlet valve

7.

Outlet valve

8.

Bypass check valve

9.

Damper

BRC-7

TROUBLE DIAGNOSIS
[ABS]

TROUBLE DIAGNOSIS
Diagnosis Procedure

PFP:00004
BFS0009A

BASIC CONCEPT
●

●

The most important point in performing trouble diagnosis is to thoroughly understand the vehicle systems
(both control and mechanical).
It is also important to clarify customer concerns before starting
the inspection.
First of all, reproduce the symptom, and understand it fully.
Ask the customer about his/her complaints carefully. In some
cases, it will be necessary to check the symptoms by driving the
vehicle with the customer.
CAUTION:
Customers are not professional. It is dangerous to make an
easy guess like “maybe the customer means that…,” or
“maybe the customer mentions this symptom”.
EFJ0028D

●

●

●

●

It is essential to check symptoms right from the beginning in
order to repair a error completely.
For an intermittent error, it is important to reproduce the symptom based on an interview with the customer and past examples. Do not perform an inspection on an ad hoc basis. Most
intermittent errors are caused by poor contacts. In this case, it
will be effective to shake the suspected harness or connector by
hand. When repairs are performed without any symptom diagnosis, no one can judge if the error has actually been eliminated.
After completing trouble diagnosis, be sure to perform “erase
memory”. Refer to BRC-19, «ERASE MEMORY» .
SEF233G
For an intermittent error, move the harness or harness connector by hand to check for poor contact or false open circuit.
Always read the GI section to be aware of the general precautions. Refer to GI-4, «General Precautions» .

BRC-8

TROUBLE DIAGNOSIS
[ABS]
DIAGNOSIS FLOW
A

B

C

D

E

BRC

G

H

I

J

K

L

M

SFIA0953E

BRC-9

TROUBLE DIAGNOSIS
[ABS]
QUESTIONNAIRE
●

●

●

Complaints against a malfunction vary depending on each person. It is important to clarify the customer complaints.
Ask the customer about what symptoms are present and under
what conditions. Use the information to reproduce the symptom
while driving.
It is also important to use the diagnosis sheet so as not to miss
the information.

SBR339B

EXAMPLE OF DIAGNOSIS SHEET

SFIA0791E

BRC-10

TROUBLE DIAGNOSIS
[ABS]

Component Parts Location

BFS0009B

A

B

C

D

E

BRC

G

H

I

J

K

L

M

MFIB9035E

BRC-11

TROUBLE DIAGNOSIS
[ABS]

Schematic

BFS0009C

MFWA0034E

BRC-12

TROUBLE DIAGNOSIS
[ABS]

Wiring Diagram — ABS —

BFS0009D

A

B

C

D

E

BRC

G

H

I

J

K

L

M

MFWA0158E

BRC-13

TROUBLE DIAGNOSIS
[ABS]

MFWA0159E

BRC-14

TROUBLE DIAGNOSIS
[ABS]
A

B

C

D

E

BRC

G

H

I

J

K

L

M

MFWA0160E

BRC-15

TROUBLE DIAGNOSIS
[ABS]

MFWA0161E

BRC-16

TROUBLE DIAGNOSIS
[ABS]
A

B

C

D

E

BRC

G

H

I

J

K

L

M

MFWA0162E

BRC-17

TROUBLE DIAGNOSIS
[ABS]

MFWA0163E

BRC-18

TROUBLE DIAGNOSIS
[ABS]

CONSULT-II Functions (ABS)

BFS0009H

A

CONSULT-II MAIN FUNCTION
In a diagnosis function (main function), there are “SELF-DIAG RESULTS”, “DATA MONITOR”, “CAN DIAG
SUPPORT MNTR”, “ACTIVE TEST”, “FUNCTION TEST”, “ECU PART NUMBER”.

B

Diagnostic
test mode

Function

SELF-DIAG
RESULTS

Self-diagnostic results can be read and erased quickly.

DATA MONITOR

Input/Output data in the ABS actuator and electric unit (control unit) can be read.

CAN DIAG
SUPPORT
MNTR

The results of transmit/receive diagnosis of communication can be read.

ACTIVE TEST

Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the
ABS actuator and electric unit (control unit) and also shifts some parameters in a
specified range.

FUNCTION
TEST

Performed by CONSULT-II instead of technician to determine whether each system
is “OK” or “NG”.

ECU PART
NUMBER

ABS actuator and electric unit (control unit) part number can be read.

Reference
BRC-19, «Self-Diagnosis»

C

BRC-21, «Data Monitor»
LAN-15, «CAN Diagnostic
Support Monitor»

D

E
BRC-22, «Active Test»
Separate volume “CONSULTII OPERATION MANUAL
(FUNCTION TEST)”

BRC

—

G

CONSULT-II BASIC OPERATION PROCEDURE
Refer to GI-36, «CONSULT-II Start Procedure» .

H

Self-Diagnosis

BFS000EV

OPERATION PROCEDURE
1.
2.
3.
4.
5.

6.
7.
8.

Turn ignition switch OFF.
Connect CONSULT-II and CONSULT-II CONVERTER to data link connector.
Turn ignition switch ON.
Start engine and drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute.
After stopping vehicle, with engine running, touch “START (NISSAN BASED VHCL)”, “ABS”, “SELF-DIAG
RESULTS” in order on CONSULT-II screen.
CAUTION:
If “START (NISSAN BASED VHCL)” is touched immediately after starting engine or turn on the
ignition switch, “ABS” might not be displayed in the “SELECT SYSTEM” screen. In this case,
repeat the operation from step 1.
The self-diagnostic results are displayed. (Touch “PRINT” to print out self-diagnostic results, If necessary.)
● Check ABS warning lamp if “NO FAILURE” is displayed.
Perform the appropriate inspection from display item list, and repair or replace the malfunctioning component. Refer to BRC-20, «DISPLAY ITEM LIST» .
Start engine and drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute.
CAUTION:
When the wheel sensor malfunctions, after inspecting the wheel sensor system, the ABS warning
lamp will not turn off even when the system is normal unless the vehicle is driving at 30 km/h (19
MPH) or more for approximately 1 minute.

ERASE MEMORY
1.
2.

3.

Turn ignition switch OFF.
Start engine and touch “START (NISSAN BASED VHCL)”, “ABS”, “SELF-DIAG RESULTS”, “ERASE
MEMORY” in order on CONSULT-II screen to erase the error memory.
If “ABS” is not indicated, go to GI-38, «CONSULT-II Data Link Connector (DLC) Circuit» .
CAUTION:
If the error memory is not erased, re-perform the operation from step 4.
Perform self-diagnosis again, and make sure that diagnostic memory is erased.

BRC-19

I

J

K

L

M

TROUBLE DIAGNOSIS
[ABS]
4.

Drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute as the final inspection, and make
sure that the ABS warning lamp turn off.

DISPLAY ITEM LIST
Code

Self-diagnostic item

Malfunction detecting condition

Check system

C100F

FR RH SENSOR

Circuit of front RH wheel sensor is open, shorted or sensor power
voltage is unusual.

C101F

FR LH SENSOR

Circuit of front LH wheel sensor is open, shorted or sensor power
voltage is unusual.

C102F

RR RH SENSOR

Circuit of rear RH wheel sensor is open, shorted or sensor power
voltage is unusual.

C103F

RR LH SENSOR

Circuit of rear LH wheel sensor is open, shorted or sensor power
voltage is unusual.

C1041

FR RH SENSOR ROTOR

ABS actuator and electric unit (control unit) cannot identify sensor
pulses, because of large gap between wheel sensor and sensor
rotor.

C1042

FR LH SENSOR ROTOR

ABS actuator and electric unit (control unit) cannot identify sensor
pulses, because of large gap between wheel sensor and sensor
rotor.

C1043

RR RH SENSOR ROTOR

ABS actuator and electric unit (control unit) cannot identify sensor
pulses, because of large gap between wheel sensor and sensor
rotor.

C1044

RR LH SENSOR ROTOR

ABS actuator and electric unit (control unit) cannot identify sensor
pulses, because of large gap between wheel sensor and sensor
rotor.

C10C6

STOP LAMP SW CIRC

Stop lamp switch is fixed at “ON” position.

BRC-31, «Inspection 5
Stop Lamp Switch System»

C10C6

STOP LAMP OR CONT

Stop lamp switch circuit is open or shorted, or controller failure.

BRC-31, «Inspection 5
Stop Lamp Switch System»

C1046

ABS SENSOR

Wheel sensor input is malfunction or wheel sensor power voltage
is too low.

BRC-27, «Inspection 1
Wheel Sensor System»
(Note 1)

C10CC

BATTERY VOLTAGE

Supply voltage for ABS actuator and electric unit (control unit) is
too low or too high, or abnormal.

BRC-29, «Inspection 4
ABS Actuator and Electric Unit Power and
Ground System»

C10C3

CONTROLLER FAILURE

Internal malfunction of ABS actuator and electric unit (control
unit)

BRC-29, «Inspection 3
ABS Actuator and Electric Unit (Control Unit)
System»

U1000

C1180

CAN COMM CIRCUIT

●

CAN communication line is open or shorted.

●

ABS actuator and electric unit (control unit) internal malfunction

●

Battery voltage for ECM is suddenly interrupted for approximately 0.5 seconds or more.

●

CAN communication line is open or shorted.

●

CAN communication signal form ECM cannot be received.

ECM

BRC-27, «Inspection 1
Wheel Sensor System»

BRC-33, «Inspection 6
CAN Communication
Circuit» (Note 1)
BRC-29, «Inspection 2
Engine System»

Note 1: If multiple malfunctions are detected including CAN communication line [U1000], perform diagnosis for
CAN communication line first.

BRC-20

TROUBLE DIAGNOSIS
[ABS]

Data Monitor

BFS000EW

A

OPERATION PROCEDURE
1.

Touch “START (NISSAN BASED VHCL)”, “ABS”, “DATA MONITOR” in order on CONSULT-II screen.
CAUTION:
When “START (NISSAN BASED VHCL)” is touched immediately after starting engine or turning on
ignition switch, “ABS” might not be displayed in “SELECT SYSTEM” screen. In this case, repeat
the operation from step 1.
At the monitor item selection screen, touch one of the item “ECU INPUT SIGNALS”, “MAIN SIGNALS” or
“SELECTION FROM MENU”.
Touch “START” to proceed to the data monitor screen.

2.
3.

B

C

D

DISPLAY ITEM LIST
CAUTION:
The display shows the control unit calculation data, so a normal value might be displayed even in the
event the output circuit (harness) is open or short-circuited.

E

E: ECU INPUT SIGNALS M: MAIN SIGNALS S: SELECTION FROM MENU
SELECT
MONITOR
ITEM

Data monitor
Monitor item

Display content

E, M, S

FR LH SENSOR
FR RH SENSOR
RR LH SENSOR
RR RH SENSOR

Vehicle wheel speed

S

STOP LAMP SWITCH

Brake pedal operation

M, S

FR LH IN SOL
FR LH OUT SOL
FR RH IN SOL
FR RH OUT SOL
RR LH IN SOL
RR LH OUT SOL
RR RH IN SOL
RR RH OUT SOL

M, S

M, S

S

M, S

ACTUATOR RLY

MOTOR RELAY

EBD WARN LAMP

ABS WARN LAMP

Condition

Reference values for
normal operation

Vehicle stopped

0 (km/h)

While driving (Note 1)

Almost in accordance
with the speedometer
display (within ±10 %)

Brake pedal depressed

ON

BRC

G

H

Brake pedal not depressed

OFF

ABS solenoid activated or failsafe activated (Note 2)

ON

I

Actuator relay is activated and
ABS solenoid is not activated

OFF

J

Vehicle stop (Ignition switch ON)

ON

K

Vehicle stopped (engine running)

ON

Motor relay and motor activated

ON

Motor relay and motor not activated

OFF

Brake warning lamp ON

ON

Brake warning lamp OFF

OFF

ABS warning lamp ON

ON

ABS warning lamp OFF

OFF

Ignition switch ON

Approximately 10 — 16 V

EBD is operating

ON

EBD is not operating

OFF

ABS activated

ON

ABS not activated

OFF

Malfunctions condition (When
system is malfunctioning)

OFF

Solenoid valve operation

Actuator relay activated

Motor relay and motor activated

EBD warning lamp ON

ABS warning lamp ON (Note 3)

E, M, S

BATTERY VOLT

Battery voltage supplied to
control unit

S

EBD SIGNAL

EBD operation signal

S

ABS SIGNAL

ABS operation signal

S

EBD FAIL SIG
ABS FAIL SIG

System error signal status

NOTE:
1. Confirm tyre pressure is normal.
2. The solenoid turns off when the actuator relay is not operating.

BRC-21

L

M

TROUBLE DIAGNOSIS
[ABS]
3. ON/OFF timing of ABS warning lamp
ON: When the switch is turned ON for approximately 1 second or when a malfunction is detected.
OFF: Approximately 1 second after ignition switch is turned ON (when the system is in normal operation).

Active Test

BFS000EX

CAUTION:
●
Do not perform active test while driving.
●
Make sure to completely bleed air from the brake system.
●
During active test, ABS and brake warning lamps are on.

OPERATION PROCEDURE
1.
2.
3.
4.
5.

Touch “ACTIVE TEST”.
The “SELECT TEST ITEM” screen is displayed.
Touch “TEST ITEM”.
Touch “START” with “MAIN SIGNALS” line inverted.
The “ACTIVE TEST” screen is displayed, and the following test
can be performed.

SFIA0840E

TEST ITEM —ABS SOLENOID VALVE—
●

Touch “UP”, “KEEP” and “DOWN” on the screen to confirm ABS
solenoid valves (inlet/outlet) operate as in the following chart.
Operation

UP

KEEP

DOWN

ABS inlet S/V

OFF

ON

ON

ABS outlet S/V

OFF

OFF

ON*

*: ON for 1 to 2 seconds after touch, and then OFF

SFIA0395E

NOTE:
●
If active test is performed with brake pedal depressed, pedal
stroke may change. This is normal.
●
“TEST STOP” is displayed 10 seconds after operation start.
●
After “TEST STOP” is displayed, to perform test again, touch
“BACK” and repeat step 6.

SFIA0396E

BRC-22

TROUBLE DIAGNOSIS
[ABS]
TEST ITEM —ABS MOTOR—
●

A

Touch “ON” and “OFF” on the screen to confirm the ABS motor
relay operates as shown in the following chart.
Operation

ON

OFF

ABS actuator relay

ON

ON

ABS motor relay

ON

OFF

NOTE:
If active test is performed with brake pedal depressed, pedal
stroke may change. This is normal.
●
“TEST STOP” is displayed 10 seconds after operation start.

B

C

●

SFIA0397E

D

E

BRC

G

H

I

J

K

L

M

BRC-23

TROUBLE DIAGNOSIS
[ABS]

CAN Communication

BFS000EY

SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
Refer to LAN-27, «CAN Communication Unit» .

BRC-24

TROUBLE DIAGNOSIS
[ABS]

For Fast and Accurate Diagnosis

BFS000EZ

PRECAUTIONS FOR TROUBLE DIAGNOSIS
●

●

●

●
●

Always read the “GI General Information” to confirm the general precautions. Refer to GI-4, «General Precautions» .
After completing the trouble diagnosis, always erase the fault memory. Refer to BRC-19, «Self-Diagnosis»
.
When inspection of the continuity or voltage between control units is performed, check connector terminals for disconnection, looseness, bend, or collapse. If any non-standard condition is detected, repair or
replace applicable part.
Intermittent errors may be caused by a poor connection in the harness, connector, or terminal.
If a circuit tester is used for the check, be careful not to forcibly extend any connector terminal.

A

B

C

D

E

BRC

G

H

I

J

K

L

M

BRC-25

TROUBLE DIAGNOSIS
[ABS]

Basic Inspection

BFS000F0

BASIC INSPECTION 1: BRAKE FLUID LEVEL, LEAK AND BRAKE PAD INSPECTION
1.
2.

3.

Check fluid level in brake reservoir tank. If fluid level is low, refill the brake fluid.
Check area around the brake piping and ABS actuator for leaks. If a leak or oozing is detected, check as
follows:
● If ABS actuator connections are loose, tighten piping to the specified torque. Check again for leaks, and
make sure there is no fluid leakage.
● If flare nuts at the connections and the threads of ABS actuator are damaged, replace damaged parts.
Then check again for leaks, and make sure that there is no fluid leak.
● If a leak or oozing is detected on other parts than ABS actuator connections, wipe the applicable part
with a clean cloth. Then check again for leaks, and if there is still a leak or oozing, replace damaged
part.
● If leaks or oozing are detected on ABS actuator body, wipe with a clean cloth and check again. If there
is still a leak or oozing, replace ABS actuator.
CAUTION:
ABS actuator body cannot be disassembled.
Check for brake pad wear. Refer to BR-21, «PAD WEAR INSPECTION» .

BASIC INSPECTION 2: INSPECTION OF POWER SUPPLY SYSTEM TERMINAL LOOSENESS
AND BATTERY
Check battery for looseness on battery positive/negative cables and ground connection. Also Make sure battery voltage dose not drop.

BASIC INSPECTION 3: ABS WARNING LAMP AND BRAKE WARNING LAMP INSPECTION
1.

Make sure ABS warning lamp and brake warning lamp turn on for approximately 1 sec. When ignition
switch is turned ON. If they do not turn on, perform CAN communication system diagnosis. Refer to BRC33, «Inspection 6 CAN Communication Circuit» .
If CAN communication system is normal, replace combination meter. Refer to DI-20, «Removal and Installation for Combination Meter» .
2. Make sure ABS warning lamp and brake warning lamp turn off after approximately 1 sec. When ignition
switch is turned ON. If they do not turn OFF, perform self-diagnosis.
3. Make sure that ABS warning lamp remains off after the vehicle has been driven at approx. 30 km/h (19
MPH) for approx. 1 minute. If it turns on, perform self-diagnosis.
4. After completing self-diagnosis, always erase self-diagnostic results memory. Refer to BRC-19, «ERASE
MEMORY» .
CAUTION:
The brake warning lamp comes on when the parking brake lever is pulled (when switch is on) and
when the brake fluid level sensor operates (insufficient brake fluid).

BRC-26

TROUBLE DIAGNOSIS
[ABS]

Inspection 1 Wheel Sensor System

BFS000F1

DTC C100F-C103F, C1041-C1043, C1046
After identifying malfunctioning wheel sensor position according to CONSULT-II self-diagnostic results, check
the each part and identify the parts to be replaced.
CAUTION:
●
Do not measure the resistance value and also voltage between sensor terminal with tester etc.,
because sensor is an active sensor.
●
Do not expand terminal of connector with a tester terminal stick, when it does the inspection with
tester.

INSPECTION PROCEDURE

A

B

C

D

1. CHECK TYRE
Check air pressure, wear and size.
Are air pressure, wear, and size within specifications?
YES >> GO TO 2.
NO
>> Adjust air pressure, or replace tyre.

2. CHECK SENSOR AND SENSOR ROTOR

E

BRC

Inspect the appearance of the sensor and sensor rotor.
●
Check sensor rotor rubber bar for damage.
●
Check sensor for disconnection or loose.
OK or NG
OK
>> GO TO 3.
NG
>> Replace sensor rotor.

G

3. SELF-DIAGNOSTIC RESULTS

I

●

Check the self-diagnostic results.

H

J

Self-diagnostic results
FR RH SENSOR

K

FR LH SENSOR
RR RH SENSOR
RR LH SENSOR

L

FR RH SENSOR ROTOR
FR LH SENSOR ROTOR

M

RR RH SENSOR ROTOR
RR LH SENSOR ROTOR

Is any of above displayed on self-diagnosis display?
YES >> GO TO 4.
NO
>> INSPECTION END

4. CHECK CONNECTOR
1.

Disconnect control unit connector E32 and malfunctioning wheel sensor connector E42 (FL), E29 (FR),
B35 (RL) or B34 (RR) and check for deformation, disconnected and loose. If there is any non-standard
condition, repair the connector.
2. Reconnect connectors, drive the vehicle at 30km/h (19 MPH) for approximately 1 minute, and then perform self-diagnosis.
OK or NG
OK
>> The connector terminal contact is loose, damage, open or shorted.
NG
>> GO TO 5.

BRC-27

TROUBLE DIAGNOSIS
[ABS]

5. CHECK WHEEL SENSOR HARNESS
1.
2.

3.

Disconnect control unit connector E32 and wheel sensor connector E42 (FL), E29 (FR), B35 (RL) and B34 (RR).
Check continuity between ABS actuator and electric unit (control
unit) and Wheel sensor (Power supply system).
A

B

Connector

ABS actuator and electric
unit (control unit)

Wheel sensor

Front LH

5

1

Front RH

10

1

Rear LH

17

1

Rear RH

19

1

Yes

MFIB9039E

Check continuity between ABS actuator and electric unit (control unit) and wheel sensor (Signal system).
A

B

ABS actuator and electric
unit (control unit)

Wheel sensor

Front LH

16

2

Front RH

9

2

Rear LH

6

2

Rear RH

8

2

Connector

4.

