<sub>FUEL GAUGE UNIT CHECK

54300120400

Remove the fuel gauge unit from the fuel tank. (Refer to GROUP 13C.) FUEL GAUGE UNIT RESISTANCE 1. Check that resistance value between the fuel gauge terminal and earth terminal is at standard value when fuel gauge unit float is at point F (highest) and point E (lowest). Standard value: Standard value W

Items Main

Sub

1 -3

Float point E

56.5 - 62.5

Float point F

1- 3

Float point E

48.5 - 54.5

2. Check that resistance value changes smoothly when float moves slowly between point F (highest) and point E (lowest). FUEL GAUGE UNIT FLOAT HEIGHT Move float and measure the height A at point F (highest) and B at point E (lowest) with float arm touching stopper.

A

Point F (highest)

Float point F

Standard value: B

Items Point E (lowest)

Main

Sub

Standard value mm Float point F

31.8 - 37.8

Float point E

128.7 - 134.7

Float point F

20.5 - 26.5

Float point E

133.7 - 139.7

CHASSIS ELECTRICAL - Combination Meters

54-23

ENGINE COOLANT TEMPERATURE GAUGE UNIT 54300150041 CHECK 1. Bleed the engine coolant. (Refer to GROUP 14 – On-vehicle Service.) 2. Remove the engine coolant temperature gauge unit. 3. Immerse the unit in 70_C water to measure the resistance. Standard value: 104 ± 13.5 W

4. After checking, apply the specified adhesive around the thread of engine coolant temperature gauge unit. Specified sealant: 3M Adhesive Nut Locking No. 4171 or equivalent 5. Add engine coolant. (Refer to GROUP 14 – On-vehicle Service.) 11 Nm

54-24

CHASSIS ELECTRICAL - Combination Meters

COMBINATION METERS

54300290286

REMOVAL AND INSTALLATION Section A - A Instrument panel

Section B - B Instrument panel Clip

1

2

2

A

B

B

B

A

B

3

Combination meter removal steps 2. Meter hood 3. Combination meter

Speed sensor removal steps D Air cleaner assembly 1. Speed sensor

INSPECTION Vehicle speed sensor

Terminal number

Resistance (3 - 10 kW) Circuit tester

Battery

54300300217

VEHICLE SPEED SENSOR INSPECTION 1. Lift up the vehicle. 2. Remove the vehicle speed sensor, and then connect the vehicle speed sensor and a resistance (3 - 10 kW) as shown in the illustration. 3. Use a circuit tester to check that the voltage between terminal 2 and terminal 3 changes when turning a shaft of the vehicle speed sensor (4 pulses per each one turn).

CHASSIS ELECTRICAL - Combination Meters Earth

Power supply

Fuel gauge

Engine coolant temperature gauge

Power supply

Earth

54-25

54300300224 FUEL GAUGE RESISTANCE CHECK 1. Remove the power supply tightening screw. 2. Use an ohmmeter to measure the resistance value between the terminals.

Standard value: Power supply - Earth: 350 W Power supply - Fuel gauge: 250 W Fuel gauge - Ground: 100 W Caution When inserting the testing probe into the power supply terminal, be careful not to touch the printed board.

ENGINE COOLANT TEMPERATURE GAUGE 54300300231 RESISTANCE CHECK 1. Remove the power supply tightening screw. 2. Use an ohmmeter to measure the resistance value between the terminals. Standard value: Power supply - Earth: 194 W Power supply - Engine coolant temperature gauge: 90 W Engine coolant temperature gauge - Earth: 254 W Caution When inserting the testing probe into the power supply terminal, be careful not to touch the printed board.

54-26 CHASSIS ELECTRICAL -

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

HEADLAMP, FRONT TURN-SIGNAL LAMP AND FRONT FOG LAMP

54200030274

SERVICE SPECIFICATIONS Items Headlamp aiming for low beam

Standard value

Limit

Vertical direction

60 mm below horizontal (H)

-

Horizontal direction

Position where the 15_ sloping section intersects the vertical line (V)

-

-

30,000 or more

Vertical direction

100 mm below horizontal (H)

-

Horizontal direction

Parallel to direction of vehicle travel

-

Headlamp intensity cd Front fog lamp aiming

SPECIAL TOOLS Tool

A

B

54200060594

Number

Name

Use

MB991502

MUT-II sub assembly

ETACS-ECU input check

MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222

Harness set A: Test harness B: LED harness C: LED harness adapter D: Probe

Making voltage and resistance measurements during troubleshooting A: Connector pin contact pressure inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection

MB990784

Ornament remover

Removal of switch garnish

C

D

CHASSIS ELECTRICAL -

TROUBLESHOOTING

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

54-27 54200070610

The special tool (MB991223) should always be used to measure voltages and resistances when carrying out troubleshooting.

DIAGNOSIS FUNCTION INPUT SIGNAL INSPECTION PROCEDURE 1. Connect the MUT-II or a voltmeter to the diagnosis connector to check input signal. (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.) 2. The following input signals can be checked: D Lighting switch (AUTO, HEAD, TAIL, Passing, Dimmer) D Turn signal lamp switch (R.H., L.H.) D Front fog lamp switch D Hazard lamp switch D Mist NOTE If all the input signals cannot be check by using the MUT-II, the diagnosis circuit may be defective. ETACS FUNCTION ADJUSTMENT PROCEDURE The following functions can be adjusted by operating input switches. The adjustments will be stored in the ECU memory even after a battery cable is disconnected: D Automatic headlamp switch-off function 1. Entry conditions to the adjustment mode The ETACS-ECU sounds a buzzer once when all of the following conditions are satisfied, and then enters the adjustment mode: D Hazard warning lamp switch: OFF D Diagnosis control: ON (Connect the MUT-II or earth the diagnosis connector No.1 terminal.) D Key reminder switch: OFF D Ignition switch: OFF D Driver’s door switch: OFF (Close the driver’s door.) If all of the conditions above are satisfied, the windshield washer switch will be turned on for ten seconds. 2. Exit conditions from the adjustment mode The ETACS-ECU cancels the adjustment mode when any of the following conditions is satisfied: D Diagnosis control: ON (Connect the MUT-II or earth the diagnosis connector No.1 terminal.) D Key reminder switch: ON (Pull out the ignition key.) D Ignition switch: Other than OFF D Driver’s door switch: ON (Open the driver’s door.) D After the ETACS-ECU has entered the adjustment mode, no adjustment is made within three minutes (If any adjustment is made within three minutes, the ETACS-ECU monitors a adjustment operation for other three minutes.) D Other warning buzzer(s) sounds

54-28 CHASSIS ELECTRICAL -

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

3. Adjustment of functions Function

Adjustment procedure

Automatic headlamp switch-off function

When the lighting switch is at HEAD position, turn signal lamp switch is at RH position and the passing switch is turned on for two seconds, the headlamp automatic switch-off function toggles on and off. D If the function toggles on, the buzzer sounds once (default condition). D If the function toggles off, the buzzer sounds twice.

Initialization of the functions above

When the windshield washer switch remains on for more than twenty seconds, the buzzer sounds twice and then all of the following functions will be initialized. D Automatic headlamp switch-off function D Keyless entry answerback function The buzzer will sound in ten seconds (indicating that the ETACS-ECU enters the adjustment mode), but the washer switch must remains off for twenty seconds in order to initialize all the functions. If the windshield washer switch remains on for more than twenty seconds without entering the adjustment mode, the system enters the adjustment mode in ten seconds, but does not initialize all of the functions.

CHASSIS ELECTRICAL -

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

54-29

INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptoms

Inspection procedure

Reference page

The lighting monitor buzzer does not sound under the following conditions while tail 1 lamps or headlamps illuminate. D When the ignition switch is turned to OFF position and the driver’s side door is open.

54-30

The headlamps and tail lamps do not switch off automatically when removing the ignition key and opening the driver’s side door while tail lamps or headlamps illuminate. (However, the lighting monitor buzzer sounds.)

2

54-31

The headlamps do not change to high beam or low beam.

3

54-31

The headlamps do not illuminate when the passing switch is operated.

4

54-32

Headlamp angle does not change when the headlamp leveling switch is operated.

5

54-33

The headlamps do not illuminate when the vehicle is in the following condition and the ignition switch is at the ON position. However, the headlamps illuminate when the lighting switch is turned to the HEAD position. D Lighting switch: OFF D Passing switch: OFF

6

54-34

7

54-35

The turn signal lamps do not flash.

8

54-35

The hazard warning lamps do not flash.

9

54-36

The headlamps do not switch off when the vehicle is in the following condition and the lighting switch is turned to the TAIL position. D Ignition switch: OFF D Passing switch: OFF The fog lamps do not illuminate when the fog lamp switch is turned on while tail lamps or headlamps illuminate. The fog lamps do not switch off when the lighting switch is turned off while fog lamps illuminate. The fog lamps do not switch off when the tail lamps switch off by the automatic headlamp switch-off function while fog lamps illuminate.

54-30 CHASSIS ELECTRICAL -

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 The lighting monitor buzzer does not sound when the ignition switch is turned to OFF position and the driver’s side door is opened while the tail lamps or headlamps illuminate. When the automatic headlamp switch-off function operates, headlamps switch off after the buzzer sounds for one second, and the buzzer ceases sounding.

Probable cause

The cause is probably a malfunction of the lighting switch input circuit system or a malfunction of the ETACS-ECU. If the ignition key reminder warning buzzer is sounding, even if the tail lamps or headlamps illuminate, the lighting monitor buzzer does not sound.

D D

MUT-II Pulse check Lighting switch input signal OK: Buzzer of MUT-II sounds once when operating the lighting switch as follows: D Turn the switch to AUTO D Turn the switch from AUTO to TAIL D Turn the switch to HEAD D Turn the passing switch from OFF to ON D Turn the dimmer switch from OFF to ON

NG

Malfunction of harness or connector Malfunction of ETACS-ECU

Check the following connectors: B-82, B-98 OK Check trouble symptom.

NG Repair

NG Check the harness between the column switch and the ETACS-ECU. Repair, if necessary.

OK MUT-II Pulse check Front door switch (R.H.) input signal OK: Buzzer of MUT-II sounds once when opening the driver’s side door. OK Replace the ETACS-ECU.

NG

Check the following connectors: C-01, B-90, B-98 OK Check trouble symptom.

NG Repair

NG Check the harness between the front door switch (R.H.) and the ETACS-ECU. OK Check trouble symptom.

NG Repair

NG Check the harness between the front door switch (R.H.) and the earth. Repair, if necessary.

CHASSIS ELECTRICAL -

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

54-31

Inspection Procedure 2 The headlamps and tail lamps do not switch off automatically when removing the ignition key and opening the driver’s side door while tail lamps or headlamps illuminate. (However, the lighting monitor buzzer sounds.)

Probable cause

The cause is probably a malfunction of the ignition switch and front door switch (R.H.) input circuit system or a malfunction of the ETACS-ECU.

D D

NG MUT-II Pulse check Lighting switch input signal OK: Buzzer of MUT-II sounds once when turning the ignition switch from OFF to ON or from OFF to ACC.

Malfunction of harness or connector Malfunction of ETACS-ECU

Check the following connectors: B-82, B-98 NG

OK Check trouble symptoms.

OK

Repair

NG Check the harness between the ignition switch and the ETACS-ECU. Repair, if necessary.

MUT-II Pulse check Front door switch (R.H.) input signal OK: Buzzer of MUT-II sounds once when opening the driver’s side door.

NG

Check the following connectors: C-01, B-90, B-98 NG

OK Check trouble symptoms.

OK

Repair

NG Check the harness between the front door switch (R.H.) and the ETACS-ECU.

Replace the ETACS-ECU.

OK

NG

Check trouble symptoms.

Repair

NG Check the harness between the front door switch (R.H.) and the earth. Repair, if necessary.

Inspection Procedure 3 The headlamps do not change to high beam or low beam.

Probable cause

The cause is probably a malfunction of the dimmer switch input circuit system or a malfunction of the ETACS-ECU.

D D D

MUT-II Pulse check Dimmer switch input signal OK: Buzzer of MUT-II sounds once when turning the dimmer switch from OFF to ON. OK

NG

Malfunction of harness or connector Malfunction of ETACS-ECU Malfunction of front ECU

Check the following connectors: B-80, B-14, B-70, A-69X Check trouble symptoms.

Repair

NG Check the harness between the column switch (dimmer switch) and the ETACS-ECU. Repair, if necessary.

Replace the ETACS-ECU.

OK

Check trouble symptoms. NG Replace the front ECU.

NG

OK

Check trouble symptoms. NG Check the harness between the column switch (dimmer switch) and the earth. Repair, if necessary.

54-32 CHASSIS ELECTRICAL -

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

Inspection Procedure 4 The headlamps do not illuminate when the passing switch is operated.

Probable cause

The cause is probably a malfunction of the passing switch input circuit system or a malfunction of the ETACS-ECU.

D D D

MUT-II Pulse check Passing switch input signal OK: Buzzer of MUT-II sounds once when turning the passing switch from OFF to ON. OK

NG

Malfunction of harness or connector Malfunction of ETACS-ECU Malfunction of front ECU

Check the following connectors: B-80, B-14, B-70, A-69X Check trouble symptoms.

Repair

NG Check the harness between the column switch (passing switch) and the ETACS-ECU. Repair, if necessary.

Replace the ETACS-ECU.

OK

Check trouble symptoms. NG Replace the front ECU.

NG

OK

Check trouble symptoms. NG Check the harness between the column switch (passing switch) and the earth. Repair, if necessary.

CHASSIS ELECTRICAL -

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

54-33

Inspection Procedure 5 Headlamp angle does not change when the headlamp leveling switch is operated.

Probable cause

The cause is probably a malfunction of the headlamp leveling switch circuit system or a malfunction of the headlamp leveling unit circuit system. If there is a blown fuse, there may also be a short-circuit in a harness.

D D D D D

Headlamp leveling switch check (Refer to P.54-44.) OK Headlamps illuminate when the lighting switch is moved to the HEAD position.

NG

NG

(1) NG

Headlamp circuit check and repair

Check the following connectors: B-75, B-81, B-48 OK Check trouble symptoms.

(2) NG

OK

Check the following connectors: B-48, B-61X OK Check trouble symptoms.

(1) NG Disconnect the headlamp leveling unit connectors A-25(LH), A-41(RH) and measure at the harness side. Both the left and right connectors of the headlamp leveling unit should be checked. (1) Voltage between terminal (3) - earth OK: System voltage (2) Continuity between terminal (1) - (2) NG earth OK: Continuity OK Disconnect the headlamp leveling unit (LH), headlamp leveling unit (RH) and headlamp leveling switch connectors A-25, A-41, B-48 and measure at the harness side. D Continuity between terminal No. 2 of the headlamp leveling unit (both) and terminal No. 4 of the headlamp leveling switch. OK: Continuity OK Replace the headlamp leveling unit.

NG

of fuse the headlamp leveling switch of connector of harness of the headlamp leveling unit

Replace

OK Disconnect the headlamp leveling switch connector B-48 and measure at the harness side. D Ignition switch: ON D Lighting switch: HEAD (1) Voltage between terminal (6) - earth OK: System voltage (2) Continuity between terminal (3) earth OK: Continuity

Malfunction Malfunction Malfunction Malfunction Malfunction

Check the following connector: B-75 OK Check trouble symptoms.

NG

NG

NG

NG

NG

NG

Repair

Check the harness between the headlamp relay and the headlamp leveling switch. Repair, if necessary.

Repair

Check the harness between the headlamp leveling switch and body earth. Repair, if necessary.

Repair

Check the harness between the headlamp relay and the headlamp leveling unit. Repair, if necessary.

Repair

Check the following connectors: A-70, A-39, B-45 OK Check trouble symptoms.

NG

NG

Repair

Check the harness between the headlamp leveling switch and the headlamp leveling unit (both). Repair, if necessary.

54-34 CHASSIS ELECTRICAL -

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

Inspection Procedure 6 The headlamps do not illuminate when the vehicle is in the following condition and the ignition switch is at the the ON position. However, they illuminate when the lighting switch is turned to the HEAD position. D Lighting switch: OFF D Passing switch: OFF

Probable cause

The headlamps do not switch off when the vehicle is in the following condition and the lighting switch is turned to the TAIL position. D Ignition switch: OFF D Passing switch: OFF The cause is probably a malfunction of the ETACS-ECU circuit system. If there may also be a open-circuit in a harness.

Check the following connectors: B-66, B-106

NG

Replace

OK Check the harness between the body earth and the ETACS-ECU. Repair, if necessary. OK Replace the ETACS-ECU.

D D D

NG Replace

Malfunction of connector Malfunction of harness Malfunction of the ETACS-ECU

CHASSIS ELECTRICAL -

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

54-35

Inspection Procedure 7 The fog lamps do not illuminate when the fog lamp switch is turned on while tail lamps or headlamps illuminate.

Probable cause

The fog lamps do not switch off when the lighting switch is turned off while fog lamps illuminate. The fog lamps do not switch off when the tail lamps switch off by the automatic headlamp switch-off function while fog lamps illuminate. The cause is probably a malfunction of the fog lamp switch input circuit system or a malfunction of the ETACS-ECU.

Fog lamp relay inspection. (Refer to P.54- 44.)

Malfunction Malfunction Malfunction Malfunction

of of of of

harness or connector ETACS-ECU front-ECU fog lamp relay

NG Replace

OK MUT-II Pulse check Fog lamp switch input signal OK: Buzzer of MUT-II sounds once when turning the fog lamp switch from OFF to ON.

D D D D

NG

Check the following connectors: B-44, B-100 NG

OK Check trouble symptoms.

OK

Repair

NG Check the harness between the fog lamp switch and the ETACS-ECU. Repair, if necessary.

Replace the ETACS-ECU.

OK

Check trouble symptoms. Check trouble symptoms.

NG

NG

Replace the front-ECU.

Check the harness between the fog lamp switch and the earth. Repair, if necessary.

Inspection Procedure 8 The turn signal lamps do not flash.

Probable cause

The cause is probably a malfunction of the turn signal lamp switch input circuit system or a malfunction of the ETACS-ECU.

D D

MUT-II Pulse check Turn signal lamp switch input signal OK: Buzzer of MUT-II sounds once when turning the turn signal lamp switch from OFF to ON. OK Replace the ETACS-ECU.

NG

Malfunction of harness or connector Malfunction of ETACS-ECU

Check the following connectors: B-80, B-14, B-100 NG

OK Check trouble symptoms.

Repair

NG Check the harness between the turn signal lamp switch and the ETACS-ECU. Repair, if necessary. OK Check trouble symptoms. NG Check the harness between the turn signal lamp switch and the earth. Repair, if necessary.

54-36 CHASSIS ELECTRICAL -

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

Inspection Procedure 9 The hazard warning lamps do not flash.

Probable cause

The cause is probably a malfunction of the hazard warning lamp switch input circuit system or a malfunction of the ETACS-ECU.

D D

MUT-II Pulse check Hazard warning lamp switch input signal OK: Buzzer of MUT-II sounds once when turning the hazard warning lamp switch from OFF to ON. OK Replace the ETACS-ECU.

NG

Malfunction of harness or connector Malfunction of ETACS-ECU

Check the following connectors: B-43, B-100 NG

OK Check trouble symptoms.

Repair

NG Check the harness between the hazard warning lamp switch and the ETACS-ECU. Repair, if necessary. OK Check trouble symptoms. NG Check the harness between the hazard warning lamp switch and the earth. Repair, if necessary.

CHASSIS ELECTRICAL -

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

ON-VEHICLE SERVICE

54-37 54200090289

HEADLAMP AIMING 1. The headlamps should be aimed with the proper beam setting equipment, and in accordance with the equipment manufacture’s instructions. NOTE If there are any regulations pertinent to the aiming of headlamps in the area where the vehicle is to be used, adjust so as to meet those requirements. 2. Alternately turn the adjusting screw to adjust the headlamp aiming. (Refer to P.54-37.)

Lamp centre



Lamp centre

Screen

5m

1. Inflate the tyres to the specified pressures and there should be no other load in the vehicles other than driver or substituted weight of approximately 75 kg placed in driver’s position. 2. Set the headlamp leveling switch to the “0” position. 3. Set the distance between the screen and the centre marks of the headlamps as shown in the illustration.

54-38 CHASSIS ELECTRICAL -

4. Check if the beam shining onto the screen is at the standard value.

(V) Distance of vertical direction (H)

Lamp centre 15 High intensity zone

Horizontal direction adjustment

Vertical and horizontal direction adjustment

Vertical and horizontal direction adjustment

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

Horizontal direction adjustment

Standard value: (Vertical direction) 60 mm below horizontal (H) (Horizontal direction) Position where the 15_ sloping section intersects the vertical line (V) NOTE The illustration shows L.H. drive vehicles. For R.H. drive vehicles, it is symmetrical. 5. Alternately turn the adjusting screw to adjust the headlamp aiming. Caution Be sure to adjust the aiming adjustment screw in the tightening direction.

CHASSIS ELECTRICAL -

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

HEADLAMP INTENSITY MEASUREMENT

54-39 54200100159

Using a photometer, and following its manufacture’s instruction manual, measure the headlamp intensity and check to be sure that the limit value is satisfied. Limit: 30,000 cd or more NOTE 1. When measuring the intensity, maintain an engine speed of 2,000 r/min, with the battery in the charging condition. 2. There may be special local regulations pertaining to headlamp intensity, be sure to make any adjustments necessary to satisfy such regulations. 3. If an illuminometer is used to make the measurements, convert its values to photometer values by using the following formula. I = Er2 Where: I=intensity (cd) E=illumination (lux) r=distance (m) from headlamps to illuminometer

FRONT FOG LAMP AIMING



54200110213

1. Measure the centre of the fog lamps, as shown in the illustration. Lamp centre

Unit: mm



66

Lamp centre

Screen

5m

47

2. Set the distance between the screen and the centre of the fog lamps as shown in the illustration. 3. Inflate the tyres to the specified pressures and there should be no other load in the vehicles other than driver or substituted weight of approximately 75 kg placed in the driver’s position. 4. With the engine running at 2,000 r/min, aim the fog lamp.

54-40 CHASSIS ELECTRICAL Lamp centre

Centre of high intensity zone

Distance of vertical direction

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

5. Check if the beam shining onto the screen is at the standard value. Standard value: (Vertical direction) 100 mm below horizontal (H) (Horizontal direction) Parallel to direction of vehicle travel

High intensity zone

Adjusting screw

NOTE The horizontal direction is non-adjustable. If the deviation of the light beam axis exceeds the standard value, check to be sure that the mounting location or some other point is not defective. Caution When making the aiming adjustment, be sure to mask those lamps which are not being adjusted.

Adjusting screw

Spring

BULB REPLACEMENT

54200130301

Unhook the spring which secures the bulb, and then remove the bulb. Caution Do not touch the surface of the bulb with hands or dirty gloves. If the surface does become dirty, clean it with alcohol or thinner, and let it dry thoroughly before installing.

CHASSIS ELECTRICAL

Position lamp bulb

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

54-41

Remove the lamp socket by turning it anti-clockwise, then pull out the bulb from the socket.

Position lamp bulb

Rotate the socket to remove the bulb from the headlamp assembly.

Fog lamp bulb

Caution (1) Always use the specified genuine part for replacement. (2) Do not touch the surface of the bulb with hands or dirty gloves. If the surface does become dirty, clean it with alcohol or thinner, and let it dry thoroughly before installing. 1. Remove the fog lamp. 2. Remove the socket cap. 3. Remove the bulb mounting spring, and then withdraw the bulb. 4. Disconnect the connector, and then replace the bulb. Caution (1) Always use the genuine part for replacement. (2) Do not touch the surface of the bulb with hands or dirty gloves. If the surface does become dirty, clean it with alcohol or thinner, and let it dry thoroughly before installing. (3) Be sure to install the socket cap. If the socket cap is improperly installed, the lens will be fogged or water may enter the lamp unit.

54-42 CHASSIS ELECTRICAL -

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

HEADLAMP AND FRONT TURN-SIGNAL LAMP

54200240257

REMOVAL AND INSTALLATION 5 Nm

2

1

5 Nm

A A

4

3

5

Section A - A Clamp Clamp

7

6

AA"

Headlamp removal steps 1. Radiator grille 2. Headlamp

AB"

Front turn-signal lamp removal steps 3. Front turn-signal lamp 4. Bulb 5. Socket

Headlamp leveling switch removal steps 6. Switch garnish 7. Headlamp leveling switch NOTE For removal and installation of the column switch (lighting switch), refer to GROUP 37A - Steering Wheel and Shaft.

CHASSIS ELECTRICAL -

54-43

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

REMOVAL SERVICE POINTS

Flat-tipped screwdriver

AA" RADIATOR GRILLE REMOVAL Pull the radiator grille toward you gently, and press the clip tab with a flat-tipped screwdriver toward the arrow to remove the radiator grille. Radiator grille clip

Radiator grille

AB" FRONT TURN SIGNAL LAMP REMOVAL

MB990784

INSPECTION

54200250090

FOG LAMP SWITCH CONTINUITY CHECK Switch position

Terminal No. 1

-

ON

ILL

OFF

ILL

2

3

4

5

6

54-44 CHASSIS ELECTRICAL Fog lamp relay

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

FOG LAMP RELAY CONTINUITY CHECK Battery voltage

Terminal No. 1

3

4

5

Not supplied Supplied

HEADLAMP LEVELING SWITCH CHECK Check the resistance between the terminals when the headlamp leveling switch is operated. Standard value: Resistance measurement terminal No.

Switch position 0

1

2

3

4

Between 3 and 4 W

1,235

1,114

977

862

747

Between 4 and 6 W

548

669

806

921

1,036

Between 3 and 6 W

1,003

CHASSIS ELECTRICAL -

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

HEADLAMP, FRONT TURN-SIGNAL LAMP AND FRONT FOG LAMP

54-45 54200240264

REMOVAL AND INSTALLATION 5 Nm

2

1

5 Nm 5 Nm

A

A

Section A - A Clamp

5

6

4

3 Clamp

8

7

AA"

AB"

Headlamp removal steps 1. Radiator grille 2. Headlamp Front turn-signal lamp and front fog lamp removal steps 3. Front turn-signal lamp 4. Bulb 5. Socket 6. Front fog lamp

Headlamp leveling switch removal steps 7. Switch garnish 8. Headlamp leveling switch NOTE For removal and installation of the column switch (lighting switch), refer to GROUP 37A - Steering Wheel and Shaft.

54-46 CHASSIS ELECTRICAL -

Headlamp, Front Turn-signal Lamp and Front Fog Lamp

REMOVAL SERVICE POINTS AA" RADIATOR GRILLE REMOVAL Pull the radiator grille toward you gently, and press the clip tab with a flat-tipped screwdriver toward the arrow to remove the radiator grille.

AB" FRONT TURN-SIGNAL LAMP REMOVAL 1. Use the special tool to remove the front turn-signal lamp.

MB990784

2. Remove the fog lamp, disconnect the front turn-signal lamp connector from the fog lamp stay, and then remove the front turn-signal lamp from the vehicle.

Front turn-signal lamp

INSPECTION Refer to P.54-43.

54200250106

CHASSIS ELECTRICAL - Side Turn-signal Lamp

SIDE TURN-SIGNAL LAMP

54-47 54200060105

SPECIAL TOOL Tool



Fender panel

MB990784

Fender panel

Number

Name

Use

MB990784

Ornament remover

Removal of side turn-signal lamp

MB990784

REMOVAL SERVICE POINT

54200330145

SIDE TURN-SIGNAL LAMP REMOVAL Use a special tool to remove the lock from the fender panel, and then remove the side turn-signal lamp.

54-48

CHASSIS ELECTRICAL - Room Lamp

ROOM LAMP

54200060600

SPECIAL TOOLS Tool

A

B

C

D

Number

Name

Use

MB991502

MUT-II sub assembly

ETACS-ECU input check

MB991529

Diagnosis code check harness

ETACS-ECU input check

MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222

Harness set A: Test harness B: LED harness C: LED harness adapter D: Probe

ETACS-ECU terminal voltage measurement A: Connector pin contact pressure inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection

54-49

CHASSIS ELECTRICAL - Room Lamp

TROUBLESHOOTING

54200070627

DIAGNOSIS FUNCTION INPUT SIGNAL INSPECTION PROCEDURE 1. Connect the MUT-II or a voltmeter to the diagnosis connector to check input signal. (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.) 2. The following input signals can be checked: D Door switch D Ignition switch D Key reminder switch D Keyless entry transmitter (LOCK, UNLOCK) NOTE If all the input signals cannot be check by using the MUT-II, the diagnosis circuit may be defective.

INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptoms

Inspection procedure

Reference page

When all the doors is closed, the room lamp is switched off immediately, but does not fade out.

1

54-49

When a door is opened with the room lamp switch in the DOOR position, the room lamp does not illuminate.

2

54-50

When the ignition switch is turned to the ON position while the room lamp is fading out, the room lamp is not switched off (However, the room lamp will be switched off after fading out).

3

54-50

The room lamp can not be switched off (However, it is switched off when the room lamp switch is set to the OFF position).

4

54-51

INSPECTION PROCEDURE 1 When all the doors is closed, the room lamp is switched off immediately, but does not fade out.

Probable cause

The harness wire in the earth circuit or the ETACS-ECU can be defective.

D D

Check the following connectors: B-98, B-106, B-83

OK

Malfunction of harness or connector Malfunction of ETACS-ECU

Check trouble symptoms. NG Check the harness wire between the ETACS-ECU and body earth. OK Replace the ETACS-ECU.

NG Repair

54-50

CHASSIS ELECTRICAL - Room Lamp

INSPECTION PROCEDURE 2 When a door is opened with the room lamp switch in the DOOR position, the room lamp does not illuminate.

Probable cause

The door switch circuit of all doors or the room lamp illumination circuit can be defective.

D D D

NG MUT-II Pulse check Check the input signals of all door switches. OK: When a door switch is turned on, the MUT-II sounds once. NG Check continuity at the room lamp switch. OK Measure at the room lamp connectors C-04 and C-07. D Disconnect the connector, and measure at the harness side. D Voltage between 1 and body earth OK Battery voltage

NG NG

Malfunction of room lamp Malfunction of harness or connector Malfunction of ETACS-ECU

Check the input circuit of all door switches. (Refer to P.54-51, INSPECTION PROCEDURE 5.)

Repair

Check the following connectors: C-04, C-07, B-27, B-88, B-103, B-66 OK

OK

NG

Check trouble symptoms.

Repair

NG

Check the following connectors: C-04, C-07 OK

Check the harness wire between the room lamp and dedicated fuse No.6.

Check trouble symptoms.

OK

NG

NG

Replace the ETACS-ECU.

Check the harness wire between the ETACS-ECU and the room lamp, and repair if necessary.

Repair

INSPECTION PROCEDURE 3 When the ignition switch is turned to the ON position while the room lamp is fading out, the room lamp is not switched off (However, the room lamp will be switched off after fading out).

Probable cause

The ignition circuit or the ETACS-ECU can be defective. In addition, a defective fuse can cause a malfunction in the indicator lamp in the combination meter or a short in the harness wire.,

D D D D

MUT-II Pulse Check Check the input signals of the ignition switch. OK: When the ignition switch is turned on and off, the MUT-II sounds once.

OK

Malfunction Malfunction Malfunction Malfunction

of of of of

fuse connector harness ETACS-ECU

Replace the ETACS-ECU.

NG Measure at the ETACS-ECU connector B-104. D Disconnect the connector, and measure at the harness side. D Ignition switch: ON D Voltage between 6 and earth OK Battery voltage

NG

Check the ignition switch (IG1) and the ETACS-ECU, and repair if necessary.

54-51

CHASSIS ELECTRICAL - Room Lamp INSPECTION PROCEDURE 4 The room lamp can not be switched off (However, it is switched off when the room lamp switch is set to the OFF position.

Probable cause

A short in the harness wire can be present, or a door switch can be defective.

D D

Measure at J/B connector B-98. D Disconnect the connector, and measure at the harness side. D Ignition switch: ON D Door switch: ON (door open) D Continuity between 10 and earth OK Continuity

OK

Malfunction of door switch Malfunction of harness

When the connector of a door switch is disconnected, does the room lamp illuminate? NO

YES Replace the door switch.

Check the harness wire between the J/B and the door switch, and repair if necessary.

NG Check the harness wire between the J/B and the room lamp, and repair if necessary.

INSPECTION PROCEDURE 5 Check the input circuit of all door switches. MUT-II Pulse Check Check the input signals of all door switches. OK: When a closed door is opened, the MUT-II sounds once.

NG

Check the following connectors: C-02, C-08, C-22, C-17, B-49, B-90, B-98, B-104 OK Check trouble symptoms. NG

NG Repair

Check the ETACS-ECU and each door harness wire. OK Check trouble symptoms. NG Replace the ETACS-ECU.

NG Repair

54-52

CHASSIS ELECTRICAL - Rear Combination Lamp

REAR COMBINATION LAMP

54200060587

SPECIAL TOOLS Tool

Number

Name

Use

MB991502

MUT-II sub assembly

ETACS-ECU input check

MB990784

Ornament remover

Removal of switch garnish

TROUBLESHOOTING Refer to P.54-27.

5420007034

CHASSIS ELECTRICAL - Rear Combination Lamp

REAR COMBINATION LAMP

54-53 54200450148

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Quarter Trim Removal and Installation (Refer to GROUP 52A.)

Section A - A

4

1

A

A

1 A A

4

A

2

A

3 Removal steps 1. Rear combination lamp 2. Socket assembly 3. Bulb 4. Grommet

NOTE For removal and installation of the column switch (lighting switch), refer to GROUP 37A - Steering Wheel and Shaft.

54-54

CHASSIS ELECTRICAL - Rear Combination Lamp

Pre-removal and Post-installation Operation Quarter Trim Removal and Installation (Refer to GROUP 52A.)

Section A - A

3

1 2

Grommet

A A

3

Removal steps 1. Socket assembly 2. Bulb 3. Rear combination lamp

NOTE For removal and installation of the column switch (lighting switch), refer to GROUP 37A - Steering Wheel and Shaft.

54-55

CHASSIS ELECTRICAL - Rear Combination Lamp INSPECTION

54200460073

REAR FOG LAMP SWITCH CHECK Switch position

Terminal No. 1

10

2

5

6

7

OFF

ILL

ON

ILL

REAR FOG LAMP RELAY CHECK Rear fog lamp relay

Battery voltage

Terminal No. 1

3

4

5

Supplied Not supplied

LIGHTING SWITCH AND TURN-SIGNAL LAMP SWITCH CHECK Refer to P.54-111.

54-56

CHASSIS ELECTRICAL - High-mounted Stop Lamp

HIGH-MOUNTED STOP LAMP

54200510310

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Tailgate Trim Removal and Installation (Refer to GROUP 42.)



3 1 2

3

Removal steps 1. Socket assembly 2. Bulb 3. High-mounted stop lamp

NOTE For removal and installation of the high-mounted stop lamp (tailgate spoiler-mounted type), refer to GROUP 51 - Aero parts.

CHASSIS ELECTRICAL - Rheostat

RHEOSTAT

54-57 54200060136

SPECIAL TOOL Tool

Number

Name

Use

MB990784

Ornament remover

Removal of switch garnish

RHEOSTAT

54200600154

REMOVAL AND INSTALLATION

2

1

Removal steps 1. Switch garnish 2. Rheostat

INSPECTION 40W

54200610218

1. Connect the battery and the test bulb (40W) as shown in the illustration. 2. Operate the rheostat, and if the brightness changes smoothly without switching off, then the rheostat function is normal.

54-58

CHASSIS ELECTRICAL - Hazard Warning Lamp Switch

HAZARD WARNING LAMP SWITCH

54200660213

REMOVAL AND INSTALLATION

2

A

1

A

B

B Section B - B

Section A - A Instrument panel

1

Instrument panel

Clip

Clip

1

Removal steps 1. Center air outlet assembly 2. Hazard warning lamp switch

INSPECTION Switch position

54200670230

Terminal No. 1

2

3

4

OFF ILL

ON ILL

54-59

CHASSIS ELECTRICAL - Horn/Cigarette Lighter

HORN

Horn relay

54300800076

INSPECTION HORN RELAY CONTINUITY CHECK Battery voltage

Terminal No. 1

3

4

5

Not supplied Supplied

CIGARETTE LIGHTER Element

Spot

54300570038

INSPECTION D D

Take out the plug, and check for a worn edge on the element spot connection, and for shreds of tobacco or other material on the element. Using a circuit tester, check the continuity of the element.

CAUTIONS FOR USE OF THE CIGARETTE LIGHTER SOCKET AS AUXILIARY POWER SOURCE 1. When using a “plug-in” type of accessory, do not use anything with a load of more than 120W. 2. It is recommended that only the lighter be inserted in the receptacle. Use of “plug-in” type accessories may damage the receptacle and result in poor retention of the lighter. 3. The specified load should be strictly observed, because overloaded cord burns the ignition switch and harness.

54-60

CHASSIS ELECTRICAL - Clock

CLOCK

54300060535

SPECIAL TOOL Tool

Number

Name

Use

MB990784

Ornament remover

Removal of switch garnish

CLOCK

54300590102

REMOVAL AND INSTALLATION View A

2 3

1

4

View A A

A

1

Section A - A

1, 2 A

Section B - B

Section C - C

1

A

1 B

B Instrument panel

C

3

Clip

Clip C : shows tabs.

Instrument panel

: shows clips.

Removal steps 1. Hood panel 2. Center hood

3. Bracket 4. Clock

2

54-61

CHASSIS ELECTRICAL - Radio and Tape Player

RADIO AND TAPE PLAYER

54400070036

TROUBLESHOOTING QUICK-REFERENCE TROUBLESHOOTING CHART Items

Problem symptom

Relevant chart

Noise

Noise appears at certain places when travelling.

A-1

Mixed with noise, only at night.

A-2

Broadcasts can be heard but UKW/MW/LW has a lot of noise.

A-3

There is noise when starting the engine.

A-4

Some noise appears when there is vibration or shocks during travelling.

A-5

Ever-present noise.

A-6

When switch is set to ON, no power is available.

B-1

No sound from one speaker.

B-2

There is noise but no reception for UKW/MW/LW or no sound from UKW/MW/LW.

B-3

Insufficient sensitivity.

B-4

Distortion on UKW/MW/LW.

B-5

Too few automatic select stations.

B-6

Insufficient memory (preset stations are erased).

B-7

Cassette tape will not be inserted.

C-1

No sound.

C-2

No sound from one speaker.

C-3

Sound quality is poor, or sound is weak.

C-4

Cassette tape will not be ejected.

C-5

Uneven revolution. Tape speed is fast or slow.

C-6

Faulty auto reverse.

C-7

Tape gets caught in mechanism.

C-8

Radio

Tape player

54-62

CHASSIS ELECTRICAL - Radio and Tape Player

CHART A. NOISE A-1 Noise appears at certain places when travelling. No

Is there a particular structure? Yes Find out the following information from the user: 1. Place 2. Locality conditions (valley, mountain, etc.) 3. Name and frequency of stations affected by noise

Do the following measures eliminate the noise?

Yes

OK

1. Change to a different station with a strong signal to boost resistance to interference. 2. Suppress high tones to reduce noise. 3. Extend antenna completely. No

If due to vehicle noise:

If due to external noise:

It may not be possible to prevent noise if the signal is weak.

In almost all cases, prevention on the receiver side is impossible. Weak signals especially are susceptible to interference.

If there is more noise than other radios, find out the noise conditions and the name and frequency of the receiving stations from the user, and consult with the service centre.

54-63

CHASSIS ELECTRICAL - Radio and Tape Player A-2 Mixed with noise, only at night. The following factors can be considered as possible causes of noise appearing at night. 1. Factors due to signal conditions: Due to the fact that long-distance signals are more easily received at night, even stations that are received without problem during the day may experience interference in a general worsening of reception conditions. The weaker a station is the more susceptible it is to interference, Is the noise still obvious even with the lamps OFF? Yes Do the following measures eliminate the noise? D D

Tune to a station with a strong signal. Tune to a station with a strong signal without completely extending the antenna. No

and a change to a different station or the appearance of a beating sound* may occur. Beat sound*: Two signals close in frequency interfere with each other, creating a repetitious high-pitched sound. This sound is generated not only by sound signals but by electrical waves as well. 2. Factors due to vehicle noise: Alternator noise may be a cause.

No

Yes

OK

Does the noise fade away when the vehicle harness is moved away from the radio chassis? (if the harness is not in the proper position.) No

If there is more noise than other radios, consult a service centre.

Yes

OK

54-64

CHASSIS ELECTRICAL - Radio and Tape Player

A-3 Broadcasts can be heard but UKW/MW/LW has a lot of noise. (1)

(2)

Noise occurs when the engine is stopped.

Noise occurs when the engine in running.

Yes Do the following measures eliminate the noise? D D D

Inspect the vehicle’s noise suppressor. (Refer to A-4.)

Tune to a station with a strong signal. Extend the antenna completely. Adjust the sound quality to suppress high tones. No

No

Is the radio body earth mounted securely? Yes Is the antenna plug properly connected to the radio? Yes Is the antenna itself in good condition or is it properly mounted? Yes

Yes

No

No

OK

Securely tighten the nuts for the body earth. Correctly attach the antenna plug.

Clean the antenna plug and earth wire mounting area. Mount the antenna securely.

Is the noise eliminated?

Yes

No If there is more noise than other radios, consult a service centre.

OK

54-65

CHASSIS ELECTRICAL - Radio and Tape Player A-4 There is noise when starting the engine. Noise type Sounds are in parentheses ( ).

Conditions

UKW/MW/LW: Ignition noise (Popping, snapping, cracking, buzzing)

D

Other electrical components

-

Static electricity (Cracking, crinkling)

D

D

D D

Cause

Increasing the engine speed D causing the popping sound to speed up, and volume D decreases. Disappears when the ignition switch is turned to ACC.

Mainly due to the spark D plugs. Due to the engine noise. D

Check or replace the earth cable. (Refer to Fig. 1 on P.54-65.) Check or replace the noise capacitor.

Noise may appear as electrical components become older.

Repair or replace electrical components.

Occurs when parts or wiring move for some reason and contact metal parts of the body.

Return parts or wiring to their proper position.

Various noises are produced Due to detachment from the depending on the body part of body of the front hood, the vehicle. bumpers, exhaust pipe and muffler, suspension, etc.

Tighten the mounting bolts securely. Cases where the problem is not eliminated by a single response to one area are common, due to several body parts being imperfectly earthed.

Disappears when the vehicle is completely stopped. Severe when the clutch is engaged.

Caution 1. Connecting a high tension cable to the noise filter may destroy the noise filter and should never be done. 2. Check that there is no external noise. Since failure caused by this may result in misdiagnosis due to inability to identify the noise source, this operation must be performed. 3. Noise prevention should be performed by suppressing strong sources of noise step by step. NOTE 1. Capacitor The capacitor does not pass D.C. current, but as the number of waves increases when it Fig. 1

Remedy

passes A.C. current, impedance (resistance against A.C.) decreases, and current flow is facilitated. A noise suppressing condenser which takes advantage of this property is inserted between the power line for the noise source and the earth. This suppresses noise by earthing the noise component (A.C. or pulse signal) to the body of the vehicle. 2. Coil The coil passes D.C. current, but impedance rises as the number of waves increases relative to the A.C. current. A noise suppressing coil which takes advantage of this property is inserted into the power line for the noise source, and works by preventing the noise component from flowing or radiating out of the line.

spot={{ID-#1}}link=GA

Earth cable

spot={{ID-#2}}link=GA

54-66

CHASSIS ELECTRICAL - Radio and Tape Player

A-5 Some noise appears when there is vibration or shocks during travelling. Are connectors properly connected? Yes Does noise appear when the radio switch is turned on while the vehicle is stopped and the radio is struck while tuned away from a station?

No No

Yes

Is the radio correctly earthed? (Is the mounting screw tightened securely?) Yes Is the antenna correctly earthed? (If noise appears when the antenna is moved, this means the earth is not securely connected.)

No

No

Ensure proper connection. Static electricity noise: Body static electric from the shock absorber rubber bushings used to prevent vibration, tyres, etc. occurs because of separation from the earth, causing a buzzing noise. Since no measures can be taken on the radio side, other steps should be taken to discharge the static electricity of the vehicle body. Tighten the screw securely.

If rust is present at the antenna earth screw, clean and tighten the earth securely.

Yes Repair or replace radio.

A-6 Ever-present noise. Noise is often created by the following factors, and often the radio is OK when it is checked individually. D Travelling conditions of the vehicle D Terrain of area travelled through D Surrounding buildings D Signal conditions D Time period

For this reason, if there are still problems with noise even after the measures described in steps A-1 to A-8 have been taken, get information on the factors listed above as well as determining whether the problem occurs with UKW/MW/LW, the station names, frequencies, etc., and contact a service centre.

CHASSIS ELECTRICAL - Radio and Tape Player B. RADIO B-1 No power is supplied when the switch is set to ON. Is dedicated fuse No. 6 blown or is the circuit open? No Is the connector at the back of the radio connected properly? Yes Disconnect and check the connector at the rear of the radio. Is the ACC power (12 V) being supplied to the radio?

Yes

No No

Replace fuse or repair harness. Connect connector securely. Repair harness.

Yes Repair or replace radio.

B-2 No sound from one speaker. Check to see if there is any sound when attached to another radio. No Remove the connector on the back of the radio and check the speaker harness for conductance. No Check the speaker for conductance. No Repair or replace speaker.

Yes

Yes

Yes

Repair or replace radio.

It conducts electricity but is shorted out.

Repair speaker harness and ensure proper connection of relay connectors.

Repair speaker harness.

54-67

54-68

CHASSIS ELECTRICAL - Radio and Tape Player

B-3 There is noise but no reception for UKW/MW/LW or no sound from UKW/MW/LW. Is the check being conducted under special electrical field conditions? No

Yes

Example: In an underground garage or inside a building.

Is proper performance obtained when the vehicle is moved?

Yes

OK

No Yes

Does tuning solve the problem?

OK

No Are the antenna plug and radio unit properly connected?

No

Reconnect

Yes Does the problem disappear if connected to another radio?

Yes

Repair or replace radio.

No Replace the antenna.

B-4 Insufficient sensitivity. Is the check being conducted under special electrical field conditions? No

Yes

Example: In an underground garage or inside a building.

Is proper performance obtained when the vehicle is moved?

Yes

OK

No Does tuning solve the problem?

Yes

OK

No Is the problem limited to the reception of a specific radio station from a specific position?

Yes

Electrical field condition related

No Is the antenna plug properly connected to the unit?

No

Ensure proper connection.

Yes Does the problem disappear when a different radio is connected? No Replace the antenna.

Yes

Repair or replace radio.

CHASSIS ELECTRICAL - Radio and Tape Player B-5 Distortion on UKW/MW/LW. Occasional

How much distortion is there? Constant

Distortion in the vicinity of the radio station No

Are the speaker cords in contact with the cone paper? No Remove the speakers and check for torn cone paper or foreign objects. No

Yes

Excessive antenna input

Remove cords away from cone paper.

Yes

Repair or replace speakers.

Yes

Check for deformation with speaker installed.

Yes

Install speaker securely.

No Repair or replace radio.

B-6 Too few automatic select stations. Is the check being conducted under special electrical field conditions? No

Yes

Example: In an underground garage or inside a building

Is proper performance obtained when the vehicle is moved?

Yes

OK

No Is the antenna plug properly connected to the equipment?

No

Ensure proper connection.

Yes Does the equipment work properly if the radio is changed? No Replace the antenna.

Yes

Repair or replace radio.

54-69

54-70

CHASSIS ELECTRICAL - Radio and Tape Player

B-7 Insufficient memory (preset stations are erased). Is dedicated fuse No. 5 blown or is the circuit open? No Disconnect and check the connector at the rear of the radio. Is the memory backup (battery) power being supplied?

Yes No

Replace fuse or repair harness. Repair harness.

Yes Repair or replace radio.

C. TAPE PLAYER C-1 Cassette tape will not be inserted. Are there any foreign objects in the tape player?

Yes

No

Does the tape player work if another tape is inserted?

Remove the object(s)*1 *1 Attempting to force a foreign object (e.g., a coin or clip, etc.) out of the tape player may damage the mechanism. The player should be taken to a service dealer for repair.

Yes

No

Replace tape*2 *2 Ensure that the tape label is not loose, that the tape itself is not deformed and that the tape is tightly wound. Also, tape of C-120 or greater length often get caught in the mechanism and should not be used.

Repair or replace tape player.

C-2 No sound (even after a tape has been inserted). Is dedicated fuse No. 6 blown or is the circuit open? No Is connector at rear of radio connected tightly? Yes Disconnect connector at rear of radio. Is ACC power being supplied to the radio? No Repair harness.

Yes No Yes

Replace fuse or repair harness. Connect connector firmly. Repair or replace tape player.

CHASSIS ELECTRICAL - Radio and Tape Player

54-71

C-3 No sound from one speaker. Clean the tape player head and check again. No Replace the tape player and check again. No Remove the connector on the back of the radio and check the speaker harness for conductance. No Check the speaker for conductance.

Yes

Yes Yes

Yes

OK Repair or replace tape player. It conducts electricity but is shorted out.

Repair harness.

Repair harness.

No Repair or replace speaker.

C-4 Sound quality is poor, or sound is weak. Does the player play properly when another tape* is inserted? No

Yes

OK

*: D Ensure that the tape label is not loose, that the tape itself is not deformed and that the tape is tightly wound. D Tapes of C-120 or greater length often get caught in the mechanism and should not be used.

Does the player play properly when the tape player head is cleaned? No Is proper operation obtained when the tape player is replaced?

Yes Yes

OK Repair or replace tape player.

No Repair or replace speaker.

C-5 Cassette tape will not be ejected. The problems covered here are all the result of the use of a bad tape (deformed or not properly tightened) or of a malfunction of the tape player itself. Malfunctions involving the tape becoming caught in the mechanism and ruining the case are

also possible, and attempting to force the tape out of the player can cause damage to the mechanism. The player should be taken to a service dealer for repair.

54-72

CHASSIS ELECTRICAL - Radio and Tape Player

C-6 Uneven revolution. Tape speed is fast or slow. Does the player play OK if the tape*1 is changed? No

OK

*1 Ensure that the tape label is not loose, that the tape itself is not deformed and that the tape is tightly wound. Also, tape of C-120 or greater length often get caught in the mechanism and should not be used.

Are there any foreign objects *2 inside the tape player? No

Yes

Yes

Remove foreign object(s).

*2 Attempting to force a foreign object (e.g., a coin or clip, etc.) out of the tape player may damage the mechanism. The player should be taken to a service dealer for repair.

Is the head or capstan roller dirty? (Refer to the illustration below.)

Yes

Clean.

No Repair or replace tape player.

Pinch roller

Head

Capstan roller

C-7 Faulty auto reverse. Does the player play OK if the tape* is changed? No

Yes

OK

*: D Ensure that the tape label is not loose, that the tape itself is not deformed and that the tape is tightly wound. D Tapes of C-120 or greater length often get caught in the mechanism and should not be used.

Does the problem only occur while the vehicle is being driven? Yes Is the tape player properly installed to the vehicle? Yes Repair or replace tape player.

No No

Repair or replace tape player. Ensure tape player installation.

CHASSIS ELECTRICAL - Radio and Tape Player C-8 Tape gets caught in mechanism*1. *1 When the tape is caught in the mechanism, the case may not eject. When this occurs, do not try to force the tape out as this may damage the tape player mechanism. Take the cassette to a service dealer for repair. Does the player play OK if the tape*2 is changed?

Yes

No *2 Ensure that the tape label is not loose, that the tape itself is not deformed and that the tape is tightly wound. Also, tapes of C-120 or greater length often get caught in the mechanism and should not be used. Repair or replace tape player.

Tape used is bad.

54-73

54-74

CHASSIS ELECTRICAL - Radio and Tape Player

RADIO AND TAPE PLAYER

54400140195

REMOVAL AND INSTALLATION 5 View A

6 8 7

4

2

3

1

View A

A

A

4

Section A - A

4, 6 A

Section B - B

4

A

B

Section C - C

4

6

B C Clip

Instrument panel

7 Clip

C : shows tabs. : shows clips.

Radio and tape player removal steps 1. Box 2. Center air outlet assembly 3. Radio and tape player

Instrument panel

Multi center display removal steps 4. Hood panel 5. Center hood and multi center display assembly 6. Center hood 7. Multi center display unit bracket 8. Multi center display unit

54-75

CHASSIS ELECTRICAL - Speaker

SPEAKER

54400260396

REMOVAL AND INSTALLATION

7 6

5

2

1

3 4 Speaker (front door) removal steps 1. Inside handle cover 2. Tweeter speaker 3. Door trim (Refer to GROUP 42) 4. Speaker

Speaker (quarter panel) removal steps 5. Lid 6. Speaker garnish 7. Speaker

54-76

CHASSIS ELECTRICAL - Speaker



5

6

2 1

3

4 Speaker (front door) removal steps 1. Inside handle cover 2. Tweeter speaker 3. Door trim (Refer to GROUP 42.) 4. Speaker

Speaker (quarter panel) removal steps 5. Quarter trim (Refer to GROUP 52A.) 6. Speaker

54-77

CHASSIS ELECTRICAL - Antenna

ANTENNA

54400290371

REMOVAL AND INSTALLATION

4

5 1

3 2

Removal steps D Center air outlet (Refer to P.54-58.) 1. Radio and tape player (Refer to P.54-74.) D Under cover assembly (Refer to GROUP 52A.)

AA"

2. Cowl side trim (Refer to GROUP 52A) 3. Antenna feeder 4. Antenna assembly 5. Antenna base

REMOVAL SERVICE POINT Feeder cable

AA" ANTENNA ASSEMBLY REMOVAL Observe the following steps to make the feeder cable of the antenna to be routed easily during reinstallation. 1. Secure a cord to the end of the feeder cable. 2. Pull out the feeder cable slightly until the tube end of the antenna can been seen. 3. Insert a cord into the tube end, and secure the cord with plastic tape as shown. Caution Make sure that the cord is not loosened.

Cord

Cord

Junction block

Tape

Hole Cord

4. Remove the antenna assembly by pulling it gradually.

54-78

CHASSIS ELECTRICAL - Rear Window Defogger

Normal characteristic curve

REAR WINDOW DEFOGGER

Voltage

54300180163

A (Centre point) approx. 6 V

Positive terminal

Printed heater line

Negative terminal

Abnormal characteristic curve Voltage Open-circuit point

Positive terminal

Printed heater line

Negative terminal

ON-VEHICLE SERVICE PRINTED-HEATER LINE CHECK (1) Run engine at 2,000 r/min. Check heater element with battery at full. (2) Turn ON rear window defogger switch. Measure heater element voltage with circuit tester at rear window glass centre A. Condition is good if it indicates about 6V. (3) If 12 V is indicated at A, there is a break in the negative terminals from A. Move test bar slowly to negative terminal to detect where voltage changes suddenly (0V). (4) If 0 V is indicated at A, there is a break in the positive terminals from A. Defect where the voltage changes suddenly (12 V) in the same method described above.

REAR WINDOW DEFOGGER RELAY CONTINUITY CHECK Battery voltage Defogger relay

Terminal No. 1

Power is not supplied Power is supplied

54300680229

2

3

5

54-79

CHASSIS ELECTRICAL - Rear Window Defogger

REAR WINDOW DEFOGGER SWITCH 54300620207

REMOVAL AND INSTALLATION Refer to GROUP 55 - Heater Control.

INSPECTION

54300630071

DEFOGGER SWITCH CONTINUITY CHECK Switch position

Terminal No. 3

10

-

11

OFF

IND

ON

IND

12

NOTE Turn on the defogger switch, and then check that there is continuity between the terminals 3 and 12 for 9 to 13 minutes and after it, the defogger switch is turned off. Defogger switch

54-80

CHASSIS ELECTRICAL - Multi Center Display

MULTI CENTER DISPLAY

54600070025

TROUBLESHOOTING NOTES WITH REGARD TO SERVICE PROCEDURES 1. Before removing the battery The multi center display has a large amount of data stored in memory which the user enters over time. When the terminals are disconnected from the battery, the memory which stores this data is affected as shown in the table below. Accordingly, it is necessary to make sure that you take notes of important information before disconnecting the battery. Function

Input function

When battery is disconnected

Radio function

Channels which are selected during a search

Disappear after a few seconds

Preset channels

Do not disappear

Navigation function

Current location Recommended route Destination Route search conditions Sensor initialization data Language selection setting Guidance volume setting

Data search function, data display and input functions

Registered location names Past destinations Average fuel consumption, average speed, cruising range

Clock display function

Current time

Vehicle model settings for travel data

Setting details for vehicle model

Monitor backlight luminance setting

Luminance setting value

Disappear after a few seconds

2. Notes on trouble diagnosis relating to the overall system (1) If a problem occurs which seems like all of the functions have developed an abnormality simultaneously, the cause is most likely a communication abnormality between the various systems. Thus you should use the communication checking service function in the trouble diagnosis service functions in order to verify the cause.

CHASSIS ELECTRICAL - Multi Center Display

54-81

(2) If the above is not the problem, check the connections of the related harness connectors. If a malfunctioning location is discovered, repair it and then re-check the trouble symptoms. (3) If there are no abnormalities in the harness connections, check the harnesses themselves. If there are no abnormalities in the harnesses, replace the relevant unit. Make a note of any error codes and service function data generated at this time.

3. (1) (2) (3)

NOTE If the cause of the problem seems to be related to system communication, carry out troubleshooting. Notes on trouble diagnosis when only specific functions are abnormal If only certain functions are showing an abnormality, use the audio checking function of the service functions to check the hardware switches. If the switch functions are normal, check the connections of the related harness connectors. If a malfunctioning location is discovered, repair it and then re-check the trouble symptoms. If there are no abnormalities in the harness connections, check the harnesses themselves. If there are no abnormalities in the harnesses, replace the unit which controls that function.

4. Notes on trouble diagnosis of the navigation function (1) The vehicle positioning accuracy of the navigation function is limited because of the principle of operation which it uses. Because of this, the system may be operating normally even though customers might be reporting a problem. Before carrying out troubleshooting, get as much information as possible from the customer regarding things such as usage conditions and driving locations. If it is possible to judge from this that the problem is not caused by a system abnormality, explain the principle of operation used by the navigation function and how to utilize it effectively. (2) If you find that there is a system abnormality, check according to the Inspection Chart Classified by Trouble Symptoms in the Troubleshooting section.

MULTI CENTER DISPLAY CONTROL PANEL F3 switch

F4 switch

F2 switch F1 switch

F5 switch F6 switch

NAVI selector switch

Tape/CD selector switch

DISP (screen selector) switch

TP (Traffic Information) switch UML (UKW/MW/LW) switch (Band selector)

54-82

CHASSIS ELECTRICAL - Multi Center Display

TROUBLE DIAGNOSIS SERVICE FUNCTIONS The Multi Center Display is equipped with the following trouble diagnosis service functions. Function

Contents

Diagnosis function

During normal use, this function constantly monitors the system communication lines, and displays an error if it finds any abnormalities.

CD-ROM checking function

This function displays a message if it cannot read the CD-ROM or if no CD-ROM is inserted.

Service functions

There are five checking modes available: monitor checking, audio checking, automatic checking by mode, self-diagnosis and diagnosis recording. This mode checks that the image display function is operating normally. This mode checks that the speakers and operating switches of the audio system are all working normally. In this mode, wiring and communication checking, audio checking, sensor checking and vehicle signal checking are carried out continuously. This mode includes functions such as wiring and communication checking, sensor checking, vehicle signals and version data checking. This checks system communication between all units.

1. 2.

Monitor checking Audio checking

3.

Automatic diagnosis by mode Self-diagnosis

4.

D

5.

Wiring and communication checking D Sensor checking D Vehicle signals D Version data Diagnosis recording

This checks all of the sensors that are necessary to the navigation system. This displays the current vehicle signal condition. This displays the version numbers for each unit in the Multi Center Display. This mode displays error codes from communication checking. (Error codes are erased when the ignition switch is turned to OFF.)

1. ACTIVATING AND ENDING SERVICE MODE (1) Activating service mode can be carried out by turning the ignition switch to the ON position while pressing the DISP switch on the audio unit and the F6 switch. (Continue pressing each switch for at least 5 seconds after turning the ignition switch to ON.) (2) If the special CD-ROM has been inserted into the navigation unit but the program has not been set up, the program will then be loaded from the CD-ROM. Service mode can be used once this process is completed. NOTE The special CD-ROM is a map CD-ROM which a distributor vends.

CHASSIS ELECTRICAL - Multi Center Display

54-83

(3) If the F1 switch is pressed at the service mode initial screen, service mode will be ended and the screen will change to navigation mode.

2. AUTOMATIC DIAGNOSIS BY MODE (1) If the F3 switch is pressed at the service mode screen, automatic diagnosis by mode will start.

(2) A colored bar will appear on the screen of the Multi Center Display unit, and all units which are connected to the navigation unit will be checked during this time.

(3) Once the transmission checking is completed, the results of the wiring and transmission checking will appear on the screen. After checking the results, press the F1 switch to proceed to the next check. The next check will start when the switch is pressed. NOTE 1) If the fuel gauge and the engine-ECU are checked while the ignition switch is at ACC, an error will be generated, but this is not a sign of an abnormality. 2) If checking is carried out while the fuel tank is full or the while ignition switch is at ACC, the fuel gauge may be shown to be not connected, but this is not a sign of an abnormality.

54-84

CHASSIS ELECTRICAL - Multi Center Display (4) The next mode is the sensor checking mode. Press the F1 switch to start sensor checking. If you would like to proceed to the next checking operation without carrying out sensor checking, press the F6 switch.

(5) When sensor checking starts, the gyro output will be checked first while the vehicle is stopped, so make sure that the vehicle is stopped for this check. If the vehicle is moving when the sensor checking starts, the vehicle speed sensor will be shown as defective. Follow the guidance message on the multi center display.

(6) Next, drive the vehicle for approximately 10 meters while changing the running direction in order to check the vehicle speed pulse and the gyro sensor output. The sensor checking will then be completed. If there is an open circuit in the vehicle speed sensor, sensor checking will not complete even after the vehicle has travelled more than 10 meters. In this case, press the F5 switch to stop checking. If the vehicle does not move or there is an open circuit in vehicle speed sensor, the vehicle speed sensor will be shown as defective. (7) When sensor checking is completed, the check results will appear on the screen. After checking the results, press the F1 switch to proceed to the next check.

(8) The next mode is the vehicle signal checking mode. The lighting switch condition, ignition key position, shift lever selection (R or a position other than R) and the power supply voltage drop will be appear on the screen. Check that the details displayed match the actual vehicle signals, and then press the F1 switch. If the vehicles does not move or there is an open circuit in vehicle speed sensor, the vehicle speed sensor will be shown as defective.

CHASSIS ELECTRICAL - Multi Center Display

54-85

(9) The next mode is speaker checking mode. The test sound will be output alternately from each speaker each time the F2 switch is pressed. At the early mass production, sometimes radio sound will be output. This is not a sign of abnormality.

(10)Press the F1 switch to end service mode. The screen will change to navigation mode.

3. MONITOR CHECKING (1) If the F6 switch is pressed at the service mode initial screen, monitor checking will start.

54-86

CHASSIS ELECTRICAL - Multi Center Display (2) A colored bar will appear on the screen. Press a function switch to change to another screen. The screen will return to the service mode initial screen if the F1 switch is pressed.

4. AUDIO CHECKING (1) If the F5 switch is pressed at the service mode initial screen, the audio checking menu screen will appear.

(2) Next, press the function switches to carry out audio checking.

CHASSIS ELECTRICAL - Multi Center Display

54-87

(3) Press the F3 switch to display the speaker checking screen. The test sound will be output alternately from each speaker each time the F2 switch is pressed. Press the F1 switch to end speaker checking and return to the audio checking menu screen. At the early mass production, sometimes radio sound will be output. This is not a sign of abnormality.

(4) Press F4 to display the audio key checking screen. When one of the audio switches is pressed, the screen display color for that switch should change. This indicates that this particular switch system is working normally. Press the F1 switch to check the operation of the F1 switch. Press the F1 switch once more to return to the audio checking menu screen.

5. SELF-DIAGNOSIS (1) If the F5 switch is pressed at the service mode initial screen, the self-diagnosis menu screen will appear.

(2) Next, use the function switches to carry out self-diagnosis.

(3) When the F5 switch is pressed, self-diagnosis for the wiring is carried out. A colored bar will appear on the screen of the Multi Center Display unit, and all units which are connected to the navigation unit will be checked during this time.

54-88

CHASSIS ELECTRICAL - Multi Center Display (4) Once the transmission checking is completed, the results of checking will appear on the screen. After checking the results, press the F1 switch to return to the self-diagnosis menu screen.

(5) If the F6 switch is pressed at the self-diagnosis menu screen, sensor checking will start. Press the F1 switch to start sensor checking. If you would like to return to the self-diagnosis menu screen without carrying out sensor checking, press the F5 switch.

(6) When sensor checking starts, the gyro output will be checked first while the vehicle is stopped, so make sure that the vehicle is stopped for this check. If the vehicle is moving when the sensor checking starts, the vehicle speed sensor will be shown as defective. Follow the guidance message on the multi center display.

(7) Next, drive the vehicle for approximately 10 meters while changing the running direction in order to check the vehicle speed pulse and the gyro sensor output. The sensor checking will then be completed. If there is an open circuit in the vehicle speed sensor, sensor checking will not complete even after the vehicle has travelled more than 10 meters. In this case, press the F5 switch to stop checking. If the vehicle does not move or there is an open circuit in vehicle speed sensor, the vehicle speed sensor will be shown as defective.

CHASSIS ELECTRICAL - Multi Center Display

54-89

(8) When sensor checking is completed, the check results will appear on the screen. After checking the results, press the F1 switch to return to the self-diagnosis menu screen.

(9) If the F6 switch is pressed at the self-diagnosis menu screen, vehicle signal checking will start. The lighting switch condition, ignition key position, shift lever selection (R or a position other than R) and the power supply voltage drop will be appear on the screen. Press the F1 switch to return to the self-diagnosis menu screen.

If the F2 switch is pressed at the self-diagnosis menu screen, version data self-diagnosis will be carried out, and the check results will appear on the screen. Press the F1 switch to return to the self-diagnosis menu screen.

6. DIAGNOSIS RECORDING (1) If the F6 switch is pressed at the service mode initial screen, the diagnosis recording screen will appear. (2) Press the F1 switch to return to the service mode initial screen.

(3) Press the F6 switch to clear any error codes which may still be remaining from diagnosis recording. When this is done, the clearing confirmation screen will appear. If it is okay to continue with the clear, press the F5 switch. To cancel clearing, press the F6 switch. If the F6 switch is pressed, the screen will return to the diagnosis recording screen.

54-90

CHASSIS ELECTRICAL - Multi Center Display (4) If the F5 switch is pressed, all past error codes will be cleared, and the screen will return to the diagnosis recording screen. The Clear button will not be displayed at this time.

(5) Press the F1 switch to return to the service mode initial screen.

7. ERROR CODE TABLE Error No.

Code

Error Details

Detection Method (Reference)

Reference Page

1011

Ambient temperature sensor not connected during diagnosis

Connection checking

54-104

1021

Fuel gauge not connected during diagnosis

Connection checking

54-105

1031

GPS abnormality during diagnosis

Connection checking

54-105

1041

Engine-ECU not connected during diagnosis

Connection checking

54-105

1051

SWS not connected during diagnosis (This error does not occur when correct car type is set)

Connection checking

54-105

1091

CD drive too hot during diagnosis

Connection checking

54-106

1092 - 1096

CD drive abnormality during diagnosis

Connection checking

54-106

10A1, 10B1

Memory of navigation unit abnormality during diagnosis

Connection checking

54-106

20D1, 30D1

Vehicle speed pulse abnormality during diagnosis

Sensor checking

54-106

20E1, 20E2, 30E1, 30E2

Gyro level abnormality during diagnosis

Sensor checking

54-106

CHASSIS ELECTRICAL - Multi Center Display

54-91

MAIN UNIT TERMINAL VOLTAGES 1. MULTI CENTER DISPLAY UNIT

Terminal No.

Input/ Output

Signal Symbol

Terminal Voltage (V)

Harness Problem

1

Input

G+SYTNC (AUDIO)

-

f

f

Noise display (random dot pattern)

2

Input

B+SYNC (AUDIO)

-

f

f

Blue, white, cyan and magenta do not appear in RGB screen.

3, 4

-

-

-

-

-

-

5

Input

ISOK

Hi: Battery voltage Lo: 0 - 1

f

f

MUT-II cannot be used to check engine-ECU.

6

-

-

-

-

-

-

7

Input/ Output

M- DATA (AUDIO)

Hi: 4 - 5 Lo: 0 - 1

f

f

Buzzer sounds 30 seconds after the power turned to on. Nighttime illumination does not appear for any navigation system.

8

Input/ Output

M- CLOCK (AUDIO)

Hi: 4 - 5 Lo: 0 - 1

f

f

Buzzer sounds 30 seconds after the power turned to on. Nighttime illumination does not appear for any navigation system.

9, 10

-

-

-

-

-

-

11

-

SHIELD- GND

-

-

-

-

12

-

-

-

-

-

-

13

Input

R+SYNC (AUDIO)

-

f

f

Red, white, yellow and magenta do not appear in RGB screen.

Open Circuit

Shortcircuit

Trouble Symptom Resulting from Harness Problem

54-92

CHASSIS ELECTRICAL - Multi Center Display

Terminal No.

Input/ Output

Signal Symbol

14

-

-

-

-

-

-

15

Input/ Output

K

Hi: Battery voltage Lo: 0 - 1

f

f

Values on Trip information screen (average speed, fuel consumption and cruising distance) are abnormal. Wiring and communication error. Communication is not possible between the engine-ECU and the MUT-II.

16

-

-

-

-

-

-

17

Input/ Output

M- BUSY (AUDIO)

Hi: 4 - 5 Lo: 0 - 1

f

-

Screen display does not appear.

-

f

Buzzer sounds 30 seconds after the power turned to on. Nighttime illumination does not appear for any navigation system.

18

-

SHIELD- GND

-

-

-

-

19 - 21

-

-

-

-

-

-

22

Input

PS- R

Hi: Battery voltage Lo: 0 - 1

f

f

Current location is not correct when reversing.

23

Input

EX- TEMP

0- 5

f

f

Outside air temperature does not appear.

24

Input

ILL+

Hi: Battery voltage Lo: 0 - 1

f

-

Nighttime illumination does not appear for any navigation system units.

-

f

Blown multipurpose fuse.

ACC (ACC power supply)

Battery voltage

f

-

Screen display does not appear.

-

f

Blown multipurpose fuse.

+B

Battery voltage

f

-

Screen display does not appear.

-

f

Blown multipurpose fuse.

25

26

Input

Input

Terminal Voltage (V)

Harness Problem Open Circuit

Shortcircuit

Trouble Symptom Resulting from Harness Problem

27

Input

VSS

Hi: 4 - 5 Lo: 0 - 1

f

-

No effect.

28

-

GND (Ground)

-

f

-

Screen display does not appear.

29, 30

-

-

-

-

-

-

31

-

GND- TEMP

-

f

f

Outside air temperature does not appear.

32

-

-

-

-

-

-

33

Input

FUEL GAUGE

0- 3

f

f

Abnormal cruising distance display.

34, 35

-

-

-

-

-

-

CHASSIS ELECTRICAL - Multi Center Display Terminal No.

Input/ Output

Signal Symbol

36

Input

IG1

Terminal Voltage (V)

Harness Problem Open Circuit

Battery voltage

Shortcircuit

54-93

Trouble Symptom Resulting from Harness Problem

f

-

Communication with engine-ECU is not possible. Driving data values displayed are abnormal.

-

f

Communication with engine-ECU is not possible. Driving data values displayed are abnormal. Blown multipurpose fuse.

Harness Problem

Trouble Symptom Resulting from Harness Problem

2. NAVIGATION UNIT

DIN cable (to audio unit)

Terminal No.

Input/ Output

Signal Symbol

1- 3

-

-

4

Input

VEHICLE PULSE

5

Input

+BATTERY

6

Input

SPEED

ACCESSORY

Terminal Voltage (V)

Open Circuit

Shortcircuit

-

-

-

-

Voltage should change when wheels are turning. Hi: 4 - 5 Lo: 0 - 1

f

f

Compass display does not change when not following a route. Guide does not appear when following a route.

Battery voltage

f

-

Navigation does not operate.

-

f

Blown fuse in +B system.

Battery voltage

f

-

Navigation does not operate.

-

f

Blown fuse in ACC system.

7 - 11

-

-

-

-

-

-

12

-

GND

-

f

-

Navigation sometimes does not operate.

54-94

CHASSIS ELECTRICAL - Multi Center Display

3. AUDIO UNIT CD control connector (DIN cable)

Antenna

Terminal No.

Input/ Output

Signal Symbol

1

Output

SPEAKER RR (+)

2

Output

SPEAKER RL (+)

Terminal Voltage (V)

Harness Problem Open Circuit

Shortcircuit

Trouble Symptom Resulting from Harness Problem

0Battery voltage (AC)

f

-

No sound is output from rear right speaker.

-

f

No sound is output from rear left and right speakers.

0Battery voltage (AC)

f

-

No sound is output from rear left speaker.

-

f

No sound is output from rear left and right speakers.

3

Output

ANTENNA +B (Radio antenna amplifier power supply)

Hi: 10 or more Lo: 0 - 1

f

f

Low radio sensitivity.

4

-

-

-

-

-

-

5

Output

SPEAKER FL (+)

0Battery voltage (AC)

f

-

No sound is output from front left speaker.

-

f

No sound is output from front left and right speakers.

0Battery voltage (AC)

f

-

No sound is output from front right speaker.

-

f

No sound is output from front left and right speakers.

0Battery voltage (AC)

f

-

No sound is output from rear right speaker.

-

f

No sound is output from rear left and right speakers.

6

7

Output

Output

SPEAKER FR (+)

SPEAKER RR (- )

CHASSIS ELECTRICAL - Multi Center Display Terminal No.

Input/ Output

Signal Symbol

8

Output

SPEAKER RL (- )

Terminal Voltage (V)

Harness Problem Open Circuit

Shortcircuit

54-95

Trouble Symptom Resulting from Harness Problem

0Battery voltage (AC)

f

-

No sound is output from rear left speaker.

-

f

No sound is output from rear left and right speakers.

9

-

-

-

-

-

-

10

Input

ACC (ACC power supply) (Battery voltage)

Battery voltage

f

-

Audio power supply does not turn on.

-

f

Blown multipurpose fuse.

+B (Battery voltage)

Battery voltage

f

-

Cassette is not ejected when ACC power turned off. Contents of memory are cleared.

-

f

Blown multipurpose fuse.

11

Input

12

Input

ILL (- )

-

-

-

-

13

Output

SPEAKER FL (- )

0Battery voltage (AC)

f

-

No sound is output from front left speaker.

-

f

No sound is output from front left and right speakers.

0Battery voltage (AC)

f

-

No sound is output from front right speaker.

-

f

No sound is output from front left and right speakers.

14

Output

SPEAKER FR (- )

21

Input/ Output

M- DATA

Hi: 4 or more Lo: 1 or less

f

f

Panel switches cannot be operated.

22

Input/ Output

M- SCK

Hi: 4 or more Lo: 1 or less

f

f

Panel switches cannot be operated.

23

Input

TELEPHONE MUTE

Hi: 4 or more Lo: 1 or less

-

-

-

24

Output

G+SYNC

0- 5

f

f

Abnormal navigation screen color.