Continuity

Continuity

Yes

Check continuity between ABS actuator and electric unit (control unit) terminal (Ground).
A

Connector

Continuity

ABS actuator and electric unit (control unit)
Front LH

5, 16

4

Front RH

9, 10

4

Rear LH

6, 17

4

Rear RH

8, 19

4

No

OK or NG
OK
>> GO TO 6.
NG
>> Repair or replace harness connector between ABS actuator and electric unit (control unit) and
wheel sensor.

6. CHECK WHEEL SENSOR POWER SUPPLY CIRCUIT
1.
2.
3.

Connect control unit connector.
Turn ignition switch ON.
Check voltage between wheel sensor power supply terminal 1
and ground.
Wheel sensor

Terminal

E42 (FL), E29 (FR),
B35 (RL), B34 (RR)

1

Voltage
Ground

8V or more

OK or NG
OK
>> Replace wheel sensor.
NG
>> Replace ABS actuator and electric unit (control unit).

BRC-28

MFIB9040E

TROUBLE DIAGNOSIS
[ABS]

Inspection 2 Engine System

BFS000F2

A

DTC C1180

INSPECTION PROCEDURE

1. CHECK SELF-DIAGNOSTIC RESULTS

B

Check the self-diagnostic results.
C

Self-diagnostic results
ECM

Is the above displayed in the self-diagnosis display items?
YES >> GO TO 2.
NO
>> INSPECTION END

D

2. CHECK ENGINE SYSTEM

E

Perform an ECM self-diagnosis refer to EC-74, «TROUBLE DIAGNOSIS» (CR engine models with
EURO-OBD), EC-491, «TROUBLE DIAGNOSIS» (CR engine models without EURO-OBD), EC-863, BRC
«TROUBLE DIAGNOSIS» (HR engine models with EURO-OBD), EC-1284, «TROUBLE DIAGNOSIS»
(HR engine models without EURO-OBD), EC-1630, «TROUBLE DIAGNOSIS» and repair or replace malfunctioning items. Re-perform ECM self-diagnosis.
G
2. Re-perform ABS actuator and electric unit (control unit) self-diagnosis.
OK or NG
OK
>> INSPECTION END
H
NG
>> Repair or replace malfunctioning items. Re-perform the self-diagnosis.

1.

Inspection 3 ABS Actuator and Electric Unit (Control Unit) System

BFS000F3

I

DTC C10C3

INSPECTION PROCEDURE

1. CHECK SELF-DIAGNOSTIC RESULTS

J

Check the self-diagnostic results.
K

Self-diagnostic results
CONTROLLER FAILURE

Is the above displayed in the self-diagnosis display items?
YES >> Replace ABS actuator and electric unit (control unit). Re-perform the self-diagnosis.
NO
>> INSPECTION END

Inspection 4 ABS Actuator and Electric Unit Power and Ground System
DTC C10CC

INSPECTION PROCEDURE

1. CHECK SELF-DIAGNOSTIC RESULTS
Check the self-diagnostic results.
Self-diagnostic results
BATTERY VOLTAGE

Does “BATTERY VOLTAGE” appear in self-diagnostic results display?
YES >> GO TO 2.
NO
>> INSPECTION END

BRC-29

L

BFS000F4

M

TROUBLE DIAGNOSIS
[ABS]

2. STARTING INSPECTION
1. Disconnect ABS actuator and electric unit (control unit) connector E32. Then reconnect it securely.
2. Perform self-diagnosis.
Do any self-diagnosis item appear?
YES >> GO TO 3.
NO
>> Poor connection. Repair or replace connector.

3. CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) POWER SUPPLY (1)
1.
2.

Disconnect ABS actuator and electric unit (control unit) connector E32.
Turn ignition switch ON (not turn on engine). Check voltage
between ABS actuator and electric unit (control unit) harness
E32 and ground.

ABS actuator and electric unit
(control unit)

Terminal

Ground

Voltage

E32

18

—

Approx. 12V

MFIB9041E

3.

Turn ignition switch OFF. Check voltage between ABS actuator
and electric unit (control unit) harness E32 and ground.

ABS actuator and electric unit
(control unit)

Terminal

Ground

Voltage

E32

2, 3

—

Approx. 12V

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 5.
MFIB9043E

4. CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) GROUND SYSTEM
Check ABS actuator and electric unit (control unit) ground system.
ABS actuator and electric unit
(control unit)

Terminal

Ground

Continuity

E32

1, 4

—

Yes

OK or NG
OK
>> Perform ABS actuator and electric unit (control unit) selfdiagnosis again.
NG
>> Repair or replace harness or connectors.
MFIB9042E

BRC-30

TROUBLE DIAGNOSIS
[ABS]

5. CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) POWER SUPPLY (2)
1.
2.

A

Check fusible links 40A (terminal 2) and 30A (terminal 3).
Turn ignition switch OFF and check continuity between battery
positive terminal and ABS actuator and electric unit (control unit)
harness connector E32.
A

B

B

ABS actuator and electric
unit (control unit)

Terminal

Battery positive terminal

E32

2, 3

—

C

Continuity
Yes

D
Check fuse 10A (terminal 18)
Check continuity between 10A fuse and ABS actuator and elecMFIB9052E
tric unit (control unit) harness connector.
E
OK or NG
OK
>> Check for non-standard conditions in battery (terminal looseness, low voltage, etc.) and alternator.
NG
>> ● Replace fusible link 40A or 30A or fuse 10A.
BRC
● Open or short in harness.

3.
4.

Inspection 5 Stop Lamp Switch System

BFS000F5

DTC C10C6

G

INSPECTION PROCEDURE

1. CHECK SELF-DIAGNOSTIC RESULTS

H

Check the self-diagnostic results.
I

Self-diagnostic results
STOP LAMP SW

Is the above displayed in the self-diagnosis display item?
YES >> GO TO 2.
NO
>> INSPECTION END

J

2. CHECK CONNECTOR

K

1.

Disconnect stop lamp switch connector E38 (LHD MODELS WITH CR ENGINE AND HR ENGINE WITH
M/T), E60 (LHD MODELS WITH HR ENGINE WITH A/T AND K9K ENGINE), M203 (RHD MODELS
WITH CR ENGINE AND HR ENGINE WITH M/T), M204 (RHD MODELS WITH HR ENGINE WITH A/T
AND K9K ENGINE) and ABS actuator and electric unit (control unit) connector E32 and check terminals
for deformation, disconnection, looseness, and so on. If any malfunction is found, repair or replace terminal.
2. Securely reconnect connectors.
3. perform self-diagnosis again.
OK or NG
OK
>> Connector terminal contact is loose, damaged, open or shorted.
NG
>> GO TO 3.

BRC-31

L

M

TROUBLE DIAGNOSIS
[ABS]

3. CHECK STOP LAMP SWITCH CIRCUIT
1.

2.

Turn ignition switch OFF and disconnect stop lamp switch connector and ABS actuator and electric unit (control unit) connector.
Check continuity between stop lamp switch harness connector
and ABS actuator and electric unit (control unit) harness connector.

MFIB9044E

A

B

C

ABS actuator and
electric unit
(control unit)

Terminal

Stop lamp switch
(CR engine and HR
engine M/T models)

Terminal

Stop lamp switch
(HR engine A/T models
and K9K engine models)

Terminal

E32

20

E38 (LHD models)
M203 (RHD models)

2

E60 (LHD models)
M204 (RHD models)

2

Continuity

Yes

OK or NG
OK
>> GO TO 4.
NG
>> Open or short in harness between stop lamp switch and ABS actuator and electric unit (control
unit). Repair or replace applied harness.

4. CHECK STOP LAMP SWITCH POWER SUPPLY
1.
2.

Turn ignition switch OFF and disconnect stop lamp switch harness connector.
Check voltage between stop lamp switch harness connector and
ground.

MFIB9047E

A

B

Stop lamp switch (CR engine and
HR engine M/T models)

Terminal

Stop lamp switch (HR engine A/T
models and K9K engine)

Terminal

E38 (LHD models)
M203 (RHD models)

1

E60 (LHD models)
M204 (RHD models)

1

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace power supply circuit.

BRC-32

Ground

Voltage

—

Approx. 12V

TROUBLE DIAGNOSIS
[ABS]

5. CHECK STOP LAMP SWITCH
1.
2.

A

Turn ignition switch OFF and disconnect stop lamp switch.
Check continuity between stop lamp switch harness connector
terminals 1 and 2.

B

C

D
MFIB9048E

E
A
Stop lamp switch (CR engine and
HR engine M/T models)

B
Terminal

Stop lamp switch (HR engine A/T
models and K9K engine)

1, 2

E60 (LHD models)
M204 (RHD models)

E38 (LHD models)
M203 (RHD models)

Terminal

1, 2

Condition

Continuity

BRC
Brake pedal
is depressed

Yes

Brake pedal
is released

No

OK or NG
OK
>> Connect connectors and conduct an ABS actuator and electric unit (control unit) self-diagnosis.
NG
>> Replace stop lamp switch.

Inspection 6 CAN Communication Circuit

BFS000F6

G

H

I

DTC U1000, C1180

INSPECTION PROCEDURE

1. CHECK CONNECTOR

J

1.

Turn ignition switch OFF and disconnect the ABS actuator and electric unit (control unit) connector, and
check the terminal for deformation, disconnection, looseness, and so on. If there is a malfunction, repair
or replace the terminal.
2. Reconnect connector to perform self-diagnosis.
Is “CAN COMM CIRCUIT” displayed in the self-diagnosis display items?
YES >> Print out the self-diagnostic results, and refer to LAN-3, «Precautions When Using CONSULT-II» .
NO
>> Connector terminal connector is loose, damaged, open, or shorted.

Symptom 1 ABS Works Frequently.

BFS000F7

1. START INSPECTION
Check brake force distribution.
OK or NG
OK
>> GO TO 2.
NG
>> Check brake system.

2. CHECK FRONT AND REAR AXLE
Check front and real axle for significant “looseness”.
OK or NG
OK
>> GO TO 3.
NG
>> Repair or replace.

BRC-33

K

L

M

TROUBLE DIAGNOSIS
[ABS]

3. CHECK WHEEL SENSOR AND ROTOR
Wheel Sensor Inspection
●
Sensor installation and damage inspection
●
Sensor rotor installation and damage inspection
●
Sensor connector engagement inspection
●
Sensor harness inspection
OK or NG
OK
>> GO TO 4.
NG
>> ● Replace wheel sensor or sensor rotor.
● Repair harness.

4. CHECK INDICATOR DISPLAY OF WARNING LAMP
Make sure warning lamp is off approximately 1 second after ignition switch is turned ON or during driving.
OK or NG
OK
>> Normal
NG
>> Perform self-diagnosis. Refer to BRC-19, «Self-Diagnosis» .

Symptom 2 Unexpected Pedal Reaction

BFS000F8

1. CHECK BRAKE PEDAL STROKE
Check brake pedal stroke.
Is brake pedal stroke not excessive?
YES >> ● Bleed air from brake piping.
● Check for looseness of brake pedal, master back, and master cylinder. Also check brake system for oil leak. Repair as necessary.
NO
>> GO TO 2.

2. PERFORMANCE CHECK
Disconnect control unit connector E32 to deactivate ABS. In this condition, make sure braking force is normal
after inspection, reconnect connector.
OK or NG
OK
>> GO TO 3. Wheel Sensor Inspection in BRC-33, «Symptom 1 ABS Works Frequently.» .
NG
>> Check brake system.

Symptom 3 Longer Stopping Distance

BFS000F9

CAUTION:
On slippery road, stopping distance could be longer when ABS is activated than when it is not.

1. CHECK FUNCTION
Disconnect control unit connector E32 to deactivate ABS. In this condition, check braking distance After
inspection, reconnect connector.
OK or NG
OK
>> ● Bleed air from brake piping.
● Check brake system.
NG
>> GO TO 3. Wheel Sensor Inspection in BRC-33, «Symptom 1 ABS Works Frequently.» .

BRC-34

TROUBLE DIAGNOSIS
[ABS]

Symptom 4 ABS Does Not Work

BFS000FA

A

CAUTION:
ABS does not operate when vehicle speed is 10 km/h (6 MPH) or lower.

1. CHECK INDICATOR DISPLAY OF WARNING LAMP

B

Make sure warning lamp is off approximately 1 second after ignition switch is turned ON or during driving.
OK or NG
OK
>> GO TO 3. Wheel Sensor Inspection in BRC-33, «Symptom 1 ABS Works Frequently.» .
NG
>> Perform a self-diagnosis. Refer to BRC-19, «Self-Diagnosis» .

Symptom 5 Pedal Vibration and ABS Operation Noise

C

D
CAUTION:
Under the following conditions, when brake pedal is lightly depressed (just place a foot on it), ABS is
activated and vibration is felt. However, this is normal.
E
●
When shifting gears and operating clutch
●
When driving on slippery road
BRC
●
During cornering at high speed
●
When passing over bumps or grooves [50 mm (1.97 in) or more]
●
When pulling away just after starting engine [at approximately 10 km/h (6 MPH) or higher]
G
SYMPTOM CHECK 1
BFS000FB

1.

Check brake system for pedal vibration or noise at engine start.
OK or NG
OK
>> GO TO 2.
NG
>> Perform self-diagnosis. Refer to BRC-19, «Self-Diagnosis» .

H

I

2. SYMPTOM CHECK 2
Operate electrical equipment (head lamp or equivalents), and confirm symptoms.
Does symptom occur when electrical switches (head lamp, etc.) are operated?
YES >> Check for radio, antenna, and antenna lead-in wires (including wiring) near the control unit. If they
are near ABS actuator and electric unit (control unit), move them.
NO
>> GO TO 3. Wheel Sensor Inspection in BRC-33, «Symptom 1 ABS Works Frequently.» .

J

K

L

M

BRC-35

WHEEL SENSORS
[ABS]

WHEEL SENSORS
Removal and Installation

PFP:47910
BFS0009X

MFIB9029E

REMOVAL
Be careful of the following.
CAUTION:
●
When removing the sensor, do not rotate it if possible, and not forcibly pull the sensor harness.
●
Before removing front or rear wheel hub, remove wheel sensor to avoid sensor wiring damage.

INSTALLATION
Be certain to tighten bolts to the specified torque. Be careful of the following:
●
Check the inside of the sensor mounting hole for foreign material, the rotor surface for iron chips and other
foreign material, and if anything is non-standard, clean it before installation, or replace it.
●
When installing the front sensor, completely push in the strut bracket and body bracket rubber grommets
until they lock so that the sensor harness does not become twisted. In addition, there should be no twists
in the harness when installed. Install the harness so that the painted part faces the outside of the vehicle.
●
When installing the rear sensor, completely push in the rubber bracket of the suspension arm bracket and
lock the marking area of the side member harness mount so that the sensor harness will not be twisted. In
addition, there should be no twists in the harness when installed.

BRC-36

SENSOR ROTOR
[ABS]

SENSOR ROTOR
Removal and Installation

PFP:47970

A
BFS0009Y

FRONT
●

Because the sensor rotor is integrated with the wheel bearing, replace it together with the wheel bearing
assembly. Refer to FAX-6, «FRONT WHEEL HUB AND KNUCKLE» .

B

REAR
●

During removal and installation, remove the wheel hub (brake drum). Refer to RAX-5, «WHEEL HUB» .
CAUTION:
The sensor rotor is a non-reusable part, it must be replaced by an new part when removing it.

C

D

E

BRC

G

H

I

J

K

L

M

BRC-37

ACTUATOR AND ELECTRIC UNIT (ASSEMBLY)
[ABS]

ACTUATOR AND ELECTRIC UNIT (ASSEMBLY)
Removal and Installation

PFP:47660
BFS0009Z

SFIA1183E

REMOVAL
Be careful of the following.
CAUTION:
●
Before servicing, disconnect the battery cables.
●
To remove brake tube, use a flare nut wrench to prevent flare nuts and brake tube from being damaged. To install, use a flare nut torque wrench and tighten to the specified torque.
●
Do not apply excessive impact to the actuator, such as dropping it.

INSTALLATION
Be careful of the following.
●
When setting the actuator in the bracket, push it in until it locks.
●
Tighten the mounting bolts and nuts to the specified torque.
●
After the work, breed the air from the brake piping. Refer to BR-10, «Bleeding Brake System» .
●
After installing the vehicle harness connector in the actuator, make sure the connector is securely locked.

BRC-38

PRECAUTIONS
[ESP/TCS/ABS]

PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
[ESP/TCS/ABS]

A

BFS000A0

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along B
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
C
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be perD
formed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
E
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
BRC
harness connectors.

Precautions for Brake System
●
●
●

●

●

●

●

●
●

BFS000A1

Recommended fluid is brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)”.
Do not reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas such as body. If brake fluid is splashed, wipe it off
and flush area with water immediately.
Do not use mineral oils such as gasoline or kerosene to clean. They will ruin rubber parts and cause
improper operation.
Using a flare nut torque wrench, securely tighten brake tube
flare nuts.
Brake system is an important safety part. If a brake fluid leak is
detected, always disassemble the affected part. If a malfunction
is detected, replace part with a new one.
Before working, turn ignition switch OFF and disconnect electrical connectors of ABS actuator and electric unit (control unit) or
battery negative terminals.
When installing brake piping, be sure to check torque.
After removing/installing any hydraulic parts of the brake or ESP
SBR820BA
system (such as actuator and piping parts, etc), bleed air from
the system.

Precautions for Brake Control
●

●

●

●

●

●

●

BFS000A2

During ESP/TCS/ABS operation, brake pedal lightly vibrates and a mechanical noise may be heard. This
is normal.
When starting engine, or just after starting vehicle, brake pedal may vibrate or motor operating noise may
be heard from engine room. This is a normal status of operation check.
Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel,
or snow-covered (fresh, deep snow) roads.
When an error is indicated by ABS or another warning lamp, collect all necessary information from the
customer (what symptoms are present under what conditions) and check for simple causes before starting diagnostic servicing. Besides the electrical system inspection, check booster operation, brake fluid
level, and fluid leaks.
If tyre size and type are used in an improper combination, or brake pads are not Genuine NISSAN parts,
stopping distance or steering stability may deteriorate.
If there is a radio, antenna, or antenna lead-in wire (including wiring) near control module, ESP/TCS/ABS
function may have a malfunction or error.
If aftermarket parts (car stereo, CD player, etc.) have been installed, check for incidents such as harness
pinches, open circuits, and improper wiring.

BRC-39

G

H

I

J

K

L

M

PRECAUTIONS
[ESP/TCS/ABS]
●

●

●

●

●

If the following components are replaced with non-genuine components or converted, ESP OFF indicator
lamp and SLIP indicator lamp may turn on or the ESP system may not operate properly. Components
related to suspension (Shock Absorber, Strut, Spring, Bush, etc.), Tyres, wheels (exclude specified size),
components related to brake (Pad, Rotor, Caliper, etc.), components related to engine (Muffler, ECM,
etc.), components related to body reinforcement (Roll bar, Tower bar, etc.).
Driving in the condition of breakage or excessive wear of suspension, tyres or components related to the
brakes may cause ESP OFF indicator lamp and SLIP indicator lamp turn on, and the ESP system may not
operate properly.
When the TCS or ESP is activated by sudden acceleration or sudden turn, some noise may occur. The
noise is a result of the normal operation of the TCS and ESP.
When driving on roads which have extreme slopes (such as mountainous roads) or high banks (such as
sharp carves on a freeway), the ESP may not operate normally, or ESP warning lamp and SLIP indicator
lamp may turn on. However, this is not a malfunction, if normal operation can be resumed after restarting
engine.
Sudden turns (such as spin turns, acceleration turns), drifting, etc. When ESP function is OFF (ESP SW
ON) may cause the G -sensor system indicate a malfunction. However, this is not a malfunction, if normal
operation can be resumed after restarting engine.

Diagnosis Precaution

BFS000A3

CAN SYSTEM
●
●
●

Do not apply voltage of 7.0 V or higher to terminal to be measured.
Maximum open terminal voltage of tester in use shall be 7.0 V or lower.
Before checking harnesses, turn ignition switch OFF and disconnect battery negative cable.

Precaution for Harness Repair

BFS000A4

CAN SYSTEM
●

Area to be repaired shall be soldered, and wrapped with a tape
[be sure that fraying of twisted wire shall be within 110 mm (4.33
in)].

PKIA0306E

●

Do not make a bypass connection to repaired area. (If it is done,
branch part will be removed and characteristics of twisted wire
will be lost.)

PKIA0307E

BRC-40

PREPARATION
[ESP/TCS/ABS]

PREPARATION
Special Service Tools

PFP:00002

A
BFS000A5

Tool number
Tool name

Description

GG94310000
Flare nut torque wrench
a: 10 mm (0.39 in)

Removing and installing each brake
piping

B

C

D
NT406

E

BRC

G

H

I

J

K

L

M

BRC-41

ON-VEHICLE SERVICE
[ESP/TCS/ABS]

ON-VEHICLE SERVICE
Adjustment of Steering Angle Sensor Neutral Position

PFP:00000
BFS000A6

In case of doing work that applies to the list below, make sure to adjust neutral position of steering angle sensor before running vehicle.
Situation

Adjustment of Steering Angle Sensor Neutral Position

Disconnecting/connecting the battery

–

Removing/Installing ABS actuator and electric unit (control unit)

×

Replacing ABS actuator and electric unit (control unit)

×

Removing/Installing steering angle sensor

×

Removing/Installing steering components

×

Removing/Installing suspension components

×

Removing/Installing the same tyre to the same position

–

Change 4 tyres to new ones

–

Change some of 4 tyres to new ones (not 4 tyres)

–

Tyre rotation

–

Adjusting wheel alignment

×

×: Required
–: Not required

CAUTION:
To adjust neutral position of steering angle sensor, make sure to use CONSULT-II.
(Adjustment cannot be done without CONSULT-II.)

OPERATION PROCEDURE
1.
2.

Stop the vehicle with the front wheels in the straight-ahead position.
Connect CONSULT-II and CONSULT-II CONVERTER to data
link connector on the vehicle, and turn the ignition switch to ON
position (engine not running).

MAIA0009E

3.

Touch “START (NISSAN BASED VHCL).

MBIB0233E

BRC-42

ON-VEHICLE SERVICE
[ESP/TCS/ABS]
4.

Touch “ABS”, “WORK SUPPORT” and “ST ANGLE SENSOR
ADJUSTMENT” on the CONSULT-II screen in this order.

A

B

C
PBR385C

D

E

BRC

G
SFIA0365E

H

I

J

SFIA0370E

5.

6.
7.

8.

Touch “START”.
CAUTION:
Do not touch the steering wheel while adjusting the steering angle sensor.
After approximately 10 seconds, touch “END”. (After approximately 60 seconds, it ends automatically.)
Turn the ignition switch OFF, then turn it ON again.
CAUTION:
Make sure to carry out the above operation.
Run the vehicle with the front wheels in the straight-ahead position, then stop.

BRC-43

K

L

M

SFIA0371E

ON-VEHICLE SERVICE
[ESP/TCS/ABS]
9.

Select “DATA MONITOR“, “SELECTION FROM MENU” on the
CONSULT-II screen. Then check that the “ST ANGLE SIG” is
within 0±5deg. If the value is more than the specification, repeat
steps 1 to 5.
10. Erase the memory of ESP/TCS/ABS control unit and ECM.
11. Turn the ignition switch OFF.

SFIA0365E

BRC-44

SYSTEM DESCRIPTION
[ESP/TCS/ABS]

SYSTEM DESCRIPTION
System Diagram

PFP:00000

A
BFS000A7

B

C

D

E

BRC

MFIB9036E

ESP Function
●

●
●

●

BFS000A8

In addition to the TCS/ABS function, the driver steering amount and brake operation amount are detected
from steering angle sensor and pressure sensor, and the vehicle’s driving status (amount of under steering / over steering) is determined from information from G-sensor, wheel sensor, etc., and this information
is used to improve vehicle stability by controlling the braking and engine power to all four wheels.
SLIP indicator lamp flashes to inform the driver of ESP operation.
During ESP operation, body and brake pedal lightly vibrate and mechanical noises may be heard. This is
normal.
ABS warning lamp, ESP OFF indicator lamp, and SLIP indicator lamp might turn on when vehicle is subject to strong shaking or large vibration, such as when vehicle is on a turn table, a ship or a steep slope
such as bank while engine is running. In this case, restart engine on a normal road, and if ABS warning
lamp, ESP OFF indicator lamp, and SLIP indicator lamp turn off, there is no problem.

TCS Function
●

●

●

●

●

●
●

H

I

J

K

BFS000A9

The wheel spin of the drive wheels is detected by ABS actuator and electric unit (control unit) from the
wheel speed signals from four wheels, so if wheel spin occurs, drive wheel right and left brake fluid pressure control and engine fuel cut are performed while throttle value is restricted to reduce the engine
torque and decrease the amount of wheel spin. In addition, the degree throttle is opened is controlled to
achieve the optimum engine torque.
Depending on road circumstances, the driver may have a sluggish feel. This is normal, because the optimum traction has the highest priority under TCS operation.
TCS may be activated any time vehicle suddenly accelerates, suddenly down/upshifts, or is driven on a
road with a varying surface friction coefficient.
During TCS operation, it informs a driver of system operation by flashing SLIP indicator lamp.

ABS Function
●

G

BFS000AA

The anti-lock brake system is a function that detects wheel revolution while braking, and it improves handling stability during sudden braking by electrically preventing 4 wheel lock. Maneuverability is also
improved for avoiding obstacles.
If the electrical system breaks down, then the fail-safe function starts, the ABS becomes inoperative, and
ABS warning lamp turns on.
Electrical system diagnosis by CONSULT-II is available.
During ABS operation, brake pedal lightly vibrates and a mechanical noise may be heard. This is normal.

BRC-45

L

M

SYSTEM DESCRIPTION
[ESP/TCS/ABS]
●

●

When starting engine, or just after starting vehicle, brake pedal may vibrate or motor operating noises
may be heard from engine compartment. This is a normal status of operation check.
Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel,
or snow-covered (fresh, deep snow) roads.

EBD Function
●

●

●
●
●

●

BFS000AB

Electronic brake distributor is a function that detects subtle slippages between front and rear wheels during braking, and it improves handling stability by electronically controlling the brake fluid pressure which
results in reduced rear wheel slippage.
In case of electrical system break down, the fail-safe function is activated, EBD and ABS becomes inoperative, and ABS warning lamp and brake warning lamp are turned on.
Electrical system diagnosis by CONSULT-II is available.
During EBD operation, brake pedal lightly vibrates and a mechanical noise may be heard. This is normal.
When starting engine, or just after starting vehicle, brake pedal may vibrate or motor operating noises
may be heard from engine compartment. This is a normal status of operation check.
Stopping distance may be longer than that of vehicles without EBD when vehicle drives on rough, gravel,
or snow-covered (fresh, deep snow) roads.

Fail-Safe Function

BFS000AC

ESP / TCS SYSTEM
In case of malfunction in the ESP/TCS system, ESP OFF indicator lamp and SLIP indicator lamp are turned
on, and the condition of vehicle is the same as the condition of vehicles without ESP/TCS system. In case of
malfunction in the ESP/TCS system, the ABS control continues to operate normally without ESP/TCS control.
CAUTION:
If the fail-safe function is activated, then perform the self-diagnosis for ESP/TCS/ABS control system.

ABS, EBD SYSTEM
In case of electrical malfunctions with the ABS, ABS warning lamp, ESP OFF indicator lamp and SLIP indicator lamp will turn on. In case of electrical malfunctions with the EBD, brake warning lamp, ABS warning lamp,
ESP OFF indicator lamp and SLIP indicator lamp will turn on. Simultaneously, the ESP/TCS/ABS become one
of the following conditions of the fail-safe function.
1. For malfunction of ABS, only the EBD is activated and the condition of vehicle is the same condition of
vehicles without TCS/ABS system.
2. For malfunction of EBD, EBD and ABS become inoperative, and the condition of vehicle is the same as
the condition of vehicles without TCS/ABS, EBD system.
NOTE:
In condition 1 described above, an ABS self-diagnosis sound may be heard. That is a normal condition
because a self-diagnosis for “Key Switch ON” and “the First Starting” are being performed.

BRC-46

SYSTEM DESCRIPTION
[ESP/TCS/ABS]

Hydraulic Circuit Diagram

BFS000AD

A

B

C

D

E

BRC

G

H

MFIA0013E

I

J

K

L

M

BRC-47

CAN COMMUNICATION
[ESP/TCS/ABS]

CAN COMMUNICATION
System Description

PFP:23710
BFS000AE

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
Refer to LAN-27, «CAN Communication Unit» .

BRC-48

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

TROUBLE DIAGNOSIS
How to Proceed With Diagnosis

PFP:00004

A
BFS000AG

BASIC CONCEPT
●

Most important point to perform diagnosis is to understand systems (control and mechanism) in vehicle
thoroughly.

●

It is also important to clarify customer complaints before inspection.
First of all, reproduce symptom, and understand it fully.
Ask customer about his/her complaints carefully. In some cases,
it will be necessary to check symptom by driving vehicle with
customer.
NOTE:
Customers are not professionals. Do not assume “maybe customer means…” or “maybe customer mentioned this symptom”.

B

C

D

E

SEF234G

BRC
●

●

●

●

It is essential to check symptoms right from beginning in order to
repair a malfunction completely.
For an intermittent malfunction, it is important to reproduce
symptom based on interview with customer and past examples.
Do not perform inspection on ad hoc basis. Most intermittent
malfunctions are caused by poor contacts. In this case, it will be
effective to shake suspected harness or connector by hand.
When repairs are performed without any symptom check, no
one can judge if malfunction has actually been eliminated.
After diagnosis, make sure to carry out “erase memory”. Refer to
BRC-62, «ERASE MEMORY» .
SEF233G
For an intermittent malfunction, move harness or harness connector by hand to check poor contact or false open circuit.
Always read “GI General Information” to confirm general precautions. Refer to GI-4, «General Precautions» .

G

H

I

J

K

L

M

BRC-49

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]
DIAGNOSIS FLOWCHART

MFIB9004E

BRC-50

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]
ASKING COMPLAINTS
●

●

●

A

Complaints against malfunction vary depending on each person.
It is important to clarify customer complaints.
Ask customer about what symptoms are present and under
what conditions. Use information to reproduce symptom while
driving.
It is also important to use diagnosis sheet so as not to miss information.

B

C

SBR339B

D

EXAMPLE OF DIAGNOSIS SHEET
E

BRC

G

H

I

J

K

L

M

SFIA0791E

BRC-51

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

Component Installation Location

BFS000AH

MFIB9037E

BRC-52

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

Schematic

BFS000AI

A

B

C

D

E

BRC

G

H

I

J

K

L

M

MFWA0164E

BRC-53

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

Wiring Diagram — ESP —

BFS000AJ

MFWA0165E

BRC-54

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]
A

B

C

D

E

BRC

G

H

I

J

K

L

M

MFWA0166E

BRC-55

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

MFWA0167E

BRC-56

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]
A

B

C

D

E

BRC

G

H

I

J

K

L

M

MFWA0168E

BRC-57

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

MFWA0170E

BRC-58

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]
A

B

C

D

E

BRC

G

H

I

J

K

L

M

MFWA0171E

BRC-59

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

MFWA0172E

BRC-60

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]
A

B

C

D

E

BRC

G

H

I

J

K

L

M

MFWA0173E

BRC-61

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

CONSULT-II Functions (ABS)

BFS000FC

CONSULT-II MAIN FUNCTION
In a diagnosis function (main function), there are “WORK SUPPORT”, “SELF-DIAG RESULTS”, “DATA MONITOR”, “CAN DIAG SUPPORT MNTR”, “ACTIVE TEST”, “FUNCTION TEST”, “ECU PART NUMBER”.
Diagnostic test mode

Function

Reference

WORK SUPPORT

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

BRC-42, «Adjustment of
Steering Angle Sensor Neutral Position»

SELF-DIAG RESULTS

Self-diagnostic results can be read and erased quickly.

BRC-62, «Self-Diagnosis»

DATA MONITOR

Input/Output data in the ABS actuator and electric unit (control unit)
can be read.

BRC-64, «Data Monitor»

CAN DIAG SUPPORT MNTR

The results of transmit/receive diagnosis of communication can be
read.

LAN-15, «CAN Diagnostic
Support Monitor»

ACTIVE TEST

Diagnostic Test Mode in which CONSULT-II drives some actuators
apart from the ABS actuator and electric unit (control unit) and also
shifts some parameters in a specified range.

BRC-66, «Active Test»

FUNCTION TEST

Performed by CONSULT-II instead of a technician to determine
whether each system is “OK” or “NG”.

Separate volume ″CONSULTII OPERATION MANUAL
(FUNCTION TEST)″

ECU PART NUMBER

ABS actuator and electric unit (control unit) part number can be read.

—

CONSULT-II BASIC OPERATION PROCEDURE
Refer to GI-36, «CONSULT-II Start Procedure» .

Self-Diagnosis

BFS000FD

OPERATION PROCEDURE
1.
2.

3.
4.
5.

6.

7.
8.

Turn ignition switch OFF.
Connect CONSULT-II and CONSULT-II CONVERTER to data link connector.
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which performs CAN communication.
Turn ignition switch ON.
Start engine and drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute.
After stopping vehicle, with the engine running, touch “START (NISSAN BASED VHCL)”, “ABS”, “SELFDIAG RESULTS” in order on the CONSULT-II screen.
CAUTION:
If “START (NISSAN BASED VHCL)” is touched immediately after starting engine or turning on the
ignition switch, “ABS” might not be displayed in the “SELECT SYSTEM” screen. In this case,
repeat the operation from step 1.
The self-diagnostic results are displayed. (Touch “PRINT” to print out self-diagnostic results, if necessary.)
● Check ABS warning lamp, ESP OFF indicator lamp and SLIP indicator lamp if “NO FAILURE” is displayed. Refer to DI-10, «Combination Meter Self-Diagnosis» .
Perform the appropriate inspection from display item list, and repair or replace the malfunctioning component. Refer to BRC-63, «DISPLAY ITEM LIST» .
Start engine and drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute.
CAUTION:
When the wheel sensor malfunctions, after inspecting the wheel sensor system, the ABS warning
lamp, ESP OFF indicator lamp, SLIP indicator lamp and brake warning lamp will not turn off even
when the system is normal unless the vehicle is driving at approximately 30 km/h (19 MPH) or
more for approximately 1 minute.

ERASE MEMORY
1.
2.

Turn ignition switch OFF.
Start engine and touch “START (NISSAN BASED VHCL)”, “ABS”, “SELF-DIAG RESULTS”, “ERASE
MEMORY” in order on the CONSULT-II screen to erase the diagnostic memory.
If “ABS” is not indicated, go to GI-38, «CONSULT-II Data Link Connector (DLC) Circuit» .

BRC-62

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]
CAUTION:
If the diagnostic memory is not erased, re-perform the operation from step 4.
3. Perform self-diagnosis again, and make sure that diagnostic memory is erased.
4. Drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute as the final inspection, and make
sure that the ABS warning lamp, ESP OFF indicator lamp, SLIP indicator lamp and brake warning lamp
turn off.
NOTE:
●
Brake warning lamp will turn on in case of parking brake operation (when switch is ON) or of brake fluid
level switch operation (when brake fluid is insufficient).
●
ESP OFF switch should not stay “ON” position.

Self-diagnostic item

Malfunction detecting condition

C100F

FR RH SENSOR

Circuit of front RH wheel sensor is open, shorted or
sensor power voltage is unusual.

C101F

FR LH SENSOR

Circuit of front LH wheel sensor is open, shorted or
sensor power voltage is unusual.

C102F

RR RH SENSOR

Circuit of rear RH wheel sensor is open, shorted or
sensor power voltage is unusual.

C103F

RR LH SENSOR

Circuit of rear LH wheel sensor is open, shorted or
sensor power voltage is unusual.

C1041

FR RH SENSOR ROTOR

ABS actuator and electric unit (control unit) cannot
identify sensor pulses, because of large gap between
wheel sensor and sensor rotor.

C1042

C1043

C1044

B

C

D

DISPLAY ITEM LIST
Code

A

FR LH SENSOR ROTOR

ABS actuator and electric unit (control unit) cannot
identify sensor pulses, because of large gap between
wheel sensor and sensor rotor.

RR RH SENSOR ROTOR

ABS actuator and electric unit (control unit) cannot
identify sensor pulses, because of large gap between
wheel sensor and sensor rotor.

RR LH SENSOR ROTOR

ABS actuator and electric unit (control unit) cannot
identify sensor pulses, because of large gap between
wheel sensor and sensor rotor.

Check system

E

BRC

G

BRC-70, «Inspection 1: Wheel Sensor System»

H

I

J

K

C10C6

STOP LAMP SW CIRC

Stop lamp switch is fixed at “ON” position.

BRC-79, «Inspection 7: Stop Lamp
Switch System»

STOP LAMP OR CONT

Stop lamp switch circuit is open or shorted, or controller failure.

BRC-79, «Inspection 7: Stop Lamp
Switch System»

L

C10C6

BRC-73, «Inspection 4: Steering
Angle Sensor System»

M

ST ANG SEN

Neutral position of steering angle sensor is dislocated, or steering angle sensor is malfunctioning initialize of steering angle sensor is not completed.

YAW RATE/G-SEN

Yaw rate/G-sensor has generated an error, or yaw
rate/G-sensor signal line is open or shorted.

BRC-75, «Inspection 5: Yaw Rate/
Side G-Sensor
System»

ABS SENSOR

Wheel sensor input is malfunction or wheel sensor
power voltage is too low.

BRC-70, «Inspection 1: Wheel Sensor System» (Note
1)

Supply voltage for ABS actuator and electric unit
(control unit) is too low or too high, or abnormal.

BRC-77, «Inspection 6: ABS Actuator and Electric
Unit (Control Unit)
Power Supply and
Ground System»

C1158

C10F4

C1046

C10CC

BATTERY VOLTAGE

BRC-63

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]
Code

C10C3

U1000

C1180

C1155

Self-diagnostic item

Malfunction detecting condition
Internal malfunction of ABS actuator and electric unit
(control unit)

CONTROLLER FAILURE

●

CAN communication line is open or shorted.

●

ABS actuator and electric unit (control unit) internal
malfunction

●

Battery voltage for ECM is suddenly interrupted for
approximately 0.5 seconds or more.

CAN COMM CIRCUIT

●

CAN communication line is open or shorted.

ECM

●

CAN communication signal form ECM cannot be
received.

BR FLUID LEVEL LOW

Brake fluid level drops or circuit between ABS actuator and electric unit (control unit) and brake fluid level
switch is open or shorted.

Check system
BRC-73, «Inspection 3: ESP/TCS/
ABS Control Unit
System»
BRC-81, «Inspection 9: CAN Communication
System» (Note 1)
BRC-73, «Inspection 2: Engine System»
BRC-81, «Inspection 8: Brake Fluid
Level Switch System»

Note 1: If multiple malfunctions are detected including CAN communication line [U1000], perform diagnosis for
CAN communication line first.

Data Monitor

BFS000FE

OPERATION PROCEDURE
1.

2.
3.

Touch “START (NISSAN BASED VHCL)”, “ABS”, “DATA MONITOR” in order on CONSULT-II screen.
CAUTION:
When “START (NISSAN BASED VHCL)” is touched immediately after starting engine or turning on
the ignition switch, “ABS” might not be displayed in the system selection screen. In this case,
repeat the operation from step 1.
At the monitor item selection screen, touch one of the items “ECU INPUT SIGNALS”, “MAIN SIGNALS” or
“SELECTION FROM MENU”.
Touch “START” to proceed to the data monitor screen.

DISPLAY ITEM LIST
CAUTION:
The display shows the control unit calculation data, so a normal value might be displayed even in the
event the output circuit (harness) is open or short — circuited.
E: ECU INPUT SIGNALS M: MAIN SIGNALS S: SELECTION FROM MENU
SELECT
MONITOR
ITEM

E, M, S

S

Data monitor
Monitor item

Display content

FR RH SENSOR
FR LH SENSOR
RR RH SENSOR
RR LH SENSOR

Wheel speed

ACCEL POS SIG

Open/close condition of
throttle valve (linked with
accelerator pedal).