25

Output

B+SYNC

0- 5

f

f

Abnormal navigation screen color.

26 - 28

-

-

-

-

-

-

29

Input/ Output

M- BUSY

Hi: 4 or more Lo: 1 or less

f

f

Panel switches cannot be operated.

30

-

SHIELD EARTH (M- BUS)

-

-

-

-

54-96

CHASSIS ELECTRICAL - Multi Center Display

Terminal No.

Input/ Output

Signal Symbol

Terminal Voltage (V)

Harness Problem

31

-

-

-

-

-

-

32

-

SHIELD EARTH

-

-

-

-

33

-

-

-

-

-

-

34

Output

R+SYNC

0- 5

f

f

Abnormal navigation screen color.

35, 36

-

-

-

-

-

-

Open Circuit

Shortcircuit

Trouble Symptom Resulting from Harness Problem

INSPECTION CHART CLASSIFIED BY TROUBLE SYMPTOMS Related Unit

Trouble Symptom

Inspection Procedure No.

Reference Page

Malfunction of navigation unit, multi center display, audio unit and related sensor, harness

TAPE/CD, UML switches do not work. No display appears after the ignition key is turned to ACC.

1

54-97

TAPE/CD, UML switches do not work. (Display appears.)

2

54-98

No display appears after the ignition key is turned to ACC, but TAPE/CD, UML switches can be operative.

3

54-99

CD changer screen display does not appear when TAPE/CD switch is operated.

4

54-100

GPS reception is not possible.

5

54-100

Outside air temperature data is not displayed.

6

54-100

Abnormal driving data display 7 D Abnormal average fuel consumption (momentary fuel consumption) and average speed displays. D Abnormal cruising distance displays

54-101

Daytime/nighttime display mode does not change in conjunction with lighting switch operations.

8

54-102

Display moves about. Screen colours do not match correctly.

9

54-102

Compass display does not rotate , or guidance does not appear when following a route.

10

54-103

One of the following messages appears during navigation 11 mode. D The CD drive has failure condition. Check and reload the disc, please. D Wrong disc is in the CD drive. Insert a map disc, please. D No disc is in the CD drive. Insert a map disc please. D A music disc is in the CD-drive.

54-103

54-97

CHASSIS ELECTRICAL - Multi Center Display INSPECTION PROCEDURES FOR EACH TROUBLE SYMPTOM INSPECTION PROCEDURE 1

TAPE/CD, UML switches do not work. No display appears after the ignition key is turned to ACC. Check connectors: B-04, B-55, B-59 and DIN connectors between audio and navigation unit

NG

Repair

OK Turn off the ignition key and turn to ACC position again. Does any screen appear about 30 seconds after it?

YES

NO

NG

Measure at the multi center display connector B-03. D Ignition switch: ACC D Voltage between terminal (25), (26) and body earth OK: Battery voltage OK

Disconnect multi center display connector B-55. D Ignition switch: ACC D Measure waveform at terminal (7), (8), (17) of harness connector with an oscilloscope. OK: Hi: 4 - 5 V, Lo: 0 - 1 V, pulse signal Check the harness between audio B-55 and multi center display B- 04connector. OK Does the sound turn on/off when the audio VOL/POWER switch operated?

NG Repair fuse or harness.

OK

NG

NO

YES

Check the harness between audio B-55 and multi center display B-04connector. OK

Repair

Measure at audio unit connector B-55. D Ignition switch: ACC D Voltage between terminal (10), (11) and body earth OK: Battery voltage NG

OK

Repair fuse or harness.

NG Repair

Replace the audio unit.

Check the DIN cable between audio and navigation unit.

Check the DIN cable between audio and navigation unit.

NG

OK

Replace the multi center display.

Replace the DIN cable.

NG

Replace the DIN cable.

OK Replace the navigation unit.

Disconnect DIN 20-pin connector from the navigation unit. D Ignition switch: ACC D Measure waveforms of terminal (8), (15), (17) of navigation unit connector with an oscilloscope. OK: 2 Vpp (AC) 15.75kHz video signal

NG

NG Measure at the navigation unit connector B-57. D Ignition switch: ACC D Voltage between terminal (5), (6) and OK body earth OK: Battery voltage

OK Connect the disconnected connector. Measure at the multi center display connector B-04. D Ignition switch: ACC D Measure waveforms of terminal (1), (2), (13) of navigation unit connector with an oscilloscope. OK: 2 Vpp (AC) 15.75kHz video signal OK To next page

NG

Replace the audio unit.

Repair fuse or harness.

Replace the audio unit.

54-98

CHASSIS ELECTRICAL - Multi Center Display

From previous page Does the sound turn on/off when the audio VOL/POWER switch operated?

NO

YES

Measure at audio unit connector B-59. D Ignition switch: ACC D Voltage between terminal (10), (11) and body earth OK: Battery voltage

NG

Repair fuse or harness.

OK Replace the audio unit. Turn off the ignition key and turn to ACC position again. Does the buzzer sound “PiPi, PiPi, PiPi” after about 30 seconds?

NG

Replace the multi center display.

OK Replace the navigation unit.

INSPECTION PROCEDURE 2 TAPE/CD, UML switches do not work. (Display appears.) Check connectors: B-04, B-55, B-59 and DIN connectors between audio and navigation unit OK Does the audio sound turn on or off when operate VOL/POWER switch?

NG

NO

YES

Repair

Measure at audio unit connector B-59. D Ignition switch: ACC D Voltage between terminal (10), (11) and body earth OK: Battery voltage

NG

Repair fuse or harness.

OK

Check the harness between audio B-55 and multi center display B-04 connector. OK Check the DIN cable between audio and navigation unit. OK Are the result of key checking (audio switch checking in the service function) normal?

NG

NG

NO

Replace the audio unit. Repair

Replace the DIN cable.

Malfunction of operation switch. Replace the audio unit.

YES Does the navigation screens appear when NAVI switch is pressed?

NO

Insert a map CD-ROM. Does the message “loading the program” appear? NO

YES

Replace the navigation unit.

Is a CD changer connected?

YES

NO Does the sound change in accordance with the switch operation? NO Replace the audio unit.

YES

Check the connector of CD changer and DIN connector between navigation unit and CD changer. Replace the navigation unit.

YES

Check again after program-loading is done. If same error happen, replace navigation unit.

54-99

CHASSIS ELECTRICAL - Multi Center Display INSPECTION PROCEDURE 3

No display appears after the ignition key is turned to ACC, but TAPE/CD, UML switches can be operative. Check connectors: B-04, B-55, B-59 and DIN connectors between audio and navigation unit OK Turn off the ignition key and turn to ACC position again. Does any screen appear about 30 seconds after it?

NG

NO

YES

Repair

Measure at the multi center display connector B-04. D Ignition switch: ACC D Measure waveforms of terminal (1), (2), (13) of multi center display connector. OK: 0 - 2 Vpp 15.75kHz video signal

OK

Measure at the multi center display connector B-03. D Ignition switch: ACC D Voltage between terminal (25), (26) and body earth OK: Battery voltage NG

OK

Repair fuse or harness.

NG

Replace the multi center display. Check the harness between audio B-55 and multi center display B-04connector.

NG

Repair

OK Check the DIN cable between audio and navigation unit.

NG

Replace the DIN cable

OK Disconnect DIN 20-pin connector from the navigation unit. D Ignition switch: ACC D Measure waveforms of terminal (8), (15), (17) of navigation unit connector with an oscilloscope. OK: 2 Vpp (AC) 15.75kHz video signal NG Replace the navigation unit. Disconnect at the multi center display connector B-04. D Ignition switch: ACC D Measure waveforms of terminal (7), (8), (17) of harness connector with an oscilloscope. OK: Hi: 4 - 5 V, Lo: 0 - 1 V pulse signal NG Check the harness between audio B-55 and multi center display B-04 connector.

OK

NG

Replace the multi center display.

Repair

OK Check the DIN cable between audio and navigation unit. OK Replace the navigation unit.

NG

Replace the DIN cable

OK

Replace the audio unit.

54-100

CHASSIS ELECTRICAL - Multi Center Display

INSPECTION PROCEDURE 4 CD changer screen displays do not appear when TAPE/CD switches are operated. Check connectors: B-04 and navigation unit DIN connector OK Does radio reception occur and does the screen change when the UML switch is pressed

NG

YES

Repair

Are the results of the hardware switch checking using the audio switch checking function (service function) normal?

NO

Replace the audio unit.

YES

NO Replace the navigation unit.

Replace the CD changer.

INSPECTION PROCEDURE 5 GPS reception is not possible. NO

Is the vehicle in a good reception area? YES Turn the ignition switch to ACC, and then wait for about 5 minutes. Is GPS reception still not possible?

Move the vehicle to a good reception area.

NO

End (no abnormality)

YES Replace the Multi Center Display unit.

INSPECTION PROCEDURE 6 Outside air temperature data is not displayed. Check connectors: A-36, B-66, B-03 OK Carry out a wiring check (service function). Does the message “Outside air temperature sensor not connected” appear? YES Check the connections between the multi center display unit and the outside air temperature sensor. NG Check the harness between the multi center display unit and the outside air temperature sensor, and replace if necessary.

NG NO

Repair Is the selected model is correct? NO Select correct model, and repeat wiring check.

OK

Replace the multi center display.

YES

End (no abnormality).

CHASSIS ELECTRICAL - Multi Center Display

54-101

INSPECTION PROCEDURE 7 Abnormal driving data displays. D D

Abnormal average fuel consumption (momentary fuel consumption) and average speed displays. Abnormal cruising distance displays.

1. When average fuel consumption (momentary fuel consumption) and average speed displays are abnormal. Check connectors: B-03, B-02 OK Carry out a wiring and communication check (service function). Does the message “Engine-ECU not connected” appear? YES Carry out a vehicle signals check (service function). Does the message “Key position : IG” appear?

NG NO

NO

YES

Check the connections between the multi center display and the engineECU.

OK

Repair End (no abnormality).

NG Measure at the multi center display connector B-03. D Connector disconnected. D Voltage between terminal (25) and body earth OK OK: IG ON: Battery voltage. IG OFF: 0 - 1 V

Check the harness between multi center display and the junction block, and replace if necessary.

Replace the multi center display.

Replace the multi center display.

NG Check the harness between the multi center display and the engine-ECU, and replace if necessary.

2. When cruising distance display is abnormal. Are the average fuel consumption and average vehicle speed displayed normally? YES Is the selected model is correct? YES Measure at the multi center display connector B-03. D Connector disconnected. D Voltage between terminal (33) and body earth OK: 0.1 - 3.0 V OK Replace the multi center display.

NO

NO NG

Carry out troubleshooting according to procedure 1.

Select correct model, and repeat wiring check. Check the fuel gauge unit. (Refer to P.54-21.) NG Replace the fuel gauge unit.

OK

Check the harness between multi center display and the fuel gauge unit, and replace if necessary.

54-102

CHASSIS ELECTRICAL - Multi Center Display

INSPECTION PROCEDURE 8 Display moves about. Screen colors do not match correctly. Check connectors: B-03, B-04, B-102, B-57 and DIN connectors between navigation unit and audio unit OK Do red, blue and green colors appear in the monitor color bar service function? NO Check the RGB wave pattern at terminal (1) of the B-03 multi center display harness-side connector. NG Check the RGB wave pattern at terminal (34) of the B-55 audio unit harness-side connector. NG Check the RGB wave pattern at the DIN connector at the audio unit side of the cable between the audio unit and the navigation unit.

NG

YES

OK

OK

OK

Repair

End (no abnormality)

Replace the multi center display unit.

Check the harness between B-55 and B-04, and repair if necessary.

Replace the audio unit.

NG

NG Check the RGB wave pattern at the DIN connector at the navigation unit side of the cable between the audio unit and the navigation unit. OK

Replace the navigation unit. Replace the DIN connector.

INSPECTION PROCEDURE 9 Daytime/nighttime display mode does not change in conjunction with lighting switch operations. NG

Check connector: B-03 OK Carry out a vehicle signal check (service function). Does LIGHT SW: ON appear when the lighting switch is ON, and LIGHT SW: OFF appear when the lighting switch is off? NO Measure at the B-03 multi center display unit connector. D Connector connected D Voltage between terminal (24) and body ground OK:Hi: 10 V or higher, Lo: 0 - 1 V NG Check the harnesses between the multi center display unit and the column switch, and between the multi center display unit and the tail lamp relay, and replace if necessary.

YES

OK

Repair End

Replace the multi center display unit.

CHASSIS ELECTRICAL - Multi Center Display

54-103

INSPECTION PROCEDURE 10 Compass display does not change when not following a route, or guide does not appear when searching for and following a route. Carry out a sensor check (service function). OK Carry out a vehicle signal check (service function). D Does “Shift position: R” appear when the shift position is R? D Does “Shift position: Except R” appear when the shift position is not R? YES Measure at the B-03 multi center display unit connector. D Connector disconnected D Voltage between terminal (22) and body ground OK: 10 V or higher when shift position is R

NG NO

NG

If no vehicle speed is input, the sensor check does not complete. End (no abnormality)

Check the harness between the back-up lamp switch and the multi center display unit, and repair if necessary.

OK Replace the multi center display unit.

INSPECTION PROCEDURE 11 One of the following messages appears during navigation mode. D D D D

The CD-drive has failure condition. Confirm and reload the disc, please. Wrong disc is in the CD-drive. Insert a map disc, please. No disc is in the CD-drive. Insert a map disc, please. A music disc is in the CD-drive.

1. “The CD-drive has failure condition. Confirm and reload the disc, please.” or “Wrong disc is in the CD-drive. Insert a map disc, please.” appears. YES

CD is dirty or damaged. NO Insert the CD once more, and then press the NAVI switch. Does the NAVI screen (compass display, outside route, route map) still not appear?

YES

Insert a proper map disc. Replace the navigation unit.

NO End

2. “No disc is in the CD-drive. Insert a map disc, please.” or “A music disc is in the CD-drive” appears. Press the eject button on the CD-drive. Is the map disc a special CD? YES Insert the map disc once more, and then press the NAVI switch. Does the NAVI screen (compass display, outside route, route map) still not appear? YES End

NO

NO

Insert a proper map disc.

Replace the navigation unit.

54-104

CHASSIS ELECTRICAL - Multi Center Display

ERROR CODE TABLE Error No.

Code

Error Details

Detection Method (Reference)

Reference Page

1011

Ambient temperature sensor not connected during diagnosis

Connection checking

54-104

1021

Fuel gauge not connected during diagnosis

Connection checking

54-105

1031

GPS abnormality during diagnosis

Connection checking

54-105

1041

Engine-ECU not connected during diagnosis

Connection checking

54-105

1051

SWS not connected during diagnosis (This error does not occur when correct car type is set)

Connection checking

54-105

1091

CD drive too hot during diagnosis

Connection checking

54-105

1092 - 1096

CD drive abnormality during diagnosis

Connection checking

54-106

10A1, 10B1

Memory of navigation unit abnormality during diagnosis

Connection checking

54-106

20D1, 30D1

Vehicle speed pulse abnormality during diagnosis

Sensor checking

54-106

20E1, 20E2, 30E1, 30E2

Gyro level abnormality during diagnosis

Sensor checking

54-106

INSPECTION PROCEDURES FOR EACH ERROR CODE Error Code No. 1011 Were the wiring check instructions followed? YES Repeat the wiring check. If the same problem occurs, check ambient temperature sensor.

NO

NG

Repeat the wiring check. Replace the ambient temperature sensor.

OK Measure at the multi center display connector B-03. D Disconnect connector. D Resistance between terminal (23) and body eartth. OK: 500 W - 100 kW OK Replace the multi center display.

NG

Check the harness between B-03 and A-36.

CHASSIS ELECTRICAL - Multi Center Display

54-105

Error Code No. 1021 Were the wiring check instructions followed? YES Repeat the wiring check. If the same problem occurs, measure at the multi center display connector B-03. D Disconnect connector. D Ignition switch: ON D Voltage between terminal (33) and body eartth. OK: 0.1 V (fuel tank full) - 3 V (fuel empty)

NO

NG

Repeat the wiring check. Check the harness between B-03 and B-01.

OK Replace the multi center display.

Error Code No. 1031 Were the wiring check instructions followed?

NO

Repeat the wiring check.

YES Replace the multi center display.

Repeat the wiring check. If the same problem occurs, there is a malfunction of the GPS inside the multi center display.

Error Code No. 1041 Were the wiring check instructions followed? YES Connect MUT-II and diagnose engine.

NO

NG

Repeat the wiring check. Check the harness between B-08 and B-30.

OK Replace the multi center display.

Error Code No. 1051 Is the selection of vehicle model is done? YES Is the selected model is correct?

NO

YES

Repeat the wiring check. Repeat the wiring check.

NO Select correct model, and repeat wiring check.

How to confirm model selection is correctly done. (1) Press “DISP” switch to get trip information display. (2) If “Please set your car type” message appears, the vehicle model is not set. Select the correct vehicle model from the list. (3) If trip information display appears normally, the vehicle model is set already. Press RESET (F1) switch and keep until the vehicle setting display appears. Current setting of vehicle model will appear on the display.

54-106

CHASSIS ELECTRICAL - Multi Center Display

Error Code No. 1091 Is the navigation unit very hot because of direct sunlight, heat air, etc.? NO

YES

Repeat the wiring check. If the same problem occurs, there is a malfunction of the CD drive within the navigation unit.

Repeat the wiring check after the navigation unit becomes cool..

Replace the navigation unit.

Error Code No. 1092, 1093, 1094, 1095, 1096 Is a CD-ROM for this navigation system inside? YES Is the CD-ROM inserted upside down? NO Is the disc dirty, damaged or iced up?

NO YES YES

Insert the CD-ROM for this navigation system. Insert the CD-ROM correctly. Repair or replace the disc.

NO Repeat the wiring check. If the same problem occurs, there is a malfunction of the CD drive within the navigation unit.

Replace the navigation unit.

Error Code No. 10A1, 10B1 Were the wiring check instructions followed?

NO

Repeat the wiring check.

YES Replace the navigation unit.

Repeat the wiring check. If the same problem occurs, there is a malfunction of the memory within the navigation unit.

Error Code No. 20D1, 30D1 Were the sensor check instructions followed? YES Check the following connectors: B-57, B-47, B-102, B-14, A-81, A-85, A-86 OK Measure at the navigation unit connector B-57. D Disconnect connector. D Turn on the Ignition switch and then move the vehicle slowly. D Voltage between terminal (4) and body eartth. OK: HI: 4 - 5 V, Lo: 0 - 1 V, pulse signal

NO

NG

NG

Repeat the sensor check. Repair

Check the vehicle speed sensor. (Refer to P.54-25.)

OK Replace the navigation unit.

Error Code No. 20E1, 20E2, 30E1, 30E2 Were the sensor check instructions followed?

NO

Repeat the sensor check.

YES Repeat the sensor check. If the same problem occurs, there is a malfunction of Gyro sensor within the navigation unit.

Replace the navigation unit.

CHASSIS ELECTRICAL - Multi Center Display

MULTI CENTER DISPLAY AND NAVIGATION UNIT

54-107 54600100021

REMOVAL AND INSTALLATION

1

3

4 2

1. Multi center display (Refer to P.54-74.)

Navigation unit removal steps D Driver’s seat (Refer to GROUP 52A.) 2. No.2 navigation unit bracket 3. Navigation unit 4. Navigation unit bracket

54-108

CHASSIS ELECTRICAL - Multi Center Display



1

3

2

1. Multi center display (Refer to P.54-74.)

4

Navigation unit removal steps D Driver’s seat (Refer to GROUP 52A.) 2. No.2 navigation unit bracket 3. Navigation unit 4. Navigation unit bracket

CHASSIS ELECTRICAL - Smart Wiring System (SWS)

54-109

SMART WIRING SYSTEM (SWS)

54900010040

COMMUNICATION LINE Data lines for multiplex communication are connected between the front-ECU, ETACS-ECU, multi-purpose centre display, column switch assembly, sunroof motor, power window main switch, and power window motors as illustrated below. ETACS-ECU

Column switch

Power window motor-ECU (front-right)

Power window motor-ECU (rear-right)

Power window motor-ECU (front-left)

Power window motor-ECU (rear-left)

Power window main switch

Front-ECU Multi center display Sunroof motor (incorporates sunroofECU)



SPECIAL TOOLS Tool

Number

Name

Use

MB991502

MUT-II sub assembly

Checking of the SWS (Diagnosis code display and input check with the MUT-II)

MB991529

Diagnosis code check harness

Simple diagnosis

54-110 Tool A

B

CHASSIS ELECTRICAL - Smart Wiring System (SWS) Number

Name

Use

MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222

Harness set A: Test harness B: LED harness C: LED harness adapter D: Probe

Measurement of terminal voltage at ECUs A: Connector pin contact pressure inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection

C

D

TROUBLESHOOTING STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.)

DIAGNOSTIC FUNCTION DIAGNOSIS CODES CHECK Use the MUT-II or the simple diagnosis mode to check a diagnosis code. (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.) NOTE Connect the MUT-II to the 16-pin diagnosis connector (black). ERASING DIAGNOSIS CODE Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points. CHECK BY USING SIMPLE DIAGNOSIS MODE (1) Set the MUT-II to simple diagnosis mode, and then select the switch diagnosis mode. (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.) (2) In this condition, the following input switches can be checked.

54900040032

CHASSIS ELECTRICAL - Smart Wiring System (SWS)

54-111

Input Signal Check Function Input signal ETACS

Buzzer/LED operation condition Ignition switch (IG1)

Turned from OFF to ON

Ignition switch (ACC)

Turned from OFF to ACC

Front door switch (driver’s side)

Driver’s door opened from closed condition

Door switches

All doors closed to any door opened

Key reminder switch

Ignition key removed from ignition key cylinder (from inserted position)

Front door lock actuator (driver’s side)

Driver’s door lock knob moved from lock position to unlock position or vice versa

Front door key switch (passenger’s side)

Passenger’s door locked or unlocked using ignition key

Back door or tailgate key switch

Back door or tailgate locked or unlocked using ignition key

Hazard lamp switch

Turned from OFF to ON

Front fog lamp switch

Column switch assembly

Back-up lamp switch

Shift lever moved to R position

Inhibitor switch (reverse)</sub>

Selector lever moved to R position

Keyless entry transmitter (LOCK and UNLOCK switches)

LOCK or UNLOCK switch turned OFF to ON

Tail lamp switch

Lighting switch turned to tail lamp position from any other position

Headlamp switch

Lighting switch turned to headlamp position from any other position

Dimmer switch

Turned from OFF to ON

Passing switch Right-hand turn signal switch Left-hand turn signal switch Windshield mist wiper switch Windshield wiper and washer switches Windshield wiper INT switch Windshield wiper LO switch Windshield wiper HI switch Rear wiper INT switch Rear wiper and washer switches Headlamp washer switch Power window switches

Any switch

Multi center display

Function switch

Sunroof

Any switch

Turned from OFF to ON

54-112

CHASSIS ELECTRICAL - Smart Wiring System (SWS)

DIAGNOSIS CODE CHART Code No.

Diagnosis item

Reference page

11

Failure concerning the ETACS-ECU

54-112

12

Failure concerning the column switch or improper connection with the ETACS-ECU

54-112

13

Failure concerning the front-ECU

54-113

21

Short circuit in communication line

54-113

DIAGNOSIS CODE INSPECTION PROCEDURES Code No.11 Failure concerning the ETACS-ECU

Probable cause

The ETACS-ECU monitors its own communication data, and sends a diagnosis code when an error takes place consecutive fifteen times in 0.6 second. The diagnosis code will be erased when the ETACS-ECU determines that its own communication data is sent consecutive 15 times in 0.6 second.

D

Malfunction of ETACS-ECU

Replace the ETACS-ECU.

Code No.12 Failure concerning the column switch or improper connection with the ETACS-ECU

Probable cause

This diagnosis code is displayed when the column switch sends a signal regardless of the transmission request signal from the ETACS-ECU (three times or more in one second). The diagnosis code is erased when the column switch continues to send a signal according to the transmission request signal from the ETACS-ECU for one second.

D D D D

Check the following connectors: B-87, B-68, B-66, B-106

NG

Malfunction Malfunction Malfunction Malfunction

of of of of

Repair

OK Check trouble symptoms. NG Check the harness wire between the column switch and the ETACS-ECU, and repair if necessary. Check trouble symptoms. NG Replace the column switch. OK Check trouble symptoms.

NG

Replace the ETACS-ECU.

column switch connector harness ETACS-ECU

CHASSIS ELECTRICAL - Smart Wiring System (SWS) Code No.13 Failure concerning the front-ECU

Probable cause

This diagnosis code is displayed when the signals that the front-ECU sends to the ETACS-ECU are errors consecutive fifteen times in 0.6 second. The diagnosis code will be erased when the front-ECU sends normal signals to the ETACS-ECU consecutive 15 times in 0.6 second.

D D D D

Check the following connectors: A-25X, B-66, B-68, B-106

NG

Malfunction Malfunction Malfunction Malfunction

of of of of

the the the the

front-ECU connector harness ETACS-ECU

Repair

OK Check trouble symptoms. NG Check the harness wire between the front-ECU and the ETACS-ECU, and repair if necessary. Check trouble symptoms. NG Replace the front-ECU. OK NG

Check trouble symptoms.

Replace the ETACS-ECU.

Code No.21 Short circuit in communication line

Probable cause

This diagnosis code is displayed when the SWS communication line voltage reaches the LO level for 0.3 second. The diagnosis code is erased when voltage in the ETACS-ECU data line reaches the HI level for 0.3 second, or the ETACS-ECU receives a normal signal from other ECUs or switches. While this code is displayed, other codes are not displayed.

D D D D

Check the following connectors: A-25X, B-66, B-68, B-87, B-04, B-106

NG

Malfunction Malfunction Malfunction Malfunction

of of of of

Repair

OK Check trouble symptoms. NG Check the harness wire between each ECU, the column switch and the ETACS-ECU, and repair if necessary.

Check trouble symptoms.

NG

Replace the ETACS-ECU.

the the the the

front-ECU connector harness ETACS-ECU

54-113

54-114

CHASSIS ELECTRICAL - Smart Wiring System (SWS)

TROUBLE SYMPTOM CHART Trouble symptom

Inspection procedure No.

Reference page

Communication with the MUT-II is impossible.

1

54-114

TROUBLE SYMPTOM INSPECTION PROCEDURES Inspection procedure 1 Communication with the MUT-II is impossible.

Probable cause

Power supply or earth circuit for the ETACS-ECU can be defective.

D D

Measure at diagnosis connector B-25. D Voltage between 16 and body earth OK Battery voltage

NG

Malfunction of the harness and connector Malfunction of the ETACS-ECU

Check the following connectors: B-91, B-92, B-66 OK Check trouble symptoms.

OK

NG Repair

NG Check the harness between the diagnosis connector and fusible link (2), and repair if necessary.

Measure at diagnosis connector B-25. D Continuity between 4, 5 and body earth OK Continuity

NG

Check the following connector: B-25 OK Check trouble symptom.

OK

NG Repair

NG Check the harness wire between the diagnosis connector and the ETACS-ECU, and repair if necessary.

Check trouble symptoms.

Check the harness wire between the diagnosis connector and body earth, and repair if necessary.

NG

Replace the ETACS-ECU.

55-1

HEATER, AIR CONDITIONER AND VENTILATION CONTENTS

55109000164

GENERAL INFORMATION . . . . . . . . . . . . . . . . 3

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 8

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . 3

Sight Glass Refrigerant Level Test . . . . . . . . . . 8

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 4 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 5

Magnetic Clutch Test . . . . . . . . . . . . . . . . . . . . . . 8 Receiver Drier Test . . . . . . . . . . . . . . . . . . . . . . . . 8 Compressor Drive Belt Adjustment . . . . . . . . . . . 8 Dual Pressure Switch Check . . . . . . . . . . . . . . . 9

CONTINUED ON NEXT PAGE

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES WARNING! (1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering the SRS inoperative). (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component. NOTE The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, side impact sensors and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).

55-2 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Performance Test . . . . . . . . . . . . . . . . . . . . . . . . 14 Refrigerant Leak Repair . . . . . . . . . . . . . . . . . . . 16 Compressor Noise . . . . . . . . . . . . . . . . . . . . . . . . 16 Power Relay Check . . . . . . . . . . . . . . . . . . . . . . 17 Idle-up Operation Check . . . . . . . . . . . . . . . . . . 18 Air Purifier Assembly Replacement . . . . . . . . . 18

HEATER CONTROL ASSEMBLY AND A/C SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

AIR THERMO SENSOR . . . . . . . . . . . . . . . . 25 BLOWER MOTOR ASSEMBLY, AUTOMATIC COMPRESSOR-ECU AND INSIDE/OUTSIDE AIR CHANGEOVER DAMPER MOTOR . 26 COMPRESSOR AND TENSION PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 CONDENSER AND CONDENSER FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 REFRIGERANT LINE . . . . . . . . . . . . . . . . . . 33

HEATER UNIT*, BLOWER UNIT*, RESISTER* AND EVAPORATOR* . . . . . . . 22

VENTILATORS* . . . . . . . . . . . . . . . . . . . . . . . . 36

HEATER, AIR CONDITIONER AND VENTILATION - General Information

GENERAL INFORMATION The heater system uses a two-way-flow full-air-mix system that features high performance and low operating noise, and includes an independent face air blowing function. The A/C system is basically the same as the conventional system, but a new Items Heater unit

55-3 55200010312

refrigerant system has been adopted as a response to restrictions on the use of chlorofluorocarbons. In addition, an air purifier which carries out fine A/C control has been included. Specifications

Type

Two-way-flow full-air-mix system

Heater control assembly

Dial type

Compressor

Model

Scroll type

Dual pressure switch kPa

High-pressure switch

ON ® OFF: 2,940, OFF ® ON: 2,350

Low-pressure switch

ON ® OFF: 196, OFF ® ON: 221

Refrigerant and quantity g

SAFETY PRECAUTIONS Because R-134a refrigerant is a hydrofluorocarbon (HFC) which contains hydrogen atoms in place of chlorine atoms, it will not cause damage to the ozone layer. Refrigerant R-134a is transparent and colourless in both the liquid and vapour state. Since it has a boiling point of - 29.8_C, at atmospheric pressure, it will be a vapour at all normal temperatures and pressures. The vapour is heavier than air, non-flammable, and nonexplosive. The following precautions must be observed when handling R-134a. Caution Wear safety goggles when servicing the refrigeration system. R-134a evaporates so rapidly at normal atmospheric pressures and temperatures that it tends to freeze anything it contacts. For this reason, extreme care must be taken to prevent any liquid refrigerant from contacting the skin and especially the eyes. Always wear safety goggles when servicing the refrigeration part of the A/C system. Keep a bottle of sterile mineral oil handy when working on the refrigeration system. Should any liquid refrigerant get into the eyes, use a few drops of mineral oil to wash them out. R-134a is rapidly absorbed by the oil. Next splash the eyes with plenty of cold water. Call your doctor immediately even though irritation has ceased after treatment. Caution Do not heat R-134a above 40_C

R-134a (HFC-134a), Approx. 500 - 600

In most instances, moderate heat is required to bring the pressure of the refrigerant in its container above the pressure of the system when charging or adding refrigerant. A bucket or large pan of hot water not over 40_C is all the heat required for this purpose. Do not heat the refrigerant container with a blow torch or any other means that would raise temperature and pressure above this temperature. Do not weld or steam clean on or near the system components or refrigerant lines. Caution Keep R-134a containers upright when charging the system. When metering R-134a into the refrigeration system keep the supply tank or cans in an upright position. If the refrigerant container is on its side or upside down, liquid refrigerant will enter the system and damage the compressor. Caution 1. The leak detector for R-134a should be used to check for refrigerant gas leaks. 2. Do not allow liquid refrigerant to touch bright metal. Refrigerant will tarnish bright metal and chrome surfaces, and in combination with moisture can severely corrode all metal surfaces.

55-4

HEATER, AIR CONDITIONER AND VENTILATION

-

Service Specifications/Lubricants/Special Tools

SERVICE SPECIFICATIONS

55200030332

Items

Standard value

Idle speed r/min

650 ± 50

Idle up speed r/min

800 ± 50

Resistor (for blower motor) W

LO: 2.30, ML:1.10, MH: 0.40

Air gap (Magnetic clutch)

0.25 - 0.55

LUBRICANTS

55200040236

Items

Specified lubricants

Quantity

Each connection of refrigerant line

DENSO OIL 8

As required

Compressor refrigerant unit lubricant mL

DENSO OIL 8

60 - 100

SPECIAL TOOLS Tool

55200060157

Number

Name

Use

MB991367

Special spanner

Removal and installation of armature mounting nut of compressor

MB991386

Pin

55-5

HEATER, AIR CONDITIONER AND VENTILATION - Troubleshooting

TROUBLESHOOTING

55200070389

TROUBLESHOOTING PROCEDURES Trouble symptom

Problem cause

Remedy

Reference page

When the ignition switch is “ON”, the A/C does not operate

Fuse is defective

Replace the fuse

-

Harness or connector is defective

Repair the harness or connector

-

A/C compressor relay is defective

Replace the A/C compressor relay

55-17

A/C compressor magnetic clutch is defective

Replace the armature plate, rotor or clutch coil

55-8

Refrigerant leak or overfilling of refrigerant

Replenish the refrigerant, repair the leak or take out some of the refrigerant

55-8

Dual pressure switch is defective

Replace the dual pressure switch

55-9

A/C switch is defective

Replace the blower switch assembly

55-20

Blower switch is defective

Replace the blower switch assembly

55-20

Automatic compressor-ECU is defective

Replace the automatic compressor-ECU

55-7

Engine-ECU is defective

Replace the engine-ECU

-

When the A/C is operating, temperature inside the passenger compartment doesn’t decrease (cool air is not emitted)

Refrigerant leak

Replenish the refrigerant and repair the leak

55-8

Dual pressure switch is defective

Replace the dual pressure switch

55-9

Automatic compressor-ECU is defective

Replace the automatic compressor-ECU

55-7

Engine-ECU is defective

Replace the engine-ECU

-

Blower fan and motor do not turn

Fuse is defective

Replace the fuse

-

Harness or connector is defective

Repair the harness or connector

-

Blower relay is defective

Replace the blower relay

55-17

Blower fan and motor are defective

Replace the blower fan and motor

55-26

Resistor (for blower motor) is defective

Replace the resistor

55-24

Blower switch is defective

Replace the blower switch assembly

55-20

55-6

HEATER, AIR CONDITIONER AND VENTILATION - Troubleshooting

Trouble symptom

Problem cause

Remedy

Reference page

Blower fan and motor do not stop turning

Harness or connector is defective

Repair the harness or connector

-

Blower switch is defective

Replace the blower switch assembly

55-20

Blower relay is defective

Replace the blower relay

55-17

Fuse is defective

Replace the fuse

-

Harness or connector is defective

Repair the harness or connector

-

Condenser fan motor is defective

Replace the condenser fan motor

55-32

Radiator fan motor is defective

Replace the radiator fan motor

-

Engine-ECU is defective

Replace the engine-ECU

-

Harness or connector is defective

Repair the harness or connector

-

Inside and outside changeover switch is defective

Replace the blower switch assembly

55-20

Inside and outside changeover damper motor is defective

Replace the inside and outside changeover damper motor

55-26

When the A/C is operating condenser fan or radiator fan does not turn

Inside and outside changeover does not operate

HEATER, AIR CONDITIONER AND VENTILATION - Troubleshooting

INSPECTION AT THE AUTOMATIC COMPRESSOR-ECU TERMINAL

55-7 55201030096

Terminal No.

Check item

Checking requirements

Normal condition

1

Earth

Always

0V

2

-

-

-

3

Input from air thermo sensor to Automatic compressor-ECU

Air thermo sensor detection temperature: 5_C

1.1 V

4

Automatic compressor-ECU power supply (IG2)

Ignition switch: ON

Battery voltage

5

Output from ECU to A/C compressor relay

A/C compressor relay: OFF

Battery voltage

A/C compressor relay: ON

0V

6

Air thermo sensor earth

Always

0V

7- 10

-

-

-

11

Input from A/C switch to Automatic compressor-ECU

A/C switch: OFF

0V

A/C switch: ON

Battery voltage

Output from ECU to engine-ECU

Air thermo sensor detection temperature: 5_C or less

Battery voltage

Air thermo sensor detection temperature: 8_C or more

0V

12

55-8

HEATER, AIR CONDITIONER AND VENTILATION - On-vehicle Service Sight glass

ON-VEHICLE SERVICE

55200840225

SIGHT GLASS REFRIGERANT LEVEL TEST The sight glass is a refrigerant level indicator. To check the refrigerant level, clean the sight glass and start the vehicle engine. Push the A/C button to operate the compressor, place the blower switch to high and move the temperature control lever to max cool. After operating for a few minutes in this manner, check the sight glass. 1. If the sight glass is clear, the magnetic clutch is engaged, the compressor discharge line is warm and the compressor inlet line is cool; the system has a full charge. 2. If the sight glass is clear, the magnetic clutch is engaged and there is no significant temperature difference between compressor inlet and discharge lines; the system has lost some refrigerant. 3. If the sight glass shows foam or bubbles, the system could be low on charge. The system has to be recharged with refrigerant.

MAGNETIC CLUTCH TEST

55200850303

1. Disconnect the connector (1-pin) to the magnetic clutch. 2. Connect battery (+) voltage directly to the connector for the magnetic clutch. 3. If the magnetic clutch is normal, there will be “click”. If the pulley and armature do not make contact (‘click’), there is a malfunction.

RECEIVER DRIER TEST

55200860115

Operate the unit and check the piping temperature by touching the receiver drier outlet and inlet. If there is a difference in the temperatures, the receiver drier is restricted. Replace the receiver drier.

COMPRESSOR DRIVE BELT ADJUSTMENT 55200100101

Refer to GROUP 11 - On-vehicle Service.