S

ENGINE SPEED

With engine running

S

STR ANGLE SIG

Steering angle detected by
steering angle sensor

Condition

Reference value in
normal operation

Vehicle stopped

0 [km/h (MPH)]

Vehicle running (Note 1)

Almost in accordance with speedometer display
(within ±10 %)

Accelerator pedal is not depressed
(ignition switch is ON)

0%

Accelerator pedal is depressed (ignition
switch is ON)

0 to 100 %

With engine stopped

0 rpm

Engine running

Almost in accordance with tachometer display

Straight-ahead

Approx. 0 deg

Steering wheel turned

L500 to R500 deg

BRC-64

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]
SELECT
MONITOR
ITEM
S

S

S

Data monitor
Monitor item

Display content
Condition

YAW RATE SEN

SIDE G-SENSOR

PRESS SENSOR

Yaw rate detected by yaw
rate sensor

Vehicle stopped

Approx. 0 d/s

Vehicle running

–200 to 200 d/s

Transverse G detected by
side G-sensor

Vehicle stopped

Approx. 0 G

Vehicle running

–1.8 to 1.8 G

With ignition switch turned ON and
brake pedal released

Approx. 0 bar

With ignition switch turned ON and
brake pedal depressed

30 to 70 bar

Ignition switch ON

10 to 16 V

Brake pedal is depressed

ON

Brake pedal is not depressed

OFF

ESP OFF switch ON
(When ESP OFF indicator lamp is ON)

ON

ESP OFF switch OFF
(When ESP OFF indicator lamp is OFF)

OFF

ABS warning lamp ON

ON

ABS warning lamp OFF

OFF

Ignition switch ON or engine running
(ABS not operated)

OFF

Ignition switch ON or engine running
(ABS operated)

ON

Actuator (solenoid) is active

ON

When actuator relay is inactive
(in fail-safe mode)

OFF

Brake fluid pressure
detected by pressure sensor

E, M, S

BATTERY VOLT

Battery voltage supplied to
ABS actuator and electric
unit (control unit)

S

STOP LAMP SW

Brake pedal operation

OFF SW

ESP OFF switch
ON/OFF status

S

M, S

M, S

M, S

S

S

M, S

S

S

S

ABS WARN LAMP

MOTOR RELAY

Reference value in
normal operation

ABS warning lamp ON condition (Note 2)

Operation status of motor
and motor relay

Actuator relay operation status

OFF LAMP

ESP OFF indicator lamp
status (Note 3)

When ESP OFF indicator lamp is ON

ON

When ESP OFF indicator lamp is OFF

OFF

SLIP indicator lamp status
(Note 4)

When SLIP indicator lamp is ON

ON

When SLIP indicator lamp is OFF

OFF

Actuator (solenoid) is active (“ACTIVE
TEST” with CONSULT-II) and actuator
relay is active (ignition switch ON)

ON

When actuator (solenoid) is not active
or actuator relay is inactive (in fail-safe
mode)

OFF

When actuator (switch-over valve) is
active (“ACTIVE TEST” with CONSULTII) and actuator relay is active (ignition
switch ON)

ON

When actuator (switch-over valve) is not
active or actuator relay is inactive (in
fail-safe mode)

OFF

FR LH IN SOL
FR LH OUT SOL
FR RH IN SOL
FR RH OUT SOL
RR RH IN SOL
RR RH OUT SOL
RR LH IN SOL
RR LH OUT SOL

D

E

BRC

G

H

K

L

M

Solenoid valve operation

ESP/TCS switch-over valve
status

FLUID LEV SW

ON/OFF status of brake fluid
level switch

When brake fluid level switch ON

ON

When brake fluid level switch OFF

OFF

Brake warning lamp on condition (Note 5)

Brake warning lamp ON

ON

Brake warning lamp OFF

OFF

BRC-65

C

J

HSV [FL-RR]
HSV [FR-RL]
USV [FL-RR]
USV [FR-RL]

EBD WARN LAMP

B

I

ACTUATOR RLY

SLIP LAMP

A

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]
Data monitor

SELECT
MONITOR
ITEM
S

S

Monitor item

Display content
Condition

PARK BRAKE SW

CRANKING SIG

Condition of parking brake

CRANKING status

Reference value in
normal operation

When parking brake is applied

ON

When parking brake is released

OFF

Cranking

ON

Not cranking

OFF

Note 1: Confirm tire pressure is normal.
Note 2: ON/OFF timing of ABS warning lamp
ON: Approx. Within 1.5 seconds after ignition switch is turned ON, or when a malfunction is detected.
OFF: Approx. 1.5 seconds after ignition switch is turned ON (when system is in normal operation) and ESP/TCS function is not activated.
Note 3: ON/OFF timing of ESP OFF indicator lamp
ON: Approx. Within 1.5 seconds after ignition switch is turned ON, or when a malfunction is detected and ESP OFF switch is ON.
OFF: Approx 1.5 seconds after ignition switch is turned ON (when system is in normal operation.) And when ESP OFF switch is OFF.
Note 4: SLIP indicator lamp ON/OFF timing
ON: Approx. Within 1.5 seconds after ignition switch is turned ON, or when a malfunction is detected and ESP/TCS function is activated while driving.
OFF: Approx. 1.5 seconds after ignition switch is turned ON (when system is in normal operation) and ESP/TCS function is not activated.
Blinking: ESP/TCS function is active during driving
Note 5: Serves as EBD warning lamp.

Active Test

BFS000FF

CAUTION:
●
Do not perform active test while driving.
●
Make sure to completely bleed air from the brake system.
●
Active test cannot be performed when EBD, ABS, TCS or ESP operation is malfunction.
●
ABS and brake warning lamps turn on during the active test.

OPERATION PROCEDURE
1.

2.
3.
4.
5.
6.

Connect CONSULT-II and CONVERTER to data link connector and start engine.
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carry out CAN communication.
Touch “START (NISSAN BASED VHCL) ” on the display screen.
Touch “ABS”.
If “ABS” is not indicated, go to GI-38, «CONSULT-II Data Link Connector (DLC) Circuit» .
Touch “ACTIVE TEST”.
The test item selection screen is displayed.
Touch necessary test item.

PFIA0301E

7.
8.

With the “MAIN SIGNALS” display shown in reverse, touch “START”.
The “ACTIVE TEST” screen will be displayed, so perform the following test.

BRC-66

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]
SOLENOID VALVE OPERATION CHART
ABS solenoid valve

A

ABS solenoid valve (ACT)

Operation
UP

KEEP

DOWN

UP

ACTUATOR
UP

ACTUATOR
KEEP

FR RH SOL

OFF

ON

ON

OFF

OFF

OFF

FR LH SOL

OFF

ON

ON

OFF

OFF

OFF

RR RH SOL

OFF

ON

ON

OFF

OFF

OFF

RR LH SOL

OFF

ON

ON

OFF

OFF

OFF

FR RH ABS SOLENOID (ACT)

OFF

OFF

OFF

OFF

ON*

OFF

FR LH ABS SOLENOID (ACT)

OFF

OFF

OFF

OFF

ON

ON

RR RH ABS SOLENOID (ACT)

OFF

OFF

OFF

OFF

ON*

OFF

RR RL ABS SOLENOID (ACT)

OFF

OFF

OFF

OFF

ON

ON

B

C

D

E

*: ON for 1 to 2 seconds after the touch, and then OFF

NOTE:
●
If active test is performed with brake pedal depressed, pedal stroke may change. This is normal.
●
“TEST IS STOPPED” is displayed approximately 10 seconds after operation starts.
●
After “TEST IS STOPPED” is displayed, touch “BACK” and conduct the test from the Step 8.

BRC

G

ABS MONITOR
Touch “ON” and “OFF” on the screen. Make sure ABS motor relay
operates as shown in table below.
Operation

ON

OFF

MOTOR RELAY

ON

OFF

ACTUATOR RELAY

ON

ON

NOTE:
●
If active test is performed with brake pedal depressed, pedal
stroke may change. This is normal.
●
“TEST IS STOPPED” is displayed approximately 10 seconds
after operation starts.

H

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SFIA0593E

K

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BRC-67

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

For Fast and Accurate Diagnosis

BFS000FG

PRECAUTIONS FOR DIAGNOSIS
●

●

●
●

●

●
●

●

●

Before performing diagnosis, always read precautions. Refer to BRC-49, «How to Proceed With Diagnosis» .
If ABS actuator and electric unit (control unit), steering angle sensor, steering system parts or suspension
system parts have been replaced, or if alignment has been adjusted, be sure to adjust neutral position of
steering angle sensor before driving. Refer to BRC-42, «Adjustment of Steering Angle Sensor Neutral
Position» .
After diagnosis is finished, be sure to erase memory. Refer to BRC-62, «ERASE MEMORY» .
When checking continuity and voltage between units, be sure to check for disconnection, looseness,
bend, or collapse of connector terminals. If any malfunction is found, repair or replace connector terminals.
For intermittent symptoms, possible cause is malfunction in harness, harness connector, or terminals.
Move harness, harness connector, and terminals to check for poor connections.
If a circuit tester is used for the check, be careful not to forcibly extend any connector terminal.
To use CONSULT-II to perform self-diagnosis of ABS actuator and electric unit (control unit), active tests,
or work support, first stop work, then connect CONSULT-II and select “ABS”.
While self-diagnostic results of CONSULT-II shows malfunction, if CONSULT-II active test is performed,
an engine system error may be indicated. In this case, start engine to resume the normal screen.
ESP/TCS/ABS system electronically controls brake operation and engine output. The following symptoms
may be caused by normal operations:
Symptom

Symptom description

Result

This is noise of motor inside ABS actuator and electric unit (control unit).
Slight noise may occur during ESP, TCS, and ABS operation.
Motor operation noise

When the vehicle speed goes over 10 km/h (6 MPH), motor and valves
operating noise may be heard. It happens only once after IGN (ignition)
is ON. This is a normal status of the system operation check.

System operation check
noise

When engine starts, slight “click” noise may be heard from engine room.
This is normal and is part of system operation check.

Normal

Normal

TCS may activate momentarily if wheel speed changes when driving
over location where friction coefficient varies, when up/downshifting, or
when fully depressing accelerator pedal.

ESP/TCS operation
(SLIP indicator lamp blinking)

For inspection of speedometer or other instruments, press
ESP OFF SW to turn ESP/TCS function off.
When accelerator pedal is depressed on a chassis dynamometer, vehicle speed will not increase. This is not normal. It is result of TCS being
activated by stationary front wheels. Warning lamp may also illuminate
to indicate “sensor system error”. This is also normal, and is the result of
the stationary front wheels being detected. To be certain, restart engine,
and drive vehicle at 30 km/h (19 MPH) or above. Make sure warning
lamp does not illuminate.

Normal
Cancel the ESP/TCS
function for the
inspection on a chassis dynamometer.

ABS operation (Longer stopping distance)

On roads with low friction coefficients, such as snowy roads or gravel
roads, vehicles with ABS may require a longer stopping distance. Therefore, when driving on such roads, avoid overconfidence and keep speed
sufficiently low.

Normal

Insufficient feeling of acceleration

Depending on road conditions, driver may feel that feeling of acceleration is insufficient. This is because traction control, which controls
engine and brakes to achieve optimal traction, has the highest priority
(for safety). As a result, there may be times when acceleration is slightly
less than usual for the same accelerator pedal operation.

Normal

BRC-68

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]
ON and OFF Timing for ABS Warning Lamp, ESP OFF Indicator Lamp, SLIP Indicator Lamp,
Brake Warning Lamp
×: ON

ABS warning lamp

ESP OFF indicator
lamp

SLIP indicator lamp

Remarks

Ignition SW OFF.

–

–

–

—

Approx. 1.5 seconds after
ignition switch is turned ON.

×

×

×

—

Condition

B

C

Approx. 1.5 seconds later
after ignition switch ON.

–

–

–

Go out 1.5 seconds after ignition switch is turned ON.

ESP OFF SW is turned ON.
(ESP/TCS function is OFF.)

–

×

–

—

D

E

BRC

ESP/TCS/ABS error.

×

×

×

There is an ABS actuator and
electric unit (control unit) error.
(Power, ground or system
malfunction)

When ESP/TCS is not functioning normally.

–

×

×

—

NOTE:
1. Brake warning lamp will turn on in case of operating parking brake (switch turned on) or of actuating brake
fluid level switch (brake fluid is insufficient).

Basic Inspection

3.

G

BFS000FH

BASIC INSPECTION 1: BRAKE FLUID AMOUNT, LEAKS, AND BRAKE PADS INSPECTION
1.
2.

A

–: OFF

Check fluid level in the brake reservoir tank. If fluid level is low, refill brake fluid.
Check brake piping and around ABS actuator and electric unit (control unit) for leaks. If there is leaking or
oozing fluid, check the following items.
● If ABS actuator and electric unit (control unit) connection is loose, tighten piping to the specified torque
and re-perform the leak inspection to make sure there are no leaks.
● If there is damage to the connection flare nut or ABS actuator and electric unit (control unit) screw,
replace the damaged part and re-perform the leak inspection to make sure there are no leaks.
● When there is fluid leaking or oozing from a part other than ABS actuator and electric unit (control unit)
connection, if fluid is just oozing out, use a clean cloth to wipe off the oozing fluid and re-check for
leaks. If fluid is still oozing out, replace the damaged part.
● When there is fluid leaking or oozing at ABS actuator and electric unit (control unit), if fluid is just oozing
out, use a clean cloth to wipe off oozing fluid and re-check for leaks. If fluid is still oozing out, replace
ABS actuator and electric unit (control unit) body.
CAUTION:
ABS actuator and electric unit (control unit) body cannot be disassembled.
Check brake pad degree of wear. Refer to BR-21, «PAD WEAR INSPECTION» and BR-28, «INSPECTION AFTER REMOVAL» .

BASIC INSPECTION 2: POWER SYSTEM TERMINAL LOOSENESS AND BATTERY INSPECTION
Make sure battery positive cable, negative cable and ground connection are not loose. If looseness is
detected, tighten the cables. In addition, check the battery voltage to make sure it has not dropped and alternator is normal.

BRC-69

H

I

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K

L

M

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]
BASIC INSPECTION 3: ABS WARNING LAMP, ESP OFF INDICATOR LAMP AND SLIP INDICATOR LAMP INSPECTION
1.

2.
3.

4.

5.

Make sure ABS warning lamp and ESP OFF indicator lamp (when ESP OFF switch is OFF) turn ON
approximately 1.5 second when ignition switch is turned ON. Make sure SLIP indicator lamp (when ESP
OFF switch is OFF) turns ON approximately 3 seconds when ignition switch is turned ON. If they do not,
check ESP OFF indicator lamp and then ESP OFF switch. Refer to BRC-82, «ESP OFF SWITCH» . Check
CAN communications. Refer to “CAN Communication Inspection”. If there are no errors with ESP OFF
switch and CAN communication system, check combination meter. Refer to DI-10, «Combination Meter
Self-Diagnosis» .
Make sure ABS warning lamp, ESP OFF indicator lamp, SLIP indicator lamp turn off approximately 1.5
second after turn ignition switch ON. If lamps do not turn off, perform self-diagnosis.
With engine running, make sure ESP OFF indicator lamp turns on and off when ESP OFF switch is turned
ON and OFF. If indicator lamp status does not correspond to switch operation, check the ESP OFF switch
system. Refer to BRC-82, «ESP OFF SWITCH» .
Make sure ABS warning lamp, ESP OFF indicator lamp, and SLIP indicator lamp turn off 1.5 seconds
after engine is started. If ABS warning lamp, ESP OFF indicator lamp, and SLIP indicator lamp have not
turned off 10 seconds after engine has been started, perform self-diagnosis of ABS actuator and electric
unit (control unit).
After performing the self-diagnosis, be sure to erase the error memory. Refer to BRC-62, «ERASE MEMORY» .

Inspection 1: Wheel Sensor System

BFS000FI

DTC C100F-C103F, C1041-C1043, C1046
After using the CONSULT-II SELF-DIAG RESULTS to determine the location of the malfunctioning wheel sensor, check all areas to determine the component to be replaced.
CAUTION:
●
Do not measure the resistance value and also voltage between sensor terminal with tester etc.,
because sensor is an active sensor.
●
Do not expand terminal of connector with a tester terminal stick, when it does the inspection with
tester.

INSPECTION PROCEDURE

1. CHECK TIRE
Check air pressure, wear and size.
Are air pressure, wear, and size within the standard values?
YES >> GO TO 2.
NO
>> Adjust air pressure, or replace tire.

2. CHECK SENSOR AND SENSOR ROTOR
Check the condition of the sensor mount (for looseness, etc.).
●
Check the surface of front sensor rotor rubber for damage.
●
Check rear sensor rotor for damage.
OK or NG
OK
>> GO TO 3.
NG
>> Repair sensor mount or replace sensor rotor.
●

BRC-70

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

3. CHECK SELF-DIAGNOSTIC RESULTS

A

Check the self-diagnostic results.
Self-diagnosis results

B

FR RH SENSOR
FR LH SENSOR

C

RR RH SENSOR
RR LH SENSOR
FR RH SENSOR ROTOR

D

FR LH SENSOR ROTOR
RR RH SENSOR ROTOR

E

RR LH SENSOR ROTOR

Is the above displayed in the self-diagnosis display items?
YES >> GO TO 4.
NO
>> INSPECTION END.

BRC

4. CHECK CONNECTOR
1.

Disconnect ABS actuator and electric unit (control unit) connector E33 and malfunctioning wheel sensor
connector E42 (FR-LH), E29 (FR-RH), B35 (RR-LH) or B34 (RR-RH). Check terminal for deformation,
open circuit, poor contact, etc., and repair or replace if any malfunctioning condition is found.
2. Reconnect connectors, drive at a speed of approximately 30 km/h (19 MPH) for approximately 1minute,
and perform self-diagnosis.
OK or NG
OK
>> Connector terminal contact is loose, damaged, open or shorted.
NG
>> GO TO 5.

G

H

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BRC-71

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

5. CHECK WHEEL SENSOR HARNESS
1.

2.

Turn ignition switch OFF and disconnect malfunctioning wheel
sensor connector E42 (FR-LH), E29 (FR-RH), B35 (RR-RH) or
B34 (RR-LH) and ABS actuator and electric unit (control unit)
connector E33.
Check continuity between ABS actuator and electric unit (control
unit) and Wheel sensor (Power supply system).
A

B

ABS actuator and electric
unit (control unit)

Wheel sensor

Front LH

5

1

Front RH

10

1

Rear LH

17

1

Rear RH

19

1

Connector

3.

4.

Continuity

MFIB9039E

Yes

Check continuity between ABS actuator and electric unit (control unit) and wheel sensor (Signal system).
A

B

Connector

ABS actuator and electric
unit (control unit)

Wheel sensor

Front LH

16

2

Front RH

9

2

Rear LH

6

2

Rear RH

8

2

Continuity

Yes

Check continuity between ABS actuator and electric unit (control unit) terminal (Ground).
A
Connector

ABS actuator and electric unit (control unit)

Front LH

5, 16

Continuity

4

Front RH

9, 10

4

Rear LH

6, 17

4

Rear RH

8, 19

4

No

OK or NG
OK
>> GO TO 6.
NG
>> Repair harness and connector between ABS actuator and electric unit (control unit) and wheel
sensor.

6. CHECK WHEEL SENSOR POWER SUPPLY CIRCUIT
1.
2.
3.

Connect ABS actuator and electric unit (control unit) connector.
Turn ignition switch ON.
Check voltage between wheel sensor power supply terminal 1
and ground.
Wheel sensor
E42 (FL), E29 (FR),
B35 (RL), B34 (RR)

Terminal

Voltage
Ground

1

8V or more

OK or NG
OK
>> Replace wheel sensor.
NG
>> Replace ABS actuator and electric unit (control unit).

BRC-72

MFIB9040E

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

Inspection 2: Engine System

BFS000FJ

A

DTC C1180

INSPECTION PROCEDURE

1. CHECK SELF-DIAGNOSTIC RESULTS

B

Check the self-diagnostic results.
C

Self-diagnostic results
ECM

Is the above displayed in the self-diagnosis display items?
YES >> GO TO 2.
NO
>> INSPECTION END

D

2. CHECK ENGINE SYSTEM

E

Perform an ECM self-diagnosis refer to EC-74, «TROUBLE DIAGNOSIS» (CR engine models with
EURO-OBD), EC-491, «TROUBLE DIAGNOSIS» (CR engine models without EURO-OBD), EC-863, BRC
«TROUBLE DIAGNOSIS» (HR engine models with EURO-OBD), EC-1284, «TROUBLE DIAGNOSIS»
(HR engine models without EURO-OBD), EC-1630, «TROUBLE DIAGNOSIS» and repair or replace malfunctioning items. Re-perform ECM self-diagnosis.
G
2. Re-perform ABS actuator and electric unit (control unit) self-diagnosis.
OK or NG
OK
>> INSPECTION END
H
NG
>> Repair or replace malfunctioning items. Re-perform the self-diagnosis.

1.

Inspection 3: ESP/TCS/ABS Control Unit System

BFS000FK

I

DTC C10C3

INSPECTION PROCEDURE

1. CHECK SELF-DIAGNOSTIC RESULTS

J

Check the self-diagnostic results.
K

Self-diagnostic results
CONTROLLER FAILURE

Is the above displayed in the self-diagnosis display items?
YES >> Replace ABS actuator and electric unit (control unit). Re-perform the self-diagnosis.
NO
>> INSPECTION END

Inspection 4: Steering Angle Sensor System
DTC C1158

INSPECTION PROCEDURE

1. CHECK SELF- DIAGNOSTIC RESULTS
Check self-diagnostic results.
Self-diagnostic results
ST ANGLE SEN CIRCUIT

Is above displayed in self-diagnosis item?
YES >> GO TO 2.
NO
>> INSPECTION END

BRC-73

L

BFS000FL

M

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

2. CHECK CONNECTOR
1.

Turn ignition switch OFF and disconnect steering angle sensor connector M40 and ABS actuator and
electric unit (control unit) connector E33 and check terminals for deformation, disconnection, looseness,
and so on. If there is an error, repair or replace terminal.
2. Connect the connector securely and perform self-diagnosis again.
OK or NG
OK
>> Connector terminal contact is loose, damaged, open or shorted.
NG
>> GO TO 3.

3. CHECK STEERING ANGLE SENSOR HARNESS
1.
2.
3.

Check CAN communication system. Refer to BRC-81, «Inspection 9: CAN Communication System» .
Turn ignition switch ON, OFF and disconnect steering angle sensor connector M40.
Check voltage between steering angle sensor harness connector M40 and ground.

Steering angle
sensor

Terminal

Ground

M40

2

—

Condition

Voltage

Ignition switch ON

Approx. 12V

Ignition switch OFF

Approx. 0V

MFIB9049E

4.

Turn ignition switch OFF. Check continuity between steering
angle sensor harness connector M40 and ground.

Steering angle sensor

Terminal

Ground

Continuity

M40

1

—

Yes

OK or NG
OK
>> GO TO 4.
NG
>> If the open or short in harness, repair or replace harness.
MFIB9050E

4. CHECK DATA MONITOR
1.
2.

Connect steering angle sensor and ABS actuator and electric unit (control unit) connectors.
Perform “DATA MONITOR” of the “STEERING ANGLE SIGNAL” to check if the status is normal.
Steering condition

Data monitor

Straight-ahead

–5° to +5°

Turn wheel to the right by 90°

Approx. — 90°

Turn wheel to the left by 90°

Approx.+ 90°

OK or NG
OK
>> Perform ABS actuator and electric unit (control unit) self-diagnosis again.
NG
>> Replace spiral cable (steering angle sensor) and adjust neutral position of steering angle sensor.
Refer to BRC-42, «Adjustment of Steering Angle Sensor Neutral Position» .

BRC-74

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

Inspection 5: Yaw Rate/Side G-Sensor System

BFS000FM

DTC C10F4
CAUTION:
Sudden turns (such as spin turns, acceleration turns), drifting, etc. May cause the G-sensor system
indicate a malfunction. However, this is not a malfunction, if normal operation can be resumed after
restarting engine.

INSPECTION PROCEDURE

A

B

C

1. CHECK SELF-DIAGNOSTIC RESULTS
Check the self-diagnostic results.

D

Self-diagnostic results
YAW RATE/G-SEN

E
CAUTION:
When on a turntable, such as at a parking structure entrance, or when on a moving object with engine
running, ESP OFF indicator lamp might turn on and self-diagnosis using CONSULT-II the yaw rate/side
G-sensor system might be displayed, but in this case there is no malfunction in yaw rate/side G-sen- BRC
sor system. As soon as vehicle leaves turntable or moving object, restart engine to return the system
to normal.
G
Is the above displayed in the self-diagnosis display items?
YES >> GO TO 2.
NO
>> INSPECTION END
H
CHECK CONNECTOR

2.
1.

Disconnect yaw rate/side G-sensor connector B7 and ABS actuator and electric unit (control unit) connector E33 and check terminals for deformation, disconnection, looseness, and so on. If any malfunction is
found, repair or replace terminal.
2. Reconnect connectors and re-perform a ABS actuator and electric unit (control unit) self-diagnosis.
OK or NG
OK
>> Connector terminal contact is loose, damaged, open or shorted.
NG
>> GO TO 3.

3. CHECK YAW RATE/SIDE G-SENSOR POWER SUPPLY
1.
2.
3.

Turn ignition switch OFF and disconnect yaw rate/side G-sensor
harness connector B7.
Turn ignition switch ON.
Check voltage between yaw rate/side G-sensor harness connector B7 and ground.

Yaw rate/side G sensor

Terminal

Ground

Voltage

B7

3

—

Approx. 12V

OK or NG
OK
>> GO TO 4.
NG
>> Repair or replace power supply circuit.

BRC-75

I

J

K

L

M

MFIB9045E

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

4. CHECK YAW RATE/SIDE G-SENSOR HARNESS
1.
2.

Turn ignition switch OFF and disconnect ABS actuator and electric unit (control unit) connector E33.
Check continuity between ABS actuator and electric unit (control
unit) harness connector E33 and yaw rate/side G-sensor harness connector B7.
A
ABS actuator and
electric unit
(control unit)

B
Terminal

Yaw rate/side G
sensor

12

5

13
E33

14

Continuity
Terminal
MFIB9046E

6
B7

4

24

1

25

2

Yes

3.

Check continuity between ABS actuator and electric unit (control unit) harness connector E33 terminals
12, 13, 14, 24 and 25 and ground. Continuity should not exist.
OK or NG
OK
>> GO TO 5.
NG
>> If the open or short in harness, repair or replace harness.

5. CHECK YAW RATE/SIDE G-SENSOR
1.
2.

Connect yaw rate/side G-sensor connector B7 and ABS actuator and electric unit (control unit) connector
E33.
Use CONSULT-II “DATA MONITOR” to check if yaw rate/side G-sensor are normal.
Vehicle status
When stopped
Right turn
Left turn

Yaw rate sensor
(Data monitor standard)
–4 to +4 d/s
Negative value
Positive value

Side G-sensor
(Data monitor standard)
–0.2 to +0.2 G
Negative value
Positive value

OK or NG
OK
>> Re-perform ABS actuator and electric unit (control unit) self-diagnosis.
NG
>> Replace malfunctioning yaw rate/side G-sensor, and then re-perform self-diagnosis for ABS actuator and electric unit (control unit).

BRC-76

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

Inspection 6: ABS Actuator and Electric Unit (Control Unit) Power Supply and
Ground System

BFS000FN

A

DTC C10CC

Inspection Procedure

B

1. CHECK SELF-DIAGNOSTIC RESULTS
Check the self-diagnostic results.

C

Self-diagnostic results
BATTERY VOLTAGE

D

Does “BATTERY VOLTAGE” appear in self-diagnostic results display?
YES >> GO TO 2.
NO
>> INSPECTION END

E

2. STARTING INSPECTION
1. Disconnect ABS actuator and electric unit (control unit) connector E32. Then reconnect it securely.
2. Perform self-diagnosis.
Do any self-diagnosis item appear?
YES >> GO TO 3.
NO
>> Poor connection. Repair or replace connector.

BRC

G

3. CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) POWER SUPPLY (1)

H

1.
2.

I

Disconnect ABS actuator and electric unit (control unit) connector E32.
Turn ignition switch ON (not turn on engine). Check voltage
between ABS actuator and electric unit (control unit) harness
E33 and ground.

ABS actuator and electric unit
(control unit)

Terminal

Ground

Voltage

E33

18

—

Approx. 12V

J

K

MFIB9041E

3.

Turn ignition switch OFF. Check voltage between ABS actuator
and electric unit (control unit) harness E33 and ground.

ABS actuator and electric unit
(control unit)

Terminal

Ground

Voltage

E33

2, 3

—

Approx. 12V

M

OK or NG
OK
>> GO TO 4.
NG
>> GO TO 5.
MFIB9043E

BRC-77

L

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

4. CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) GROUND SYSTEM
Check ABS actuator and electric unit (control unit) ground system.
ABS actuator and electric unit
(control unit)

Terminal

Ground

Continuity

E33

1, 4

—

Yes

OK or NG
OK
>> Perform ABS actuator and electric unit (control unit) selfdiagnosis again.
NG
>> Repair or replace harness or connectors.
MFIB9042E

5. CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) POWER SUPPLY (2)
1.
2.

Check fusible links 40A (terminal 2) and 30A (terminal 3).
Turn ignition switch OFF and check continuity between battery
positive terminal and ABS actuator and electric unit (control unit)
harness connector E33.
A

B

ABS actuator and electric
unit (control unit)

Terminal

Battery positive terminal

E33

2, 3

—

Continuity
Yes

3.
4.

Check fuse 10A (terminal 18)
Check continuity between 10A fuse and ABS actuator and elecMFIB9052E
tric unit (control unit) harness connector.
OK or NG
OK
>> Check for non-standard conditions in battery (terminal looseness, low voltage, etc.) and alternator.
NG
>> ● Replace fusible link 40A or 30A or fuse 10A.
● Open or short in harness.

BRC-78

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

Inspection 7: Stop Lamp Switch System

BFS000FO

A

DTC C10C6

INSPECTION PROCEDURE

1. CHECK SELF-DIAGNOSTIC RESULTS

B

Check the self-diagnostic results.
C

Self-diagnostic results
STOP LAMP SW

Is the above displayed in the self-diagnosis display item?
YES >> GO TO 2.
NO
>> INSPECTION END

D

2. CHECK CONNECTOR

E

1.

Disconnect stop lamp switch connector E38 (LHD MODELS WITH CR ENGINE AND HR ENGINE WITH
M/T), E60 (LHD MODELS WITH HR ENGINE WITH A/T AND K9K ENGINE), M203 (RHD MODELS BRC
WITH CR ENGINE AND HR ENGINE WITH M/T), M204 (RHD MODELS WITH HR ENGINE WITH A/T
AND K9K ENGINE) and ABS actuator and electric unit (control unit) connector E33 and check terminals
for deformation, disconnection, looseness, and so on. If any malfunction is found, repair or replace termiG
nal.
2. Securely reconnect connectors.
3. perform self-diagnosis again.
H
OK or NG
OK
>> Connector terminal contact is loose, damaged, open or shorted.
NG
>> GO TO 3.
I

3. CHECK STOP LAMP SWITCH CIRCUIT
1.

2.

J

Turn ignition switch OFF and disconnect stop lamp switch connector and ABS actuator and electric unit (control unit) connector.
Check continuity between stop lamp switch harness connector
and ABS actuator and electric unit (control unit) harness connector.

K

L

MFIB9044E

A

B

C

ABS actuator and
electric unit
(control unit)

Terminal

Stop lamp switch
(CR engine and HR
engine M/T models)

Terminal

Stop lamp switch
(HR engine A/T models
and K9K engine models)

Terminal

E33

20

E38 (LHD models)
M203 (RHD models)

2

E60 (LHD models)
M204 (RHD models)

2

Continuity

Yes

OK or NG
OK
>> GO TO 4.
NG
>> Open or short in harness between stop lamp switch and ABS actuator and electric unit (control
unit). Repair or replace applied harness.

BRC-79

M

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

4. CHECK STOP LAMP SWITCH POWER SUPPLY
1.
2.

Turn ignition switch OFF and disconnect stop lamp switch harness connector.
Check voltage between stop lamp switch harness connector and
ground.

MFIB9047E

A

B

Stop lamp switch (CR engine and
HR engine M/T models)

Terminal

Stop lamp switch (HR engine A/T
models and K9K engine)

Terminal

E38 (LHD models)
M203 (RHD models)

1

E60 (LHD models)
M204 (RHD models)

1

Ground

Voltage

—

Approx. 12V

OK or NG
OK
>> GO TO 5.
NG
>> Repair or replace power supply circuit.

5. CHECK STOP LAMP SWITCH
1.
2.

Turn ignition switch OFF and disconnect stop lamp switch.
Check continuity between stop lamp switch harness connector
terminals 1 and 2.

MFIB9048E

A
Stop lamp switch (CR engine and
HR engine M/T models)
E38 (LHD models)
M203 (RHD models)

B
Terminal

Stop lamp switch (HR engine A/T
models and K9K engine)

1, 2

E60 (LHD models)
M204 (RHD models)

Terminal

1, 2

Condition

Continuity

Brake pedal
is depressed

Yes

Brake pedal
is released

No

OK or NG
OK
>> Connect connectors and conduct an ABS actuator and electric unit (control unit) self-diagnosis.
NG
>> Replace stop lamp switch.

BRC-80

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

Inspection 8: Brake Fluid Level Switch System

BFS000FP

A

DTC C1155

INSPECTION PROCEDURE

1. CHECK SELF-DIAGNOSTIC RESULTS-1

B

Check the self-diagnostic results.
C

Self-diagnosis results
CAN COMM CIRCUIT

Is the above displayed in the self-diagnosis item?
YES >> GO TO Inspection 9, refer to BRC-81, «Inspection 9: CAN Communication System» .
NO
>> GO TO 2.

D

2. CHECK SELF-DIAGNOSTIC RESULTS-2

E

1.
2.

Check fluid level in brake fluid reservoir tank. If the level is low, add brake fluid.
Clear the stored self-diagnostic results and check self-diagnosis results.

BRC

Self-diagnostic results

G

BR FLUID LEVEL LOW

Is the above displayed in the self-diagnosis display item?
YES >> GO TO 3.
NO
>> INSPECTION END

H

3. CHECK WARNING LAMP SYSTEM
Perform an WARNING LAMP self-diagnosis refer to DI-32, «WARNING LAMPS» and repair or replace
malfunctioning items. Re-perform WARNING LAMP self-diagnosis.
2. Re-perform ABS actuator and electric unit (control unit) self-diagnosis.
OK or NG
OK
>> INSPECTION END
NG
>> Repair or replace malfunctioning items. Re-perform the self-diagnosis.

1.

Inspection 9: CAN Communication System

I

J

K

BFS000FQ

DTC U1000, C1180

L

INSPECTION PROCEDURE

1. CHECK CONNECTOR
M

1.

Turn ignition switch OFF and disconnect the ABS actuator and electric unit (control unit) connector, and
check the terminal for deformation, disconnection, looseness, and so on. If there is a malfunction, repair
or replace the terminal.
2. Reconnect connector to perform self-diagnosis.
Is “CAN COMM CIRCUIT” displayed in the self-diagnosis display items?
YES >> Print out the self-diagnostic results, and refer to LAN-3, «Precautions When Using CONSULT-II» .
NO
>> Connector terminal connector is loose, damaged, open, or shorted.

BRC-81

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

Component Inspection

BFS000FR

ESP OFF SWITCH
●

Turn ignition switch OFF and disconnect ESP OFF switch connector M16, and check continuity between ESP OFF switch connector terminals 1 and 2.
ESP OFF switch
M16

Terminal
1, 2

Ground

Continuity

Switch is pressed

Yes

Switch is released

No

MFIB9051E

Symptom 1: Excessive ABS Function Operation Frequency

BFS000FS

1. FRONT AND REAR AXLE INSPECTION
Make sure there is no excessive looseness in the front and rear axles.
OK or NG
OK
>> GO TO 2.
NG
>> Check front or rear axle system.

2. WHEEL SENSOR INSPECTION
Perform following inspection for wheel sensor:
●
Sensor mount and damage inspection
●
Sensor rotor mount and damage inspection
●
Sensor connector connection inspection
●
Sensor harness inspection
OK or NG
OK
>> GO TO 3.
NG
>> Sensor or sensor rotor replacement

3. ABS WARNING LAMP DISPLAY CHECK
Make sure warning lamp turns off approximately 2 sec. After turn ignition switch ON or when driving.
OK or NG
OK
>> Normal
NG
>> Perform self-diagnosis. Refer to BRC-62, «Self-Diagnosis» .

Symptom 2: Unexpected Pedal Reaction

BFS000FT

1. CHECK BRAKE PEDAL STROKE
Check brake pedal stroke.
Is the stroke too long?
YES >> ● Bleed air from brake piping.
● Check brake pedal, brake booster, and master cylinder mount for play, looseness, and brake
system for fluid leaks, etc. If any malfunctions are found, make repair.
NO
>> GO TO 2.

BRC-82

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

2. CHECK FUNCTION

A

Disconnect ABS actuator and electric unit (control unit) connector E33 and make sure that braking force is sufficient when ABS in not operating. After the inspection, reconnect connector.
OK or NG
OK
>> GO TO symptom 1 “Step 2”. Refer to BRC-82, «Symptom 1: Excessive ABS Function Operation
Frequency» .
NG
>> Check brake system.

Symptom 3: The Braking Distance Is Long

B

C

BFS000FU

CAUTION:
On slippery road surfaces, the stopping distance might be longer with the ABS operating than when
the ABS is not operating.

1. CHECK FUNCTION

D

E

Disconnect ABS actuator and electric unit (control unit) connector E33 to deactivate ABS. In this condition,
check stopping distance. After inspection, connect connector.
BRC
OK or NG
OK
>> ● Bleed air from brake piping.
● Check brake system.
G
NG
>> GO TO symptom 1 “Step 2”. Refer to BRC-82, «Symptom 1: Excessive ABS Function Operation
Frequency» .

Symptom 4: The ABS Function Does Not Operate

BFS000FV

H

CAUTION:
The ABS does not operate when the speed is 10 km/h (6 MPH) or less.

1. CHECK ABS WARNING LAMP DISPLAY

I

Make sure warning lamp turns off approximately 2 second after the ignition switch is turned on or when driving.
OK or NG
OK
>> GO TO symptom 1 “Step 2”. Refer to BRC-82, «Symptom 1: Excessive ABS Function Operation
Frequency» .
NG
>> Perform self-diagnosis. Refer to BRC-62, «Self-Diagnosis» .

Symptom 5: Pedal Vibration or ABS Operation Sound Occurs

Check if pedal vibration or operation sound occurs when engine is started.
OK or NG
OK
>> Perform self-diagnosis. Refer to BRC-62, «Self-Diagnosis» .
NG
>> GO TO 2.

BRC-83

K

BFS000FW

CAUTION:
Under the following conditions, when brake pedal is lightly depressed (just place a foot on it), ABS is
activated and vibration is felt. However, this is normal.
●
When shifting gears
●
When driving on slippery road
●
During cornering at high speed
●
When passing over bumps or grooves
●
When pulling away just after starting engine [at approximately 10 km/h (6MPH) or higher]

1. SYMPTOM CHECK 1

J

L

M

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

2. SYMPTOM CHECK 2
Check symptom when electrical component (headlamps, etc.) switches are operated.
Does the symptom occur when the electrical component (headlamp, etc.) switches are operated?
YES >> Check if there is a radio, antenna, antenna lead wire, or wiring close to ABS actuator and electric
unit (control unit) (or its wiring), and if there is, move it farther away.
NO
>> GO TO symptom 1 “Step 2”. Refer to BRC-82, «Symptom 1: Excessive ABS Function Operation
Frequency» .

Symptom 6: Vehicle Jerks During ESP/TCS/ABS Control

BFS000FX

1. CHECK ENGINE SPEED SIGNAL
Perform CONSULT-II “DATA MONITOR” to check engine speed.
Is engine speed at idle 400 rpm or higher?
YES >> GO TO 3.
NO
>> GO TO 2.

2. ABS WARNING LAMP DISPLAY CHECK
Make sure warning lamp turns off approximately 2 sec. After turn ignition switch ON or when driving.
OK or NG
OK
>> System is normal.
NG
>> GO TO 3.

3. CHECK ECM SELF-DIAGNOSTIC RESULTS
Perform ECM self-diagnosis.
Are self-diagnosis items displayed?
YES >> Check the corresponding items. Refer to EC-74, «TROUBLE DIAGNOSIS» (CR engine models
with EURO-OBD), EC-491, «TROUBLE DIAGNOSIS» (CR engine models without EURO-OBD),
EC-863, «TROUBLE DIAGNOSIS» (HR engine models with EURO-OBD), EC-1284, «TROUBLE
DIAGNOSIS» (HR engine models without EURO-OBD), EC-1630, «TROUBLE DIAGNOSIS»
(K9K engine).
NO
>> GO TO 4.

4. CHECK SELF-DIAGNOSTIC RESULTS 1
Perform self-diagnosis of ABS actuator and electric unit (control unit).
Are self-diagnosis items displayed?
YES >> Check the corresponding items, make repairs, and re-perform ABS actuator and electric unit (control unit) self-diagnosis.
NO
>> GO TO 5.

5. CHECK CONNECTOR
1.

Disconnect ABS actuator and electric unit (control unit) connector E47 and ECM connector, check terminals for deformation, disconnection, looseness, and so on. If any malfunction is found, repair or replace
connector.
2. Securely reconnect connector and perform self-diagnosis.
OK or NG
OK
>> If poor connect, damaged, open or short circuit is found, repair or replace connector terminal.
NG
>> GO TO 6.

BRC-84

TROUBLE DIAGNOSIS
[ESP/TCS/ABS]

6. CHECK SELF-DIAGNOSTIC RESULTS 2

A

Re-perform ABS actuator and electric unit (control unit) self-diagnosis.
Are self-diagnosis items displayed?
YES >> Repair or replace malfunctioning items.
NO
>> GO TO 7.

B

7. CHECK CIRCUIT BETWEEN ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) AND ECM

C

Check CAN communication system. Refer to BRC-81, «Inspection 9: CAN Communication System» .
OK or NG
OK
>> INSPECTION END
NG
>> Connect connectors, and re-perform ABS actuator and electric unit (control unit) self-diagnosis.

D

E

BRC

G

H

I

J

K

L

M

BRC-85

WHEEL SENSORS
[ESP/TCS/ABS]

WHEEL SENSORS
Removal and Installation

PFP:47910
BFS000B4

MFIB9030E

REMOVAL
Be careful of the following.
CAUTION:
●
When removing the sensor, do not rotate it if possible, and not forcibly pull the sensor harness.
●
Before removing front or rear wheel hub, remove wheel sensor to avoid sensor wiring damage.