HEATER, AIR CONDITIONER AND VENTILATION - On-vehicle Service

DUAL PRESSURE SWITCH CHECK Suction hose

Dual pressure switch LOW-PRESSURE SIDE ON

HIGH-PRESSURE SIDE

OFF 196 ± 20

196 - 250 2550 ± 200 3140 ± 200 kPa

55-9 55201040235

1. Remove the dual pressure switch connector and connect the high/low pressure side terminals located on the harness side as shown in the illustration. 2. Install a gauge manifold to the high-pressure side service valve of the refrigerant line. (Refer to Performance Test.) 3. When the high/low pressure sides of the dual pressure switch are at operation pressure (ON) and there is continuity between the respective terminals, then the condition is normal. If there is no continuity, replace the switch.

55-10

HEATER, AIR CONDITIONER AND VENTILATION - On-vehicle Service

CHARGING High-pressure valve

Low-pressure valve

Gauge manifold Charging hose (yellow)

Adapter valve Charging hose (blue) Switch R-12 connection port Vacuum pump Quick joint (for adaptor low pressure)

Vacuum pump

R-134a connection port

Power supply plug

Switch Low-pressure service valve A Sleeve

55200120275

1. With the handles turned back all the way (valve closed), install the adaptor valve to the low-pressure side of the gauge manifold. 2. Connect the charging hose (blue) to the adaptor valve. 3. Connect the quick joint (for low-pressure) to the charging hose (blue). 4. Connect the quick joint (for low-pressure) to the lowpressure service valve. NOTE The low-pressure service valve should be connected to the suction hose. Caution (1) Use tools that are suited to R-134a. (2) To install the quick joint, press section “A” firmly against the service valve until a click is heard. When connecting, run your hand along the hose while pressing to ensure that there are no bends in the hose. 5. Close the high and low-pressure valves of the gauge manifold. 6. Install the vacuum pump adaptor to the vacuum pump. 7. Connect the vacuum pump plug to the vacuum pump adaptor. 8. Connect the charging hose (yellow) to the R-134a connection port of the vacuum pump adaptor. 9. Tighten the adaptor valve handle (valve open). 10. Open the low-pressure valve of the gauge manifold. 11. Turn the power switch of the vacuum pump to the ON position. NOTE Even if the vacuum pump power switch is turned ON, the vacuum pump will not operate because of the power supply connection in step (7).

HEATER, AIR CONDITIONER AND VENTILATION - On-vehicle Service

55-11

12. Turn the vacuum pump adaptor switch to the R-134a side to start the vacuum pump. Caution Do not operate the compressor for evacuation. 13. Evacuate to a vacuum reading of 100 kPa or higher (takes approx. 10 minutes). 14. Turn the vacuum pump adaptor switch OFF and allow to stand it for 5 minutes. Caution Do not operate the compressor in the vacuum condition; damage may occur. 15. Carry out a leak test. (Good if the negative pressure does not drop.)

Low-pressure service valve

Caution If the negative pressure drops, increase the tightness of the connections, and then repeat the evacuation procedure from step (12). Vacuum pump

Valve open Valve close Charging valve Adaptor valve

16. With the handle turned back all the way (valve open), install the charging valve to the service can. 17. Turn the handle of the adaptor valve back all the way (valve closed), remove it from the gauge manifold and install the service can. 18. Tighten the handle of the charging valve (valve closed) to puncture the service can.

Service can

Charging valve

19. Turn the handle of the charging valve back (valve open) and tighten the handle of the adaptor valve (valve open) to charge the system with refrigerant. Caution If the service can is inverted, liquid refrigerant may be drawn into the compressor damaging it by liquid compression. Keep the service can upright to ensure that refrigerant is charged in gas state. 20. If the refrigerant is not drawn in, turn the handle of the adaptor valve back all the way (valve closed). 21. Check for gas leaks using a leak detector. If a gas leak is detected, re-tighten the connections, and then repeat the charging procedure from evacuation in step (12).

Service can (Refrigerant container)

Low-pressure service valve

Caution The leak detector for R-134a should be used. 22. Start the engine. 23. Operate the A/C and set to the lowest temperature (MAX. COOL).

55-12

HEATER, AIR CONDITIONER AND VENTILATION - On-vehicle Service 24. Fix the engine speed at 1,500 r/min. 25. Tighten the handle of the adaptor valve (valve open) to charge the required volume of refrigerant. Caution If the service can is inverted, liquid refrigerant may be drawn into the compressor damaging it by liquid compression. Keep the service can upright to ensure that refrigerant is charged in gas state. 26. After charging with refrigerant, turn the handle of the adaptor valve back all the way (valve closed). 27. Tighten the charging valve handle (valve closed). Remove the quick joint (for low-pressure) from the low-pressure service valve. NOTE If the service can is not emptied completely, keep the handles of the charging valve and adaptor valve closed for the next charging.

Valve open Charge valve Valve close

Service can (Refrigerant container)

Adaptor valve

Charging hose (blue)

Quick joint (for low-pressure)

Quick joint (for low-pressure)

Low-pressure service valve

CORRECTING LOW REFRIGERANT LEVEL IN CASE THE SERVICE CAN IS USED. 1. Install the charge valve with the handle turned all the way back (valve open) to the service can. 2. Install the adaptor valve with the handle turned all the way back (valve close) to the charging valve. 3. Connect the charging hose (blue) to the adaptor valve. 4. Connect the charging hose (blue) to the quick joint (for low-pressure). 5. Tighten the handle of the charge valve (valve close), and pierce the service can. 6. Turn the handle of the adaptor valve to bleed the air. 7. Install the quick joint (for low-pressure) to the low-pressure service valve. NOTE The low-pressure service valve should be connected to the suction hose.

HEATER, AIR CONDITIONER AND VENTILATION - On-vehicle Service

Charging valve

55-13

8. Start the engine. 9. Operate the air conditioner and set at the lowest temperature (MAX. COOL). 10. Fix the engine speed at 1,500 r/min. 11. Tighten the handle of the adaptor valve (valve open), and replenish refrigerant while checking the quantity through the sight glass. Caution If the service can is inverted, liquid refrigerant may be draw into the compressor damaging it by liquid compression. Keep the service can upright to ensure that refrigerant is changed in gas state.

Service can (Refrigerant container)

12. After replenishing is completed, turn the handle of the adaptor valve all the way back (valve close), and remove the quick joint. NOTE When there is remainder of refrigerant in the service can, keep it for next use with the charge value and the valve of the adaptor valve being closed.

Low-pressure service valve

DISCHARGING SYSTEM 1. Run the engine at an engine speed of 1,200 - 1,500 r/min for approximately 5 minutes with the A/C operating to return to the oil. A

Sleeve

Charging hose (blue)

Quick joint

Low-pressure service valve

NOTE Returning the oil will be more effective if it is done while driving. 2. Stop the engine. 3. Connect the charging hose (blue) to the adaptor valve with its handle turned back all the way (valve closed). 4. Connect the quick joint to the charging hose (blue). 5. Install the quick joint to the low-pressure service valve. NOTE The low-pressure service valve should be connected to the suction hose. Caution To connect the quick joint, press section “A” firmly against the service valve until a click is heard. When connecting, run your hand along the hose while pressing to ensure that there are no bends in the hose. 6. Place the adaptor valve inside the container and discharge the refrigerant by opening the handle gradually so that oil does not gush out.

Adaptor valve Oil

NOTE Any oil remaining in the container should be returned to the A/C system.

55-14

HEATER, AIR CONDITIONER AND VENTILATION - On-vehicle Service REFILLING OF OIL IN THE A/C SYSTEM Too little oil will provide inadequate compressor lubrication and cause a compressor failure. Too much oil will increase discharge air temperature. When a compressor is installed at the factory, it contains 120 mL of refrigerant oil. While the A/C system is in operation, the oil is carried through the entire system by the refrigerant. Some of this oil will be trapped and retained in various parts of the system. When the following system components are changed, it is necessary to add oil to the system to replace the oil being removed with the component. Compressor oil: DENSO OIL 8 Quantity Condenser: 10 mL Evaporator: 40 mL Suction hose: 6.5 mL

PERFORMANCE TEST Low-pressure valve

High-pressure valve

Gauge manifold Charging hose (red) Charging hose (blue) A Adaptor valve (for low pressure)

Sleeve Adaptor valve (for high pressure)

Lowpressure service valve

Highpressure service valve

55200140257

1. The vehicles to be tested should be in a place that is not in direct sunlight. 2. Close the high and low-pressure valve of the gauge manifold. 3. Connect the charging hose (blue) to the low-pressure valve and connect the charging hose (red) to the high-pressure valve of the gauge manifold. 4. Install the quick joint (for low-pressure) to the charging hose (blue), and connect the quick joint (for high-pressure) to the charging hose (red). 5. Connect the quick joint (for low-pressure) to the low-pressure service valve and connect the quick joint (for high-pressure) to the high-pressure service valve. NOTE The high-pressure service valve is on liquid pipe A and the low-pressure service valve is on the suction hose. Caution To connect the quick joint, press section “A” firmly against the service valve until a click is heard. When connecting, run your hand along the hose while pressing to ensure that there are no bends in the hose. 6. Start the engine.

HEATER, AIR CONDITIONER AND VENTILATION - On-vehicle Service

55-15

7. Set the controls to the A/C as follows: A/C switch: A/C - ON position Mode selection: Face position Temperature control: Max. cooling position Air selection: Recirculation position Blower switch: HI (Fast) position 8. Adjust engine speed to 1,000 r/min with A/C clutch engaged. 9. Engine should be warmed up with doors and windows closed. 10. Insert a thermometer in the center A/C outlet and operate the engine for 20 minutes. 11. Note the discharge air temperature.

Thermometer

NOTE If the clutch cycles, take the reading before the clutch disengages.

Performance Temperature Chart Garage ambient temperature _C

20

25

35

40

Discharge air temperature _C

2.5 - 4.5

2.5 - 4.5

4.0 - 6.5

6.5 - 9.0

Compressor high-pressure kPa

765 - 960

765 - 960

1,325 - 1,420

1,570 - 1,765

Compressor low-pressure kPa

40 - 135

40 - 135

80 - 175

155 - 255

55-16

HEATER, AIR CONDITIONER AND VENTILATION - On-vehicle Service

REFRIGERANT LEAK REPAIR

55200150045

LOST CHARGE If the system has lost all charge due to a leak: 1. Evacuate the system. (See procedure.) 2. Charge the system with approximately one pound of refrigerant. 3. Check for leaks. 4. Discharge the system. 5. Repair leaks. 6. Replace receiver drier. Caution Replacement filter-drier units must be sealed while in storage. The drier used in these units will saturate water quickly upon exposure to the atmosphere. When installing a drier, have all tools and supplies ready for quick reassembly to avoid keeping the system open any longer than necessary. 7. Evacuate and charge system. LOW CHARGE If the system has not lost all of its refrigerant charge; locate and repair all leaks. If it is necessary to increase the system pressure to find the leak (because of an especially low charge) add refrigerant. If it is possible to repair the leak without discharging the refrigerant system, use the procedure for correcting low refrigerant level.

COMPRESSOR NOISE

55200870033

You must first know the conditions when the noise occurs. These conditions are: weather, vehicle speed, in gear or neutral, engine temperature or any other special conditions. Noises that develop during A/C operation can often be misleading. For example: what sounds like a failed front bearing or connecting rod, may be caused by loose bolts, nuts, mounting brackets, or a loose clutch assembly. Verify accessory drive belt tension (power steering or alternator). Improper accessory drive belt tension can cause a misleading noise when the compressor is engaged and little or no noise when the compressor is disengaged. Drive belts are speed-sensitive. That is, at different engine speeds, and depending upon belt tension, belts can develop unusual noises that are often mistaken for mechanical problems within the compressor.

HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The following precautions must be observed. The system must be completely discharged before opening any fitting of connection in the refrigeration system. Open fittings with caution even after the system has been discharged. If any pressure is noticed as a fitting is loosened, allow trapped pressure to bleed off very slowly. Never attempt to rebend formed lines to fit. Use the correct line for the installation you are servicing. A good rule for the flexible hose lines is keep the radius of all bends at least 10 times the diameter of the hose. Sharper bends will reduce the flow of refrigerant. The flexible hose lines should be routed so that they are at least 80 mm from the exhaust manifold. It is good practice to inspect all flexible hose lines at least once a year to make sure they are in good condition and properly routed. Unified plumbing connections with O-rings, these O-rings are not reusable.

ADJUSTMENT 1. Select a quiet area for testing. Duplicate conditions as much as possible. Switch compressor on and off several times to clearly identify compressor noise. To duplicate high ambient conditions (high head pressure), restrict air flow through condenser. Install manifold gauge set to make sure discharge pressure doesn’t exceed 2,070 kPa. 2. Tighten all compressor mounting bolts, clutch mounting bolt, and compressor drive belt. Check to assure clutch coil is tight (no rotation or wobble). 3. Check refrigerant hoses for rubbing or interference that can cause unusual noises. 4. Check refrigerant charge. (See “Charging System”.) 5. Recheck compressor noise as in Step 1. 6. If noise still exists, loosen compressor mounting bolts and retorque. Repeat Step 1. 7. If noise continues, replace compressor and repeat Step 1.

HEATER, AIR CONDITIONER AND VENTILATION - On-vehicle Service

POWER RELAY CHECK

55-17 55200880296

BLOWER RELAY Battery voltage

Terminal No. 1

Blower relay

3

2

5

4

5

Power is not supplied Power is supplied

A/C compressor relay

A/C COMPRESSOR RELAY Battery voltage

Terminal No. 1

Power is not supplied Power is supplied

FAN CONTROL RELAY Refer to GROUP 14 - Radiator.

3

55-18

HEATER, AIR CONDITIONER AND VENTILATION - On-vehicle Service

IDLE-UP OPERATION CHECK

55200160338

1. Before inspection and adjustment, set vehicle in the following condition: D Engine coolant temperature: 80 - 90_C D Lights, electric cooling fan and accessories: Set to OFF D Transmission: Neutral (N or P for vehicles with A/T) D Steering wheel: Straightforward 2. Check whether or not the idling speed is the standard value. Standard value: 650 ± 50 r/min 3. When the A/C is running after turning the A/C switch to ON, and the blower switch to the MH or HI position, check to be sure that the idle speed is at the standard value. Standard value: 800 ± 50 r/min NOTE There is no necessity to make an adjustment, because the idling speed is automatically adjusted by the ISC system. If, however, there occurs a deviation from the standard value for some reason, check the ISC system. (Refer to GROUP 13A - On-vehicle Service.)

AIR PURIFIER ASSEMBLY REPLACEMENT Air purifier assembly

Air purifier cover

55501100024

1. Remove the glove box. 2. Remove the air purifier cover and the air purifier assembly. 3. Install a new air purifier assembly and install the air purifier cover. 4. Install the glove box.

Heater Control Assembly and

HEATER, AIR CONDITIONER AND VENTILATION - A/C switch

HEATER CONTROL ASSEMBLY AND A/C SWITCH

55-19 55200240162

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Center Air Outlet Assembly, Instrument Under Cover Removal and Installation (Refer to GROUP 52A Instrument Panel.)

D

Radio, Tape Player Removal and Installation (Refer to GROUP 54.)

3

2 1

Removal steps "BA 1. Air mix damper cable connection "AA 2. Air outlet changeover damper cable connection 3. Heater control assembly

INSTALLATION SERVICE POINTS Air outlet changeover damper lever

DEF position

Air mix damper lever

MAX HOT position

"AA AIR OUTLET CHANGEOVER DAMPER CABLE CONNECTION 1. Set the air outlet changeover control knob on the heater control assembly to the DEF position. 2. Set the air outlet changeover damper lever of the heater unit to the DEF position (turn clockwise the damper lever unit it stops), and then connect the cable to the lever.

"BA AIR MIX DAMPER CABLE CONNECTION 1. Set the temperature control knob on the heater control assembly to the MAX HOT position. 2. Set the air mix damper lever of the heater unit to the MAX HOT position (turn clockwise the damper lever until it stops), and then connect the cable to the lever.

55-20

Heater Control Assembly and

HEATER, AIR CONDITIONER AND VENTILATION - A/C switch

INSPECTION

55201250027

BLOWER SWITCH CONTINUITY CHECK Switch position

Terminal No. 1

2

3

4

5

6

OFF D (LO)

D (ML)

D

(MH)

D (HI)

Inside/outside air changeover switch

INSIDE/OUTSIDE AIR CHANGEOVER SWITCH CONTINUITY CHECK Switch position

Terminal No. 1

2

3

IND

4

8

9

RECIRC

ILL

FRESH

A/C SWITCH CONTINUITY CHECK A/C switch

Switch position

Terminal No. 5

IND

6

7

8

9

OFF ON ILL

Heater Control Assembly and

HEATER, AIR CONDITIONER AND VENTILATION - A/C switch

DISASSEMBLY AND REASSEMBLY

55-21 55100130084

6

2

5 1

4 3

AA"

Disassembly steps 1. Knob assembly 2. Bulb harness 3. Air outlet changeover damper cable

AA"

4. Air mix damper cable 5. Heater control panel 6. Blower switch assembly

DISASSEMBLY SERVICE POINT Flat-tipped screwdriver Claw part

AA" AIR OUTLET CHANGEOVER DAMPER CABLE/AIR MIX DAMPER CABLE REMOVAL Insert a flat-tipped screwdriver into the control base clip from inner side, and then remove the cable by lifting the claw part of the clip.

55-22

Heater Unit, Blower Unit,

HEATER, AIR CONDITIONER AND VENTILATION - Resister and Evaporator

HEATER UNIT, BLOWER UNIT, RESISTER AND EVAPORATOR

55201270054

REMOVAL AND INSTALLATION Caution: SRS When removing and installing the floor console assembly from vehicles equipped with SRS, do not let it bump against the SRS-ECU or the components. 41 Nm

7

7

10

1 2

4 3

8

18 Nm

9

Piping connection

6 8 O-ring

5

A/C compressor oil: DENSO OIL 8 Heater unit and blower unit removal steps D Discharging and Charging of Refrigerant (Refer to P.55-10.) D Discharging and Charging of Engine Coolant (Refer to GROUP 14 On- vehicle Service.) D Engine Cover Removal and Installation (Refer to GROUP 11 - Engine Assembly.) D Air Cleaner Assembly Removal and Installation. D Front Scuff Plate, Rear Scuff Plate and Cowl Side Trim Removal and Installation (Refer to GROUP 52A Trims.) D Glove Box and Instrument Under Cover Removal and Installation (Refer to GROUP 52A - Instrument Panel.) D Front Seat Assembly (Driver’s side) Removal and Installation (Refer to GROUP 52A - Seat.) D Shift Lever Assembly Removal and Installation (Refer to GROUP 22 Transmission Control.)

D Selector Lever Assembly Removal and Installation (Refer to GROUP 23 - Transmission Control.) D Floor Carpet Removal and Installation. D Door check and body connection (driver side) 1. Air bag module (Refer to GROUP 52B) 2. Steering wheel 3. Key inter lock cable 4. Steering column shaft assembly connection 5. Rear heater duct C 6. Rear heater duct B 7. Heater hoses connection 8. Front pipe assembly connection 9. Instrument panel side cover 10. Instrument panel assembly

Heater Unit, Blower Unit,

HEATER, AIR CONDITIONER AND VENTILATION - Resister and Evaporator

55-23

11 11

13 18 19

16

21

12

15

20 15 17 14

11

11. 12. 13. 14. 15. 16. 17. 21.

Instrument panel wiring harness Blower unit Intake duct Glove box support bracket Foot duct Joint duct A Joint duct B Heater unit

Evaporator and Resister removal steps D Discharging and Charging of Refrigerant (Refer to P.55-10.) D Engine Cover (Refer to GROUP 11 - Engine Assembly.) D Air Cleaner Assembly D Front Scuff Plate, Rear Scuff Plate and Cowl Side Trim (Refer to GROUP 52A - Trims.) D Glove Box and Instrument Under Cover (Refer to GROUP 52A Instrument Panel.) 8. Front pipe assembly connection 19. Expansion valve 14. Glove box support bracket 16. Joint duct A 17. Joint duct B 18. Resistor 15. Foot duct (passenger’s side) 20. Evaporator

55-24

Heater Unit, Blower Unit,

HEATER, AIR CONDITIONER AND VENTILATION - Resister and Evaporator

INSPECTION RESISTOR CHECK

55100510031

Use a circuit tester to measure the resistance between the terminals as indicated below. Check that the measured value is at the standard value. Standard value: Measurement terminal

Standard value W

Between terminals 3 and 2 (LO)

2.30

Between terminals 3 and 4 (ML)

1.10

Between terminals 3 and 1 (MH)

0.40

DISASSEMBLY AND REASSEMBLY

55100540016

2

1

3

Disassembly steps 1. Heater core 2. Expansion valve 3. Evaporator

HEATER, AIR CONDITIONER AND VENTILATION - Air Thermo Sensor

AIR THERMO SENSOR

55-25 55201350017

REMOVAL AND INSTALLATION

1

2

Removal steps 1. Air thermo sensor clip 2. Air thermo sensor

INSPECTION

Resistance kW 8

AIE THERMO SENSOR CHECK Measure the resistance between terminals under two or more temperature conditions. The resistance should be close to the values shown in the graph.

6 4 2 0

- 10

55201360010

0

10 20 Temperature

30

40_C

55-26

HEATER, AIR CONDITIONER AND VENTILATION

-

Blower Motor Assembly, Automatic compressor - ECU and Inside/Outside Air Changeover Damper Motor

BLOWER MOTOR ASSEMBLY, AUTOMATIC COMPRESSOR-ECU AND INSIDE/OUTSIDE AIR CHANGEOVER DAMPER MOTOR 55100500045 REMOVAL AND INSTALLATION 3

4

2

1

1. Blower motor assembly 2. Automatic compressor-ECU

Inside/outside air changeover damper motor removal steps 3. Instrument panel (Refer to GROUP 52A) 4. Inside/outside air changeover damper motor

INSPECTION

55100510048

BLOWER MOTOR CHECK When battery voltage is applied between the terminals, check that the motor operates. Also, check that there is no abnormal noise.

INSIDE/OUTSIDE CHANGEOVER DAMPER MOTOR CHECK Battery connection terminal 1

5

Lever operation

7 Moves to the outside air position Moves to the inside air position

Inside/outside air changeover damper motor

Caution Cut off the battery voltage when the damper is in the inside air position or outside air position.

HEATER, AIR CONDITIONER AND VENTILATION - Compressor and Tension Pulley

COMPRESSOR AND TENSION PULLEY

55-27 55200410471

REMOVAL AND INSTALLATION Pre-removal Operation D Discharging of Refrigerant (Refer to P.55-13.)

Piping connection

Post-installation Operation D Charging of Refrigerant (Refer to P.55-10.) D Drive Belt Tension Adjustment (Refer to GROUP 11 - On-vehicle Service.)

< 4G9-GDI>

4

2 26 Nm

3 O-ring

5 Compressor oil: DENSO OIL 8

3

4

< 4G6-GDI>

1

2

26 Nm

5

3

4 1

AA"

Removal steps D Under cover D Condenser fan (Refer to P.55-33.) 1. Drive belt 2. Tension pulley

AB"

3. Suction hose and discharge hose connection AC" "AA 4. Compressor 5. Compressor bracket

55-28

HEATER, AIR CONDITIONER AND VENTILATION - Compressor and Tension Pulley

REMOVAL SERVICE POINTS B A

AA" DRIVE BELT REMOVAL 1. Loosen the nut “A” for holding. 2. Loosen the bolt “B” for adjustment. 3. Remove the drive belt. AB" SUCTION HOSE, DISCHARGE HOSE DISCONNECTION Plug the disconnected hose and the compressor nipple not to let foreign matter get into them. Caution Seal the hoses completely, otherwise the compressor oil and receiver will absorb water vapour easily. AC" COMPRESSOR REMOVAL When doing this work, be careful not to spill the compressor oil.

INSTALLATION SERVICE POINT "AA COMPRESSOR INSTALLATION If a new compressor is installed, first adjust the amount of oil according to the procedures described below, and then install the compressor. 1. Measure the amount (X mL) of oil within the removed compressor. 2. Drain (from the new compressor) the amount of oil calculated according to the following formula, and then install the new compressor. New compressor oil amount 80 mL - X mL = Y mL NOTE (1) Y mL indicates the amount of oil in the refrigerant line, the condenser, the evaporator etc. (2) When replacing the following parts at the same time as the compressor, subtract the rated oil amount of the each part from Y mL and discharge from the new compressor. Quantity Evaporator: 40 mL Condenser: 10 mL Suction hose: 6.5 mL

HEATER, AIR CONDITIONER AND VENTILATION - Compressor and Tension Pulley

55-29

INSPECTION

55200850310

COMPRESSOR MAGNETIC CLUTCH OPERATION INSPECTION Connect the battery (+) terminal to the compressor side terminal, and earth the battery ( - ) terminal to the body of the compressor. The condition is normal if the sound of the magnetic clutch (click) can be heard.

MAGNETIC CLUTCH

55200460346

DISASSEMBLY AND REASSEMBLY

6 5 4 3 1 2 14 Nm

Magnetic clutch disassembly steps "BA D Air gap adjustment AA" 1. Armature plate 2. Shims "AA 3. Snap ring 4. Rotor 5. Snap ring 6. Clutch coil

DISASSEMBLY SERVICE POINT MB991386 MB991367

AA" ARMATURE PLATE REMOVAL

55-30 Snap ring

HEATER, AIR CONDITIONER AND VENTILATION - Compressor and Tension Pulley Rotor

Clutch coil

REASSEMBLY SERVICE POINTS "AA SNAP RING INSTALLATION Install the snap ring so that the tapered surface is at the outer side.

Tapered part

"BA AIR GAP ADJUSTMENT Check whether or not the air gap of the clutch is within the standard value. Standard value: 0.25 - 0.55 mm NOTE If there is a deviation of the air gap from the standard value, make the necessary adjustment by adjusting the number of shims.

Condenser and Condenser

HEATER, AIR CONDITIONER AND VENTILATION - Fan Motor

CONDENSER AND CONDENSER FAN MOTOR

55-31 55200670381

REMOVAL AND INSTALLATION 1 4 Piping connection

5

3 2

8 14

12

9

7 8 O-ring

11 13

Compressor oil: DENSO OIL 8

6 12 Nm

10

Condenser fan motor removal steps 1. Condenser fan motor and shroud assembly 2. Condenser fan motor cover 3. Condenser fan motor assembly 4. Condenser fan 5. Condenser fan shroud

Condenser removal steps D Discharging and charging of refrigerant (Refer to P.55-10.) D Discharging and charging of engine coolant (Refer to GROUP 14 - On- vehicle service.) D Air cleaner assembly D Radiator grille (Refer to GROUP 51 - Radiator grille.) 6. Reserve tank 7. Air intake duct AA" 8. Discharge hose and liquid pipe A connection 9. Condenser upper bracket D Under Cover Removal and Installation 10. Air guide panel 11. Radiator upper mounting bolts 12. Condenser side cover 13. Condenser lower bracket AB" "AA 14. Condenser assembly

55-32

Condenser and Condenser

HEATER, AIR CONDITIONER AND VENTILATION - Fan Motor

REMOVAL SERVICE POINTS AA" DISCHARGE HOSE AND LIQUID PIPE A DISCONNECTION Plug the disconnected pipe, hose and the condenser nipple not to let foreign matter get into them. Caution Seal the hoses completely, otherwise the compressor oil and receiver will absorb water vapour easily.

AB" CONDENSER ASSEMBLY REMOVAL 1. Remove the installation bolts from headlamp support member side. 2. Disengage the lower part of the radiator, and then move the radiator slightly toward the engine. 3. Raise the condenser assembly to remove it from the engine compartment.

INSTALLATION SERVICE POINT "AA CONDENSER ASSEMBLY INSTALLATION When replacing the condenser, refill it with a specified amount of compressor oil and install it. (to the vehicle). Compressor oil: DENSO OIL 8 Quantity: 10 mL

INSPECTION

55200680209

CONDENSER FAN MOTOR CHECK Check to be sure that the condenser fan motor operates. Terminals connected to battery 1 2

Condenser fan condition Operates

HEATER, AIR CONDITIONER AND VENTILATION - Refrigerant Line

REFRIGERANT LINE

55-33 55200640375

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Discharging and Charging of Refrigerant (Refer to P.55-10.) D Engine Cover Removal and Installation (Refer to GROUP 11 - Engine Assembly.)

D D

Air Cleaner Assembly Removal and Installation. Canister Removal and Installation (Refer to GROUP 17.)

1, 3

Piping connection

1, 2, 3, 5

5

O-ring

O-ring

Compressor oil: DENSO OIL 8

4 1

5

3

2

AA" "AA AA" AA"

Removal steps 1. Suction hose 2. Discharge hose 3. Liquid pipe A

AA"

4. Clamp 5. Front pipe assembly

55-34

HEATER, AIR CONDITIONER AND VENTILATION - Refrigerant Line

Pre-removal and Post-installation Operation D Discharging and Charging of Refrigerant (Refer to P.55-10.) D Engine Cover Removal and Installation (Refer to GROUP 11 - Engine Assembly.)

D D

Air Cleaner Assembly Removal and Installation. Canister Removal and Installation (Refer to GROUP 17.)

Piping connection

1, 3

1, 2, 3, 5

5

O-ring

O-ring

Compressor oil: DENSO OIL 8

6

4 1

5

3

2

AA" "AA AA" AA"

Removal steps 1. Suction hose 2. Discharge hose 3. Liquid pipe A

AA"

4. Clamp 5. Front pipe assembly 6. Clamp

HEATER, AIR CONDITIONER AND VENTILATION - Refrigerant Line

55-35

REMOVAL SERVICE POINT AA" HOSE/PIPE DISCONNECTION Plug the disconnected hose, the receiver, the evaporator and the compressor nipple not to let foreign matter get into them. Caution Seal the hoses completely, otherwise the compressor oil and receiver will absorb water vapour easily.

INSTALLATION SERVICE POINT "AA SUCTION HOSE INSTALLATION When replacing the suction hose, refill them with a specified amount of compressor oil, and then install them. Compressor oil: DENSO OIL 8 Quantity: Suction hose: 6.5 mL

55-36

HEATER, AIR CONDITIONER AND VENTILATION - Ventilators

VENTILATORS

55300160287

REMOVAL AND INSTALLATION Caution: SRS When removing and installing the floor console assembly from vehicles equipped with SRS, do not let it bump against the SRS-ECU or the components. 2 3 4 5

6

1

Rear heater duct B removal steps D Front scuff plate, cowl side trim and center console assembly (Refer to GROUP 52A - Instrument Panel.) D Floor carpet 1. Rear heater duct B Defroster nozzle and distribution duct removal steps D Instrument panel (Refer to GROUP 52A.) 2. Side defroster duct 3. Defroster nozzle assembly 4. Distribution duct

Foot distribution duct and rear heater duct A removal steps D Instrument panel (Refer to GROUP 52A.) D Blower unit, joint duct and glove box support bracket (Refer to P.55-22.) 5. Foot distribution duct 6. Rear heater duct A NOTE For the center air outlet assembly and the side air outlet assembly, refer to GROUP 52A - Instrument panel.

HEATER, AIR CONDITIONER AND VENTILATION - Ventilators



4

55-37

5

6 7

8

3 1

2

Rear heater duct B and rear heater duct C removal steps D Front scuff plate, rear scuff plate, cowl side trim and center console assembly (Refer to GROUP 52A - Instrument Panel.) D Front seats and second seats (Refer to GROUP 52A - Seats.) D Seat adjuster side cover and seat adjuster end cover (Refer to GROUP 52A - Seats.) D Floor carpet 1. Rear heater nozzle garnish 2. Rear heater duct C 3. Rear heater duct B Defroster nozzle and distribution duct removal steps D Instrument panel (Refer to GROUP 52A.) 4. Side defroster duct 5. Defroster nozzle assembly 6. Distribution duct

Foot distribution duct and rear heater duct A removal steps D Instrument panel (Refer to GROUP 52A.) D Blower unit, joint duct and glove box support bracket (Refer to P.55-22.) 7. Foot distribution duct 8. Rear heater duct A NOTE For the center air outlet assembly and the side air outlet assembly, refer to GROUP 52A - Instrument panel.

55-38

HEATER, AIR CONDITIONER AND VENTILATION - Ventilators



Rear ventilation duct



Rear ventilation duct

NOTE For the front deck garnish, refer to GROUP 51 - Windshield wiper and washer.

RJST809004 - 1164

00-1

GENERAL CONTENTS

00109000829

HOW TO USE THIS MANUAL . . . . . . . . . . . . . . 2

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Scope of Maintenance, Repair and Servicing Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Model Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Engine Model Number . . . . . . . . . . . . . . . . . . . . . . . 17

Indication of Tightening Torque . . . . . . . . . . . . . . . . 2

Chassis Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Model Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

MAJOR SPECIFICATIONS . . . . . . . . . . . . . . . . 18

Explanation of Manual Contents . . . . . . . . . . . . . . . 4

PRECAUTIONS BEFORE SERVICE . . . . . . . 20

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . 24

Troubleshooting Contents . . . . . . . . . . . . . . . . . . . . . 6 Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 How to Use the Inspection Procedures . . . . . . . . 9 Connector Measurement Service Points . . . . . . . 10 Connector Inspection . . . . . . . . . . . . . . . . . . . . . . . . 11 Inspection Service Points for a Blown Fuse . . . 12 Points to Note for Intermittent Malfunctions . . . . 12

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . 13 Vehicle Information Code Plate . . . . . . . . . . . . . . . 13

SUPPORT LOCATIONS FOR LIFTING AND JACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Support Positions for a Garage Jack and Axle Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Support Positions for a Single-Post Lift or Double-Post Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Support Positions and Support Method for an H-Bar Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

STANDARD PART/TIGHTENING-TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

00-2

GENERAL - How to Use This Manual

HOW TO USE THIS MANUAL

00100010302

SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS

DEFINITION OF TERMS

This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Note, however, that for engine and transmission-related component parts, this manual covers only on-vehicle inspections, adjustments, and the removal and installation procedures for major components. For detailed information concerning the inspection, checking, adjustment, disassembly and reassembly of the engine, transmission and major components after they have been removed from the vehicle, please refer to separate manuals covering the engine and the transmission.

Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted. It is given by tolerance.

ON-VEHICLE SERVICE

REFERENCE VALUE

“On-vehicle Service” is procedures for performing inspections and adjustments of particularly important locations with regard to the construction and for maintenance and servicing, but other inspection (for looseness, play, cracking, damage, etc.) must also be performed.

Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be completed in a shorter time).

INSPECTION Under this title are presented inspection and checking procedures to be performed by using special tools and measuring instruments and by feeling, but, for actual maintenance and servicing procedures, visual inspections should always be performed as well.

STANDARD VALUE

LIMIT Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in strength. It is a value established outside the range of standard value.

CAUTION Indicates the presentation of information particularly vital to the worker during the performance of maintenance and servicing procedures in order to avoid the possibility of injury to the worker, or damage to component parts, or a reduction of component or vehicle function or performance, etc.

INDICATION OF TIGHTENING TORQUE The tightening torque shown in this manual is a basic value with a tolerance of ±10% except the following cases when the upper and lower limits of tightening torque are given. (1) The tolerance of the basic value is within ±10%. (2) Special bolts or the like are in use. (3) Special tightening methods are used.

GENERAL - How to Use This Manual

00-3

MODEL INDICATIONS The following abbreviations are used in this manual for classification of model types. 1800: Indicates models equipped with the 1,800 mL <4G93> petrol engine. 2400: Indicates models equipped with the 2,400 mL <6G64> petrol engine. GDI: Indicates the gasoline direct injection. M/T: Indicates the manual transmission, or models equipped with the manual transmission. A/T: Indicates the automatic transmission, or models equipped with the automatic transmission. A/C: Indicates the air conditioner.

00-4

GENERAL - How to Use This Manual

EXPLANATION OF MANUAL CONTENTS

Indicates procedures to be performed before the work in that section is started, and procedures to be performed after the work in that section is finished. Component Diagram A diagram of the component parts is provided near the front of each section in order to give a reader a better understanding of the installed condition of component parts. Indicates (by symbols) where lubrication is necessary.

Maintenance and Servicing Procedures The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures. D Removal steps: The part designation number corresponds to the number in the illustration to indicate removal steps. D Disassembly steps: The part designation number corresponds to the number in the illustration to indicate disassembly steps.

D Installation steps: Specified in case installation is impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of removal steps. D Reassembly steps: Specified in case reassembly is impossible in reverse order of disassembly steps. Omitted if reassembly is possible in reverse order of disassembly steps.

Classifications of Major Maintenance/Service Points When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.), these are arranged together as major maintenance and service points and explained in detail. AA" "AA

: Indicates that there are essential points for removal or disassembly. : Indicates that there are essential points for installation or reassembly.

Symbols for Lubrication, Sealants and Adhesives Information concerning the locations for lubrication and for application of sealants and adhesives is provided, by using symbols, in the diagram of component parts or on the page following the component parts page, and explained.

: Grease (multipurpose grease unless there is a brand or type specified) : Sealant or adhesive : Brake fluid or automatic transmission fluid : Engine oil, gear oil or air conditioner compressor oil : Adhesive tape or butyl rubber tape

GENERAL - How to Use This Manual Indicates the group title.

Indicates the section title.

Indicates the group number.

00-5

Indicates the page number.

Denotes non-reusable part. Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the “Standard Partstightening-torque Table”. Repair kit or set parts are shown. (Only very frequently used parts are shown.)

Operating procedures, cautions, etc. on removal, installation, disassembly and reassembly are described.

indicates that there is a continuity between the terminals. indicates terminals to which battery voltage is applied.

The title of the page (following the page on which the diagram of component parts is presented) indicating the locations of lubrication and sealing procedures.

00-6

GENERAL - How to Use Troubleshooting/Inspection Service Points

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

00100020152

Troubleshooting of electronic control systems for which the MUT-II can be used follows the basic outline described below. Furthermore, even in systems for which the MUT-II cannot be used, part of these systems still follow this outline.