INSTALLATION
Be certain to tighten bolts to the specified torque. Be careful of the following:
●
Check the inside of the sensor mounting hole for foreign material, the rotor surface for iron chips and other
foreign material, and if anything is non-standard, clean it before installation, or replace it.
●
When installing the front sensor, completely push in the strut bracket and body bracket rubber grommets
until they lock so that the sensor harness does not become twisted. In addition, there should be no twists
in the harness when installed. Install the harness so that the painted part faces the outside of the vehicle.
●
When installing the rear sensor, completely push in the rubber bracket of the suspension arm bracket and
lock the marking area of the side member harness mount so that the sensor harness will not be twisted. In
addition, there should be no twists in the harness when installed.

BRC-86

SENSOR ROTOR
[ESP/TCS/ABS]

SENSOR ROTOR
Removal and Installation

PFP:47970

A
BFS000B5

FRONT
●

Because the sensor rotor is integrated with the wheel bearing, replace it together with the wheel bearing
assembly. Refer to FAX-6, «FRONT WHEEL HUB AND KNUCKLE» .

B

REAR
●

During removal and installation, remove the wheel hub (brake drum). Refer to RAX-5, «WHEEL HUB» .
CAUTION:
The sensor rotor is a non-reusable part, it must be replaced by an new part when removing it.

C

D

E

BRC

G

H

I

J

K

L

M

BRC-87

ACTUATOR AND ELECTRIC UNIT (ASSEMBLY)
[ESP/TCS/ABS]

ACTUATOR AND ELECTRIC UNIT (ASSEMBLY)
Removal and Installation

PFP:47660
BFS000B6

MFIA0015E

REMOVAL
1. Disconnect ABS actuator and electric unit (control unit) connector.
2. Loosen brake tube flare nuts, then remove brake tubes from ABS actuator and electric unit (control unit).
3. Remove ABS actuator and electric unit (control unit) mounting nuts.
4. Remove ABS actuator and electric unit (control unit) from vehicle.
CAUTION:
Be careful of the following when removing ABS actuator and electric unit (control unit).
●
If the part number on the part number label (pasted on actuator upper surface) is the same, ABS
actuator and electric unit (control unit) cannot be used on another vehicle.
If it is used on another vehicle, ABS warning lamp, SLIP indicator lamp and ESP OFF indicator
lamp may turn ON or ESP/TCS/ABS may not operate normally.
When replacing ABS actuator and electric unit (control unit), must use new service parts.
●
Before servicing, disconnect battery cables.
●
To remove brake tube, use a flare nut wrench to prevent flare nuts and brake tube from being damaged. To install, use a flare nut torque wrench (commercial service tool) and tighten to the specified torque.
●
Do not apply excessive impact to actuator, such as dropping it.
●
Do not remove and install ABS actuator and electric unit (control unit) by holding harness.

INSTALLATION
To install, follow procedure for removal in reverse order.
CAUTION:
Be careful of the following when installing ABS actuator and electric unit (control unit).
●
Tighten the mounting bolts and nuts to the specified torque.
●
After the work, bleed air from brake piping. Refer to BR-10, «Bleeding Brake System» .
●
After installing vehicle harness connector in the actuator, make sure connector is securely locked.

BRC-88

YAW RATE/SIDE G SENSOR
[ESP/TCS/ABS]

YAW RATE/SIDE G SENSOR
Removal and Installation

PFP:47931

A
BFS000B7

B

C

D

E

BRC

G

H

I
MFIA0016E

J

REMOVAL
1. Remove center console. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
2. Disconnect yaw rate/side G-sensor harness connector.
3. Remove yaw rate/side G-sensor mounting bolts. Then remove yaw rate/side G-sensor from vehicle.
CAUTION:
●
Do not drop or strike yaw rate/side G-sensor, because it has little endurance to impact.
●
Do not use power tool etc., because yaw rate/side G-sensor is weak for the impact.

K

L

INSTALLATION
To install, follow procedure for removal in reverse order.
CAUTION:
●
Do not drop or strike yaw rate/side G-sensor, because it has little endurance to impact.

BRC-89

M

STEERING ANGLE SENSOR
[ESP/TCS/ABS]

STEERING ANGLE SENSOR
Removal and Installation

PFP:25554
BFS000B8

REMOVAL
1.
2.

Remove spiral cable assembly. Refer to SRS-38, «SPIRAL CABLE» .
Remove steering angle sensor from spiral cable assembly.

MFIB9038E

INSTALLATION
Installation is the reverse order of removal.
NOTE:
In the case that ABS actuator and electric unit (control unit) are replaced, make sure to adjust neutral position
of steering angle sensor. Refer to BRC-42, «Adjustment of Steering Angle Sensor Neutral Position» .

BRC-90

BRAKE SYSTEM

F BRAKES

SECTION

BR

BRAKE SYSTEM

A

B

C

D

CONTENTS
PRECAUTIONS …………………………………………………. 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ………………………………………………………… 3
PrecautionsforProcedureswithoutCowlTopCover….. 3
Precautions for Brake System ……………………………. 3
PREPARATION ………………………………………………….. 4
Special Service Tools ……………………………………….. 4
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ………………………………………… 5
NVH Troubleshooting Chart ………………………………. 5
BRAKE PEDAL …………………………………………………. 6
Inspection and Adjustment ………………………………… 6
PLAY AND CLEARANCE BETWEEN BRAKE
PEDAL AND FLOOR PANEL WITH PEDAL
DEPRESSED. ………………………………………………. 6
Removal and Installation …………………………………… 7
COMPONENTS ……………………………………………. 7
REMOVAL ……………………………………………………. 7
INSPECTION AFTER REMOVAL ……………………. 8
INSTALLATION …………………………………………….. 8
BRAKE FLUID …………………………………………………… 9
Level Inspection ………………………………………………. 9
Checking Brake Line ………………………………………… 9
Drain and Refill ………………………………………………… 9
Bleeding Brake System …………………………………… 10
BRAKE PIPING AND HOSE ……………………………….11
Hydraulic Circuit ………………………………………………11
Removal and Installation of Front Brake Piping and
Brake Hose …………………………………………………….11
REMOVAL ……………………………………………………11
INSTALLATION …………………………………………… 12
Removal and Installation of Rear Brake Piping and
Brake Hose …………………………………………………… 12
REMOVAL ………………………………………………….. 12
INSTALLATION …………………………………………… 12
Inspection ……………………………………………………… 13
BRAKE MASTER CYLINDER ……………………………. 14

Removal and Installation …………………………………. 14
REMOVAL ………………………………………………….. 14
INSTALLATION …………………………………………… 14
Disassembly and Assembly ……………………………… 14
DISASSEMBLY …………………………………………… 15
INSPECTION AFTER DISASSEMBLY …………… 15
ASSEMBLY ………………………………………………… 15
BRAKE BOOSTER …………………………………………… 17
On-Vehicle Service …………………………………………. 17
OPERATING CHECK …………………………………… 17
AIRTIGHTNESS INSPECTION ……………………… 17
Removal and Installation …………………………………. 17
COMPONENTS …………………………………………… 17
REMOVAL ………………………………………………….. 17
INSTALLATION …………………………………………… 18
VACUUM LINES ………………………………………………. 19
Components ………………………………………………….. 19
Removal and Installation …………………………………. 19
VACUUM HOSE ………………………………………….. 19
VACUUM PUMP ………………………………………….. 19
Inspection ……………………………………………………… 20
VISUAL INSPECTION ………………………………….. 20
CHECK VALVE INSPECTION ……………………….. 20
FRONT DISC BRAKE ……………………………………….. 21
On Board Inspection ……………………………………….. 21
PAD WEAR INSPECTION …………………………….. 21
Components ………………………………………………….. 21
Removal and Installation of Brake Pad ……………… 22
REMOVAL ………………………………………………….. 22
INSTALLATION …………………………………………… 22
RemovalandInstallationofBrakeCaliperAssembly
… 23
REMOVAL ………………………………………………….. 23
INSTALLATION …………………………………………… 23
Disassembly and Assembly of Brake Caliper
Assembly ………………………………………………………. 23
DISASSEMBLY …………………………………………… 23
BRAKE CALIPER INSPECTION ……………………. 24

BR-1

E

BR

G

H

I

J

K

L

M

ASSEMBLY ………………………………………………… 24
Removal and Installation of Disc Rotor ………………. 25
REMOVAL ………………………………………………….. 25
INSTALLATION ……………………………………………. 25
DISC ROTOR INSPECTION …………………………. 25
BRAKE BURNISHING PROCEDURE …………….. 26
REAR DRUM BRAKE ……………………………………….. 27
Components ………………………………………………….. 27
Removal and Installation of Drum Brake Assembly… 28
REMOVAL ………………………………………………….. 28
INSPECTION AFTER REMOVAL …………………… 28
INSTALLATION ……………………………………………. 29
Removal and Installation of Wheel Cylinder ……….. 30

REMOVAL ……………………………………………………30
INSTALLATION …………………………………………….30
Disassembly and Assembly of Wheel Cylinder …….30
DISASSEMBLY …………………………………………….30
ASSEMBLY ………………………………………………….30
Wheel Cylinder Inspection ………………………………..31
SERVICE DATA AND SPECIFICATIONS (SDS) ……32
General Specifications ……………………………………..32
Brake Pedal ……………………………………………………32
Brake Booster …………………………………………………32
Check Valve ……………………………………………………32
Front Disc Brake ……………………………………………..33
Rear Drum Brake …………………………………………….33

BR-2

PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

A

BFS0007Q

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along B
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front C
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Manual.
D
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
E
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
BR
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
G

Precautions for Procedures without Cowl Top Cover

BFS0007R

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

H

I

J

PIIB3706J

Precautions for Brake System
●
●
●
●

●
●
●

●

●

●

K

BFS0007S

Clean dust on front brake and rear brake with a vacuum dust collector. Do not blow with compressed air.
Recommended fluid is brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)”.
Never reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed
on painted areas, wash it away with water immediately.
To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use new brake fluid.
Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.
Use a flare nut wrench when removing flare nuts, and use a flare
nut torque wrench when tightening flare nuts.
Always tighten brake lines to the specified torque when installing.
Before working, turn ignition switch OFF and disconnect electrical connector of ABS actuator and electric unit (control unit) or
the battery cables.
Burnish the brake contact surfaces after refinishing or replacing
drums or rotors, after replacing pads or linings, or if a soft pedal
occurs at very low mileage.
SBR820BA
Refer to BR-26, «BRAKE BURNISHING PROCEDURE» .

BR-3

L

M

PREPARATION
PREPARATION
Special Service Tools

PFP:00002
BFS0007T

Tool number
Tool name

Description

GG94310000
Flare nut torque wrench
a: 10 mm (0.39 in)

Removing and installing each brake
piping

NT406

BR-4

Symptom
BRAKE
Noise
×
×
×

BR-5

Shake
×

Shimmy, Judder
×
×
×
×
×
×
×

×
×
×

×
×
×

STEERING

×

DRIVE SHAFT

×
×

ROAD WHEEL

NVH in PS section

NVH in FAX section

NVH in WT section

NVH in WT section

NVH in FAX, RAX and FSU, RSU section

BR-26

—

—

—

BR-25

BR-25, BR-29

—

—

BR-21, BR-28

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

×

×

TYRES

×

AXLE AND SUSPENSION

Rotor thickness variation

Rotor or drum rust

Rotor or drum deflection

Rotor or drum deformation

Rotor runout

Rotor or drum damage

Rotor or drum imbalance

Return spring damaged

Possible cause and
SUSPECTED PARTS
Pads or linings — uneven wear

BR-21, BR-28

Reference page

Pads or linings — damaged

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
BFS0007U

A

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
B

C

×
×

D

E

BR

G

H

I

J

X: Applicable

K

L

M

BRAKE PEDAL
BRAKE PEDAL
Inspection and Adjustment

PFP:46501
BFS0007V

PLAY AND CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR PANEL WITH PEDAL
DEPRESSED.
●
●
●

Check the pedal play.
Check the brake pedal free height from the dash floor panel.
If value is outside the standard, make an adjustment to the following dimension.

SFIA1116E

LHD
H1

Brake pedal height
RHD

M/T models

161 — 171 mm (6.34 — 6.73 in)

A/T models

171 — 181 mm (6.73 — 7.13 in)

M/T models

156 — 166 mm (6.14 — 6.54 in)

A/T models

166 — 176 mm (6.54 — 6.93 in)

M/T models

80 mm (3.15 in) or more

A/T models

85 mm (3.35 in) or more

H2

Depressed pedal height
[under a force of 490 N (50 kg, 110 lb) with the engine running]

C

Clearance between the stopper rubber and the threaded end of stop lamp switch.

A

Pedal play

0.74 — 1.96 mm (0.029 — 0.077 in)
3 — 11 mm (0.12 — 0.43 in)

BR-6

BRAKE PEDAL
Removal and Installation

BFS0007W

A

COMPONENTS

B

C

D

E

BR

SFIA1114E

1.

Snap pin

2.

Stop lamp switch

4.

Brake pedal assembly

5.

Clevis pin

3.

H

CAUTION:
● Be careful not to deform brake tube.
●

Do not strike the brake pedal assembly against anything during removal and installation.

I

REMOVAL
1.
2.
3.
4.
5.

6.

G

Clip

Remove instrument finisher lower. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Remove accelerator pedal harness clip and connector. Refer to ACC-2, «ACCELERATOR CONTROL
SYSTEM» .
Disconnect stop lamp switch harness connector and remove stop lamp switch from the pedal assembly.
(Remove it by rotating the switch by 45°)
Remove snap pin and clevis pin from the brake booster clevis.
Remove pedal assembly mounting nut and then remove pedal assembly from the vehicle while moving
the master cylinder and brake booster to the engine room side while being careful not to deform the brake
tube.
Remove accelerator pedal from the brake pedal assembly.

J

K

L

M

SFIA1115E

BR-7

BRAKE PEDAL
INSPECTION AFTER REMOVAL
Check brake pedal for bend, damage, and cracks on the welded parts. Replace applicable part if any nonstandard condition is detected.
CAUTION:
Brake pedal is equipped with a crash system.
During serious vehicle collision and system activation, brake pedal
pivot bolt (1) is displaced rearwards, resulting in brake pedal pad displacement into footwell away from the vehicle occupant.
Replace pedal unit complete if Crash System shear rivet (2) has broken following collision (LHD vehicles).
●

MFIB9031E

During serious vehicle collision and system activation, brake pedal
pivot point is displaced rearwards, resulting in brake pedal pad displacement into footwell away from the vehicle occupant.
Replace pedal unit complete if Crash System shear rivet (1) has broken or sliding latch plate (2) has de-latched following collision (RHD
vehicles).

MFIB9032E

INSTALLATION
●

●

For information regarding the tightening torque, refer to BR-7, «COMPONENTS» . Install in the reverse
order of removal.
After installing brake pedal assembly to the vehicle, adjust brake pedal. Refer to BR-6, «BRAKE PEDAL» .

BR-8

BRAKE FLUID
BRAKE FLUID
Level Inspection
●

●
●
●

PFP:KN100

A
BFS0007X

Make sure the fluid level in the reservoir tank is within the standard (between MAX and MIN lines).
Visually check around the reservoir tank for fluid leaks.
If fluid level is excessively low, check brake system for leaks.
If warning lamp remains illuminated after parking lever is
released, check brake system for fluid leakage and the wear of
brake pads or brake linings.

B

C

D
SFIA0527J

E

Checking Brake Line

BFS0007Y

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

BR

G

H

I
SBR389C

Drain and Refill

BFS0007Z

CAUTION:
●
Refill with new brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)”.
●
Do not mix different types of brake fluid (DOT 3, DOT 4).
●
Never reuse drained brake fluid.
●
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
1. Turn ignition switch OFF, and remove ABS actuator connector.
2. Connect a vinyl tube to the air bleeder.
3. Drain brake fluid gradually from the air bleeder of each wheel
while depressing the brake pedal.

BRA0007D

BR-9

J

K

L

M

BRAKE FLUID
4.
5.

Make sure that there is no foreign material in the reservoir tank,
and refill with new brake fluid.
Rest foot on brake pedal. Loosen air bleeder. Slowly depress
pedal until it stops. Tighten air bleeder. Release brake pedal.
Repeat this process a few times, then pause to add new brake
fluid to master cylinder. Continue until new brake fluid flows out.
For information regarding air bleeding work, refer to BR-10,
«Bleeding Brake System» .

BRA0006D

Bleeding Brake System

BFS00080

CAUTION:
●
While bleeding, pay attention to master cylinder fluid level.
●
Fill reservoir with new brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS
No.116)”
●
Do not mix different types of brake fluid (DOT 3, DOT 4)
1. Turn ignition switch OFF, and remove ABS actuator connector.
2. Connect a vinyl tube to the rear left wheel air bleeder.
3. Fully depress brake pedal 4 to 5 times.
4. With brake pedal depressed, loosen air bleeder and bleed air, and then quickly tighten the air bleeder.
5. Repeat steps 3 — 4 until all of the air is out of the brake line.
6. Tighten the air bleeder to the specified torque.
Tightening torque
7.

: 10 N·m (1.0 kg-m, 7 ft-lb)

Repeat steps 2 to 6. Occasionally refill master cylinder reservoir tank with brake fluid in order to keep it at
least half-full. Bleed air in the following order: front RH wheel, RH rear wheel, and front LH wheel.

BR-10

BRAKE PIPING AND HOSE
BRAKE PIPING AND HOSE
Hydraulic Circuit

PFP:46210

A
BFS00081

B

C

D

E

BR

MFIB9017E

Removal and Installation of Front Brake Piping and Brake Hose

G

BFS00082

REMOVAL

H

CAUTION:
●
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
●
All hose must be free from excessive bending, twisting and pulling.
●
Cover brake fluid line connections to prevent dust and other foreign material from entering.
1. Drain brake fluid. Refer to BR-9, «Drain and Refill» .
2. Using a flare nut wrench, remove the flare nuts of the brake tube
and disconnect the brake tube from the brake hose.
3. Remove brake caliper union bolts and disconnect caliper
assembly from brake hose.
4. First remove the lock plate from the mounting positions of brake
tubes and struts, and then brake hose.

I

J

K

L

M
SFIA1118E

BR-11

BRAKE PIPING AND HOSE
INSTALLATION
CAUTION:
●
Refill with new brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)”.
●
Do not mix different types of brake fluid (DOT3, DOT4).
●
Never reuse the drained brake fluid.
1. Install the brake hose to the caliper assembly and tighten union
bolts to the specified torque.
Tightening torque

2.
3.
4.

CAUTION:
● Install brake hose securely by inserting the hose fitting
protrusion into the caliper hole.
● Do not reuse the copper washer for union bolts.
Connect brake hose to the strut and fix with lock plate.
Connect brake hose to brake tube. Temporarily tighten flare nuts
by hand as far as they will go. Secure them with the lock plate.
Using a flare nut torque wrench, tighten to the specified torque.
Tightening torque

5.
6.

: 18 N·m (1.8 kg-m, 13 ft-lb)

SFIA1119E

: 16.2 N·m (1.7 kg-m, 12 ft-lb)

Add new brake fluid. Refer to BR-9, «Drain and Refill» .
Bleed the air. Refer to BR-10, «Bleeding Brake System» .

Removal and Installation of Rear Brake Piping and Brake Hose

BFS00083

REMOVAL
CAUTION:
●
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
●
All hose must be free from excessive bending, twisting and pulling.
●
Cover brake fluid line connections to prevent dust and other foreign material from entering.
1. Drain brake fluid. Refer to BR-9, «Drain and Refill» .
2. Using a flare nut wrench, remove the flare nuts of the brake tube
and disconnect the brake tube from the brake hose.
3. Remove the lock plate and remove the brake hose from the
vehicle.

SFIA1120E

INSTALLATION
CAUTION:
●
Refill with new brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)”.
●
Do not mix different types of brake fluid (DOT3, DOT4).
●
Never reuse the drained brake fluid.
1. Connect brake hose to the brake tube. Temporarily tighten flare nut by hand as far as it will go.
2. Secure brake hose with the lock plate, and then use a flare nut wrench to tighten the flare nuts to the
specified torque.
Tightening torque
3.
4.

: 16.2 N·m (1.7 kg-m, 12 ft-lb)

Add new brake fluid. Refer to BR-9, «Drain and Refill» .
Bleed the air. Refer to BR-10, «Bleeding Brake System» .

BR-12

BRAKE PIPING AND HOSE
Inspection

BFS00084

CAUTION:
If leak is detected at the connections, retighten it or replace the damaged part if necessary.
1. Check hose, tube, and connections for fluid leaks, damage, twist, deformation, contact with other parts,
and loose connections.
2. While depressing brake pedal with engine running for approximately 5 seconds, check for fluid leak from
each part.

A

B

C

D

E

BR

G

H

I

J

K

L

M

BR-13

BRAKE MASTER CYLINDER
BRAKE MASTER CYLINDER
Removal and Installation

PFP:46010
BFS00085

REMOVAL
1.
2.
3.
4.
5.