TROUBLESHOOTING CONTENTS 1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING The troubleshooting sections follow the basic diagnosis flow which is given below. If the diagnosis flow is different from that given below, or if additional explanation is required, the details of such differences or additions will also be listed. Diagnosis method Gathering information from the customer.

Check trouble symptom. Reoccurs

Does not reoccur.

Read the diagnosis code No diagnosis code or communication with MUT-II not possible

Read the diagnosis code Diagnosis code displayed.

Refer to the INSPECTION CHART FOR TROUBLE SYMPTOMS (Refer to applicable group.)

Diagnosis code displayed.

No diagnosis code

After taking note of the malfunction code, erase the diagnosis code memory

Recheck trouble symptom.

Read the diagnosis codes. Diagnosis code displayed.

Refer to the INSPECTION CHART FOR DIAGNOSIS CODES (Refer to applicable group.)

No diagnosis code

INTERMITTENT MALFUNCTIONS (Refer to P.00-12.)

2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS If verification of the trouble symptoms is difficult, procedures for checking operation and verifying trouble symptoms are shown. 3. DIAGNOSIS FUNCTION Details which are different from those in the “Diagnosis Function” section on the next page are listed.

GENERAL - How to Use Troubleshooting/Inspection Service Points

00-7

4. INSPECTION CHART FOR DIAGNOSIS CODES 5. INSPECTION PROCEDURE FOR DIAGNOSIS CODES Indicates the inspection procedures corresponding to each diagnosis code. (Refer to P.00-9 for how to use the inspection procedures.) 6. INSPECTION CHART FOR TROUBLE SYMPTOMS If there are trouble symptoms even though the results of inspection using the MUT-II show that all diagnosis codes are normal, inspection procedures for each trouble symptom will be found by means of this chart. 7. INSPECTION PROCEDURE FOR TROUBLE SYMPTOM Indicates the inspection procedures corresponding to each trouble symptoms classified in the Inspection Chart for Trouble Symptoms. (Refer to P.00-9 for how to use the inspection procedures.) 8. SERVICE DATA REFERENCE TABLE Inspection items and normal judgement values have been provided in this chart as reference information. 9. CHECK AT ECU TERMINALS Terminal numbers for the ECU connectors, inspection items and standard values have been provided in this chart as reference information. 10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE When there are inspection procedures using an oscilloscope, these are listed here.

DIAGNOSIS FUNCTION METHOD OF READING DIAGNOSIS CODES WHEN USING THE MUT-II Connect the MUT-II to the diagnosis connector and take a reading of the diagnosis codes. MUT-II

Caution Turn off the ignition switch before connecting or disconnecting the MUT-II.

00-8

GENERAL - How to Use Troubleshooting/Inspection Service Points WHEN USING THE WARNING LAMP 1. Use the special tool to earth No.1 terminal (diagnosis control terminal) of the diagnosis connector. 2. To check ABS system, remove the valve relay.

Diagnosis connector

NOTE That is because the valve relay is off and the warning lamp remains illuminated if there is a fault in the ABS system.

MB991529

3. Turn on the ignition switch. 4. Read out a diagnosis code by observing how the warning lamp flashes. Applicable systems System name

Warning lamp name

GDI

Engine warning lamp

A/T

Neutral position indicator lamp

ABS

ABS warning lamp

Indication of diagnosis code by warning lamp When the diagnosis code No.24 is output

On Off

1.5 secs.

Pause time 3 secs.

0.5 sec.

Tens signal

Place division 2 secs.

When no diagnosis code is output* 0.5 sec.

Units signal

0.5 sec. 0.25 sec. On Off

NOTE *: Even if the ABS system is normal, removing the valve relay causes the diagnosis code No.52 to be output. METHOD OF ERASING DIAGNOSIS CODES WHEN USING THE MUT-II Connect the MUT-II to the diagnosis connector and erase the diagnosis code. Caution Turn off the ignition switch before connecting or disconnecting the MUT-II. WHEN NOT USING THE MUT-II 1. Turn the ignition switch to OFF. 2. After disconnecting the battery cable from the battery ( - ) terminal for 10 seconds or more, reconnect the cable. 3. After the engine has warmed up, run it at idle for about 15 minutes.

GENERAL - How to Use Troubleshooting/Inspection Service Points

00-9

HOW TO USE THE INSPECTION PROCEDURES The causes of a high frequency of problems occurring in electronic circuitry are generally the connectors, components, the ECU and the harnesses between connectors, in that order. These inspection procedures follow this order, and they first try to discover a problem with a connector or a defective component. 1.

CHECKING PROCEDURE 4 D Indicator does not turn on or off even if control mode switch is pressed. D Indicator switch should not be illuminated is illuminated.

Probable cause 2.

Indicates inspection carried out using the MUT-II. Indicates the operation and inspection procedures. Indicates the OK judgement conditions.

3.

Detailed inspection procedures (methods) such as component inspection and circuit inspection are listed on a separate page, and are given here for reference.

In the above cases, the ECS switch circuit is defective or the indicator circuit is defective.

MUT-II Data list 17 Control mode selection switch OK: Voltage changes between approx. 0V ® approx. 2.5V ® approx. 5V when the switch is operated.

Comments on the diagnosis code or trouble symptom above.

OK

NG

4. Indicates voltage and resistance to be measured at a particular NG connector. (Refer to Connector Measurement Service Points.) OK The connector position can be located in the wiring diagram in the OK electrical wiring manual by means of this symbol. Measure at switch connector A-44 Indicates operation and inspection procedures, inspection terminals D Disconnect the connector, and measure at the harness and inspection conditions. side. Indicates the OK judgement conditions. D Voltage between terminal 6 - earth and terminal 8 ECU switch component inspection (Refer to P.33-44.)

earth OK: Approx. 5V

OK NG

Check the following connector. A-44

OK

5.

Check trouble symptom. Replace the ECS-ECU.

6.

7.

Repair

Inspect the contact condition at each connector terminal. (Refer to Connector Inspection Service Points.) The connector position can be located in the wiring diagram in the electrical wiring manual by means of this symbol. Caution After carrying out connector inspection, always be sure to reconnect the connector as it was before.

Confirm that there are trouble symptoms. If trouble symptoms have disappeared, the connector may have been inserted incorrectly and the trouble symptom may have disappeared during inspection. If it seems that trouble symptoms still remain, proceed to the next page of instructions.

If trouble symptoms still remain up to this stage, there is a possibility that there is an open or short circuit in the harness between the connectors, so check the harness. Alternatively, the cause may be a defective ECU, so try replacing the ECU and check if the trouble symptom disappears.

HARNESS INSPECTION Check for an open or short circuit in the harness between the terminals which were defective according to the connector measurements. Carry out this inspection while referring to the electrical wiring manual. Here, “Check harness between power supply and terminal xx” also includes checking for blown fuses. For inspection service points when there is a blown fuse, refer to “Inspection Service Points for a Blown Fuse.” MEASURES TO TAKE AFTER REPLACING THE ECU If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedure from the beginning.

00-10

GENERAL - How to Use Troubleshooting/Inspection Service Points CONNECTOR MEASUREMENT SERVICE POINTS Turn the ignition switch to OFF when connecting disconnecting the connectors, and turn the ignition switch to ON when measuring if there are no instructions to be contrary.

Harness connector

Extra-thin probe

Test bar

IF INSPECTING WITH THE CONNECTOR CONNECTED (WITH CIRCUIT IN A CONDITION OF CONTINUITY) Waterproof Connectors Be sure to use the special tool (harness connector). Never insert a test bar from the harness side, because to do so will reduce the waterproof performance and result in corrosion.

Ordinary (non-waterproof) Connectors Check by inserting the test bar from the harness side. Note that if the connector (control unit, etc.) is too small to permit insertion of the test bar, it should not be forced; use a special tool (the extra-thin probe in the harness set for checking for this purpose.

Connector

Inspection harness for connector pin contact pressure

IF INSPECTING WITH THE CONNECTOR DISCONNECTED Use the special tool (inspection harness for connector pin contact pressure in the harness set for inspection). The inspection harness for connector pin contact pressure should be used. the test bar should never be forcibly inserted, as it may cause a defective contact.

Touch the pin directly with the test bar. Caution At this time, be careful not to short the connector pins with the test bars. To do so may damage the circuits inside the ECU.

GENERAL - How to Use Troubleshooting/Inspection Service Points Connector disconnected or improperly connected

00-11

CONNECTOR INSPECTION VISUAL INSPECTION D Connector is disconnected or improperly connected D Connector pins are pulled out D Due to harness tension at terminal section D Low contact pressure between male and female terminals D Low connection pressure due to rusted terminals or foreign matter lodged in terminals

Defective connector contact

Harness wire breakage at terminal section Low contact pressure

CONNECTOR PIN INSPECTION If the connector pin stopper is damaged, the terminal connections (male and female pins) will not be perfect even if the connector body is connected, and the pins may pull out of the reverse side of the connector. Therefore, gently pull the harnesses one by one to make sure that no pins pull out of the connector.

MB991219

CONNECTOR ENGAGEMENT INSPECTION Use the special tool (connector pin connection pressure inspection harness of the inspection harness set) to inspect the engagement of the male pins and females pins. (Pin drawing force : 1 N or more)

00-12

GENERAL - How to Use Troubleshooting/Inspection Service Points INSPECTION SERVICE POINTS FOR A BLOWN FUSE 0W

Battery

Fuse

Load switch

Connector inspection

Remove the fuse and measure the resistance between the load side of the fuse and the earth. Set the switches of all circuits which are connected to this fuse to a condition of continuity. If the resistance is almost 0 W at this time, there is a short somewhere between these switches and the load. If the resistance is not 0 W, there is no short at the present time, but a momentary short has probably caused the fuse to blow. The main causes of a short circuit are the following. D Harness being clamped by the vehicle body D Damage to the outer casing of the harness due to wear or heat D Water getting into the connector or circuitry D Human error (mistakenly shorting a circuit, etc.)

Load

POINTS TO NOTE FOR INTERMITTENT MALFUNCTIONS Intermittent malfunctions often occur under certain conditions, and if these conditions can be ascertained, determining the cause becomes simple. In order to ascertain the conditions under which an intermittent malfunction occurs, first ask the customer for details about the driving conditions, weather conditions, frequency of occurrence and trouble symptoms, and then try to recreate the trouble symptoms. Next, ascertain whether the reason why the trouble symptom occurred under these conditions is due to vibration, temperature or some other factor. If vibration is thought to be the cause, carry out the following checks with the connectors and components to confirm whether the trouble symptom occurs. The objects to be checked are connectors and components which are indicated by inspection procedures or given as probable causes (which generates diagnosis codes or trouble symptoms.) D Gently shake the connector up, down and to the left and right. D Gently shake the wiring harness up, down and to the left and right. D Gently rock each sensor and relay, etc. by hand. D Gently shake the wiring harness at suspensions and other moving parts. NOTE If determining the cause is difficult, the flight recorder function of the MUT-II can also be used.

00-13

GENERAL - Vehicle Identification

VEHICLE IDENTIFICATION

00100540085

VEHICLE INFORMATION CODE PLATE LOCATION Vehicle information code plate is riveted on the toeboard inside the engine compartment.

1 2 3 4 5

CODE PLATE DESCRIPTION The plate shows model code, engine model, transmission model, and body colour code. No.

Item

Contents

1

MODEL

N84W LNUCL6

N84W: Vehicle model LNUCL6: Model series

2

ENGINE

4G64

Engine model

3

EXT

A69A

Exterior code

4

TRANS AXLE

F5M42

Transmission code

5

COLOR INT OPT

A69 50H 03V

A69: Body colour code 50H: Interior code 03V: Equipment code

For monotone colour vehicles, the body colour code shall be indicated. For two-tone or three-way two-tone colour vehicles, each colour code only shall be indicated in series.

MODELS

00100030223

Model code N61W

SNUCL6/R6 SNFCL6

Engine model

Transmission model

Fuel supply system

4G93-DOHC-GDI (1,834 mL)

F5M42 (2WD-5M/T)

GDI

SNUGL6 SRUCL6/R6 SRFCL6 SRUGL6

F4A42 (2WD-4A/T)

00-14

GENERAL - Vehicle Identification

Model code N84W

LNUCL6/R6 LNFCL6

Engine model

Transmission model

Fuel supply system

4G64-DOHC-GDI (2,351 mL)

F5M42 (2WD-5M/T)

GDI

LNUGL6 LNHCL6/R6 LNGCL6 LNHGL6 LRUCL6/R6 LRFCL6

F4A42 (2WD-4A/T)

LRUGL6 LRHCL6/R6 LRGCL6 LRHGL6 N94W

LNUCL6/R6 LNFCL6 LNHCL6/R6 LNGCL6

W5M42 (4WD-5M/T)

00-15

GENERAL - Vehicle Identification MODEL CODE

00100040257

No.

Items

Contents

1

Development

N6: SPACE RUNNER (2WD) N8: SPACE WAGON (2WD) N9: SPACE WAGON (Full time 4WD)

2

Engine type

1: 1,800 mL petrol engine 4: 2,400 mL petrol engine

3

Body type

W: Wagon

4

Body style

S: 3-door station wagon L: 4-door station wagon

5

Transmission type

N: 5-speed manual transmission R: 4-speed automatic transmission

6

Trim level

U,F,H,G: GLX

7

Specification engine feature

C,G: GDI-DOHC

8

Steering wheel location

L: Left hand R: Right hand

9

Destination

6: For Europe

1 2 3 4 5 6 7 8 9

00-16

GENERAL - Vehicle Identification CHASSIS NUMBER

00100560104

The chassis number is stamped on the toeboard inside the engine compartment.

1

2

3

4

5

6

8

7

9

10

11

No.

Items

1

Fixed figure

J

Asia

2

Distribution channel

M

Japan channel

3

Destination

A

For Europe, right hand drive

B

For Europe, left hand drive

S

3-door station wagon

L

4-door station wagon

N

5-speed manual transmission

R

4-speed automatic transmission

N6

SPACE RUNNER (2WD)

N8

SPACE WAGON (2WD)

N9

SPACE WAGON (Full time 4WD)

1

4G93: 1,834 mL petrol engine

4

4G64: 2,351 mL petrol engine

4

5

6

7

Body style

Transmission type

Development order

Engine

Contents

8

Sort

W

Station wagon

9

Model year

X

1999

10

Plant

Z

Okazaki Motor Vehicle Works

11

Serial number

-

-

00-17

GENERAL - Vehicle Identification <4G93>

ENGINE MODEL NUMBER

00100570107

1. The engine model number is stamped at the cylinder block as shown in the following. Engine model

Engine displacement

4G93 4G64

1,834 2,351

2. The engine serial number is stamped near the engine model number. Engine serial number <4G64>

AA0201 to YY9999

00-18

GENERAL - Major Specifications

MAJOR SPECIFICATIONS

00100080143



3 3*

9

5

7

2

Vehicle weight kg

8

6

1

N61W SNUCL6, SNUCR6, SNFCL6, SNUGL6

Items

Vehicle dimensions mm

4

N61W SRUCL6, SRUCR6, SRFCL6, SRUGL6

Overall length

1 4,290

4,290

Overall width

2 1,695

1,695

Overall height (unladen)

3 1,650 1,680*

1,650 1,680*

Wheelbase

4 2,550

2,550

Track-front

5 1,460

1,460

Track-rear

6 1,465

1,465

Overhang-front

7 890

890

Overhang-rear

8 850

850

Ground clearance (unladen)

9 155

155

Kerb weight

1,360

1,380

Max. gross vehicle weight

1,880

1,880

Max. axle weight rating-front

1,000

1,000

Max. axle weight rating-rear

900

900

Seating capacity

5

5

Engine

Model No.

4G93

4G93

Total displacement mL

1,834

1,834

Transmission

Model No.

F5M42

F4A42

Type

5-speed manual

4-speed automatic

Fuel system

Fuel supply system

Gasoline Direct Injection

*: Vehicles with roof rails

00-19

GENERAL - Major Specifications

3 3*

9 7

5

4

2

Vehicle weight kg

6

1

N84W LNUCL6, LNUCR6, LNFCL6, LNUGL6

Items

Vehicle dimensions mm

8

N84W LNHCL6, LNHCR6, LNGCL6, LNHGL6

N84W LRUCL6, LRUCR6, LRFCL6, LRUGL6

N84W LRHCL6, LRHCR6, LRGCL6, LRGHL6

N94W LNUCL6, LNUCR6, LNFCL6

N94W LNHCL6, LNHCR6, LNGCL6

Overall length

1 4,600

4,600

4,600

4,600

4,600

4,600

Overall width

2 1,775

1,775

1,775

1,775

1,775

1,775

Overall height (unladen)

3 1,650 1,690*

1,650 1,690*

1,650 1,690*

1,650 1,690*

1,650 1,690*

1,650 1,690*

Wheelbase

4 2,780

2,780

2,780

2,780

2,780

2,780

Track-front

5 1,500

1,500

1,500

1,500

1,500

1,500

Track-rear

6 1,535

1,535

1,535

1,535

1,535

1,535

Overhang-front

7 890

890

890

890

890

890

Overhang-rear

8 930

930

930

930

930

930

Ground clearance (unladen)

9 155

155

155

155

155

155

Kerb weight

1,510

1,510

1,530

1,530

1,610

1,610

Max. gross vehicle weight

2,180

2,180

2,180

2,180

2,260

2,260

Max. axle weight rating-front

1,070

1,070

1,070

1,070

1,090

1,090

Max. axle weight rating-rear

1,130

1,130

1,130

1,130

1,190

1,190

Seating capacity

7

6

7

6

7

6

Engine

Model No.

4G64

4G64

4G64

4G64

4G64

4G64

Total displacement mL

2,351

2,351

2,351

2,351

2,351

2,351

Transmission

Model No.

F5M42

F5M42

F4A42

F4A42

W5M42

W5M42

Type

5-speed manual

5-speed manual

4-speed automatic

4-speed automatic

5-speed manual

5-speed manual

Fuel system

Fuel supply system

Gasoline Direct Injection

*: Vehicles with roof rails

00-20

GENERAL - Precautions Before Service

PRECAUTIONS BEFORE SERVICE

00100050229

SUPPLEMENTAL RESTRAINT SYSTEM (SRS), SEAT BELT WITH PRE-TENSIONER 1. Items to follow when servicing SRS (1) Be sure to read GROUP 52B - Supplemental Restraint System (SRS). For safe operations, please follow the directions and heed all warnings. (2) Wait at least 60 seconds after disconnecting the battery cable before doing any further work. The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected. Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected. (3) Warning labels must be heeded when servicing or handling SRS components and seat belt with pre-tensioner. Warning labels are located in the following locations. D Sun visor D Glove box D SRS air bag control unit D Steering wheel D Steering gear and linkage D Air bag module (driver’s side and front passenger’s side) D Clock spring D Seat belt with pre-tensioner D Side air bag module D Side impact sensor (4) Always use the designated special tools and test equipment. (5) Store components removed from the SRS and seat belt with pre-tensioner in a clean and dry place. The air bag module and seat belt with pre-tensioner should be stored on a flat surface and placed so that the pad surface is facing upward. Do not place anything on top of it. (6) Never attempt to disassemble or repair the SRS components (SRS air bag control unit, air bag module, clock spring and side impact sensor) and seat belt with pre-tensioner. (7) Whenever you finish servicing the SRS and seat belt with pre-tensioner, check the SRS warning lamp operation to make sure that the system functions properly. (8) Be sure to deploy the air bag and seat belt with pre-tensioner before disposing of the air bag module and seat belt with pre-tensioner or disposing of a vehicle equipped with an air bag and seat belt with pre-tensioner. (Refer to GROUP 52B - Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures.) 2. Observe the following when carrying out operations on places where SRS components and seat belt with pre-tensioner are installed, including operations not directly related to the SRS air bag and seat belt with pre-tensioner. (1) When removing or installing parts do not allow any impact or shock to the SRS components and seat belt with pre-tensioner. (2) SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS components and seat belt with pre-tensioner before drying or baking the vehicle after painting. D SRS air bag control unit, air bag module, clock spring and side impact sensor: 93_C or more D Seat belt with pre-tensioner 90_C or more After re-installing them, check the SRS warning lamp operation to make sure that the system functions properly.

GENERAL - Precautions Before Service

00-21

SERVICING THE ELECTRICAL SYSTEM Before replacing a component related to the electrical system and before undertaking any repair procedures involving the electrical system, be sure to first disconnect the negative ( - ) cable from the battery in order to avoid damage caused by short-circuiting. Caution Before connecting or disconnecting the negative ( - ) cable, be sure to turn off the ignition switch and the lighting switch. (If this is not done, there is the possibility of semiconductor parts being damaged.)

APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS If oil or grease gets onto the oxygen sensor, it will cause a drop in the performance of the sensor. Cover the oxygen sensor with a protective cover when applying anti-corrosion agents and undercoats.

PRE-INSPECTION CONDITION “Pre-inspection condition” refers to the condition that the vehicle must be in before proper engine inspection can be carried out. If you see the words “Set the vehicle to the pre-inspection condition”. in this manual, it means to set the vehicle to the following condition. D Engine coolant temperature: 80 - 90_C D Lamps, electric cooling fan and all accessories: OFF D M/T: Neutral D A/T: P range

VEHICLE WASHING Approx. 40 cm

If high-pressure car-washing equipment or steam car-washing equipment is used to wash the vehicle, be sure to note the following information in order to avoid damage to plastic components, etc. D Spray nozzle distance: Approx. 40 cm or more D Spray pressure: 3,900 kPa or less D Spray temperature: 82_C or less D Time of concentrated spray to one point: within 30 sec.

00-22

GENERAL - Precautions Before Service MUT-II

MUT-II sub-assembly

Refer to the “MUT-II REFERENCE MANUAL” or “MUT-II OPERATING INSTRUCTIONS” for instructions on handling the MUT-II.

ROM pack

Connect the MUT-II to the diagnosis connector as shown in the illustration. Caution Connection and disconnection of the MUT-II should always be made with the ignition switch in the OFF position. MUT-II

IN ORDER TO PREVENT VEHICLES FROM FIRE “Improper installation of electrical or fuel related parts could cause a fire. In order to retain the high quality and safety of the vehicle, it is important that any accessories that may be fitted or modifications/repairs that may be carried out which involve the electrical or fuel systems, MUST be carried out in accordance with MMC’s information/Instructions”.

ENGINE OILS Health Warning Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.

Recommended Precautions The most effective precaution is to adapt working practices which prevent, as far as practicable, the risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine oil and by degreasing components, where practicable, before handling them.

GENERAL - Precautions Before Service

00-23

Other precautions: D Avoid prolonged and repeated contact with oils, particularly used engine oils. D Wear protective clothing, including impervious gloves where practicable. D Avoid contaminating clothes, particularly underpants, with oil. D Do not put oily rags in pockets, the use of overalls without pockets will avoid this. D Do not wear heavily soiled clothing and oil-impregnated foot-wear. Overalls must be cleaned regularly and kept separately from personal clothing. D 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. D Obtain First Aid treatment immediately for open cuts and wounds. D Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin cleansers and nail brushes will help). After cleaning, the application of preparations containing lanolin to replace the natural skin oils is advised. D Do not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin. D Use barrier creams, applying them before each work period, to help the removal of oil from the skin after work. D If skin disorders develop, obtain medical advice without delay.

00-24

GENERAL -

Supplemental Restraint System (SRS) and Seat Belt with Pre-tensioner

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT 00100590073 WITH PRE-TENSIONER To improve safety, the SRS and seat belts with pre-tensioner are available as optional parts. These systems enhance collision safety by restraining the front passengers in case of an accident. The SRS works with the pre-tensioner simultaneously when a collision is detected. The SRS consists of four air bag modules, SRS air bag control unit (SRS-ECU), side impact sensor, SRS warning lamp and clock spring. The air bags are located in the centre of the steering wheel, above the glove box, and built into the front seat back assemblies. Each air bag has a folded air bag and an inflator unit. The SRS-ECU under the floor console monitors the system and has a safing G sensor and an analog G sensor. The side impact sensor inside the center pillar monitors any shocks coming from the side of the vehicle. The warning lamp on the instrument panel indicates the

operational status of the SRS. The clock spring is installed in the steering column. The SRS side air bag deploys if an impact received at the side of the vehicle is stronger than a certain set value, in order to protect the upper bodies of front seat passengers in the event of a collision. The seat belt pre-tensioner is built into the front seat belt retractor. Only authorized service personnel should do work on or around the SRS components and seat belt with pre-tensioner. Those service personnel should read this manual carefully before starting any such work. Extreme care must be used when servicing the SRS to avoid injury to the service personnel (by inadvertent deployment of the air bags or inadvertent operation of the seat belt with pre-tensioner) or the driver (by rendering the SRS or the seat belt with pre-tensioner inoperative).

SRS warning lamp Front passenger’s side air bag module

Clock spring Driver’s side air bag module

Seat belt with pre-tensioner

Driver’s side air bag Front passenger’s side air bag

Diagnosis connector SRS-ECU

Seat belt with pre-tensioner

Side air bag module Side impact sensor Side air bag

GENERAL -

Supplemental Restraint System (SRS) and Seat Belt with Pre-tensioner

SEAT BELT WITH PRE-TENSIONER The seat belts with pre-tensioners are installed on both center pillars. The pre-tensioner, which is controlled by the SRSECU, works simultaneously with the SRS air bag in a head-on collision. When triggered, the SRSECU sends a squib igniting signal to the gas generator. Generated gas moves the rotor to take up seat

00-25

belt slack. This prevents a passenger from moving forwards excessively. After this, the ELR works to inhibit the seat belt. Caution Never disassemble or give an impact to the seat belt with pre-tensioner.

Seat belt

Rotor SRS-ECU

Gas generator

SRS SERVICE PRECAUTIONS 1. In order to avoid injury to yourself or others from accidental deployment of the air bag and accidental operation of the seat belt with pre-tensioner during servicing, read and carefully follow all the precautions and procedures described in this manual. 2. Do not use any electrical test equipment on or near SRS components, except those specified on GROUP 52B. 3. Never Attempt to Repair the Following Components: D SRS air bag control unit (SRS-ECU) D Clock Spring D Air bag module (Driver’s side or front passenger’s side) D Side air bag module D Side impact sensor D Seat belt with Pre-tensioner

00100600073

NOTE If any of these components are diagnosed as faulty, they should only be replaced, in accordance with the INDIVIDUAL COMPONENTS SERVICE procedures in this manual, starting at page GROUP 52B.

00-26

GENERAL -

Insulating tape

Battery

SRS-ECU connector

Supplemental Restraint System (SRS) and Seat Belt with Pre-tensioner

4. After disconnecting the battery cable, wait 60 seconds or more before proceeding with the following work. The SRS system is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected, so serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cables are disconnected.

5. Do not attempt to repair the wiring harness connectors of the SRS. If any of the connectors are diagnosed as faulty, replace the wiring harness. If the wires are diagnosed as faulty, replace or repair the wiring harness according to the following table.

SRS-ECU Terminal No.

Destination of harness

Corrective action

3

Instrument panel wiring harness ® Earth

4

Instrument panel wiring harness ® Combination meter (SRS warning lamp)

Correct or replace each wiring harness.

5, 6

Instrument panel wiring harness ® Air bag module (Front passenger’s side)

7, 8

Instrument panel wiring harness ® Clock spring

Correct or replace the dash wiring harness. Replace the clock spring.

9

Instrument panel wiring harness ® Junction block (fuse No.8)

12

Instrument panel wiring harness ® Junction block (fuse No.6)

Correct or replace each wiring harness.

16

Instrument panel wiring harness ® Diagnosis connector

21, 22

Side air bag wiring harness ® Side air bag module (L.H.)

23, 24

Side air bag wiring harness ® Side air bag module (R.H.)

27, 28

Assist wiring harness ® Seat belt with pre-tensioner (Front passenger’s side)

29, 30

Floor wiring harness ® Seat belt with pre-tensioner (Driver’s side)

34, 36

Side air bag wiring harness ® Floor wiring harness , Assist wiring harness ® Side impact sensor (L.H.)

40, 42

Side air bag wiring harness ® Assist wiring harness , Floor wiring harness ® Side impact sensor (R.H.)

GENERAL -

Supplemental Restraint System (SRS) and Seat Belt with Pre-tensioner

00-27

6. Inspection of the SRS-ECU harness connector should be carried out by the following procedure. Insert the special tool (narrow probe in the harness set) into connector from harness side (rear side), and connect the tester to this probe. If any to other than the special tool is used, it may cause damage to the harness and other components. Furthermore, measurement should not be carried out by touching the probe directly against the terminals from the front of the connector. The terminals are plated to increase their conductivity, so that if they are touched directly by the probe, the plating may break, which will cause drops in reliability. MB991222

SRS-ECU harness connector SRS-ECU harness connector (rear side)

7. SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, air bag module (driver’s side and front passenger’s side), clock spring, side impact sensor, front seat assembly (side air bag module), and seat belt with pre-tensioner before drying or baking the vehicle after painting. D SRS-ECU, air bag module, clock spring, side impact sensor: 93_C or more D Seat belt with pre-tensioner: 90_C or more 8. Whenever you finish servicing the SRS, check warning lamp operation to make sure that the system functions properly. (Refer to GROUP 52B.) 9. Make certain that the ignition switch is OFF when the MUT-II is connected or disconnected. 10. If you have any questions about the SRS, please contact your local distributor. NOTE SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO USE ONLY THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL.

00-28

GENERAL - Support Locations for Lifting and Jacking

SUPPORT LOCATIONS FOR LIFTING AND JACKING

00100070065

Caution Do not support the vehicles at locations other than specified supporting points. If do so, this will cause damage, etc.

SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS GARAGE JACK Caution Never support any point other than the specified one, or it will be deformed.

AXLE STANDS Notch

Notch

Rubber

Rubber

GENERAL - Support Locations for Lifting and Jacking SUPPORT POSITIONS FOR A SINGLE-POST LIFT OR DOUBLE-POST LIFT

DOUBLE-POST LIFT

SINGLE-POST LIFT

Notch

00-29

Caution When service procedures require removing rear suspension, spare tyre and rear bumper, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes.

Notch

00-30

GENERAL - Support Locations for Lifting and Jacking SUPPORT POSITIONS AND SUPPORT METHOD FOR AN H-BAR LIFT

H-bar lift H-bar lift

Caution When service procedures require removing rear suspension, fuel tank, spare tyre and rear bumper, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes. When H-bar lift is used to lift up vehicles, use of metallic attachment attached to the H-bar lift may cause damage to the suspension arm etc. Therefore, lift up the vehicle by the following procedure.

1. Place the vehicle on the H-bar lift (same direction). 2. Place attachments on the H-bar lift at the designated chassis-support positions. When making the attachments, refer to the section concerning making them.

Chassis-support position (side sill) Attachment

Section A - A Side sill

H-bar lift Attachment

A

A

H-bar lift

Caution If support is at any location other than the designated positions, the body or suspension might be deformed or otherwise damaged, so care should be taken to support only at the correct (designated) positions. 3. Raise the H-bar lift to the height at which the vehicle is slightly raised and check to be sure that the vehicle is correctly and sufficiently secured; then raise the vehicle.

00-31

GENERAL - Support Locations for Lifting and Jacking

PREPARATION OF “ATTACHMENTS” 1. Prepare the blocks (wooden) and nails as shown in the figure.

mm

Block (A) 1,800 90 95 Block (B) 15

Block (C) 40

15 20

40 60

40

40

20

140 100

40

Block (C) 100 Block (C) Nail

140

Block (B) Finished attachment

Movable according to vehicle width

Item

Dimensions mm

Quantity

Block (A)

90 ´ 95 ´ 1,800

2

Block (B)

60 ´ 100 ´ 95

4

Block (C)

140 ´ 40 ´ 95

8

Nail

70 or more

32

Caution The wood selected for the blocks must be hard. 2. For the (B) blocks and (C) blocks, use a saw and chisel or similar tool to make grooves of the dimensions shown in the figure. 3. Make four “ATTACHMENTS” such as shown in the figure nailing (B) and (C) blocks so that each (B) blocks is sandwiches between (C) blocks.

00-32

GENERAL - Standard Part/Tightening-Torque Table

STANDARD PART/TIGHTENING-TORQUE TABLE Each torque value in the table is a standard value for tightening under the following conditions. (1) Bolts, nuts and washers are all made of steel and plated with zinc. (2) The threads and bearing surface of bolts and nuts are all in dry condition.

00100110033

The values in the table are not applicable: (1) If toothed washers are inserted. (2) If plastic parts are fastened. (3) If bolts are tightened to plastic or die-cast inserted nuts. (4) If self-tapping screws or self-locking nuts are used.

Standard bolt and nut tightening torque Thread size

Torque Nm

Bolt nominal diameter (mm)

Pitch (mm)

Head mark “4”

Head mark “7”

Head mark “8”

M5

0.8

2.5

4.9

5.9

M6

1.0

4.9

8.8

9.8

M8

1.25

12

22

25

M10

1.25

24

44

52

M12

1.25

41

81

96

M14

1.5

72

137

157

M16

1.5

111

206

235

M18

1.5

167

304

343

M20

1.5

226

412

481

M22

1.5

304

559

647

M24

1.5

392

735

853

Flange bolt and nut tightening torque Thread size

Torque Nm

Bolt nominal diameter (mm)

Pitch (mm)

Head mark “4”

Head mark “7”

Head mark “8”

M6

1.0

4.9

9.8

12

M8

1.25

13

24

28

M10

1.25

26

49

57

M10

1.5

24

44

54

M12

1.25

46

93

103

M12

1.75

42

81

96

11A-1

ENGINE CONTENTS

ENGINE <4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A ENGINE <4G9> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B

11109000276

11A-2

ENGINE <4G6> CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3

Lash Adjuster Check . . . . . . . . . . . . . . . . . . . . . . . . 14

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3

CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . 17

SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAMSHAFT AND CAMSHAFT OIL SEAL . . 18

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5

OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6

CRANKSHAFT OIL SEAL . . . . . . . . . . . . . . . . . 24

Drive Belt Tension Check and Adjustment . . . . . . 6 Ignition Timing Check . . . . . . . . . . . . . . . . . . . . . . . 10 Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Compression Pressure Check . . . . . . . . . . . . . . . . 13 Manifold Vacuum Check . . . . . . . . . . . . . . . . . . . . . 14

CYLINDER HEAD GASKET . . . . . . . . . . . . . . . 27 TIMING BELT AND TIMING BELT B . . . . . . 30 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 37

ENGINE <4G6> - General Information/Service Specifications

11A-3

GENERAL INFORMATION Items

4G64-GDI

Total displacement mL

2,350

Bore ´ Stroke mm

86.5 ´ 100.0

Compression ratio

11.5

Combustion chamber

Pentroof + ball-in-piston

Camshaft arrangement

DOHC

Number of valve

Valve timing

Intake

8

Exhaust

8

Intake

Exhaust

Opening

BTDC 16_

Closing

ABDC 60_

Opening

BBDC 56_

Closing

ATDC 16_

Fuel system

Electronically controlled multipoint fuel injection

Rocker arm

Roller type

Auto-lash adjuster

Equipped

SERVICE SPECIFICATIONS Items Alternator drive belt tension

Vibration frequency Hz

Tension N

Deflection (Reference value) mm

Standard value

Limit

When checked

189 - 232

-

When a used belt is installed

201 - 222

-

When a new belt is installed

241 - 276

-

When checked

392 - 588

-

When a used belt is installed

441 - 539

-

When a new belt is installed

637 - 833

-

When checked

6.7 - 9.0

-

When a used belt is installed

7.2 - 8.4

-

When a new belt is installed

5.0 - 6.4

-

11A-4

ENGINE <4G6> - Service Specifications/Sealants

Items

Standard value

Limit

When checked

108 - 132

-

When a used belt is installed

114 - 126

-

When a new belt is installed

137 - 157

-

When checked

392 - 588

-

When a used belt is installed

441 - 539

-

When a new belt is installed

637 - 834

-

When checked

11.7 - 15.3

-

When a used belt is installed

12.5 - 14.3

-

When a new belt is installed

8.8 - 11.0

-

Basic ignition timing

5_ BTDC ± 3_

-

Ignition timing

Approx. 20_BTDC*1

-

M/T

600 ± 100*2

-

A/T

650 ± 100

-

CO contents %

0.5 or less

-

HC contents ppm

100 or less

-

Compression pressure kPa - r/min

1,570 - 300

1,210 - 300

Compression pressure difference of all cylinder kPa

-

Max. 100

Intake manifold vacuum kPa

-

Min. 56*3

Cylinder head bolt shank length mm

-

99.4

Auto-tensioner push rod movement mm

Within 1

-

Timing belt tension torque Nm (Reference value)

2.5

-

Auto-tensioner rod protrusion amount mm

3.8 - 4.5

-

Power steering oil pump and A/C compressor drive belt tension

Vibration frequency Hz

Tension N

Deflection (Reference value) mm

Idle speed r/min

NOTE

*1: Indicates the value measured within 4 minutes since the engine was started. *2: Varies depending on the transmission oil temperature. For details, refer to P.11A-11. *3: Indicates the value when more than 4 minutes have passed since the engine was started.