Drain brake fluid. Refer to BR-9, «Drain and Refill» .
Remove harness connector of fluid level sensor.
Remove clutch reservoir hose. (M/T models)
Using a flare nut wrench, disconnect master cylinder assembly
and brake tube.
First remove nuts on master cylinder assembly, and then master
cylinder assembly from brake booster assembly.

SFIA1122E

INSTALLATION
1.
2.

Install brake tube to the master cylinder assembly and temporarily tighten the flare nuts by hand.
Install the master cylinder assembly to the brake booster assembly and tighten mounting nuts to the specified torque.
Tightening torque

3.

Tighten flare nuts of the brake tube to the specified torque.
Tightening torque

4.
5.
6.

: 14 N·m (1.4 kg-m, 10 ft-lb)

: 16.2 N·m (1.7 kg-m, 12 ft-lb)

Install the clutch reservoir hose. (M/T models)
Add new brake fluid. Refer to BR-9, «Drain and Refill» .
Bleed the air. Refer to BR-10, «Bleeding Brake System» .

Disassembly and Assembly

BFS00086

MFIB9016E

1.

Stopper cap

2.

Primary piston assembly

3.

Fluid level sensor harness connector

4.

Clutch reservoir hose (M/T models)

5.

Reservoir tank

6.

Secondary piston assembly

7.

Grommet

8.

Screw

9.

Piston stopper

10. Reservoir tank cap

BR-14

BRAKE MASTER CYLINDER
DISASSEMBLY
A

CAUTION:
Remove master cylinder reservoir tank only when necessary.
1. As shown in the figure, use a screwdriver to lift up the stopper
cap hooks and remove the stopper cap from the master cylinder.

B

C

D
BRA0031D

E

2.
3.
4.

5.

Remove reservoir tank mounting screw from cylinder body.
Remove reservoir tank and grommet from cylinder body.
Using a flat-bladed screwdriver, press and hold piston as shown
in the figure. Remove piston stopper from secondary tank boss
hole in the cylinder body.
CAUTION:
Be careful not to damage the inner wall of the cylinder.
Carefully pull the primary piston assembly straight out to prevent
cylinder inner wall from being damaged.

BR

G

H

BRA0519D

6.

Tap the flange against a soft block such as wood, and carefully
pull the secondary piston assembly straight out to prevent cylinder inner wall from damage.

I

J

K

L
BRA0033D

M

INSPECTION AFTER DISASSEMBLY
●

Check inner wall of master cylinder for damage, wear, corrosion, and pinholes. Replace cylinder if any
non-standard condition is detected.

ASSEMBLY
CAUTION:
●
Never use mineral oils such as kerosene or gasoline during the cleaning and assembly processes.
●
Make sure there is no foreign material such as dirt and dust on cylinder inner wall, piston, and cup
seal. Be careful not to damage the parts with a service tool when assembling.
●
Do not drop the parts. Do not use any dropped parts.

BR-15

BRAKE MASTER CYLINDER
1.
2.

3.

Apply brake fluid to the cylinder inner wall body and contact surface of the piston assembly.
Insert the secondary piston assembly and primary piston
assembly into the cylinder body in this order.
CAUTION:
● Do not reuse primary and secondary piston assemblies.
● Pay attention to direction of piston cups, and insert
straight to prevent the cup from being caught by the
inner wall of the cylinder.
● Do not disassemble the new part inner kit. Always
replace it as a complete assembly.
Visually check secondary piston slit position through cylinder
body secondary tank boss hole and install piston stopper.

MFIA0009E

BRA0519D

4.

5.

6.

While holding the piston with the stopper cap, press the stopper
cap fully until its tabs are engaged with the groove on the cylinder body to install.
CAUTION:
Do not reuse the stopper cap.
Apply brake fluid to a grommet, and press it into cylinder body.
CAUTION:
Do not reuse the grommet.
Install reservoir tank and reservoir tank mounting screw to cylinder body.

BR-16

BRA0535D

BRAKE BOOSTER
BRAKE BOOSTER
On-Vehicle Service

PFP:47200

A
BFS00087

OPERATING CHECK
●

●

Depress brake pedal several times with engine off, and check
that there is no change in pedal stroke.
Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.

B

C

D

BRA0037D

E

AIRTIGHTNESS INSPECTION
●

●

Start engine, and stop it after one or two minutes. Depress brake
pedal several times slowly. If pedal goes further down the first
time and gradually rises after second or third time, booster is airtight.
Depress brake pedal while engine is running, and stop engine
with pedal depressed. If there is no change in pedal stroke after
holding pedal down 30 seconds, brake booster is airtight.

BR

G

H

SBR365AA

I

Removal and Installation

BFS00088

COMPONENTS
J

K

L

M

MFIB9018E

REMOVAL
CAUTION:
●
Be careful not to deform or bend brake piping while removing and installing the brake booster.
●
Replace clevis pin if it is damaged.
●
Be careful not to damage brake booster stud bolt threads. If brake booster is tilted or inclined during installation, the dash panel may damage the threads.
●
Be sure to install check valve in the correct orientation.
1. Remove the vacuum hose from the brake booster.

BR-17

BRAKE BOOSTER
2.
3.
4.
5.
6.
7.
8.

Remove brake master cylinder. Refer to BR-14, «Removal and Installation» .
Remove snap pin and clevis pin from the brake pedal mounting area via the vehicle cabin.
Remove brake booster and brake pedal assembly nuts.
Remove clutch master cylinder from the panel and pull it out through the engine room side and place it
where it will not be in the way. Refer to CL-9, «Removal and Installation» (M/T models).
Remove the air conditioner lower pressure hose holding
bracket.
Remove cowl top cover. Refer to EI-12, «Removal and Installation» .
Remove booster assembly from engine room.

SFIA1127E

INSTALLATION
1.

Check input rod length so that length B (in the figure) satisfies
the specified value.
Length B standard
LHD models
RHD models

2.

3.
4.
5.
6.
7.
8.
9.

: 158.25 mm (6.23 in)
: 115.35 mm (4.54 in)

Install booster assembly in the vehicle.
CAUTION:
Be sure to install the gasket between the booster assembly
and the vehicle.
SFIA1128E
Connect the brake pedal with the clevis of the input rod.
Install nuts to booster assembly and tighten to the specified torque.
Install brake master cylinder to the booster assembly. Refer to BR-14, «Removal and Installation» .
Install the clutch master cylinder. Refer to CL-9, «Removal and Installation» (M/T models).
Install the air conditioner lower pressure hose holding bracket.
Install cowl top cover. Refer to EI-12, «Removal and Installation» .
Bleed air. Refer to BR-10, «Bleeding Brake System» .

BR-18

VACUUM LINES
VACUUM LINES
Components

PFP:41920

A
BFS00089

B

C

D

E

BR

G

H

I
MFIA0010E

Removal and Installation

BFS0008A

J

VACUUM HOSE
CAUTION:
●
Because vacuum hose contains a check valve, it must be installed in the correct orientation. Refer
to the stamp or label to confirm correct installation. The brake booster will not operate normally if
the hose is installed in the wrong direction.
●
Insert the vacuum hose for at least 24 mm (0.94 in).
●
Never use lubricating oil during assembly.

K

L

M

SBR225B

VACUUM PUMP
For information regarding vacuum pump removal and installation, refer to EM-261, «VACUUM PUMP» .

BR-19

VACUUM LINES
Inspection

BFS0008B

VISUAL INSPECTION
Check for improper assembly, damage and aging.

CHECK VALVE INSPECTION
Airtightness Inspection
Use a hand-held vacuum pump to check.
When connected to booster side (1):
Vacuum decrease should be within 1.3 kPa
(10 mmHg, 0.39 inHg) for 15 seconds under
a vacuum of -66.7 kPa (-500 mmHg, -19.69
inHg)
When connected to engine side (2):
Vacuum should not exist.
SFIA0210E

BR-20

FRONT DISC BRAKE
FRONT DISC BRAKE
On Board Inspection

PFP:41000

A
BFS0008C

PAD WEAR INSPECTION
Inspect the thickness of pad through cylinder body inspection
hole. Use a scale for inspection if necessary.

●

Standard thickness
Wear limit thickness

B

: 12.4 mm (0.488 in)
: 2.0 mm (0.079 in)

C

D

BRA0010D

Components

E

BFS0008D

BR

G

H

I

J

K

L

M

SFIA1129E

1.

Torque member

2.

Sliding pin

3.

Pin boot

4.

Pad retainer (upper)

5.

Pad retainer (lower)

6.

Inner pad

7.

Outer pad

8.

Cylinder body

9.

Piston seal

10. Piston

11.

Piston boots

12. Union bolt

13. Copper washer

14. Air bleeder

CAUTION:
● Clean dust on the caliper and brake pad with a vacuum dust collector. Do not blow with compressed air.
●

While removing the cylinder body, do not depress the brake pedal because the piston will pop out.

●

Do not remove brake hose and torque member bolts unless disassembling or replacing caliper assembly. Hang cylinder
body with a wire so that brake hose is not under tension.

●

Be careful not to damage the piston boot. Do not allow brake fluid to get on the rotor.

BR-21

FRONT DISC BRAKE
Removal and Installation of Brake Pad

BFS0008E

REMOVAL
CAUTION:
Always replace the inner cover and outer shim as a set when replacing the brake pads.
1. Remove tyre from vehicle.
2. Remove brake master cylinder reservoir tank cap.
3. Remove lower sliding pin bolt.

SFIA1130E

4.

Hang cylinder body with a wire, and remove pads and pad
retainers from torque member.

SFIA1133E

INSTALLATION
1.
2.
3.

4.
5.

Apply PBC (Poly Butyl Cuprysil) or silicone-based grease on inner pad (rear surface) and outer pad (rear
surface).
Apply PBC (Poly Butyl Cuprysil) or silicone-based grease to pad contact surface on pad retainer. Install
pad retainers and pads to the torque member.
Install cylinder body to torque member.
CAUTION:
When replacing pads with new ones, press in piston until pads can be installed. In this case, carefully monitor brake fluid level in the reservoir tank because brake fluid will return to the reservoir
tank of master cylinder.
Insert the lower sliding pin bolt to tighten to the specified torque.
Check brake for drag.

BR-22

FRONT DISC BRAKE
Removal and Installation of Brake Caliper Assembly

BFS0008F

REMOVAL

A

1.
2.
3.

B

Remove tyre from vehicle.
Drain brake fluid. Refer to BR-9, «Drain and Refill» .
Remove union bolts and torque member bolts, and remove
brake caliper assembly.

C

D

E
SFIA1136E

INSTALLATION
CAUTION:
BR
●
Refill with new brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)”.
●
Do not mix different types of brake fluid (DOT 3, DOT 4).
●
Never reuse the drained brake fluid.
G
1. Install brake caliper assembly to the vehicle, and tighten bolts on torque member to the specified torque.
CAUTION:
Before installing brake caliper assembly, wipe off oil and grease on the nut washer seats and H
brake caliper assembly mounting surface.
2. Install brake hose to the brake caliper assembly, and tighten
union bolts to the specified torque.
I
CAUTION:
● Do not reuse the copper washer for union bolts.
● Assemble brake hose securely to the cylinder body
J
mounting hole.
3. Add new brake fluid. Refer to BR-9, «Drain and Refill» .
4. Bleed air. Refer to BR-10, «Bleeding Brake System» .
K
SFIA1137E

Disassembly and Assembly of Brake Caliper Assembly

L
BFS0008G

DISASSEMBLY
WARNING:
Be careful not to pinch your fingers in the piston.
CAUTION:
Be careful not to damage cylinder inner wall.
1. Place a wooden block as shown in the figure, and blow air from
the union bolt mounting hole to remove piston and piston boots.

M

MAA0272D

BR-23

FRONT DISC BRAKE
2.

Using a flat-bladed screwdriver, remove piston seals.

PFIA0269E

BRAKE CALIPER INSPECTION
Cylinder Body
CAUTION:
Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene.
Check the inner wall of the cylinder for wear or damage. If any non-standard condition is detected, replace the
cylinder.

Torque Member
Check for wear, cracks, and damage. If any non-standard condition is detected, replace the applicable part.

Piston
CAUTION:
Piston sliding surface is plated. Do not polish with sandpaper.
Check piston surface for corrosion, wear, and damage. If any non-standard condition is detected, replace
applicable part.

Sliding Pin and Pin Boots
Check sliding pin and pin boot for wear, damage, and cracks. If damage or deformation is present, replace the
affected part.

ASSEMBLY
CAUTION:
When assembling, use only rubber lubricant specified below.
1. Apply polyglycol ether based lubricant to the piston seals, and
install them to the cylinder body.
CAUTION:
Do not reuse the piston seals.

SFIA1060E

2.

Apply polyglycol ether based lubricant to the piston boot, cover
the end of the piston with the piston boot, evenly insert the piston boot into the cylinder side, and make sure it is in the cylinder
body groove.
CAUTION:
Do not reuse the piston boot.

SFIA1061E

BR-24

FRONT DISC BRAKE
3.

Apply brake fluid to piston. Press piston into cylinder body by
hand. Assemble piston side lip on piston boot properly into
groove on piston.
CAUTION:
Press the piston evenly and change the pressing point to
prevent the inner wall of the cylinder from being rubbed.

A

B

C
SFIA1062E

Removal and Installation of Disc Rotor

D
BFS0008H

REMOVAL
1.
2.

3.

Remove tyre from vehicle.
Remove brake caliper assembly. Refer to BR-23, «REMOVAL» .
CAUTION:
● Brake hose need not be disconnected brake caliper.
● Suspend brake caliper with wire so as not to stretch brake hose.
● Be careful not to depress brake pedal, or caliper piston will pop out.
● Make sure brake hose is not twisted.
Remove disc rotor mounting screw (torx), then remove disc rotor
from front axle.

E

BR

G

H

I

J
SFIA1141E

INSTALLATION
●

K

Install in the reverse order of removal. Tighten the mounting screw (torx) to the specified torque.
CAUTION:
Do not use any disc rotors that have once dropped.

L

DISC ROTOR INSPECTION
Visual Inspection
Check surface of the disc rotor for uneven wear, cracks, and serious damage. If any non-standard condition is
detected, replace applicable part.

Runout Inspection
1.
2.

Using wheel bolts, fix disc rotor to the wheel hub. (2 or more positions)
Using a dial indicator, check the runout.
Measurement position
: At a point 10 mm (0.39 in) from outer edge of the disc
Runout limit: 0.058 mm (0.0023 in) or less

3.

NOTE:
Make sure that wheel bearing axial end play is within the specifications before measuring. Refer to FAX-6, «FRONT WHEEL
BEARING» .
If the runout is outside the limit, find the minimum runout point by
shifting the mounting positions of the disc rotor and wheel hub
by one hole.

BR-25

BRA0013D

M

FRONT DISC BRAKE
4.

If the runout is still out of specification, turn rotor with on-car brake lathe (“MAD DL-8700”, “AMMCO 700
and 705” or equivalent).

Thickness Inspection
Using a micrometer, check thickness of the disc rotor. If thickness is
outside the standard, replace disc rotor.
Standard thickness
Wear limit
Maximum uneven wear
(measured at 8 positions)

: 22.0 mm (0.87 in)
: 20.0 mm (0.79 in)
: 0.03 mm (0.0012 in) or less

SBR020B

BRAKE BURNISHING PROCEDURE
Burnish the brake contact surfaces according to the following procedure after refinishing or replacing drums or
rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH).
Adjust brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.

BR-26

REAR DRUM BRAKE
REAR DRUM BRAKE
Components

PFP:43206

A
BFS0008I

B

C

D

E

BR

G

H

I
SFIA1142E

1.

Drum

2.

Return spring (lower)

3.

Return spring (upper)

4.

Adjuster

5.

Retaining clip

6.

Shoe

7.

Cylinder body

Boots

8.

Air bleeder

9.

10. Piston

11.

Piston cup

12. Spring

13. Back plate

14. Shoe hold pin

WARNING:
Clean dust on drum and back plate with a vacuum dust collector. Do not blow with compressed air.

J

K

L

CAUTION:
● While removing drum, never depress brake pedal because the piston will pop out.
●

Make sure parking brake lever is released completely.

BR-27

M

REAR DRUM BRAKE
Removal and Installation of Drum Brake Assembly

BFS0008J

REMOVAL
1.
2.

Remove tyre from vehicle.
With the parking brake lever released, remove the brake drum. Refer to RAX-5, «Removal and Installation» .

3.

While pushing and rotating the retainer, pull out shoe hold pin,
and remove shoe assembly.
CAUTION:
Do not damage the wheel cylinder piston boot.

SFIA1145E

4.

5.

Remove the parking brake cable from the operating lever.
CAUTION:
Do not bend the parking brake cable.
Disassemble the shoe assembly (shoe, springs, spacer,
adjuster).

SFIA1146E

INSPECTION AFTER REMOVAL
Lining Thickness Inspection
Check lining thickness.
Standard thickness
Wear limit of thickness (A)

: 4.5 mm (0.177 in)
: 1.5 mm (0.059 in)

SBR021A

Drum Inner Diameter Inspection
Check the drum inside diameter.

BR-28

REAR DRUM BRAKE
Measurement area: lining contact surface (center)
A

Standard inner diameter
: 202 mm (7.95 in) dia.
Wear limit of inner diameter : 203.2 mm (8.0 in) dia.

B

C
SBR022A

D

Wheel Cylinder Leakage Inspection
Check wheel cylinder for brake fluid leakage.
Check for wear, damage, and looseness. If any non-standard
condition is found, replace it.

●
●

E

BR

G
SFIA1147E

H

Other Inspections
Check inside of the drum for excessive wear, damage, and cracks.
Check lining for excessive wear, damage, and peeling.
Check shoe sliding surface for excessive wear and damage.
Check return spring for sagging.
Check back plate for damage, cracks, and deformation.
Check bolts on the back plate for looseness.

●
●
●
●
●
●

I

J

INSTALLATION
1.

K

Apply Nissan brake grease special (KRF0000005) or equivalent
to brake shoes sliding surfaces (the shaded areas) and other
parts on the back plate as indicated by arrows in the figure.

L

M

SFIA1148E

2.

Shorten adjuster by rotating it.

Wheel

Screw

Left

Left-hand thread

Right

Right-hand thread

SFIA1149E

3.

Assemble the shoe, springs, adjuster and spacer to form the shoe assembly.

BR-29

REAR DRUM BRAKE
4.
5.

6.

Connect the parking brake cable to the operating lever.
Install the shoe assembly. After assembly, be sure that each part
is installed properly.
CAUTION:
Do not damage the wheel cylinder piston boot.
Install the brake drum. Refer to RAX-5, «Removal and Installation» .

SFIA1217E

7.
8.

When installing a new wheel cylinder or overhauling wheel cylinder, bleed air. Refer to BR-10, «Bleeding
Brake System» .
Adjust the parking brake. Refer to PB-3, «Adjustment» .

Removal and Installation of Wheel Cylinder

BFS0008K

REMOVAL
1.
2.
3.
4.

Drain brake fluid. Refer to BR-9, «Drain and Refill» .
Remove the rear brake shoe assembly.
Remove the brake tube from the wheel cylinder.
Remove bolts on the wheel cylinder, and then remove wheel cylinder from the back plate.

INSTALLATION
●

●

Install in the reverse order of removal. Tighten bolts to the specified torque. Refer to BR-27, «Components» .
Refill with new brake fluid and bleed air. Refer to BR-10, «Bleeding Brake System» .

Disassembly and Assembly of Wheel Cylinder

BFS0008L

DISASSEMBLY
1.
2.

Remove dust boots at the right and left of the wheel cylinder,
and pull out the pistons from cylinder.
Remove the piston cups from the pistons.

SFIA1151E

ASSEMBLY
CAUTION:
When assembling, use only rubber lubricant specified below.
1. Apply brake fluid to the piston sliding surface on the wheel cylinder.
2. Apply polyglycol ether based lubricant to the cups and boots and
assemble as shown in the figure.

SFIA1152E

BR-30

REAR DRUM BRAKE
Wheel Cylinder Inspection

BFS0008M

Check the pistons, piston cups, and inner wall of the cylinder for wear, corrosion, and damage. If a failure is
detected, replace the applicable part.
CAUTION:
When inserting the piston, be careful not to scratch the cylinder.