SEALANTS Items

Specified sealants

Remarks

Beam camshaft cap Cylinder head

3M ATD Part No.8660 or equivalent

-

Cam position sensor support Oil pan

MITSUBISHI GENUINE MD970389 or equivalent

Semi-drying sealant

Flywheel or drive plate bolt

3M Stud Locking 4170 or equivalent

PART

-

ENGINE <4G6> - Special Tools

11A-5

SPECIAL TOOLS Tool

Number

Name

Use

MB991502

MUT-II sub assembly

D D D D

MB991668

Belt tension meter set

Measuring the drive belt tension (used together with the MUT-II)

MB990767

End yoke holder

D D

Holding the camshaft sprocket Holding the crankshaft sprocket

Crankshaft pulley holder pin

D D

Holding the camshaft sprocket Holding the crankshaft sprocket

MD998713

Camshaft oil seal installer

Press-in of the camshaft oil seal

MD998727

Oil pan remover

Removal of oil pan

MD998781

Flywheel stopper

Securing the flywheel

MD998776

Crankshaft rear oil seal installer

Press-in of the crankshaft rear oil seal

MB990938

Handle

Press-in of the crankshaft rear oil seal

MD998719 MD998754

or

Measuring the drive belt tension Checking the ignition timing Checking the idle speed Erasing diagnosis code

11A-6 Tool

ENGINE <4G6> - Special Tools/On-vehicle Service Number

Name

Use

MD998382

Crankshaft front oil seal installer

Installation of crankshaft front oil seal

MD998285

Crankshaft front oil seal guide

MD998767

Tension pulley socket wrench

Timing belt tension adjustment

GENERAL SERVICE TOOL MZ203827

Engine lifter

Supporting the engine assembly during removal and installation of the transmission

MB991453

Engine hanger assembly

ON-VEHICLE SERVICE DRIVE BELT TENSION CHECK AND ADJUSTMENT ALTERNATOR DRIVE BELT TENSION CHECK Check the drive belt tension in the following procedure. Standard value: Vibration frequency Hz

189 - 232

Tension N

392 - 588

Deflection (Reference value) mm

6.7 - 9.0

ENGINE <4G6> - On-vehicle Service

15_

15_

10 - 20 mm Water pump pulley

MB991668 (Microphone)

Crankshaft pulley

Alternator pulley

11A-7

1. Connect the special tool (belt tension meter set) to the MUT-II. 2. Connect the MUT-II to the diagnosis connector. 3. Turn the ignition switch to ON and select “Belt Tension Measurement” from the menu screen. 4. Hold the microphone to the middle of the drive belt between the pulleys (at the place indicated by the arrow), about 10 - 20 mm away from the rear surface of the belt and so that it is perpendicular to the belt (within an angle of ± 15_). 5. Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value. Caution (1) The temperature of the surface of the belt should be as close as possible to normal temperature. (2) Do not let any contaminants such as water or oil get onto the microphone. (3) If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values. (4) If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values. (5) Do not take the measurement while the vehicle’s engine is running.

Belt tension gauge Water pump pulley

Use a belt tension gauge to check that the belt tension is within the standard value.

Crankshaft pulley

Alternator pulley

98 N Water pump pulley Crankshaft pulley

Alternator pulley

Apply 98 N of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.

11A-8 Adjusting bolt

ENGINE <4G6> - On-vehicle Service ALTERNATOR DRIVE BELT TENSION ADJUSTMENT 1. Loosen the nut of the alternator pivot bolt. 2. Loosen the lock bolt. 3. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values. Standard value:

Lock bolt

Items

When a used belt is installed

When a new belt is installed

Vibration frequency Hz 201 - 222

241 - 276

Tension N

441 - 539

637 - 833

Deflection (Reference value) mm

7.2 - 8.4

5.0 - 6.4

4. Tighten the nut of the alternator pivot bolt. Tightening torque: 49 Nm 5. Tighten the lock bolt. Tightening torque: 22 Nm 6. Tighten the adjusting bolt. Tightening torque: 5 Nm

11A-9

ENGINE <4G6> - On-vehicle Service Oil pump pulley 98 N A

B

Crankshaft pulley

Standard value: Tensioner pulley

Oil pump pulley 98 N Crankshaft pulley

POWER STEERING OIL PUMP AND AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION CHECK AND 11100130127 ADJUSTMENT 1. Check if the belt tension is within the standard value using one of the methods below.

Tensioner pulley A

B A/C compressor pulley

Items

When checked

When a used belt is installed

When a new belt is installed

Vibration frequency Hz

108 - 132

114 - 126

137 - 157

Tension N

392 - 588

441 - 539

637 - 834

Deflection (Reference value) mm

11.7 - 15.3

12.5 - 14.3

8.8 - 11.0

With your finger tip lightly tap the centre of the belt between the pulleys in the location shown by the arrow in the illustration and then measure the belt vibration frequency. NOTE Refer to P.11A-7 for information regarding the vibration frequency measurement method using MUT-II. Use a belt tension gauge to measure the belt tension. Apply 98 N of pressure against the location between the pulleys shown by the arrow in the illustration and then measure the deflection. 2. If the tension or deflection is outside the standard value, adjust by the following procedure. (1) Loosen tensioner pulley fixing nut A. (2) Adjust the amount of belt deflection using adjusting bolt B. (3) Tighten fixing nut A. Tightening torque: 25 Nm (4) Check the belt deflection amount and tension, and readjust if necessary. Caution Check after turning the crankshaft once or more clockwise (right turn).

11A-10

ENGINE <4G6> - On-vehicle Service

Idle speed r/min 900 800 700 600 - 10 20 50 Transmission oil temperature _C

IGNITION TIMING CHECK 1. Before inspection, set the vehicle to the pre-inspection condition. For vehicles with manual transmission, drive the vehicle for 15 minutes or more to warm the engine, and then carry out the checking while the transmission oil temperature is more than 50°C. NOTE The idle speed in vehicles with manual transmission varies as shown in the illustration in accordance with the transmission oil temperature. 2. Turn off the ignition switch and then connect the MUT-II to the diagnosis connector.

3. Set the timing light to the power supply line (terminal No.1) of the ignition coil No.1. NOTE The power supply line is looped and also longer than the other ones.

No.1 ignition coil

4. Start the engine and let it run at idle. 5. Use the MUT-II to measure engine idle speed and check that it is within the standard value. Standard value: Items

Idle speed r/min

M/T

600 ± 100 (700 ± 100)*

A/T

650 ± 100 (700 ± 100)*

NOTE *: Indicates the values when more than 4 minutes have passed since the idling condition was started. 6. Select No.17 of the MUT-II Actuator test. NOTE At this time, the engine speed will become approximately 700 r/min. 7. Check that basic ignition timing is within the standard value. Standard value: 5_ BTDC ± 3_ 8. If the basic ignition timing is outside the standard value, inspect the GDI system while referring to GROUP 13A Troubleshooting.

ENGINE <4G6> - On-vehicle Service

11A-11

9. Press the MUT-II clear key (Select a forced driving cancel mode) to release the Actuator test. Caution If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engine. 10. Check that ignition timing is at the standard value. Standard value: approx. 20_BTDC NOTE (1) The ignition timing will become approximately 5_BTDC after more than 4 minutes have passed since the basic ignition timing set mode was released. (2) The ignition timing may fluctuate within ±7_BTDC. This is normal. (3) In higher altitude, the ignition timing is more advanced than the standard value by approximately 5 degree. 11. Remove the timing light. 12. Turn off the ignition switch and then remove the MUT-II.

Idle speed r/min 900 800 700 600 - 10 20 50 Transmission oil temperature _C

IDLE SPEED CHECK 1. Before inspection, set the vehicle to the pre-inspection condition. For vehicles with manual transmission, drive the vehicle for 15 minutes or more to warm the engine, and then carry out the checking while the transmission oil temperature is more than 50°C. NOTE The idle speed in vehicles with manual transmission varies as shown in the illustration in accordance with the transmission oil temperature. 2. Turn off the ignition switch and then connect the MUT-II to the diagnosis connector. 3. Check the basic ignition timing. NOTE Refer to P.11A-10 concerning the check procedure of the basic ignition timing. Standard value: 5_ BTDC ± 3_ 4. Run the engine at idle for 2 minutes.

11A-12

ENGINE <4G6> - On-vehicle Service 5. Check the idle speed. Select item No. 22 and take a reading of the idle speed. Standard value: Items

Idle speed r/min

M/T

600 ± 100 (700 ± 100)*

A/T

650 ± 100 (700 ± 100)*

NOTE (1) *: Indicates the values when more than 4 minutes have passed since the idling condition was started. (2) The idle speed is controlled automatically by the idle speed control system. 6. If the idle speed is outside the standard value, inspect the GDI components by referring to GROUP 13A Troubleshooting.

IDLE MIXTURE CHECK 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Connect the MUT-II to the diagnosis connector. 3. Check that the basic ignition timing is within the standard value. NOTE Refer to P.11A-10 concerning the check procedure of the basic ignition timing. Standard value: 5_ BTDC ± 3_ 4. Run the engine at 2,500 r/min for 2 minutes. 5. Set the CO, HC tester. 6. Check the CO contents and the HC contents at idle. NOTE This measurement should be performed in less than approximately 4 minutes since the engine speed become the idle speed. Standard value CO contents: 0.5% or less HC contents: 100 ppm or less 7. If there is a deviation from the standard value, check the following items: D Diagnosis output D Fuel pressure D Injector D Ignition coil, spark plug D EGR control system D Evaporative emission control system D Compression pressure NOTE Replace the three way catalyst when the CO and HC contents are not within the standard value, even though the result of the inspection is normal on all items.

ENGINE <4G6> - On-vehicle Service

11A-13

COMPRESSION PRESSURE CHECK 1. Before inspection, check that the engine oil, starter and battery are normal. In addition, set the vehicle to the pre-inspection condition. 2. Remove all of the ignition coils and spark plugs. 3. Disconnect the crank angle sensor connector. Crank angle sensor connector

NOTE Doing this will prevent the engine-ECU from carrying out ignition and fuel injection. 4. Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel. Caution (1) Keep away from the spark plug hole when cranking. (2) If compression is measured with water, oil, fuel, etc., that has come from cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous.

Compression gauge

5. Set compression gauge to one of the spark plug holes. 6. Crank the engine with the throttle valve fully open and measure the compression pressure. Standard value (at engine speed of 300 r/min): 1,570 kPa Limit (at engine speed of 300 r/min): Min. 1,210 kPa 7. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: Max. 100 kPa 8. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 6 and 7. (1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface. (2) If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket. 9. Connect the crank angle sensor connector. 10. Install the spark plugs and ignition coils. 11. Use the MUT-II to erase the diagnosis codes. NOTE This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected.

11A-14

ENGINE <4G6> - On-vehicle Service MANIFOLD VACUUM CHECK Vacuum gauge

Plug

1. Before inspection, set the vehicle to the pre-inspection condition. 2. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve, and then connect a vacuum gauge to the ventilation hose. 3. Check the intake manifold vacuum while the engine is idling. Limit: Min. 56 kPa

LASH ADJUSTER CHECK If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and does not stop, carry out the following check. NOTE (1) The abnormal noise which is caused by a problem with the lash adjusters is generated after the engine is started, and will vary according to the engine speed. However, this noise is not related to the actual engine load. Because of this, if the noise does not occur immediately after the engine is started, if it does not change in accordance with the engine speed, or if it changes in accordance with the engine load, the source of the noise is not the lash adjusters. (2) If there is a problem with the lash adjusters, the noise will almost never disappear, even if the engine has been run at idle to let it warm up. The only case where the noise might disappear is if the oil in the engine has not been looked after properly and oil sludge has caused the lash adjusters to stick. 1. Start the engine. 2. Check that the noise occurs immediately after the engine is started, and that the noise changes in accordance with changes in the engine speed. If the noise does not occur immediately after the engine is started, or if it does not change in accordance with the engine speed, the problem is not being caused by the lash adjusters, so check for some other cause of the problem. Moreover, if the noise does not change in accordance with the engine speed, the cause of the problem is probably not with the engine. (In these cases, the lash adjusters are normal.) 3. While the engine is idling, check that the noise level does not change when the engine load is varied (for example, by shifting from N ® D). If the noise level changes, the cause of the noise is probably parts striking because of worn crankshaft bearings or connecting rod bearings. (In such cases, the lash adjusters are normal.)

ENGINE <4G6> - On-vehicle Service

11A-15

4. After the engine has warmed up, run it at idle and check if any noise can be heard. If the noise has become smaller or disappeared, oil sludge could make the lash adjusters stick. Clean the lash adjusters. (Refer to the Engine Workshop Manual.) If not improved, go to step 5. 5. Bleed air from the lash adjusters. (Refer to P.11A-15.) 6. If the noise has not disappeared even after the air bleeding, clean the lash adjusters. (Refer to the Engine Workshop Manual.) NOTE (1) If the vehicle is parked on a slope for a long period of time, the amount of oil inside the lash adjuster will decrease, and air may get into the high pressure chamber when starting the engine. (2) After parking the vehicle for long periods, the oil drains out of the oil passage, and it takes time for the oil to be supplied to the lash adjuster, so air can get into the high pressure chamber. (3) If either of the above situations occur, the abnormal noise can be eliminated by bleeding the air from inside the lash adjusters.

1. Check the engine oil and replenish or replace the oil if necessary.

Good

NOTE (1) If there is a only small amount of oil, air will be drawn in through the oil screen and will get into the oil passage. (2) If the amount of oil is greater than normal, then the oil will being mixed by the crankshaft and a large amount of air may get mixed into the oil. (3) If the oil is degenerated, air and oil will not separate easily in oil, and the amount of air mixed into the oil will increase.

11A-16

ENGINE <4G6> - On-vehicle Service

High-pressure chamber

Drive pattern for air bleeding Gradually open the Close the throttle throttle valve. valve. Approx. 3,000 r/min Idle speed 15 seconds

15 seconds

Once

(4) If the air which has been mixed in with the oil due to any of the above reasons gets into the high pressure chamber of the lash adjuster, the air inside the high pressure chamber will be compressed when the valve is open and the lash adjuster will over-compress, resulting in abnormal noise when the valve closes. This is the same effect as if the valve clearance is adjusted to be too large by mistake. If the air inside the lash adjusters is then released, the operation of the lash adjusters will return to normal. 2. Run the engine at idle for 1 - 3 minutes to let it warm up. 3. With no load on the engine, repeat the drive pattern shown in the illustration at left and check if the abnormal noise disappears. (The noise should normally disappear after 10 - 30 repetitions, but if there is no change in the noise level after 30 repetitions or more, the problem is probably not due to air inside the lash adjusters.) 4. After the noise has disappeared, repeat the drive pattern shown in the illustration at left a further 5 times. 5. Run the engine at idle for 1 - 3 minutes and check that the noise has disappeared.

ENGINE <4G6> - Crankshaft Pulley

CRANKSHAFT PULLEY

11A-17 11200160303

REMOVAL AND INSTALLATION Pre-removal Operation Under Cover Removal

Post-installation Operation D Drive Belt Tension Adjustment (Refer to P.11A-6.) D Under Cover Installation

e 2 3 1 25 Nm

Removal steps 1. Drive belt (Power steering and A/C)

2. Drive belt (Alternator) 3. Crankshaft pulley

11A-18

ENGINE <4G6> - Camshaft and Camshaft Oil Seal

CAMSHAFT AND CAMSHAFT OIL SEAL

11200190418

REMOVAL AND INSTALLATION Pre-removal Operation D Air Intake Hose Assembly Removal D Timing Belt Removal (Refer to P.11A-30.) D Engine Coolant Draining D Intake Manifold Removal (Refer to GROUP 15.) D Fuel Pump (High Pressure) Removal (Refer to GROUP 13A.)

Post-installation Operation D Fuel Pump (High Pressure) Installation (Refer to GROUP 13A.) D Intake Manifold Installation (Refer to GROUP 15.) D Timing Belt Installation (Refer to P.11A-30.) D Air Intake Hose Assembly Installation D Engine Coolant Supplying D Drive Belt Tension Adjustment (Refer to P.11A-6.)

3.4 Nm

12

8 10 Nm

9

11 2 3

19 - 21 Nm

1 7

22 Nm

4

12 - 15 Nm

13

5

9 Nm

10

10 - 12 Nm

88 Nm

6

Removal steps 1. Cam position sensor 2. Cover 3. Gasket "EA 4. Camshaft position sensing cylinder 5. Camshaft position sensor support AA" "DA 6. Camshaft sprocket 7. Timing belt rear cover

8. 9. "CA 10. "BA 11. 12. "AA 13.

Rocker cover Rocker cover gasket Camshaft oil seal Beam camshaft cap Beam camshaft cap gasket Camshaft

ENGINE <4G6> - Camshaft and Camshaft Oil Seal

11A-19

Lubrication points

f3mm

Sealant: 3M ATD Part No.8660 or equivalent

Lip section

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent



Sealant: 3M ATD Part No.8660 or equivalent

Engine oil

11A-20

ENGINE <4G6> - Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINTS AA" CAMSHAFT SPROCKET REMOVAL

MB990767

MD998715 or MD998719

Camshaft sprocket side

Screw hole

"BA BEAM CAMSHAFT CAP INSTALLATION 1. Place the camshaft dowel pin as shown in the illustration.

Dowel pin

Exhaust side

Intake side

28

2. Tighten the beam camshaft cap mounting bolts to the specified torque in the order shown in the illustration.

27 20 19 12 11

8

23

24

15 16

3

5

7 1

6

14 13

2

9

10

22 21

4

17

18

30

29

"AA CAMSHAFT INSTALLATION 1. Apply engine oil to journals and cams of the camshafts. 2. Install the camshafts on the cylinder head. Caution Be careful not to confuse the intake camshaft with the exhaust one. There is a screw hole for the cam position sensing cylinder mounting bolt on the exhaust-side camshaft.

Exhaust camshaft

Approx. 12_

INSTALLATION SERVICE POINTS

25

26

Tightening torque: 19 - 21 Nm

ENGINE <4G6> - Camshaft and Camshaft Oil Seal

11A-21

"CA CAMSHAFT OIL SEAL INSTALLATION 1. Apply engine oil to the entire circumference of the oil seal lip. 2. Press-fit the oil seal as shown in the illustration.

MD998713

"DA CAMSHAFT SPROCKET INSTALLATION Use the special tool to secure the camshaft sprocket in the same way as during removal, and then tighten the bolt to the specified torque. Tightening torque: 88 Nm

Dowel pin 90_

Identification paint

"EA CAM POSITION SENSING CYLINDER INSTALLATION Position the identification paint of cam position sensing cylinder as shown in the illustration.

11A-22

ENGINE <4G6> - Oil Pan

OIL PAN

11200280207

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Under Cover Removal and Installation D Engine Oil Draining and Supplying (Refer to GROUP 12 - On-vehicle Service.)

D D

Oil Level Gauge Removal and Installation Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.)

6 6 f 4 ± 1 mm

Groove

39 Nm Bolt hole

Sealant: MITSUBISHI GENUINE MD970389 or equivalent

2

1 4 PART 9 Nm

5 9 Nm

9 Nm

3 44 Nm 22 Nm

Removal steps 1. Drain plug "AA 2. Drain plug gasket 3. Transmission stay

MD998727

MD998727

AA"

4. Bell housing cover 5. Oil level sensor 6. Oil pan

REMOVAL SERVICE POINT AA" OIL PAN REMOVAL After removing the oil pan mounting bolts, remove the oil pan with the special tool and a brass bar. Caution Perform this slowly to avoid deformation of the oil pan flange.

ENGINE <4G6> - Oil Pan

11A-23

INSTALLATION SERVICE POINT Oil pan side Drain plug gasket

"AA DRAIN PLUG GASKET INSTALLATION Install the drain plug gasket in the direction so that it faces as shown in the illustration.

11A-24

ENGINE <4G6> - Crankshaft Oil Seal

CRANKSHAFT OIL SEAL

11200310135

REMOVAL AND INSTALLATION 127 - 137 Nm

4

5 7 9



127 - 137 Nm

9 3

4

2 6

1

8







Crankshaft

Crankshaft

3

Lip section

(Engine oil: bolt washer surface)

9

Lip section

(Engine oil: bolt washer surface)

5 6

Engine oil

Sealant: 3M Stud locking 4170 or equivalent

Crankshaft front oil seal removal steps D Timing belt (Refer to P.11A-30.) 1. Crankshaft sprocket B 2. Key "CA 3. Crankshaft front oil seal

AA" AB" AB" AB" AB"

"BA "BA "BA "BA "AA

Crankshaft rear oil seal removal steps D Transmission assembly D Clutch cover and disc 4. Adapter plate 5. Flywheel 6. Drive plate 7. Adapter plate 8 Crankshaft bushing 9. Crankshaft rear oil seal

ENGINE <4G6> - Crankshaft Oil Seal

11A-25

REMOVAL SERVICE POINTS



AA" TRANSMISSION ASSEMBLY REMOVAL : Refer to GROUP 22.

Flywheel Bolt

Caution Do not remove the flywheel mounting bolt shown by the arrow. If this bolt Is removed, the flywheel will become out of balance and damaged. : Refer to GROUP 23. AB" ADAPTER PLATE/FLYWHEEL /DRIVE PLATE REMOVAL Use the special tool to secure the flywheel or drive plate, and remove the bolts.

MD998781

Crankshaft rear oil seal MD990938

MD998776

INSTALLATION SERVICE POINTS Crankshaft

"AA CRANKSHAFT REAR OIL SEAL INSTALLATION 1. Apply a small mount of engine oil to the entire circumference of the oil seal lip. 2. Install the oil seal by tapping it as far as the chamfered position of the oil seal case as shown in the illustration.

11A-26

ENGINE <4G6> - Crankshaft Oil Seal "BA DRIVE PLATE /FLYWHEEL /ADAPTER PLATE INSTALLATION 1. Clean off all sealant, oil and other substances which are adhering to the threaded bolts, crankshaft thread holes and the flywheel or drive plate. 2. Apply oil to the bearing surface of the flywheel or drive plate bolts. 3. Apply oil to the crankshaft thread holes. 4. Apply sealant to the threaded mounting holes. Specified sealant: 3M Stud locking 4170 or equivalent 5. Use the special tool to hold the flywheel or drive plate in the same manner as removal, and install the bolt.

Crankshaft

MD998382

Oil seal

MD998285 (Apply oil to entire circumference)

"CA CRANKSHAFT FRONT OIL SEAL INSTALLATION 1. Apply a small amount of engine oil to the entire circumference of the oil seal lip. 2. Use the special tool to press-fit the oil seal unit it is flush with the oil seal case.

11A-27

ENGINE <4G6> - Cylinder Head Gasket

CYLINDER HEAD GASKET

11200400542

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Fuel Discharge Prevention (Refer to GROUP 13A - On-vehicle Service.) D Engine Coolant Draining and Supplying (Refer to GROUP 14 - On-vehicle Service.) D Engine Oil Draining and Supplying (Refer to GROUP 12 - On-vehicle Service.) D Intake Manifold Removal and Installation (Refer to GROUP 15.)

D D D

Fuel Pressure Regulator (High Pressure) and Fuel Pump (High Pressure) Removal and Installation (Refer to GROUP 13A.) Thermostat Case Assembly Removal and Installation (Refer to GROUP 14 - Water Hose and Pipe.) Timing Belt Removal and Installation (Refer to P.11A-30.)

7 78 Nm ® 0 Nm ® 20 Nm ® +90_ ® +90_

8 3.4 Nm

9 4 3

10 6

1

5

24 Nm

2

44 Nm 34 Nm

Removal steps 1. Injector harness connector 2. Front exhaust pipe connection 3. Water hose connection 4. Water pipe assembly mounting bolt 5. EGR valve and stay assembly

6. 7. AA" "BA 8. 9. "AA 10.

Engine oil level gauge Rocker cover Cylinder head bolt Cylinder head assembly Cylinder head gasket

11A-28

ENGINE <4G6> - Cylinder Head Gasket REMOVAL SERVICE POINT AA" CYLINDER HEAD BOLT REMOVAL Use the special tool to loosen the bolts in two or three steps in the order of the numbers shown in the illustration, and then remove the bolts. If the washer is caught on valve spring and the bolt is not removed, pull up the bolt slightly and remove the bolt while tilting the washer by using a magnet, etc.

MB991653

Intake side

Front of engine

3

5

10

8

2

1

7

9

6

4

Exhaust side

INSTALLATION SERVICE POINTS "AA CYLINDER HEAD GASKET INSTALLATION 1. Wipe off all oil and grease from the gasket mounting surface. 2. Install so that the shapes of the cylinder head holes match the shapes of the respective cylinder head gasket holes.

Burred side

A

Head bolt washer Cylinder head

Head bolt (Engine oil)

"BA CYLINDER HEAD BOLT INSTALLATION 1. When installing the cylinder head bolts, the length below the head of the bolts should be within the limit. If it is outside the limit, replace the bolts. Limit (A): 99.4 mm 2. The head bolt washer should be installed with the burred side caused by tapping out facing upwards. 3. Apply a small amount of engine oil to the thread section and the washer of the cylinder head bolt.

11A-29

ENGINE <4G6> - Cylinder Head Gasket

4. Tighten the bolts by the following procedure. Step

MB991653

Intake side

Operation

Remarks

1

Tighten to 78 Nm.

Carry out in the order shown in the illustration.

2

Fully loosen.

Carry out in the reverse order of that shown in the illustration.

3

Tighten to 20 Nm.

Carry out in the order shown in the illustration.

4

Tighten 90_ of a turn.

In the order shown in the illustration. Mark the head of the cylinder head bolt and cylinder head by paint.

5

Tighten 90_ of a turn.

In the order shown in the illustration. Check that the painted mark of the head bolt is lined up with that of the cylinder head.

Front of engine

8

6

1

3

9

10

4

2

5

7

Exhaust side

Step 4 90_

Painted mark

Caution 1. Always make a tightening angle just 90_. If it is less than 90_, the head bolt will be loosened. 2. If it is more than 90_, remove the head bolt and repeat the procedure from step 1.

Step 5 90_

Painted mark

11A-30

ENGINE <4G6> - Timing Belt and Timing Belt B

TIMING BELT AND TIMING BELT B

11200430473

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Engine Cover Removal and Installation D Under Cover Removal and Installation D Crankshaft Pulley Removal and Installation (Refer to P.11A-17.)

D

Engine Mount Bracket Removal and Installation (Refer to GROUP 32 - Engine Mounting.)

48 Nm

4

6

22 Nm 24 Nm

2 10 - 12 Nm

5 10

1 19 Nm

9 Nm

8 3

11

9

108 - 127 Nm

7

9 Nm 10 - 12 Nm 9 Nm

Removal steps 1. Water pump pulley 2. Timing belt front upper cover 3. Timing belt front lower cover "FA D Timing belt tension adjustment AA" "EA 4. Timing belt "DA 5. Auto tensioner

AB" "CA "BA "AA AC" "AA

6. 7. 8. 9. 10. 11.

Tensioner pulley assembly Crankshaft position sensor Crankshaft sprocket Crankshaft sensing blade Timing belt B tensioner Timing belt B

ENGINE <4G6> - Timing Belt and Timing Belt B

11A-31

REMOVAL SERVICE POINT

Timing marks

AA" TIMING BELT REMOVAL 1. Turn the crankshaft clockwise (right turn) to align each timing mark and to set the No. 1 cylinder at compression top dead centre. Caution The crankshaft should always be turned only clockwise.

2. Loosen the tension pulley centre bolt. 3. Move the tension pulley to the water pump side, and then remove the timing belt. Centre bolt

Crankshaft sprocket

MD998719 or MD998754

Caution If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction.

AB" CRANKSHAFT SPROCKET REMOVAL

MB990767

AC" TIMING BELT B REMOVAL Caution If timing belt B is to be re-used, use chalk to mark it with an arrow on its flat side indicating the turning direction (to the right).

11A-32

ENGINE <4G6> - Timing Belt B and Timing Belt B Counterbalance shaft sprocket Belt tension side

Timing marks

Timing marks Crankshaft sprocket B

INSTALLATION SERVICE POINTS "AA TIMING BELT B/TIMING BELT B TENSIONER INSTALLATION 1. Install timing belt B by the following procedure. (1) Ensure that crankshaft sprocket B timing mark and the counterbalance shaft sprocket timing mark are aligned. (2) Fit timing belt B over crankshaft sprocket B and the counterbalance shaft sprocket. Ensure that there is no slack in the belt. 2. Adjust the tension of timing belt B by the following procedure. (1) Temporarily fix the timing belt B tensioner such that the centre of the tensioner pulley is to the left and above the centre of the installation bolt, and temporarily attach the tensioner pulley so that the flange is toward the front of the engine.

Centre of tensioner pulley

Centre of installation bolt

(2) Holding the timing belt B tensioner up with your finger in the direction of the arrow, place pressure on the timing belt so that the tension side of the belt is taut. Now tighten the bolt to fix the tensioner.

Shaft

Caution When tightening the bolt, ensure that the tensioner pulley shaft does not rotate with the bolt. Allowing it to rotate with the bolt can cause excessive tension on the belt.

3. To ensure that the tension is correct, depress the belt (point A) with a finger. If not, adjust.

A

Standard value: 5 - 7 mm Centre of tensioner pulley Centre of installation bolt

Crankshaft sprocket

Crankshaft sensing blade

Crankshaft

Crankshaft sprocket B

"BA CRANKSHAFT SENSING BLADE INSTALLATION Confirm the installation direction of crankshaft sensing blade and install it as shown in the illustration.

ENGINE <4G6> - Timing Belt and Timing Belt B

11A-33

"CA CRANKSHAFT SPROCKET INSTALLATION 1. Apply the minimum amount of engine oil to the seat surface and thread of the crankshaft bolt. 2. Hold the crankshaft sprocket as same as for removal, and then tighten the bolt to the specified torque. Tightening torque: 108 - 127 Nm

"DA AUTO TENSIONER INSTALLATION 1. Apply 98 - 196 N force to the auto tensioner by pressing it against a metal (cylinder block, etc.), and measure the movement of the push rod.

98 - 196N

A

Movement

B

Push rod

Auto tensioner

Standard value: Within 1 mm A: Length when it is free (not pressed) B: Length when it is pressed A - B: Movement 2. If it is out of the standard value, replace the auto tensioner.

A

B

3. Use a press or vice to gently compress the auto tensioner push rod until pin hole A of the push rod and pin hole B of the tensioner cylinder are aligned. Caution If the compression speed is too fast, the rod may become damaged, so be sure to carry out this operation slowly.

Set pin

4. Once the holes are aligned, insert the set pin. NOTE When replacing the auto tensioner with a new part, the pin will be in the auto tensioner. 5. Install the auto tensioner to the engine.

11A-34

ENGINE <4G6> - Timing Belt and Timing Belt B "EA TIMING BELT INSTALLATION 1. Align the timing marks on the camshaft sprocket, crankshaft sprocket and oil pump sprocket.

Timing marks

Camshaft sprocket

Timing marks Timing marks

Oil pump sprocket

Crankshaft sprocket

Plug

60 mm or more

8 mm

Screwdriver Counterbalance shaft

Intake camshaft sprocket Tensioner pulley Crankshaft sprocket

Cylinder block

Exhaust camshaft sprocket

2. After aligning the timing mark on the oil pump sprocket, remove the cylinder block plug and insert a Phillips screwdriver with a diameter of 8 mm, and check to be sure that the screwdriver goes in 60 mm or more. If the screwdriver will only go in 20 - 25 mm before striking the counterbalance shaft, turn the sprocket once, realign the timing mark and check that the screwdriver goes in 60 mm or more. The screwdriver should not be taken out until the timing belt is installed.

3. Install the timing belt by the following procedure. Take care not to slacken the belt at the tension side. (1) Install the timing belt to the crankshaft sprocket, oil pump sprocket and idler pulley in that order.,

Idler pulley Oil pump sprocket

Paper clip

(2) Place the timing belt on the exhaust-side camshaft sprocket, and hold it in the position shown in the illustration with a paper clip.

ENGINE <4G6> - Timing Belt and Timing Belt B

11A-35

(3) Place the timing belt on the intake-side sprocket while using two wrenches to align the timing marks.

Timing marks

Paper clip

(4) Hold the belt in the position shown in the illustration with another paper clip. (5) Place the timing belt on the tensioner pulley. (6) Remove the two paper clips. Caution After installing the timing belt, apply force to turn the camshaft sprocket in the reverse direction, and recheck to be sure that the belt is fully tensioned and that each timing mark is in the proper position. 4. Set the tension pulley so that the pin holes of centre bolt are at the bottom, press the tension pulley lightly against the timing belt, and then provisionally tighten the centre bolt. 5. Check to be sure that all timing marks are aligned. 6. Adjust the timing belt tension.

50 Nm

MD998767

Tension direction

"FA TIMING BELT TENSION ADJUSTMENT 1. After turning the crankshaft 1/4 of a revolution in the anticlockwise direction, turn it in the clockwise direction until the timing marks are aligned. 2. Loosen the tension pulley fixing bolt, and then use the special tool and a torque wrench to tighten the fixing bolt to the specified torque while applying tension to the timing belt. Standard value: 3.5 Nm Caution When tightening the fixing bolt, make sure that the tension pulley does not turn with the bolt.

11A-36

A

ENGINE <4G6> - Timing Belt and Timing Belt B 3. Turn the crankshaft two revolutions in the clockwise direction so that the timing marks are aligned. After leaving it for 15 minutes, measure the amount of protrusion of the auto tensioner. Standard value (A): 3.8 - 4.5 mm

Auto tensioner

4. If the amount of protrusion is outside the standard value, repeat the operation in steps (1) to (3). 5. Check again to be sure that the timing marks of each sprocket are aligned.

11A-37

ENGINE <4G6> - Engine Assembly

ENGINE ASSEMBLY

11200090015

REMOVAL AND INSTALLATION Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Pre-removal and Post-installation Operation D Fuel Discharge Prevention (Refer to GROUP 13A - On-vehicle Service.) D Engine Cover Removal and Installation D Under Cover Removal and Installation D Engine Coolant Draining and Supplying (Refer to GROUP 14 - On-vehicle Service.)

D D D

Hood Removal and Installation (Refer to GROUP 42.) Transmission Assembly Removal and Installation (Refer to GROUP 22 or 23.) Drive Belt Tension Adjustment (Refer to P.11A-6.)

2 3 16 12

8 5

7

11 9

6

67 Nm

10 15

1

57 Nm

15

4

14 13

98 - 118 Nm*

AA" AB"

Removal steps 1. Drive belt (Power steering and A/C) 2. Engine harness connector 3. Earth cable connection 4. Alternator connector 5. Power steering hose clamp 6. A/C compressor 7. Power steering oil pump 8. Vacuum hose connection

9. Brake booster vacuum hose connection 10. Heater hose connection 11. Fuel return hose connection 12. Fuel pressure hose connection 13. Power steering oil reservoir AC" "CA 14. Engine mount bracket "BA 15. Engine mount stopper AD" "AA 16. Engine assembly

11A-38

ENGINE <4G6> - Engine Assembly REMOVAL SERVICE POINTS AA" A/C COMPRESSOR REMOVAL Disconnect the A/C compressor connector and remove the compressor from the compressor bracket with the hose still attached. NOTE Place the removed A/C compressor where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord. AB" POWER STEERING OIL PUMP REMOVAL Remove the power steering oil pump and bracket assembly from the engine with the hose attached. NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.

MZ203827

MB991453

AC" ENGINE MOUNT BRACKET REMOVAL 1. Support the engine with a garage jack. 2. Remove the special tool which was attached when the transmission assembly was removed. 3. Hold the engine assembly with a chain block or similar tool. 4. Place a garage jack against the engine oil pan with a piece of wood in between, jack up the engine so that the weight of the engine is no longer being applied to the engine mount bracket, and then remove the engine mount bracket. AD" ENGINE ASSEMBLY REMOVAL After checking that all cables, hoses and harness connectors, etc., are disconnected from the engine, lower the chain block slowly to remove the engine assembly downward from the engine compartment.

ENGINE <4G6> - Engine Assembly

11A-39

INSTALLATION SERVICE POINTS "AA ENGINE ASSEMBLY INSTALLATION Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped.

Engine side Arrow

"BA ENGINE MOUNT STOPPER INSTALLATION Clamp the engine mount stopper so that the arrow points in the direction as shown in the diagram.

Engine mount stopper Engine mount bracket

"CA ENGINE MOUNT BRACKET INSTALLATION 1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mount bracket while adjusting the position of the engine. 2. Support the engine with the garage jack. 3. Remove the chain block and support the engine assembly with the special tool.

NOTES

11B-1

ENGINE <4G9> CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2

Lash Adjuster Check . . . . . . . . . . . . . . . . . . . . . . . . 13

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2

CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . 16

SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAMSHAFT AND CAMSHAFT OIL SEAL . . 17

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 4

OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6

CRANKSHAFT OIL SEAL . . . . . . . . . . . . . . . . . 23

Drive Belt Tension Check and Adjustment . . . . . . 6 Ignition Timing Check . . . . . . . . . . . . . . . . . . . . . . . . 9 Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Compression Pressure Check . . . . . . . . . . . . . . . . 12 Manifold Vacuum Check . . . . . . . . . . . . . . . . . . . . . 13

CYLINDER HEAD GASKET . . . . . . . . . . . . . . . 25 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 33

11B-2

ENGINE <4G9> - General Information/Service Specifications

GENERAL INFORMATION Items

4G93

Total displacement mL

1,834

Bore ´ Stroke mm

81.0 ´ 89.0

Compression ratio

12.5

Combustion chamber

Pentroof + ball-in-piston

Camshaft arrangement

DOHC

Number of valve

Valve timing

Intake

8

Exhaust

8

Intake

Exhaust

Opening

BTDC 15_

Closing

ABDC 56_

Opening

BBDC 55_

Closing

ATDC 15_

Fuel system

Electronically controlled multipoint fuel injection

Rocker arm

Roller type

Auto-lash adjuster

Equipped

SERVICE SPECIFICATIONS Items Alternator drive belt tension

Vibration frequency Hz

Tension N

Deflection (Reference value) mm

Standard value

Limit

When checked

143 - 185

-

When a used belt is installed

155 - 175

-

When a new belt is installed

203 - 234

-

When checked

294 - 490

-

When a used belt is installed

343 - 441

-

When a new belt is installed

588 - 784

-

When checked

9.7 - 12.9

-

When a used belt is installed

10.5 - 12.0

-

When a new belt is installed

6.7 - 8.5

-

11B-3

ENGINE <4G9> - Service Specifications Items

Standard value

Limit

When checked

114 - 139

-

When a used belt is installed

121 - 133

-

When a new belt is installed

145 - 166

-

When checked

392 - 588

-

When a used belt is installed

441 - 539

-

When a new belt is installed

637 - 833

-

When checked

10.0 - 12.0

-

When a used belt is installed

10.0 - 11.0

-

When a new belt is installed

7.0 - 9.0

-

Basic ignition timing

5_ BTDC ± 3_

-

Ignition timing

Approx. 16_BTDC (Approx. 6_BTDC)*2

-

M/T

600 ± 100*1 (750 ± 100)*2

-

A/T

650 ± 100 (750 ± 100)*2

-

CO contents %

0.5 or less

-

HC contents ppm

100 or less

-

Compression pressure kPa - r/min

1,790 - 300

1,400 - 300

Compression pressure difference of all cylinder kPa

-

Max. 100

Intake manifold vacuum kPa

-

Min. 37

Cylinder head bolt shank length mm

-

99.4

Timing belt tension torque Nm (Reference value)

2.5 - 4.0

-

Auto-tensioner rod protrusion amount mm

3.8 - 4.5

-

Power steering oil pump and A/C compressor drive belt tension

Vibration frequency Hz

Tension N

Deflection (Reference value) mm

Idle speed r/min

NOTE

*1: Varies depending on the transmission oil temperature. For details, refer to P. 11B-10. *2: Indicates the value when more than 4 minutes have passed since the engine was started.

11B-4

ENGINE <4G9> - Sealants/Special Tools

SEALANTS Items

Specified sealants

Remarks

Beam camshaft cap Cylinder head

3M ATD Part No.8660 or equivalent

-

Cam position sensor support Oil pan

MITSUBISHI GENUINE MD970389 or equivalent

Semi-drying sealant

Flywheel or drive plate bolt

3M Stud Locking 4170 or equivalent

PART

-

SPECIAL TOOLS Tool

Number

Name

Use

MB991502

MUT-II sub assembly

D D D D

MB991668

Belt tension meter set

Measuring the drive belt tension (used together with the MUT-II)

MB990767

End yoke holder

D D

MD998719 MD998754

or

Measuring the drive belt tension Checking the ignition timing Checking the idle speed Erasing diagnosis code

Holding the camshaft sprocket Holding the crankshaft sprocket

Crankshaft pulley holder pin

MD998713

Camshaft oil seal installer

Press-in of the camshaft oil seal

MD998781

Flywheel stopper

Securing the flywheel or drive plate

ENGINE <4G9> - Special Tools Tool

11B-5

Number

Name

Use

MD998776

Crankshaft rear oil seal installer

Press-in of the crankshaft rear oil seal

MB990938

Handle

MD998717

Crankshaft front oil seal installer

Press-in of the crankshaft front oil seal

MD998767

Tension pulley socket wrench

Timing belt tension adjustment

GENERAL SERVICE TOOL MZ203827

Engine lifter

Supporting the engine assembly during removal and installation of the transmission

MB991453

Engine hanger assembly

11B-6

ENGINE <4G9> - On-vehicle Service

ON-VEHICLE SERVICE DRIVE BELT TENSION CHECK AND ADJUSTMENT ALTERNATOR DRIVE BELT TENSION CHECK Check the drive belt tension by the following procedure.

15_

15_ MB991668 (Microphone) 10 - 20 mm

Tap lightly with a finger. Alternator pulley

Crankshaft pulley

1. Connect the special tool (belt tension meter kit) to the MUT-II. 2. Connect the MUT-II to the diagnosis connector. 3. Turn the ignition switch to ON and select “Belt Tension Measurement” from the menu screen. 4. Hold the microphone to the middle of the drive belt between the pulleys (at the place indicated by the arrow), about 10 - 20 mm away from the rear surface of the belt and so that it is perpendicular to the belt (within an angle of ± 15_). 5. Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value. Caution (1) The temperature of the surface of the belt should be as close as possible to normal temperature. (2) Do not let any contaminants such as water or oil get onto the microphone. (3) If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values. (4) If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values. (5) Do not take the measurement while the vehicle’s engine is running.

Belt tension gauge Crankshaft pulley

Alternator pulley

Use a belt tension gauge to check that the belt tension is within the standard value.

11B-7

ENGINE <4G9> - On-vehicle Service Deflection 98 N Crankshaft pulley

Alternator pulley

Adjusting bolt

Lock bolt

Apply 98 N of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value. Standard value: Vibration frequency Hz

143 - 185

Tension N

294 - 490

Deflection (Reference value) mm

9.7 - 12.9

ALTERNATOR DRIVE BELT TENSION ADJUSTMENT 1. Loosen the nut of the alternator pivot bolt. 2. Loosen the lock bolt. 3. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values. Standard value: Items

Pivot bolt

When a used belt is installed

When a new belt is installed

Vibration frequency Hz 155 - 175

203 - 234

Tension N

343 - 441

588 - 784

Deflection (Reference value) mm

10.5 - 12.0

6.7 - 8.5

NOTE Refer to P.11B-6 concerning the measurement procedure of the alternator drive belt tension. 4. Tighten the nut of the alternator pivot bolt. Tightening torque: 44 Nm 5. Tighten the lock bolt. Tightening torque: 22 Nm 6. Tighten the adjusting bolt. Tightening torque: 5.0 Nm

11B-8

ENGINE <4G9> - On-vehicle Service

Oil pump pulley 98 N A

B

Crankshaft pulley

Standard value: Tensioner pulley

Oil pump pulley 98 N Crankshaft pulley

POWER STEERING OIL PUMP AND AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION CHECK AND 11100130127 ADJUSTMENT 1. Check if the belt tension is within the standard value using one of the methods below.

Tensioner pulley A

B A/C compressor pulley

Items

When checked

When a used belt is installed

When a new belt is installed

Vibration frequency Hz

114 - 139

121 - 133

145 - 166

Tension N

392 - 588

441 - 539

637 - 833

Deflection (Reference value) mm

10.0 - 12.0

10.0 - 11.0

7.0 - 9.0

With your finger tip lightly tap the centre of the belt between the pulleys in the location shown by the arrow in the illustration and then measure the belt vibration frequency. NOTE Refer to P.11B-6 for information regarding the vibration frequency measurement method using MUT-II. Use a belt tension gauge to measure the belt tension. Apply 98 N of pressure against the location between the pulleys shown by the arrow in the illustration and then measure the deflection. 2. If the tension or deflection is outside the standard value, adjust by the following procedure. (1) Loosen tensioner pulley fixing nut A. (2) Adjust the amount of belt deflection using adjusting bolt B. (3) Tighten fixing nut A. Tightening torque: 25 Nm (4) Check the belt deflection amount and tension, and readjust if necessary. Caution Check after turning the crankshaft once or more clockwise (right turn).

ENGINE <4G9> - On-vehicle Service Idle speed r/min 900 800 700 600 - 10 20 50 Transmission oil temperature _C

11B-9

IGNITION TIMING CHECK 1. Before inspection, set the vehicle to the pre-inspection condition. For vehicles with manual transmission, drive the vehicle for 15 minutes or more to warm the engine, and then carry out the checking while the transmission oil temperature is more than 50°C. NOTE The idle speed in vehicles with manual transmission varies as shown in the illustration in accordance with the transmission oil temperature. 2. Turn off the ignition switch and then connect the MUT-II to the diagnosis connector. 3. Set the timing light to the power supply line (terminal No.1) of the ignition coil No.1. NOTE The power supply line is looped and also longer than the other ones. 4. Start the engine and let it run at idle. 5. Use the MUT-II to measure engine idle speed and check that it is within the standard value. Standard value: Items

Idle speed r/min

M/T

600 ± 100 (750 ± 100)*

A/T

650 ± 100 (750 ± 100)*

NOTE *: Indicates the values when more than 4 minutes have passed since the idling condition was started. 6. Select No.17 of the MUT-II Actuator test. NOTE At this time, the engine speed will become approximately 750 r/min. 7. Check that basic ignition timing is within the standard value. Standard value: 5_ BTDC ± 3_ 8. If the basic ignition timing is outside the standard value, inspect the GDI system while referring to GROUP 13B - Troubleshooting. 9. Press the MUT-II clear key (Select a forced driving cancel mode) to release the Actuator test. Caution If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engine.

11B-10

ENGINE <4G9> - On-vehicle Service 10. Check that ignition timing is at the standard value. Standard value: approx. 16_BTDC NOTE (1) The ignition timing will become approximately 6_BTDC after more than 4 minutes have passed since the basic ignition timing set mode was released. (2) The ignition timing may fluctuate within ±7_BTDC. This is normal. 11. Remove the timing light. 12. Turn off the ignition switch and then remove the MUT-II.

Idle speed r/min 900 800 700 600 - 10 20 50 Transmission oil temperature _C

IDLE SPEED CHECK 1. Before inspection, set the vehicle to the pre-inspection condition. For vehicles with manual transmission, drive the vehicle for 15 minutes or more to warm the engine, and then carry out the checking while the transmission oil temperature is more than 50°C. NOTE The idle speed in vehicles with manual transmission varies as shown in the illustration in accordance with the transmission oil temperature. 2. Turn off the ignition switch and then connect the MUT-II to the diagnosis connector. 3. Check the basic ignition timing. NOTE Refer to P.11B-9 concerning the check procedure of the basic ignition timing. Standard value: 5_ BTDC ± 3_ 4. Run the engine at idle for 2 minutes. 5. Check the idle speed. Select item No. 22 and take a reading of the idle speed. Standard value: Items

Idle speed r/min

M/T

600 ± 100 (750 ± 100)*

A/T

650 ± 100 (750 ± 100)*

NOTE (1) *: Indicates the values when more than 4 minutes have passed since the idling condition was started. (2) The idle speed is automatically controlled by the idle speed control (ISC) system.

ENGINE <4G9> - On-vehicle Service

11B-11

6. If the idle speed is outside the standard value, inspect the GDI components by referring to GROUP 13B Troubleshooting.

IDLE MIXTURE CHECK 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Connect the MUT-II to the diagnosis connector. 3. Check that the basic ignition timing is within the standard value. NOTE Refer to P.11B-9 concerning the check procedure of the basic ignition timing. Standard value: 5_ BTDC ± 3_ 4. Run the engine at 2,500 r/min for 2 minutes. 5. Set the CO, HC tester. 6. Check the CO contents and the HC contents at idle. NOTE This measurement should be performed in less than approximately 4 minutes since the engine speed become the idle speed. Standard value CO contents: 0.5% or less HC contents: 100 ppm or less 7. If there is a deviation from the standard value, check the following items: D Diagnosis output D Fuel pressure D Injector D Ignition coil, spark plug D EGR control system D Evaporative emission control system D Compression pressure NOTE Replace the three way catalyst when the CO and HC contents are not within the standard value, even though the result of the inspection is normal on all items.

11B-12 Crank angle sensor connector

ENGINE <4G9> - On-vehicle Service COMPRESSION PRESSURE CHECK 1. Before inspection, check that the engine oil, starter and battery are normal. In addition, set the vehicle to the pre-inspection condition. 2. Remove all of the ignition coils and spark plugs. 3. Disconnect the crank angle sensor connector. NOTE Doing this will prevent the engine-ECU from carrying out ignition and fuel injection. 4. Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel. Caution (1) Keep away from the spark plug hole when cranking. (2) If compression is measured with water, oil, fuel, etc., that has come from cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous.

Compression gauge

5. Set compression gauge to one of the spark plug holes. 6. Crank the engine with the throttle valve fully open and measure the compression pressure. Standard value (at engine speed of 300 r/min): 1,790 kPa Limit (at engine speed of 300 r/min): Min. 1,400 kPa 7. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: Max. 100 kPa 8. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 6 and 7. (1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface. (2) If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket. 9. Connect the crank angle sensor connector. 10. Install the spark plugs and ignition coils. 11. Use the MUT-II to erase the diagnosis codes. NOTE This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected.

ENGINE <4G9> - On-vehicle Service

11B-13

MANIFOLD VACUUM CHECK 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve, and then connect a vacuum gauge to the ventilation hose. 3. Check the intake manifold negative pressure while the engine is idling.

Ventilation hose

PCV valve

Vacuum gauge

Limit: Min. 37 kPa

LASH ADJUSTER CHECK If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and does not stop, carry out the following check. NOTE (1) The abnormal noise which is caused by a problem with the lash adjusters is generated after the engine is started, and will vary according to the engine speed. However, this noise is not related to the actual engine load. Because of this, if the noise does not occur immediately after the engine is started, if it does not change in accordance with the engine speed, or if it changes in accordance with the engine load, the source of the noise is not the lash adjusters. (2) If there is a problem with the lash adjusters, the noise will almost never disappear, even if the engine has been run at idle to let it warm up. The only case where the noise might disappear is if the oil in the engine has not been looked after properly and oil sludge has caused the lash adjusters to stick. 1. Start the engine. 2. Check that the noise occurs immediately after the engine is started, and that the noise changes in accordance with changes in the engine speed. If the noise does not occur immediately after the engine is started, or if it does not change in accordance with the engine speed, the problem is not being caused y the lash adjusters, so check for some other cause of the problem. Moreover, if the noise does not change in accordance with the engine speed, the cause of the problem is probably not with the engine. (In these cases, the lash adjusters are normal.) 3. While the engine is idling, check that the noise level does not change when the engine load is varied (for example, by shifting from N ® D). If the noise level changes, the cause of the noise is probably parts striking because of worn crankshaft bearings or connecting rod bearings. (In such cases, the lash adjusters are normal.)

11B-14

ENGINE <4G9> - On-vehicle Service 4. After the engine has warmed up, run it at idle and check if any noise can be heard. If the noise has become smaller or disappeared, oil sludge could make the lash adjusters stick. Clean the lash adjusters. (Refer to the Engine Workshop Manual.) If not improved, go to step 5. 5. Bleed air from the lash adjusters. 6. If the noise has not disappeared even after the air bleeding, clean the lash adjusters. (Refer to the Engine Workshop Manual.) NOTE (1) If the vehicle is parked on a slope for a long period of time, the amount of oil inside the lash adjuster will decrease, and air may get into the high pressure chamber when starting the engine. (2) After parking the vehicle for long periods, the oil drains out of the oil passage, and it takes time for the oil to be supplied to the lash adjuster, so air can get into the high pressure chamber. (3) If either of the above situations occur, the abnormal noise can be eliminated by bleeding the air from inside the lash adjusters.

1. Check the engine oil and replenish or replace the oil if necessary.

Good

NOTE (1) If there is a only small amount of oil, air will be drawn in through the oil screen and will get into the oil passage. (2) If the amount of oil is greater than normal, then the oil will being mixed by the crankshaft and a large amount of air may get mixed into the oil. (3) If the oil is degenerated, air and oil will not separate easily in oil, and the amount of air mixed into the oil will increase.

ENGINE <4G9> - On-vehicle Service

High-pressure chamber

Drive pattern for air bleeding Gradually open the Close the throttle throttle valve. valve. Approx. 3,000 r/min Idle speed 15 seconds

15 seconds

Once

11B-15

(4) If the air which has been mixed in with the oil due to any of the above reasons gets into the high pressure chamber of the lash adjuster, the air inside the high pressure chamber will be compressed when the valve is open and the lash adjuster will over-compress, resulting in abnormal noise when the valve closes. This is the same effect as if the valve clearance is adjusted to be too large by mistake. If the air inside the lash adjusters is then released, the operation of the lash adjusters will return to normal. 2. Run the engine at idle for 1 - 3 minutes to let it warm up. 3. With no load on the engine, repeat the drive pattern shown in the illustration at left and check if the abnormal noise disappears. (The noise should normally disappear after 10 - 30 repetitions, but if there is no change in the noise level after 30 repetitions or more, the problem is probably not due to air inside the lash adjusters.) 4. After the noise has disappeared, repeat the drive pattern shown in the illustration at left a further 5 times. 5. Run the engine at idle for 1 - 3 minutes and check that the noise has disappeared.

11B-16

ENGINE <4G9> - Crankshaft Pulley

CRANKSHAFT PULLEY

11200160303

REMOVAL AND INSTALLATION Pre-removal Operation Under Cover Removal

Post-installation Operation D Drive Belt Tension Adjustment (Refer to P.11B-6.) D Under Cover Installation

1

2 177 - 186 Nm

3

4 (Engine oil)

Removal steps 1. Drive belt (Power steering and A/C) 2. Drive belt (Alternator)

5

AA" "AA 3. Crankshaft pulley bolt 4. Crankshaft pulley washer 5. Crankshaft pulley

REMOVAL SERVICE POINT AA" CRANKSHAFT PULLEY BOLT REMOVAL

MD990767 MD998719 or MD998754

INSTALLATION SERVICE POINT "AA CRANKSHAFT PULLEY BOLT INSTALLATION When installing the crankshaft bolt, apply the minimum amount of engine oil to the bearing surface and thread of the bolt.

11B-17

ENGINE <4G9> - Camshaft and Camshaft Oil Seal

CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Air Intake Hose Removal and Installation D Timing Belt Removal and Installation (Refer to P.11B-28.) D Intake Manifold Removal and Installation (Refer to GROUP 15.)

1

D

Pump Camshaft Case Removal and Installation (Refer to GROUP 13B - Fuel Pump (High Pressure).)

3.4 Nm Apply engine oil to all sliding parts during installation.

2

4

13 5 3 21 - 25 Nm 10 - 12 Nm

12 - 15 Nm

21 - 25 Nm

12

10 - 12 Nm

11 15 14 9

6

10 - 12 Nm 22 Nm

7

10

35 Nm

88 Nm

8

Removal steps 1. Connector bracket mounting bolt (Injector Harness) 2. Breather hose connection 3. PCV hose connection 4. Rocker cover 5. Rocker cover gasket 6. Cam position sensor support 7. Cam position sensing cylinder

AA" "DA 8. Camshaft sprocket "CA 9. Camshaft oil seal 10. Idler pulley 11. Timing belt rear cover "BA 12. Beam camshaft cap 13. Beam camshaft cap gasket "AA 14. Camshaft (exhaust side) "AA 15. Camshaft (intake side)

11B-18

ENGINE <4G9> - Camshaft and Camshaft Oil Seal

Lubrication points

f3mm



Sealant: 3M ATD Part No.8660 or equivalent

Lip section

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

Engine oil



Sealant: 3M ATD Part No.8660 or equivalent

ENGINE <4G9> - Camshaft and Camshaft Oil Seal

11B-19

REMOVAL SERVICE POINT MB990767

AA" CAMSHAFT SPROCKET REMOVAL

MD998719

Camshaft sprocket side

Screw hole

"AA CAMSHAFT INSTALLATION 1. Apply engine oil to journals and cams of the camshafts. 2. Install the camshafts on the cylinder head. Caution Be careful not to confuse the intake camshaft with the exhaust one. There is a screw hole for the cam position sensing cylinder mounting bolt on the exhaust-side camshaft.

Exhaust camshaft

Approx. 106_

INSTALLATION SERVICE POINTS

"BA BEAM CAMSHAFT CAP INSTALLATION 1. Place the camshaft dowel pin as shown in the illustration.

Approx. 101_

Dowel pin Intake side

Exhaust side

28

27

20 19 12 11

8

7

31

2. Tighten the beam camshaft cap mounting bolts to the specified torque in the order shown in the illustration.

32

Tightening torque: D : 10 - 12 Nm d : 21 - 25 Nm

23 24 3

1

15 16

5

6

Intake side

Exhaust side 14 13

2

9

22 21

4

17 18

30 29 Front of engine

10

25 26

11B-20

ENGINE <4G9> - Camshaft and Camshaft Oil Seal "CA CAMSHAFT OIL SEAL INSTALLATION 1. Apply engine oil to the entire circumference of the oil seal lip. 2. Press-fit the oil seal as shown in the illustration.

MD998713

"DA CAMSHAFT SPROCKET INSTALLATION Use the special tool to secure the camshaft sprocket in the same way as during removal, and then tighten the bolt to the specified torque. Tightening torque: 88 Nm

11B-21

ENGINE <4G9> - Oil Pan

OIL PAN REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Under Cover Removal and Installation D Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.)

D

Engine Oil Draining and Supplying (Refer to GROUP 12 - On-vehicle Service.)

5

Groove

7 Nm

Bolt hole

6 1

5

Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent 24 Nm

7 Nm

2 4 39 Nm 7 Nm

3

49 Nm

1 7 Nm

Removal steps AA" 1. Lower oil pan 2. Drain plug "AA 3. Drain plug gasket

AB"

4. Cover 5. Upper oil pan 6. Baffle plate

7 Nm

11B-22

ENGINE <4G9> - Oil Pan REMOVAL SERVICE POINTS AA" LOWER OIL PAN REMOVAL Place a piece of wood against the lower oil pan, and tap the piece of wood with a hammer to remove the lower oil pan. Caution Because the upper oil pan used is made from aluminium, the oil pan remover (MB998727) should not be used.

Lower oil pan

AB" UPPER OIL PAN REMOVAL Insert a flat-tipped screwdriver into the notch of the upper oil pan as shown in the illustration, and turn it to remove the oil pan. Caution Because the upper oil pan used is made from aluminium, the oil pan remover (MB998727) should not be used.

INSTALLATION SERVICE POINT

Drain plug gasket

Oil pan side

"AA DRAIN PLUG GASKET INSTALLATION Install the drain plug gasket in the direction so that it faces as shown in the illustration.

11B-23

ENGINE <4G9> - Crankshaft Oil Seal

CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION 93 - 103 Nm



6 7

8 10

11 93 - 103 Nm



5 7

4

3

1

9

2

Crankshaft

(Engine oil: bolt seat and threaded hole)

Crankshaft

(Engine oil: bolt seat and threaded hole)

11

5

9

(Bolt thread)

(Bolt thread)

Sealant: 3M Stud Locking 4170 or equivalent

Crankshaft front oil seal removal steps D Timing belt (Refer to P.11B-28.) D Crank angle sensor (Refer to GROUP 16.) 1. Crankshaft sprocket 2. Key 3. Crankshaft sensing blade 4. Crankshaft spacer "CA 5. Crankshaft front oil seal

Lip

Lip

Engine oil

AA" AA" AA" AA" AA"

"BA "BA "BA "BA "BA "AA

Crankshaft rear oil seal removal steps D Transmission assembly (M/T: Refer to GROUP 22.) (A/T: Refer to GROUP 23.) D Clutch cover and disc 6. Plate 7. Adapter plate 8. Flywheel 9. Drive plate 10. Adapter plate 11. Crankshaft rear oil seal

11B-24

ENGINE <4G9> - Crankshaft Oil Seal REMOVAL SERVICE POINT AA" PLATE /ADAPTOR PLATE/FLYWHEEL /DRIVE PLATE REMOVAL Use the special tool to secure the flywheel or drive plate, and remove the bolts.

MD998781

INSTALLATION SERVICE POINTS

Crankshaft rear oil seal

Crankshaft

MD990938

"AA CRANKSHAFT REAR OIL SEAL INSTALLATION 1. Apply a small mount of engine oil to the entire circumference of the oil seal lip. 2. Install the oil seal by tapping it as far as the chamfered position of the oil seal case as shown in the illustration.

MD998776

"BA DRIVE PLATE /FLYWHEEL /ADAPTOR PLATE/PLATE INSTALLATION 1. Clean off all sealant, oil and other substances which are adhering to the threaded bolts, crankshaft thread holes and the flywheel or drive plate. 2. Apply oil to the bearing surface of the flywheel or drive plate bolts. 3. Apply oil to the crankshaft thread holes. 4. Apply sealant to the threaded mounting holes. Specified sealant: 3M Stud locking 4170 or equivalent 5. Use the special tool to hold the flywheel or drive plate in the same manner as removal, and install the bolt.

Crankshaft MD998717

MD998717 Oil seal

"CA CRANKSHAFT FRONT OIL SEAL INSTALLATION 1. Apply a small amount of engine oil to the entire circumference of the oil seal lip. 2. Tap the oil seal unit it is flush with the oil seal case.

11B-25

ENGINE <4G9> - Cylinder Head Gasket

CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Prevention of Fuel Discharge (Refer to GROUP 13B - On-vehicle Service.) D Engine Coolant Draining and Supplying (Refer to GROUP 14 - On-vehicle Service.) D Engine Oil Draining and Supplying (Refer to GROUP 12 - On-vehicle Service.) D Timing Belt Removal and Installation (Refer to P.11B-28.) D Intake Manifold Removal and Installation (Refer to GROUP 15.)

D

Fuel Pump (High pressure) and Fuel Pressure Regulator (High pressure) Removal and Installation (Refer to GROUP 13B.) EGR Valve Assembly Removal and Installation (Refer to GROUP 17.) Thermostat Case Assembly and Radiator upper hose Removal and Installation (Refer to GROUP 14 - Water Hose and Water Pipe.)

D D

3.4 Nm 74 Nm ® 0 Nm ® 20 Nm ® +90_ ® +90_

10 9 22 Nm

5

11

7 44 Nm

1 10 - 12 Nm

12

49 Nm

6

4 35 Nm 35 Nm

3

2

35 Nm

3

8 19 Nm

34 Nm 49 Nm 19 Nm

11B-26

ENGINE <4G9> - Cylinder Head Gasket Removal steps 1. Injector harness connector 2. Front exhaust pipe connection 3. Exhaust manifold bracket 4. Power steering oil pump bracket stay 5. Power steering oil pump and bracket assembly

AA"

6. 7. 8. 9. AB" "BA 10. 11. "AA 12.

Idler pulley Timing belt rear cover Engine oil level gauge assembly Rocker cover Cylinder head bolt Cylinder head assembly Cylinder head gasket

REMOVAL SERVICE POINTS AA" POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL Remove the power steering oil pump and bracket assembly from the engine with the hose attached. NOTE Place the removed power steering oil pump and bracket assembly in a place where it will not be a hindrance when removing and installing the cylinder head assembly, and tie it with a cord. AB" CYLINDER HEAD BOLT REMOVAL Use the special tool to loosen the bolts in two or three steps in the order of the numbers shown in the illustration, and then remove the bolts.

MB991653

Intake side

Front of engine

3

5

10

8

2

1

7

9

6

4

Exhaust side

INSTALLATION SERVICE POINTS "AA CYLINDER HEAD GASKET INSTALLATION 1. Wipe off all oil and grease from the gasket mounting surface. 2. Install so that the shapes of the cylinder head holes match the shapes of the respective cylinder head gasket holes.

11B-27

ENGINE <4G9> - Cylinder Head Gasket Burred side

Head bolt (Engine oil)

Head bolt washer

A

Cylinder head

"BA CYLINDER HEAD BOLT INSTALLATION 1. When installing the cylinder head bolts, the length below the head of the bolts should be within the limit. If it is outside the limit, replace the bolts. Limit (A): 96.4 mm 2. The head bolt washer should be installed with the burred side caused by tapping out facing upwards. 3. Apply a small amount of engine oil to the thread section and the washer of the cylinder head bolt. 4. Tighten the bolts by the following procedure. Step

MB991653

Intake side

Operation

Remarks

1

Tighten to 74 Nm.

Carry out in the order shown in the illustration.

2

Fully loosen.

Carry out in the reverse order of that shown in the illustration.

3

Tighten to 20 Nm.

Carry out in the order shown in the illustration.

4

Tighten 90_ of a turn.

In the order shown in the illustration. Mark the head of the cylinder head bolt and cylinder head by paint.

5

Tighten 90_ of a turn.

In the order shown in the illustration. Check that the painted mark of the head bolt is lined up with that of the cylinder head.

Front of engine

8

6

1

3

9

10

4

2

5

7

Exhaust side

Step 4 90_

Painted mark

Caution (1) Always make a tightening angle just 90_. If it is less than 90_, the head bolt will be loosened. (2) If it is more than 90_, remove the head bolt and repeat the procedure from step 1. Step 5 90_

Painted mark

11B-28

ENGINE <4G9> - Timing Belt

TIMING BELT REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Engine Cover Removal and Installation D Under Cover Removal and Installation

D

Crankshaft Pulley Removal and Installation (Refer to P.11B-16.)

2 9 7 49 Nm 20 - 25 Nm 9 Nm

10 - 12 Nm

6

1

3

8

4

10

49 Nm 12 - 15 Nm 35 Nm

5 9 Nm

Removal steps 1. Alternator brace 2. Timing belt front upper cover 3. Power steering pump bracket stay 4. Timing belt front lower cover 5. Flange D Engine mount bracket (Refer to GROUP 32.)

6. Engine support bracket "CA D Timing belt tension adjustment AA" "BA 7. Timing belt "AA 8. Auto tensioner 9. Tensioner pulley and arm assembly 10. Idler pulley

ENGINE <4G9> - Timing Belt Timing marks

Timing marks

11B-29

REMOVAL SERVICE POINT AA" TIMING BELT REMOVAL 1. Turn the crankshaft clockwise to align each timing mark. Caution The crankshaft must always be turned clockwise. 2. Loosen the tensioner pulley center bolt and remove the timing belt. Caution If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction.

INSTALLATION SERVICE POINTS 98 - 196 N

A

Movement

B

Auto tensioner

Push rod

B

A

"AA AUTO TENSIONER INSTALLATION 1. Apply 98 - 196 N force to the push rod of the auto tensioner by pressing it against a metal (cylinder block, etc.), and measure the movement of the push rod. Standard value: Within 1 mm A: Length when it is free (not pressed) B: Length when it is pressed A - B: Movement 2. If it is out of the standard value, change the auto tensioner. 3. Use a press or vice to gently compress the auto tensioner push rod until pin hole A of the push rod and pin hole B of the tensioner cylinder are aligned. Caution If the compression speed is too fast, the push rod may become damaged, so be sure to carry out this operation slowly.

Contact piece Contact piece

4. Once the holes are aligned, insert the set pin. NOTE When replacing the auto tensioner with a new part, the pin will be in the auto tensioner. 5. Install the auto tensioner to the engine. Set pin

11B-30

ENGINE <4G9> - Timing Belt

Camshaft sprocket Timing marks

Timing marks

"BA TIMING BELT INSTALLATION 1. Align the timing marks of each camshaft sprocket and the crankshaft sprocket. 2. Loosen the tensioner pulley center bolt. 3. Move the crankshaft sprocket half a tooth width in the anti-clockwise direction.

Crankshaft sprocket Timing marks

Paper clip

Timing marks

4. Place the timing belt on the exhaust-side camshaft sprocket, and hold it in the position shown in the illustration with a paper clip.

5. Place the timing belt on the intake-side sprocket while using two wrenches to align the timing marks.

Timing marks

6. Hold the belt in the position shown in the illustration with another paper clip.

ENGINE <4G9> - Timing Belt

11B-31

7. Place the belt onto the idler pulley, water pump sprocket, crankshaft sprocket and tensioner pulley in that order. 8. Remove the two paper clips. Idler pulley

Tensioner pulley

Water pump sprocket

Crankshaft sprocket

9. Lift the tensioner pulley in the direction of the arrow and tighten the tensioner pulley bolt. 10. Check to be sure that all timing marks are aligned. 11. Adjust the timing belt tension.

Fixing bolt

Pin hole

Tensioner pulley

MD998767

"CA TIMING BELT TENSION ADJUSTMENT 1. After turning the crankshaft a 1/4 turn anti-clockwise, turn it clockwise to the position where the timing marks are aligned. 2. Loosen the fixing bolt of the tensioner pulley and using the special tool and a torque wrench, apply tension to the timing belt; then tighten the fixing bolt at the specified torque. Standard Value: 2.5 - 4.0 Nm {timing belt tension torque (reference value)} Caution When tightening the fixing bolt, ensure that the tensioner pulley shaft doesn’t rotate with the bolt.

2 mm Allen wrench

3. Take out the 2 mm Allen wrench from the auto tensioner. At this time, check to be sure that 2 mm Allen wrench can be pulled out easily. Turn the crankshaft clockwise 2 turns, and after leaving it in this position for 5 minutes or more, check again to be sure that the auto tensioner 2 mm Allen wrench can be pulled out or inserted easily.

11B-32 A

ENGINE <4G9> - Timing Belt NOTE Even if the 2 mm Allen wrench cannot be easily inserted, then it is satisfactory if the amount of protrusion of the auto tensioner rod is within the standard value. Standard value (A): 3.8 - 4.5 mm If it is outside the standard value, repeat the operations in steps 1 to 4. 4. Check to be sure that the timing marks on all sprockets are aligned.

11B-33

ENGINE <4G9> - Engine Assembly

ENGINE ASSEMBLY REMOVAL AND INSTALLATION Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened when the body is supporting the full weight of the engine. Pre-removal and Post-installation Operation D Prevention of Fuel Discharge (Refer to GROUP 13B - On-vehicle Service.) D Engine Coolant Draining and Supplying (Refer to GROUP 14 - On-vehicle Service.)

D D

Hood Removal and Installation (Refer to GROUP 42.) Drive Belt Tension adjustment (Refer to P.11B-6.)

1 10

6

O-ring

8

2 Engine oil

7

13 3

4 12 5

9

8.8 Nm

10

Removal steps 1. Ignition coil connector 2. Cam position sensor connector 3. Engine coolant temperature sensor connector 4. Engine coolant temperature gauge unit connector 5. Detonation sensor connector 6. Purge solenoid valve connector 7. Fuel pressure sensor connector

11

8. Throttle valve control servo connector 9. Throttle position sensor connector "CA 10. High-pressure fuel hose connection 11. Fuel return hose connection 12. Vacuum hose connection 13. Brake booster vacuum hose connection

11B-34

ENGINE <4G9> - Engine Assembly

15

12 Nm

14

24 24 22 Nm

22

44 Nm

26

16

49 Nm

21 23

17 18 19

20 67 Nm 57 Nm

25

98 - 118 Nm*

14. 15. 16. 17. 18. 19.

Crank angle sensor connector Injector harness connector Heater hose connection Oxygen sensor connector Alternator connector Engine oil pressure switch connector 20. Drive belt (Power steering and A/C)

21. Power steering oil pump bracket stay AA" 22. Power steering oil pump and bracket assembly AB" 23. A/C compressor 24. Power steering hose mounting bolt D Transmission assembly (Refer to GROUP 22.) AC" "BA 25. Engine mount bracket AD" "AA 26. Engine assembly

ENGINE <4G9> - Engine Assembly

11B-35

REMOVAL SERVICE POINTS AA" POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL Remove the power steering oil pump and bracket assembly from the engine with the hose attached. NOTE Place the removed power steering oil pump where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord. AB" A/C COMPRESSOR REMOVAL Disconnect the A/C compressor connector and remove the compressor from the compressor bracket with the hose still attached. NOTE Place the removed A/C compressor where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.

MZ203827

MB991453

AC" ENGINE MOUNT BRACKET REMOVAL 1. Support the engine with a garage jack. 2. Remove the special tool which was attached when the transmission assembly was removed. 3. Hold the engine assembly with a chain block or similar tool. 4. Place a garage jack against the engine oil pan with a piece of wood in between, jack up the engine so that the weight of the engine is no longer being applied to the engine mount bracket, and then remove the engine mount bracket. AD" ENGINE ASSEMBLY REMOVAL After checking that all cables, hoses and harness connectors, etc., are disconnected from the engine, lift the chain block slowly to remove the engine assembly downward from the engine compartment.

11B-36

ENGINE <4G9> - Engine Assembly INSTALLATION SERVICE POINTS "AA ENGINE ASSEMBLY INSTALLATION Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped.

MZ203827

"BA ENGINE MOUNT BRACKET INSTALLATION 1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mount bracket while adjusting the position of the engine. 2. Support the engine with the garage jack. 3. Remove the chain block and support the engine assembly with the special tool.

MB991453

"CA HIGH-PRESSURE FUEL HOSE INSTALLATION 1. Apply a small amount of new engine oil to the O-ring. Caution Do not let any engine oil get into the delivery pipe. 2. While turning the high-pressure fuel hose to the right and left, install the delivery pipe, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly. 3. If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the high-pressure fuel hose and check the O-ring for damage. After this, re-insert the delivery pipe and check that the hose turns smoothly.

12-1

ENGINE LUBRICATION CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3 SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4 Engine Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine Oil Replacement . . . . . . . . . . . . . . . . . . . . . . . 4 Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . 5 Oil Level Warning System Check . . . . . . . . . . . . . . 6 Oil Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . 7

12-2

ENGINE LUBRICATION - General Information

GENERAL INFORMATION The lubrication method is a fully force-fed, full-flow filtration type. The oil pump for 4G9 engines is a trochoid type which is directly mounted to the crankshaft, and the one for 4G6 engines is a gear type which is driven by the crankshaft via the timing

belt. Furthermore, the oil level sensor is located in the oil pan, and a system is equipped whereby an indicator gives a warning when the oil level drops.

ENGINE OILS Health Warning Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially

harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.

Recommended Precautions The most effective precaution is to adapt working practices which prevent, as far as practicable, the risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine oil and by decreasing components, where practicable, before handling them. Other precautions: D Avoid prolonged and repeated contact with oils, particularly used engine oils. D Wear protective clothing, including impervious gloves where practicable. D Avoid contaminating clothes, particularly underpants, with oil. D Do not put oily rags in pockets, the use of overalls without pockets will avoid this. D Do not wear heavily soiled clothing and oil-impregnated foot-wear. Overalls must be cleaned regularly and kept separate from personal clothing.

D

D D

D D D

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. Obtain First Aid treatment immediately for open cuts and wounds. Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin cleansers and nail brushes will help). After cleaning, the application of preparations containing lanolin to replace the natural skin oils is advised. Do not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin. Use barrier creams, applying them before each work period, to help the removal of oil from the skin after work. If skin disorders develop, obtain medical advice without delay.