A

B

C

D

E

BR

G

H

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BR-31

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications

PFP:00030
BFS0008N

Unit: mm (in)
Brake model
Front brake

CL22

Rotor outer diameter × thickness

260 × 22.0 (10.24 × 0.87)

Pad (thickness)

12.4 (0.488)

Piston diameter

53.95 (2.124)

Brake model

LT20

Drum inner diameter
Rear brake

202 (7.95)
195 × 38 × 4.5
(7.68 × 1.50 × 0.177)

Lining
Length × width × thickness
Cylinder bore diameter

19.05 (3/4)

Master cylinder

Cylinder bore diameter

23.81 (0.94)

Control valve

Valve model

Linkage type load sensing valve

Booster model
Brake booster

T52/ 5/ 255

Diaphragm diameter

254 (10)
Nissan Genuine Brake Fluid or DOT 3 or DOT 4
(US FMVSS No.116)

Recommended brake fluid

Brake Pedal

BFS0008O

LHD
Brake pedal height (from dash panel top surface)
RHD
Depressed pedal height
[under a force of 490 N (50 kg, 110 lb) with the engine running]

M/T models

161 — 171 mm (6.34 — 6.73 in)

A/T models

171 — 181 mm (6.73 — 7.13 in)

M/T models

156 — 166 mm (6.14 — 6.54 in)

A/T models

166 — 176 mm (6.54 — 6.93 in)

M/T models

More than 80 mm (3.15 in)

A/T models

More than 85 mm (3.35 in)

Clearance between the stopper rubber and the threaded end of stop lamp switch.
Pedal play

0.74 — 1.96 mm (0.029 — 0.077 in)
3 — 11 mm (0.12 — 0.43 in)

Brake Booster

BFS0008P

Vacuum type
Vacuum leakage
[at vacuum of – 66.7 kPa (– 500 mmHg, –19.69 inHg)]
Input rod installation standard dimension

Within 3.3 kPa (25 mmHg, 0.98 inHg) of vacuum for 15 seconds

LHD models

158.25 mm (6.23 in)

RHD models

115.35 mm (4.54 in)

Check Valve
Vacuum leakage
[at vacuum of – 66.7 kPa(– 500 mmHg, – 19.69 inHg)]

BFS0008Q

within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds

BR-32

SERVICE DATA AND SPECIFICATIONS (SDS)
Front Disc Brake

BFS0008R

A
Brake model
Brake pad

CL22
Standard thickness (new)

12.4 mm (0.488 in)

Repair limit thickness

2.0 mm (0.079 in)

Standard thickness (new)

22.0 mm (0.87 in)

Repair limit thickness
Disc rotor

20 mm (0.79 in)

Maximum uneven wear (measured at 8 positions)

0.03 mm (0.0012 in) or less

Runout limit
(with it attached to the vehicle)

0.058 mm (0.0023 in) or less

BFS0008S

Brake model

Drum

C

D

Rear Drum Brake
Lining

B

LT20
Standard thickness (new)

4.5 mm (0.177 in)

Repair limit thickness

1.5 mm (0.059 in)

Standard inner diameter (new)

202 mm (7.95 in)

Repair limit inner diameter

203.2 mm (8.0 in)

E

BR

G

H

I

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L

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BR-33

SERVICE DATA AND SPECIFICATIONS (SDS)

BR-34

CLUTCH

C TRANSMISSION/TRANSAXLE

SECTION

CL

CLUTCH

A

B

CL

D

CONTENTS
APPLICATION NOTICE ………………………………………. 2
How to Check Vehicle Type ………………………………. 2
PRECAUTIONS …………………………………………………. 3
Caution …………………………………………………………… 3
PREPARATION ………………………………………………….. 4
Special Service Tools ……………………………………….. 4
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ………………………………………… 5
NVH Troubleshooting Chart ………………………………. 5
CLUTCH ………………………………………………………. 5
CLUTCH PEDAL ……………………………………………….. 6
On Board Inspection ………………………………………… 6
HEIGHT INSPECTION …………………………………… 6
PLAY INSPECTION ………………………………………. 6
CLEARANCE CHECK ……………………………………. 6
Removal and Installation …………………………………… 7
REMOVAL ……………………………………………………. 7
INSPECTION AFTER REMOVAL ……………………. 7
INSTALLATION …………………………………………….. 7
CLUTCH FLUID …………………………………………………. 8
Air Bleeding Procedure …………………………………….. 8

CLUTCH MASTER CYLINDER ……………………………. 9
Removal and Installation …………………………………… 9
REMOVAL ……………………………………………………. 9
INSTALLATION …………………………………………….. 9
CSC (CONCENTRIC SLAVE CYLINDER) ……………. 10
Removal and Installation …………………………………. 10
REMOVAL ………………………………………………….. 10
INSPECTION ……………………………………………… 10
INSTALLATION …………………………………………… 10
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL… 11
Removal and Installation …………………………………. 11
REMOVAL ………………………………………………….. 12
INSPECTION AND ADJUSTMENT AFTER
REMOVAL (CR ENGINE) ……………………………… 12
INSPECTION AND ADJUSTMENT AFTER
REMOVAL (K9K ENGINE) ……………………………. 13
INSTALLATION …………………………………………… 13
SERVICE DATA AND SPECIFICATIONS (SDS) …… 15
Clutch Pedal ………………………………………………….. 15
Clutch Disc ……………………………………………………. 15
Clutch Cover ………………………………………………….. 15
Clutch Control System …………………………………….. 15
Clutch Master Cylinder ……………………………………. 15

E

F

G

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CL-1

APPLICATION NOTICE
APPLICATION NOTICE
How to Check Vehicle Type

PFP:00000
BCS000KL

Confirm K9K engine type with Model written on identification plate (refer to GI-45, «IDENTIFICATION INFORMATION» ),then refer to service information in CL section.
Vehicle type

Engine type

xTKxxxxE11xxE

50kW

xTKxxxxE11xxA

63kW

CL-2

PRECAUTIONS
PRECAUTIONS
Caution

PFP:00001

A
BCS000KM

Recommended fluid is brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS
No.116)». Refer to MA-24, «Fluids and Lubricants».
B
●
Never reuse drained brake fluid.
●
Be careful not to splash brake fluid on painted areas.
CL
●
Use new brake fluid to clean or wash all parts of master cylinder and concentric slave cylinder.
●
Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic
system.
●
If manual transaxle is removed from the vehicle, always replace CSC (concentric slave cylinder). D
CSC insert is returned to original position to remove transaxle. Dust on clutch disc sliding parts
may damage CSC seal and may cause fluid leak.
E
●
Do not disassemble master cylinder and CSC.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not use compressed air.
F
●

G

H

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K

L

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CL-3

PREPARATION
PREPARATION
Special Service Tools

PFP:00002
BCS000KN

Tool number
(Renault tool number)
Tool name

Description

ST20050240
Diaphragm spring adjusting wrench

Inspecting diaphragm spring of
clutch cover

ZZA0508D

EM07020000
Clutch aligner

Installing clutch cover and disc

PCIB0017E

KV30101000
Clutch aligner
a:15.9mm(0.626in)dia
b:19.8mm(0.780in)dia

Installing clutch disc

ZZA1178D

CL-4

Clutch pedal spongy

Symptom
Clutch slips
1

Clutch does not disengage
1

Clutch grabs/chatters

1

2

Clutch noisy

3

CL-5
1

4
4
4
4

CLUTCH DISC (Hardened)

2
2
2

2

4
2
4
5

3
5
4

6

FLYWHEEL (Distortion)

CL-11

CL-12.

CL-12.

CL-12.

CL-11

CL-11

CL-11.

CL-11.

CL-11.

CL-11.

CL-11.

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

PRESSURE PLATE (Distortion)

DIAPHRAGM SPRING (Out of tip alignment)

DIAPHRAGM SPRING (Damaged)

CLUTCH DISC (Lack of spline grease)

CLUTCH DISC (Worn out)

2

CLUTCH DISC (Oily)

CLUTCH DISC (Dirty or burned)

CLUTCH DISC (Lining broken)

CLUTCH DISC (Runout is excessive)

CL-11.

CL-10

RELEASE BEARING (Worn, dirty or damaged)
CLUTCH DISC (Out of true)

EM-70 .

CL-9.

MASTER CYLINDER PISTON CUP (Damaged)
ENGINE MOUNTING (Loose)

CL-8.

CL-6.

SUSPECTED PARTS (Possible cause)
CLUTCH LINE (Air in line)

Reference page

CLUTCH PEDAL (Free play out of adjustment)

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
BCS000KO

A

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.

2

B

CLUTCH

CL

D

E

F

G

H

2

I

1
5

J

K

L

M

CLUTCH PEDAL
CLUTCH PEDAL
On Board Inspection

PFP:46540
BCS000KP

HEIGHT INSPECTION
1.

Make sure clutch pedal height H1 from upper surface of the
dash panel is within the specified range.
Pedal height H1
: 160 — 169 mm (6.30 — 6.65 in)
: 164 — 174 mm (6.46 — 6.85 in)
: 170 — 180 mm (6.69 — 7.09 in)
: 175 — 185 mm (6.89 — 7.23 in)

2.
3.

(LHD with CR engine)
(LHD with HR engine)
(RHD with CR engine)
(LHD K9K 50/63 kW)
(RHD K9K 50/63 kW)
(RHD with HR engine)

If pedal height H1 is outside the specification, replace pedal
assembly.
Make sure free play A at pedal pad top surface and pedal height
H2 when clutch is disengaged are within the ranges specified
below.
A: Pedal free play at the pedal pad
: 0.5 mm (0.02 in)
Pedal height H2 when clutch is disengaged
: 100 mm (3.94 in) or more (CR engine)

4.

SCIA1256E

If free play A at pedal pad top surface and pedal height H2 when
clutch is disengaged are outside the specification, replace clutch pedal assembly.

PLAY INSPECTION
●

Press the clutch pedal by hand until certain resistance can be
felt. Using a scale, Make sure the free play is within the specified
range.
Pedal free play
: 0.5 mm (0.02 in)

MAA0023D

CLEARANCE CHECK
1.
2.
3.
4.
5.

Start the engine and let it idle.
Apply parking brake.
Depress the brake pedal.
Fully depress clutch pedal and shift to 1st gear.
Release clutch pedal gradually. Using a scale, check the clearance between the clutch pedal and floor panel to see if it is
within the specified range.
Pedal height when the clutch disengages
: 100 mm (3.94 in) or more (CR engine)
MAA0024D

NOTE:
Pedal height at clutch disengagement varies slightly from the clutch engagement point. Despite this, pedal
height at clutch engagement is commonly used for both cases in order to simplify the inspection.

CL-6

CLUTCH PEDAL
Removal and Installation

BCS000KQ

A

REMOVAL
1.
2.
3.
4.

Remove instrument panel under tray. Refer to IP-4, «INSTRUMENT PANEL ASSEMBLY» .
Unlock master cylinder rod end and separate master cylinder
from clutch pedal.
Remove clutch switch harness clamp from pedal bracket.
Disconnect clutch switch connector.

B

CL

D

SCIA1284E

E

5.

Remove nuts (3), and remove clutch pedal assembly.
F

G

H

I

J

K

SCIA1260E

L

INSPECTION AFTER REMOVAL
●

Check clutch pedal for bend, damage, and a cracked weld. If bend, damage, or a cracked weld is found,
replace clutch pedal assembly.

INSTALLATION
●

Install in the reverse order of removal.

CL-7

M

CLUTCH FLUID
CLUTCH FLUID
Air Bleeding Procedure

PFP:00017
BCS000KR

CAUTION:
●
Monitor fluid level in the reservoir tank to make sure it does not empty.
●
Do not spill brake fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
●
Bleed the bleeding connector.
1. Fill the master cylinder reservoir tank with new brake fluid.
2. Remove rubber cap and connect a transparent vinyl hose to air
bleeder of bleeding connector.

SCIA1261E

3.

4.

Lift tube side lock pin of bleeding connector up one step.
CAUTION:
Do not remove lock pin.
“Depress” and “release” the clutch pedal slowly and fully 15
times at an interval of 2 to 3 seconds and hold it.
CAUTION:
Hold it to prevent releasing tube from bleeding connector
when fluid pressure is applied in the tube.
SCIA1262E

5.
6.
7.
8.

Slide tube 5 mm (0.20 in) to the direction shown by the arrow
and drain clutch fluid.
Return tube to its original position.
Release clutch pedal and wait for 5 seconds.
Repeat steps 4 to 7 until no bubbles can be observed in the
brake fluid.

SCIA1263E

CL-8

CLUTCH MASTER CYLINDER
CLUTCH MASTER CYLINDER
Removal and Installation

PFP:30610

A
BCS000KS

REMOVAL
1.

2.

Drain brake fluid from reservoir tank and remove hose from the nipple.
B
CAUTION:
Do not spill brake fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
CL
Unlock master cylinder rod end in the passenger room and separate master cylinder from clutch pedal.
D

E

F
SCIA1284E

3.
4.

Remove lock pin from master cylinder and separate clutch tube.
Rotate master cylinder clockwise by 45° and remove it from the
vehicle.

G

H

I

SCIA1285E

J

INSTALLATION
1.

2.

Tilt master cylinder clockwise by 45° and insert to the mounting
hole. Rotate counter clockwise and secure it. At this time, nipple
is upward of the vehicle.
After finishing work, perform clutch pedal height inspection and
clutch piping air bleeding.
● Refer to CL-6, «On Board Inspection» ,CL-8, «Air Bleeding
Procedure»

K

L

M
SCIA1286E

CL-9

CSC (CONCENTRIC SLAVE CYLINDER)
CSC (CONCENTRIC SLAVE CYLINDER)
Removal and Installation

PFP:30500
BCS000KT

CAUTION:
●
Do not spill brake fluid onto painted surfaces.
If it spills, wipe up immediately and wash the affected area with water.
●
If manual transaxle is removed from the vehicle, always replace CSC (concentric slave cylinder).
CSC insert is returned to original position to remove transaxle. Dust on clutch disc sliding parts
may damage CSC seal and may cause brake fluid leak.

REMOVAL
1.
2.

Remove manual transaxle. Refer to MT-7, «REMOVAL AND INSTALLATION»
«REMOVAL AND INSTALLATION» (JR5).
Remove bolts and CSC from manual transaxle.

(JH3) or MT-37,

MCIA0172E

INSPECTION
NOTE:
●
Cannot disassemble CSC and release bearing because they are integral parts. Replace them as an
assembly.
Inspect for the following, and replace parts if necessary.
●
CSC: damage, foreign material, wear or pinholes on the cylinder outer surface.
●
Release bearing: damage, incorrect rotation direction, or has poor aligning function, and dust seal is
deformed or cracked.

INSTALLATION
1.

Install new CSC to manual transaxle. Tighten to the specified torque.
Tightening torque
: 21 N·m (2.15 kg-m, 15.5 ft- lb)

2.
3.

CAUTION:
Do not insert and operate CSC because piston and stopper of CSC components may fall off.
Install manual transaxle to the vehicle. Refer to MT-7, «REMOVAL AND INSTALLATION» (JH3) or MT-37,
«REMOVAL AND INSTALLATION» (JR5).
Bleed air from the clutch piping. Refer to CL-8, «Air Bleeding Procedure» .

CL-10

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Removal and Installation

PFP:30100

A
BCS000KU

CAUTION:
●
If manual transaxle is removed from the vehicle, always replace CSC (concentric slave cylinder). B
CSC insert is returned to original position to remove transaxle. Dust on clutch disc sliding parts
may damage CSC seal and may cause brake fluid leak.
●
Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface, CL
or flywheel surface.

Petrol Engine
D

E

F

G

H

I
SCIA1268E

Diesel Engine

J

K

L

M

YCL032

CL-11

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
REMOVAL
1.
2.

Remove manual transaxle from the vehicle. Refer to MT-7, «REMOVAL AND INSTALLATION» (JH3) or
MT-37, «REMOVAL AND INSTALLATION» (JR5).
Loosen clutch cover mounting bolts evenly. Remove clutch cover and clutch disc.

INSPECTION AND ADJUSTMENT AFTER REMOVAL (CR ENGINE)
Clutch Disc
●

Measure circumferential runout relative to the clutch disc center
spline. If it is outside the specification, replace the clutch disc.
Runout limit/diameter of the area to be measured:
CR14 engine :1.0mm (0.039 in) or less/180
(7.08 in) mm dia.
HR engine :1.0mm (0.039 in) or less/190
(7.48 in) mm dia.

SCIA1270E

●

Using calipers, measure the depth to the clutch disc facing rivet
heads. If it exceeds the allowable wear limit, replace the clutch
disc.
Facing wear limit (depth to the rivet head)
: 0.3 mm (0.012 in)

SCL229

Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using a diaphragm adjusting wrench (SST).
Tolerance for diaphragm spring lever unevenness
CR engine
: 0.7 mm (0.028 in)
HR engine
: 0.7 mm (0.028 in)
K9K 50/63kW
: 0.8 mm (0.031 in)
●

●

Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly.
CLA0069D
NOTE:
● Worn thrust ring will generate a beating noise when tapped at the rivet with a hammer.
● Broken thrust ring will make a clinking sound when cover is shaken up and down.
If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.

CL-12

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Flywheel Runout
A

Using a dial gauge, measure runout at the flywheel clutch contact
surface. If runout is outside the specification, replace the flywheel. If
a trace of burn or discoloration is found on the surface, repair it with
sandpaper.

B

Flywheel surface runout
: EM-93, «FLYWHEEL RUNOUT» .
CL

CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch
cover mounting hole).
PCIB0016E

INSPECTION AND ADJUSTMENT AFTER REMOVAL (K9K ENGINE)
Clutch Disc

D

E

The hubs of the clutch discs are nickel plated to improve their
sliding performance.
●
Clean the splines of the clutch shaft and install the assembly
without lubricant.
●
Degrease the friction face of the flywheel.
●
Install the clutch disc (offset (A) from the hub on the flywheel
side).
CAUTION:
Reworking on the clutch face is not permitted.
●

F

G

H
YCL034

Flywheel Runout
I

Replace the flywheel if it has been damaged.

INSTALLATION
1.
2.

3.

4.

Clean input shaft spline by removing grease and dust from wear.
Apply recommended Grease to clutch disk and input shaft spline.
NOTE:
Applied amount of grease is 0.4 g. Coating thickness is 1 mm (0.04 in) or less.
Insert clutch disc to input shaft. Wipe off any grease oozing from the parts.
CAUTION:
● Excessive grease may cause slip or judder. And if it adheres to CSC seal, it cause clutch fluid
leak. Wipe off excess grease.
● If grease is not applied, it may cause noise, poor disengagement, or damage to the clutch. Be
sure to apply grease.
Install clutch disc and clutch cover. Pre-tighten mounting bolts
and install a clutch aligner (SST).
Tool number

5.

A: EM07020000 (CR,K9K engine)
A: KV30101000 (HR engine)

Tighten clutch cover attaching bolts evenly in two steps in the
order shown in the figure.
Tightening torque (CR engine)
First step
: 9.9 — 19 N·m (1.0 — 2.0 kg-m, 8 — 14 ft-lb)
Final step : 22 — 29 N·m (2.2 — 3.0 kg-m, 17 — 21 ft-lb)
Tightening torque (HR engine)
First step
: 19 N·m (2.0 kg-m, 14 ft-lb)
Final step : 22 — 29 N·m (2.2 — 3.0 kg-m, 17 — 21 ft-lb)
Tighten clutch cover attaching bolts according to the order shown in the figure. (K9K engine)

CL-13

PCIB1503E

J

K

L

M

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
6.

Install manual transaxle. Refer to MT-7, «REMOVAL AND INSTALLATION» (JH3) or MT-37, «REMOVAL
AND INSTALLATION» (JR5).

CL-14

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Clutch Pedal

PFP:00030

A
BCS000KV

Unit mm (in)
Engine type

CR

K9K

B

HR

50/63kW
Pedal height

LHD models

160 — 169 (6.30 — 6.65)

170 — 180 (6.69 — 7.09)

160 — 169 (6.30 — 6.65)

RHD models

164 — 174 (6.46 — 6.85)

175 — 185 (6.89 — 7.23)

175 — 185 (6.89 — 7.23)

Pedal height at clutch disengagement

100 (3.94)
or more

Pedal free play

—

D

0.5 (0.02)

Clutch Disc

BCS000KW

Unit: mm (in)
Engine type
Size
Wear limit (depth to rivet head)

CR14

K9K 50/63kW

HR

190 (7.48) dia.

216 (8.50) dia.

200 (7.87) dia.

0.3 (0.012)

—

0.3 (0.012)

—

1 (0.039)

—

1.0 (0.039)
or less / 180 (7.08) dia.

—

1.0 (0.039)
or less / 190 (7.48) dia.

—

6.8 — 7.2
(0.27 — 0.28)

—

Wearing thickness of facing
Runout limit/diameter of the area to be measured

CL

Thickness of disc assy with load (new)

Clutch Cover

E

F

G

H
BCS000KX

Unit: mm (in)
Engine type
Size
Diaphragm spring lever height
Uneven limit diaphragm spring toe height

I

CR

K9K 50/63kW

HR

190 (7.48) dia.

216 (8.50) dia.

215 (8.46) dia.

32.0 — 34.0
(1. 26 — 1.34)

—

29.0 — 31.0
(1.14 — 1.22)

0.7 (0.028) or less

0.8 (0.031) or less

0.7 (0.028) or less

Clutch Control System

J

BCS000KY

Type of clutch control

K

Hydraulic

L

Clutch Master Cylinder

BCS000KZ

Unit: mm (in)
Inner diameter

15.87 (5/8)

CL-15

M

SERVICE DATA AND SPECIFICATIONS (SDS)

CL-16