ENGINE LUBRICATION -

Service Specifications/Sealant/Lubricants/Special Tools

12-3

SERVICE SPECIFICATIONS Item Oil pressure kPa

Standard value

Limit

at idle

29 or more

-

at 3,500 r/min

294 - 686

-

SEALANT Item

Specified sealant

Remark

Oil pressure switch

3M ATD Part No. 8660 or equivalent

-

LUBRICANTS Items

Specifications

Engine oil (API classification)

SG or higher

Engine oil quantity L

Oil filter

0.3

Total

3.8

SPECIAL TOOLS Tool

Number

Name

Use

MB991610

Oil filter wrench

Removal and installation of engine oil filter (When using the oil filter of MD136466 and MD356000)

MD998054

Oil pressure switch wrench

Removal and installation of oil pressure switch

12-4

ENGINE LUBRICATION - On-vehicle Service

ON-VEHICLE SERVICE ENGINE OIL CHECK 1. Pull out the level gauge slowly and check that the oil level is in the illustrated range. 2. Check that the oil is not excessively dirty, that there is no coolant or gasoline mixed in, and that it has sufficient viscosity.

ENGINE OIL REPLACEMENT 1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80_C to 90_C. 2. Remove the engine oil filler cap. 3. Remove the drain plug to drain oil. Caution Use care as oil could be hot.

Drain plug gasket Oil pan side

4. Install a new drain plug gasket so that it faces in the direction shown in the illustration, and then tighten the drain plug to the specified torque. NOTE Install the drain plug gasket so it faces in the direction shown in the illustration.

39 Nm

Barometric temperature

5. Refill with specified quantity of oil. Specified Engine Oil (API classification): SG or higher Total quantity (Includes volume inside oil filter and oil cooler): 3.8 L 6. Install the engine oil filler cap. 7. Check oil level.

ENGINE LUBRICATION - On-vehicle Service

12-5

OIL FILTER REPLACEMENT MB991610 or commerciallyavailable tool

1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80_C to 90_C. 2. Remove the engine oil filler cap. 3. Remove the drain plug to drain oil. Caution Use care as oil could be hot. 4. Remove the under cover. 5. Use the respective tool in the following table to remove the engine oil filter. 6. Clean the filter bracket side mounting surface.

O-ring

7. Apply a small amount of engine oil to the O-ring of the new oil filter. 8. Once the O-ring of the oil filter is touching the flange, use the respective tool in the following table to tighten to the specified torque. 9. Install the drain plug and refill engine oil. (Refer to Engine Oil Replacement on P.12-3.) 10. Race the engine 2 - 3 times, and check to be sure that no engine oil leaks from installation section of the oil filter.

Number

Tool

Tightening torque

MD136466

MB991610 or equivalent tool

Approx. 3/4 turn (17 Nm)

MD322508

Commercially-available tool

Approx. 3/4 turns (17 Nm)

MD356000

MB991610 or equivalent tool

Approx. 3/4 turn (14 Nm)

12-6

ENGINE LUBRICATION - On-vehicle Service OIL LEVEL WARNING SYSTEM CHECK <4G6> 1. Check that the proper amount of oil has been filled. 2. When the ignition switch is turned to ON (do not start the engine), check that the oil level warning lamp illuminates.

Engine oil level relay

NOTE If the oil level warning lamp does not illuminate, the cause is probably a blown lamp, or a malfunction in the relay. 3. When the engine is started, check that the oil level warning lamp turns off. If the oil level warning lamp will not go out, disconnect the connector of the oil level relay and measure the voltage of the No.1 terminal on the harness side of the connector while idling the engine in order to confirm that it is the same as the battery voltage.

Engine oil level sensor connector (Harness side)

NOTE (1) If the voltage at the connector is the same as the battery voltage, the problem is probably a malfunction of either the oil level relay or the oil level sensor. (2) If the voltage at the connector is lower than the battery voltage, the problem is probably a malfunction of either the alternator or the wiring harness. 4. Disconnect the oil level sensor connector. Check that the oil level warning lamp illuminates after approximately 40 seconds. If the oil level warning lamp does not illuminate, replace the oil level relay.

5. Check the continuity between the oil level sensor terminals.

Engine oil level sensor connector (Equipment side)

Engine oil temperature

Oil level

Continuity

At 50_C or lower

Normal (proper volume)

Continuity

Low (drained)

Continuity

Normal (proper volume)

Continuity

Low (drained)

No continuity

At 60_C or higher

6. If there is a defect, replace the oil level sensor. 9 Nm

Engine oil level sensor

ENGINE LUBRICATION - On-vehicle Service

12-7

OIL PRESSURE CHECK

<4G6>

1. Check engine oil quantity. 2. Remove the oil pressure switch terminal.

Oil pressure switch

<4G9> Oil pressure switch

MD998054

3. Use the special tool (oil pressure switch wrench) to remove the oil pressure switch. Caution Since sealant is applied to the thread of oil pressure switch, take care not to damage the oil pressure switch when removing it. 4. Install the oil pressure gauge. NOTE Use a adapter of PT 1/8 thread. 5. Run the engine to warm it. 6. After the engine has been warmed up, check that oil pressure is within the standard value. Standard value: At idle: 29 kPa or more At 3,500 r/min: 294 - 686 kPa 7. Remove the oil pressure gauge.

8. Apply the specified sealant to the thread of oil pressure switch. Specified sealant: 3M ATD Part No. 8660 or equivalent

12-8

ENGINE LUBRICATION - On-vehicle Service MD998054

9. Use the special tool to tighten the oil pressure switch to the specified torque. Tightening torque: 19 Nm Caution Do not start the engine within one hour after the oil pressure switch has been installed. 10. Install the oil pressure switch terminal.

13A-1

FUEL CONTENTS

GASOLINE DIRECT INJECTION (GDI) <4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A GASOLINE DIRECT INJECTION (GDI) <4G9> . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C

13A-2

GASOLINE DIRECT INJECTION (GDI) <4G6> CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 7 SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Engine Coolant Temperature Sensor Check . . 106 Throttle Position Sensor Check . . . . . . . . . . . . . . 107 Accelerator Pedal Position Sensor (1st channel) Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Accelerator Pedal Position Sensor (2nd channel) Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Accelerator Pedal Position Switch Check . . . . . 109

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 9

Oxygen Sensor Check . . . . . . . . . . . . . . . . . . . . . . 109

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 97

Injector Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Throttle Body (Throttle Valve Area) Cleaning . . 97 Throttle Position Sensor Adjustment . . . . . . . . . . 97 Accelerator Pedal Position Switch and Accelerator Pedal Position Sensor Adjustment . . . . . . . . . . . . 98 Fuel Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Fuel Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Fuel Pump Connector Disconnection (How to Reduce the Fuel Pressure) . . . . . . . . . . . . . . . . . 103

Throttle Valve Control Servo Check . . . . . . . . . . 111 Clutch Switch Check . . . . . . . . . . . . . . . . . . . . . . . 111 Purge Control Solenoid Valve Check . . . . . . . . . 112 EGR Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . 112

FUEL PUMP (HIGH PRESSURE) AND FUEL PRESSURE REGULATOR (HIGH PRESSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Fuel Pump Operation Check . . . . . . . . . . . . . . . . 104

INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Component Location . . . . . . . . . . . . . . . . . . . . . . . . 105

THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . 120

Engine Control Relay, Fuel Pump Relay, Injector Driver Control Relay and Throttle Valve Control Servo Relay Continuity Check . . . . . . . . . . . . . . . 106 Intake Air Temperature Sensor Check . . . . . . . 106

INJECTOR DRIVER . . . . . . . . . . . . . . . . . . . . . 123 THROTTLE VALVE CONTROLLER . . . . . . . 124

GDI <4G6> - General Information

13A-3

GENERAL INFORMATION The Gasoline Direct Injection System consists of sensors which detect the engine conditions, the engine-ECU which controls the system based on signals from these sensors, and actuators which operate under the control of the engine-ECU. The engine-ECU carries out FUEL INJECTION CONTROL The injector drive times and injector timing are controlled so that the optimum air/fuel mixture is supplied to the engine to correspond to the continually-changing engine operation conditions. A single injector for each cylinder is mounted at the cylinder head. The fuel is sent under pressure from the fuel tank to the fuel pressure regulator (low pressure) by the fuel pump (low pressure). The pressure is regulated by the fuel pressure regulator (low pressure) and the fuel regulated is then sent to the fuel pump (high pressure). The fuel under increased pressure generated by the fuel pump (high pressure) is then regulated by the fuel pressure regulator (high pressure) and is then distributed to each of the injectors via the delivery pipes. THROTTLE VALVE OPENING ANGLE CONTROL This system controls throttle valve opening angle electronically. The engine-ECU determines how deeply the accelerator pedal is depressed by means of the accelerator position sensor (APS). Then the engine-ECU sends a IDLE SPEED CONTROL This system maintains engine idle speed at a predetermined condition by controlling the air flow that passes through the throttle valve according to engine idling condition and engine loads at idling. IGNITION TIMING CONTROL The power transistor located in the ignition primary circuit turns ON and OFF to control the primary current flow to the ignition coil. This controls the ignition timing in order to provide the optimum ignition timing with respect to the engine operating conditions. The ignition timing

activities such as fuel injection control, idle speed control and ignition timing control. In addition, the engine-ECU is equipped with several diagnosis modes which simplify troubleshooting when a problem develops.

Fuel injection is normally carried out once for each cylinder for every two rotations of the crankshaft. The firing order is 1-3-4-2. This is called sequential fuel injection. When the engine is cold or under a severe load, the “open-loop” control keeps the air/fuel ratio at a richer than usual level to maintain driveability. When the engine is under low or medium loads, the air/fuel ratio becomes leaner to reduce fuel consumption. When the engine is running at medium or high loads after having warmed up, the “closed-loop” control uses the signal from the oxygen sensor to keep the air/fuel ratio at the optimum theoretical level.

target value of the throttle valve opening angle to the throttle valve controller. The throttle valve control servo operates the throttle valve so that it reaches the target opening angle.

The engine-ECU operates the throttle valve control servo so that engine speed is maintained within a map value. The map value is predetermined according to engine coolant temperature and air-conditioning load. is determined by the engine-ECU from the engine speed, intake air volume, engine coolant temperature, atmospheric pressure and injection timing (intake stroke or compression stroke).

13A-4

GDI <4G6> - General Information

SELF-DIAGNOSIS FUNCTION D When an abnormality is detected in one of the sensors or actuators related to emission control, the engine warning lamp (check engine lamp) illuminates as a warning to the driver. D When an abnormality is detected in one of the sensors or actuators, a diagnosis

D

OTHER CONTROL FUNCTIONS 1. Fuel Pump Control Turns the fuel pump relay ON so that current is supplied to the fuel pump while the engine is cranking or running. 2. A/C Relay Control Turns the compressor clutch of the A/C ON and OFF. 3. Fan Motor Control The revolutions of the radiator fan and

condenser fan are controlled in response to the engine coolant temperature and vehicle speed. 4. Purge Control Solenoid Valve Control Refer to GROUP 17. 5. EGR valve Control Refer to GROUP 17.

code corresponding to the abnormality is output. The RAM data inside the engine-ECU that is related to the sensors and actuators can be read by means of the MUT-II. In addition, the actuators can be force-driven under certain circumstances.

GENERAL SPECIFICATIONS Items Throttle body

Engine-ECU

Specifications Throttle bore mm

65

Throttle position sensor

Variable resistor type

Throttle valve control servo

Torque motor type

Identification model No.

Except vehicles for Germany

E2T72571 E2T72574

Vehicles for Germany

E2T72575 E2T73576

GDI <4G6> - General Information Items Sensors

Actuators

13A-5

Specifications Air flow sensor

Karman vortex type

Barometric pressure sensor

Semiconductor type

Intake air temperature sensor

Thermistor type

Engine coolant temperature sensor

Thermistor type

Oxygen sensor

Zirconia type

Accelerator pedal position sensor (1st and 2nd channels)

Variable resistor type

Accelerator pedal position switch

Rotary contact type, within accelerator pedal position sensor (1st channel)

Vehicle speed sensor

Magnetic resistive element type

Inhibitor switch

Contact switch type

Camshaft position sensor

Hall element type

Crank angle sensor

Hall element type

Detonation sensor

Piezoelectric type

Fuel pressure sensor

Metallic membrane type

Power steering fluid pressure switch

Contact switch type

Engine control relay type

Contact switch type

Fuel pump relay type

Contact switch type

Injector driver control relay

Contact switch type

Injector type and number

Electromagnetic type, 4

Injector identification mark

DIM 1100G

Throttle valve control servo relay

Contact switch type

Throttle valve control servo

Torque motor type

EGR valve

Stepper motor type

Purge control solenoid valve

Duty cycle type solenoid valve

Fuel pressure Regulator pressure kPa regulator (low pressure)

324

Fuel pressure Regulator pressure MPa regulator (high pressure)

5.5

13A-6

GDI <4G6> - General Information

GASOLINE DIRECT INJECTION SYSTEM DIAGRAM *1 Oxygen sensor (front) *2 Air flow sensor *3 Intake air temperature senor *4 Throttle position sensor (2nd channel) *5 Camshaft position sensor *6 Crank angle sensor *7 Barometric pressure sensor *8 Engine coolant temperature sensor *9 Detonation sensor *10 Fuel pressure sensor *11 Oxygen Sensor (rear)

D D D D D D D D D D D D D D D D D D D

*12 Throttle position sensor 1

D D D D

Power supply Ignition switch - IG Ignition switch - ST Accelerator pedal position sensor (1st channel) Accelerator pedal position switch Vehicle speed sensor A/C switch (1st channel) A/C switch (2nd channel) M/T oil temperature sensor Inhibitor switch Power steering fluid pressure switch Alternator FR terminal Stop lamp switch Small lamp switch Clutch switch Brake vacuum sensor Injector wire open circuit check signal Throttle valve controller A/T-ECU

EngineECU

Power supply Ignition switch - IG Accelerator pedal position sensor 2 Engine-ECU

Throttle valve controller

z1 Injector driver (Injector) z2 EGR valve (Stepper motor) z3 Purge control solenoid valve

D D D D D D D D D D D D

z4 Throttle valve con- D trol servo

From fuel pump (low pressure)

Engine control relay Fuel pump relay Injector driver relay Throttle valve control servo relay A/C relay Ignition coil Fan controller Engine warning lamp Diagnosis output Alternator G terminal Throttle valve controller A/T-ECU

Engine-ECU

*3 Intake air temperature sensor

To fuel tank *4 Throttle position sensor 2 *12 Throttle position sensor 1

z4 Throttle valve control servo

*2 Air flow sensor

*10 Fuel pressure sensor *5 Camshaft position sensor

*7 Barometric pressure sensor

z2 EGR valve High-pressure fuel regulator assembly [integrated in fuel pressure regulator (high pressure)]

Fuel pump (high pressure)

Injector

z1 Injector driver

*8 Engine coolant temperature sensor *9 Detonation sensor

Canister z3 Purge control solenoid valve

*1 Oxygen sensor (front)

*6 Crank angle sensor

*11 Oxygen sensor (rear)

13A-7

GDI <4G6> - Service Specifications/Sealant

SERVICE SPECIFICATIONS Item

Standard value

Adjustment voltage of throttle position sensor (1st channel) V

0.4 - 0.6

Adjustment voltage of throttle position sensor (2nd channel) V

4.2 - 4.8

Resistance of throttle position sensor kW

1.7 - 3.8

Adjustment voltages (1) and (2) of accelerator pedal position sensor V

0.4 - 1.0

Resistance (1) and (2) of throttle position sensor kW

3.5 - 6.5

Intake air temperature sensor resistance kW

at 20_C

2.3 - 3.0

at 80_C

0.30 - 0.42

Engine coolant temperature sensor resistance kW

at 20_C

2.1 - 2.7

at 80_C

0.26 - 0.36

Fuel pressure

High-pressure side MPa

4 - 7.5

Low-pressure side kPa

Approximately 324

Injector coil resistance W

0.9 - 1.1

Oxygen sensor output voltage V

0.6 - 1.0

Oxygen sensor heater resistance W

11 - 18

Throttle valve control servo resistance W

1.35 - 1.65

SEALANT Item

Specified sealant

Remark

Engine coolant temperature sensor threaded portion

3M Nut Locking Part No. 4171 or equivalent

Drying sealant

13A-8

GDI <4G6> - Special Tools

SPECIAL TOOLS Tool A

Number

Name

Use

MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222

Harness set A: Test harness B: LED harness C: LED harness adapter D: Probe

D A: B: C: D:

Fuel gauge simple inspection Connector pin contact pressure inspection Power circuit inspection Power circuit inspection Commercial tester connection

MB991502

MUT-II sub assembly

D D

Reading diagnosis code GDI system inspection

MB991348, MB991658

Test harness set

D

Measurement of voltage during troubleshooting Inspection using an analyzer

MB991709

Test harness

MB991519

Alternator harness connector

Measurement of voltage during troubleshooting

MD998478

Test harness (3-pin, triangle)

D

Test harness (4-pin, square)

Inspection of oxygen sensor

B

C

D

MD998464

D

D

Measurement of voltage during troubleshooting Inspection using an analyzer

GDI <4G6> - Special Tools/Troubleshooting Tool

Number

Name

Use

MB991529

Diagnosis code check harness

Reading diagnosis code

MD998709

Adaptor hose

Measurement of fuel pressure

MD998742

Hose adaptor

MB991637

Fuel pressure gauge set

13A-9

TROUBLESHOOTING DIAGNOSIS TROUBLESHOOTING FLOW Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points. NOTE If the engine-ECU is replaced, the steering lock cylinder and ignition key should be replaced together with it.

DIAGNOSIS FUNCTION ENGINE WARNING LAMP (CHECK ENGINE LAMP) If an abnormality occurs in any of the following items related to the Gasoline Direct Injection (GDI) system, the engine warning lamp will illuminate. If the lamp remains illuminated or if the lamp illuminates while the engine is running, check the diagnosis code output. Engine warning lamp (check engine lamp)

13A-10

GDI <4G6> - Troubleshooting Engine warning lamp inspection items Engine-ECU Oxygen sensor Air flow sensor Intake air temperature sensor Throttle position sensor (1st channel) Throttle position sensor (2nd channel) Engine coolant temperature sensor Crank angle sensor Camshaft position sensor Barometric pressure sensor Detonation sensor Injector Abnormal combustion Immobilizer system Abnormal fuel pressure Brake vacuum sensor Fuel system malfunction Accelerator pedal position sensor (1st channel) Accelerator pedal position sensor (2nd channel) Electronic-controlled throttle valve system Throttle valve control servo Throttle valve controller

METHOD OF READING AND ERASING DIAGNOSIS CODES Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points. INSPECTION USING MUT-II DATA LIST AND ACTUATOR TESTING 1. Carry out inspection by means of the data list and the actuator test function. If there is an abnormality, check and repair the chassis harnesses and components. 2. After repairing, re-check using the MUT-II and check that the abnormal input and output have returned to normal as a result of the repairs. 3. Erase the diagnosis code memory. 4. Remove the MUT-II. 5. Start the engine again and carry out a road test to confirm that the problem has disappeared.

GDI <4G6> - Troubleshooting

13A-11

FAIL-SAFE FUNCTION REFERENCE TABLE If the diagnosis system detects any sensor malfunction, the vehicle can be driven safely by using a default control logic instead of the faulty sensors. Defective part or function

What to do when a sensor is defective

Air flow sensor

(1) Disables lean-mixture combustion. (2) Determines injector basic operating time and basic ignition timing according to map value, which has been predetermined by throttle position sensor and crank angle sensor signals.

Intake air temperature sensor

Controls as the intake air temperature is 25_C.

Throttle position sensor (1st channel)

(1) Disables lean-mixture combustion. (2) Controls throttle valve opening angle by closed loop control by using the throttle position sensor (2nd channel) signal. (3) Disables the throttle valve opening angle control when the throttle position sensor (2nd channel) signal is also defective.

Throttle position sensor (2nd channel)

(1) Disables lean-mixture combustion. (2) Controls throttle valve opening angle by closed loop control by using the throttle position sensor (1st channel) signal. (3) Disables the throttle valve opening angle control when the throttle position sensor (1st channel) signal is also defective.

Engine coolant temperature sensor

Controls as if the engine coolant temperature is 80_C. (Note that this control will continue until the ignition switch is turned off even if the sensor signal return to normal.)

Camshaft position sensor

Controls according to the conditions before a failure is detected.

Vehicle speed sensor

(1) Disables lean-mixture combustion. However, if a predetermined time elapses at an engine speed of 1,500 r/min or more, the lean-mixture combustion will return to normal. (2) Disables lean-mixture combustion during engine idling.

Barometric pressure sensor

Controls as if the barometric pressure is 101 kPa.

Detonation sensor

Holds the ignition timing at that for regular gasoline.

Injector

(1) Disables lean-mixture combustion. (2) Shuts down exhaust gas recirculation.

Abnormal combustion

Disables lean-mixture combustion.

Communication line with A/T-ECU

Disables ignition timing retard control (engine and transmission total control) during shift change.

Alternator FR terminal

Disables inhibition control of the alternator output according to electrical load (treats the alternator as if it is conventional one).

Fuel pressure sensor

(1) Controls as if the fuel pressure is 5.5 MPa (if there is open or short circuit). (2) Turns off the fuel pump relay (if the fuel pressure is excessively high). (3) Shuts off the fuel injection (If an excessively low pressure is detected or the engine speed exceeds 3,000 r/min).

13A-12

GDI <4G6> - Troubleshooting

Defective part or function

What to do when a sensor is defective

Accelerator pedal position sensor (1st channel)

(1) Disables lean-mixture combustion. (2) Controls the throttle valve position by using the accelerator pedal position sensor (2nd channel) signal. (3) Disables the electronic-controlled throttle valve system if the accelerator pedal position sensor (2nd channel) signal is also defective, and holds the throttle valve at a predetermined angle where the vehicle can be driven safely although its performance is reduced.

Accelerator pedal position sensor (2nd channel)

(1) Disables lean-mixture combustion. (2) Controls the throttle valve position by using the accelerator pedal position sensor (1st channel) signal. (3) Disables the electronic-controlled throttle valve system if the accelerator pedal position sensor (1st channel) signal is also defective.

Electronic-controlled throttle valve system

(1) Disables the electronic-controlled throttle valve system. (2) Disables lean-mixture combustion. (3) Disables idle engine speed feedback control.

Throttle valve position feedback

(1) Disables the electronic-controlled throttle valve system. (2) Disables lean-mixture combustion. (3) Disables idle engine speed feedback control.

Throttle valve control servo motor malfunction (1st phase)

Disables lean-mixture combustion.

Throttle valve control servo motor malfunction (2nd phase)

(1) Disables the electronic-controlled throttle valve system. (2) Disables lean-mixture combustion. (3) Disables idle engine speed feedback control.

Communication line with the throttle valve controller

(1) Error in communication between the throttle valve controller and engine-ECU D Disables lean-mixture combustion. D Shuts off fuel supply when engine speed exceeds 3,000 r/min. (1) Error in communication between the throttle valve controller and engine-ECU D Disables lean-mixture combustion. D Shuts off fuel supply when engine speed exceeds 3,000 r/min. D The throttle valve controller controls the throttle valve opening angle by using the accelerator pedal position sensor (2nd channel) signal.

13A-13

GDI <4G6> - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No.

Diagnosis item

Reference page

11

Oxygen sensor (front) system

13A-14

12

Air flow sensor system

13A-15

13

Intake air temperature sensor system

13A-16

14

Throttle position sensor (2nd channel) system

13A-17

21

Engine coolant temperature sensor system

13A-18

22

Crank angle sensor system

13A-19

23

Camshaft position sensor system

13A-20

24

Vehicle speed sensor system

13A-21

25

Barometric pressure sensor system

13A-22

31

Detonation sensor system

13A-23

41

Injector system

13A-24

44

Abnormal combustion

13A-26

54

Immobilizer system

13A-27

56

Abnormal fuel pressure system

13A-28

59

Oxygen sensor (rear) system

13A-30

61

Communication line with A/T-ECU system

13A-31

64

Alternator FR terminal system

13A-31

66

Brake vacuum sensor system

13A-32

77

Accelerator pedal position sensor (2nd channel) system

13A-33

78

Accelerator pedal position sensor (1st channel) system

13A-34

79

Throttle position sensor (1st channel) system

13A-35

89

Abnormality in fuel pressure system

13A-36

91

Electronic-controlled throttle valve system

13A-36

92

Throttle valve position feedback system

13A-37

94

Communication line system with throttle valve controller

13A-37

95

Malfunction in throttle valve control servo motor system (1st phase)

13A-38

99

Malfunction in throttle valve control servo motor system (2nd phase)

13A-38

NOTE Code No. 56 may be also output when air is sucked in high-pressure fuel line due to no fuel supply.

13A-14

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code No. 11 Oxygen sensor (front) system

Probable cause

Range of check D 3 minutes have passed after engine was started. D Engine coolant temperature is approx. 80_C or more. D Intake air temperature is 20 - 50_C. D Engine speed is approx. 2,000 - 3,000 r/min D Vehicle is moving at constant speed on a flat, level road surface Set conditions D The oxygen sensor output voltage is around 0.6 V for 30 seconds (does not cross 0.6 V for 30 seconds). D When the range of check operations given above which accompany starting of the engine are carried out four time in succession, a problem is detected after each operation.

D D

Check the oxygen sensor (front). (Refer to P.13A-109.)

NG

D

Malfunction of the oxygen sensor (front) Improper connector contact, open circuit short-circuited harness wire Malfunction of the engine-ECU

or

Replace

OK

(1) NG Measure at the oxygen sensor (front) connector B-17. D Disconnect the connector, and measure at the harness side. (1) Voltage between 2 and earth (Ignition switch: ON) (2) NG OK: System voltage (2) Continuity between 4 and earth OK: Continuity

Check the harness wire between the oxygen sensor (front) and the engine control relay connector, and repair if necessary. Check the following connector: B-54 NG

Repair

OK

OK

Check trouble symptom. NG Check the harness wire between the en- NG gine-ECU and the oxygen sensor connector.

Repair

OK Replace the engine-ECU.

Measure at the engine-ECU connector B-54. D Disconnect the connector, and measure at the NG harness side. D Voltage between 6 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: B-54

NG

Check the following connector: B-17 NG OK Repair

Check trouble symptom. Check the harness wire between the engine-ECU and the oxygen sensor (front) connector. OK Replace the engine-ECU.

NG Check the harness wire between the engine-ECU and the oxygen sensor (front) connector, and repair if necessary.

OK NG

Check trouble symptom.

NG

Repair

Repair

13A-15

GDI <4G6> - Troubleshooting Code No.12 Air flow sensor system

Probable cause

Range of check D Engine speed is 500 r/min or more. Set conditions D Sensor output frequency is 3.3 Hz or less for 4 seconds.

D D

(1) NG Measure at the air flow sensor connector A-07. D Connect the connector (Use the test harness MB991709) (1) Voltage between 3 and earth (Engine: Idling) OK: 2.2 - 3.2 V (2) Voltage between 7 and earth (2) NG OK: 0 - 0.1 V (Engine: Idling) OK: 6 - 9 V (Engine speed: 4,000 r/min) OK

D

Malfunction of the air flow sensor Open circuit or short-circuited harness wire of air flow sensor circuit Malfunction of the engine-ECU

(1) NG Check the harness wire between the Measure at the air flow sensor connector air flow sensor and the engine control A-07. relay, and repair if necessary. D Disconnect the connector, and measure at the harness side. (2), (3) NG (1) Voltage between 4 and earth Check the following connectors: (Ignition switch: ON) B-51, B-52 OK: System voltage OK NG (2) Voltage between 3 and earth (Ignition switch: ON) Repair OK: 4.8 - 5.2 V (3) Continuity between 5 and earth OK: Continuity Check trouble symptom. OK NG Check the harness wire between the engine-ECU and the air flow sensor, and repair if necessary. OK NG

Check the following connector: A-07 OK NG Repair

Repair Check trouble symptom.

Replace the engine-ECU.

NG Replace the air flow sensor. Measure at the engine-ECU connector B-54. D Connect the connector D Voltage between 19 and earth (Ignition switch: ON) OK: 6 - 9 V OK

NG Repair

Replace the engine-ECU.

NG Check trouble symptom.

Check the following connector: A-07 OK NG Repair Check trouble symptom.

Check the following connector: B-54 OK

NG

NG Replace the air flow sensor.

13A-16

GDI <4G6> - Troubleshooting

Code No.13 Intake air temperature sensor system

Probable cause

Range of check D After 60 seconds have passed since the engine have started Set conditions D Sensor resistance is 0.14 kW or less for 4 seconds. or D Sensor resistance is 50 kW or more for 4 seconds.

D D

Check the intake air temperature sensor. (Refer to P.13A-106.) OK Measure at the air flow sensor connector A-07. D Disconnect the connector, and measure at the harness side. D Voltage between 6 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 5 and earth OK: Continuity

NG NG

Replace Check the following connectors: B-51, B-52 OK

Check trouble symptom. NG Check the harness wire between the engine-ECU and the intake air temperature sensor.

Check the following connector: A-07

OK

NG

NG Repair

Repair Check trouble symptom.

NG Repair

OK

OK

D

Malfunction of the intake air temperature sensor Open circuit or short-circuited harness wire of the intake air temperature sensor circuit Malfunction of the engine-ECU

NG

Replace the engine-ECU.

13A-17

GDI <4G6> - Troubleshooting Code No.14 Throttle position sensor system (2nd channel)

Probable cause

The throttle valve controller determines whether a failure is present or not, and sends a signal indicating its result to the engine-ECU. Range of check D Ignition switch: ON D Throttle position sensor (1st channel) is normal Set conditions D The throttle position sensor (1st channel) output voltage is 1.24 V or more, and the (2nd channel) output voltage is 4.6 V or more for one second. or D The throttle position sensor (1st channel) output voltage is 3.53 V or less, and the (2nd channel) output voltage is 0.2 V or less for one second. or D Throttle position sensor (1st and 2nd channels) output voltages are outside 4 to 6 V.

D D

Check the throttle position sensor. (Refer to P.13A-107.)

NG

D D

Malfunction of throttle position sensor (2nd channel) Open circuit or short-circuited harness wire in throttle position sensor (2nd channel) or poor connector contact Faulty throttle valve controller Malfunction of the engine-ECU

Replace

OK Measure at throttle position sensor connector A-73. D Disconnect the connector, and measure at the harness side. D Voltage 1 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 3 and earth OK: Continuity

NG

Check the following connector: B-50 OK Check trouble symptom.

NG NG

Repair

Check the harness wire between the throttle position sensor and throttle valve controller. OK NG Repair

OK

Replace the throttle valve controller. Measure at engine-ECU connector B-51. D Connect the connector. D Disconnect the throttle control servo connector (Close the throttle valve fully by finger). D Voltage between terminal 84 and earth (Ignition switch: ON) OK: 4.2 - 4.8 V

NG

Check the following connector: A-73

NG

Repair

OK Check trouble symptom. NG Check the harness wire between the engine-ECU and throttle position sensor.

OK

NG

OK

Adjust the throttle position sensor. (Refer to P.13A-97.) Check trouble symptom.

Repair

NG Replace the engine-ECU.

Measure at throttle valve controller connector B-50. D Connect the connector. D Disconnect the throttle control servo connector (Close the throttle valve fully by finger). D Voltage between 7 and earth (Ignition switch: ON) OK: 0.4 - 0.6 V OK Replace the throttle valve controller.

NG

Check the following connector: A-73 OK Check trouble symptom. NG Check the harness wire between the throttle valve controller and throttle position sensor, and repair if necessary.

NG

Repair

13A-18

GDI <4G6> - Troubleshooting

Code No.21 Engine coolant temperature sensor system

Probable cause

Range of check D After 60 seconds have passed since the engine have started Set conditions D Sensor resistance is 50 W or less for 4 seconds. or D Sensor resistance is 72 kW or more for 4 seconds.

D D D

Malfunction of the engine coolant temperature sensor Open circuit or short-circuited harness wire of the engine coolant temperature sensor circuit Malfunction of the engine-ECU

Range of check D After engine starts Set conditions D After 5 minutes or more have passed since the engine coolant temperature after filtering has dropped from 40_C or more to less than this temperature

Check the engine coolant temperature sensor. (Refer to P.13A-106.) OK Measure at the engine coolant temperature sensor connector A-80. D Disconnect the connector, and measure st the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 2 and earth OK: Continuity

NG NG

Check the following connectors: B-51, B-52 OK

Check trouble symptom. NG Check the harness wire between the engine-ECU and the engine coolant temperature sensor.

Check the following connector: A-80

OK

NG

NG Repair

Repair Check trouble symptom.

NG Repair

OK

OK

Replace

NG

Replace the engine-ECU.

13A-19

GDI <4G6> - Troubleshooting Code No.22 Crank angle sensor system

Probable cause

Range of check D Engine: During cranking Set conditions D Sensor output voltage does not change for 4 seconds (no pulse signal is being input).

D D

Measure at the crank angle sensor connector A-71. D Connect the connector (Use the test harness MD998478) D Voltage between 2 (black clip) and earth (Engine: Cranking) OK: 0 - 4.0 V D Voltage between 2 (black clip) and earth (Engine: Idling) OK: 1.5 - 2.5 V OK Replace the engine-ECU.

NG

D

Malfunction of the crank angle sensor Open circuit or short-circuited harness wire of the crank angle sensor circuit Malfunction of the engine-ECU

(1) NG Measure at the crank angle sensor connector A-71. D Disconnect the connector, and measure at the harness side. (2) NG (1) Voltage between 3 and earth (Ignition switch: ON) OK: System voltage (2) Voltage between 2 and earth (3) NG (Ignition switch: ON) OK: 4.8 - 5.2 V (3) Continuity between 1 and earth OK: Continuity OK

Check the harness wire between the crank angle sensor and the engine control relay, and repair if necessary. Check the following connector: B-51 OK NG Repair Check trouble symptom. NG

Check the following connector: A-71 OK NG Repair

Check the harness wire between the engine-ECU and the crank angle sensor. OK NG Repair

Check trouble symptom. NG

Replace the engine-ECU.

Replace the crank angle sensor. Check the harness wire between the crank angle sensor and the earth, and repair if necessary.

13A-20

GDI <4G6> - Troubleshooting

Code No.23 Camshaft position sensor system

Probable cause

Range of check D While engine is cranking or running Set conditions D Sensor output voltage does not change for 4 seconds (no pulse signal is being input). or D Abnormal pulse signal pattern is output.

D D

Measure at the camshaft position sensor connector A-78. D Connect the connector (Use the test harness MB991709) D Voltage between 2 and earth (Engine: Cranking) OK: 0 - 4.0 V D Voltage between 2 and earth (Engine: Idling) OK: 0.5 - 2.0 V OK Replace the engine-ECU.

NG

D

Malfunction of the camshaft position sensor Open circuit or short-circuited harness wire of the camshaft position sensor Malfunction of the engine-ECU

(1) NG Measure at the camshaft position sensor connector A-78. D Disconnect the connector, and measure at the harness side. (2) NG (1) Voltage between 3 and earth (Ignition switch: ON) OK: System voltage (3) NG (2) Voltage between 2 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V (3) Continuity between 1 and earth OK: Continuity OK

Check the following connector: B-51 OK NG Repair Check trouble symptom. NG

Check the following connector: A-78 OK

Check the harness wire between the camshaft position sensor and the engine control relay, and repair if necessary.

NG Repair

Check the harness wire between the engine-ECU and the camshaft position sensor. OK NG Repair

Check trouble symptom. NG

Replace the engine-ECU.

Replace the camshaft position sensor. Check the harness wire between the camshaft position sensor and the earth, and repair if necessary.

13A-21

GDI <4G6> - Troubleshooting Code No. 24 Vehicles speed sensor system

Probable cause

Range of check D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. D Engine speed is 3,000 r/min or more. D Driving under high engine load conditions. Set conditions D Sensor output voltage does not change for 4 seconds (no pulse signal input).

D D

No

Does the speedometer operate normally? Yes Measure at engine-ECU connector B-51. D Connect the connector. D Voltage between terminal 86 and earth (Ignition switch: ON) OK: If the vehicle is moved forward without starting the engine, 0 V and system voltage alternates. NG Check the following connectors: A-81, A-85, A-86 NG

OK

Repair Check trouble symptom. NG Check the harness wire between the vehicle speed sensor and engine-ECU.

OK

D

Malfunction of the vehicle speed sensor Improper connector contact, open circuit or short-circuited harness wire of the vehicle speed sensor circuit Malfunction of the engine-ECU

Check the vehicle speed sensor circuit. (Refer to GROUP 54 Combination Meter.) Check the following connector: B-51 NG

OK

Repair Check trouble symptom. NG Replace the engine-ECU.

13A-22

GDI <4G6> - Troubleshooting

Code No.25 Barometric pressure sensor system

Probable cause

Range of check D After 60 seconds have passed since the engine have started D Battery voltage is 8 V or more. Set conditions D Sensor output voltage is 0.2 V or less for 4 seconds. or D Sensor output voltage is 4.5 V or more for 4 seconds.

D D

Measure at the air flow sensor connector A-07. D Connect the connector. (Use test harness MB991709) D Voltage between 2 and earth (Ignition switch: ON) OK: 3.9 - 4.1 V (at altitude of 0 m) 3.3 - 3.6 V (at altitude of 1,200 m) OK

NG

D

Measure at the air flow sensor connector A-07. D Disconnect the connector, and measure at the harness side. (1) Voltage between 1 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V (2) Continuity between 5 and earth OK: Continuity

Malfunction of the barometric pressure sensor Open circuit or short-circuited harness wire of the barometric pressure sensor Malfunction of the engine-ECU

NG

OK

Check trouble symptom. NG Check the harness wire between the engine-ECU and the barometric pressure sensor. OK NG

Check the following connector: A-07 OK NG

Repair Replace the engine-ECU.

Repair

OK Check the following connector: B-51 NG Repair

OK

Check trouble symptom.

NG Repair

OK

Measure at the engine-ECU connector B-51. D Connect the connector. D Voltage between 85 and earth (Ignition switch: ON) OK: 3.9 - 4.1 V NG (at altitude of 0 m) 3.3 - 3.6 V (at altitude of 1,200 m)

Check the following connector: B-51

NG

Check the harness wire between the engine-ECU and the barometric pressure sensor. OK

Repair

Check the harness wire between the engine-ECU and the barometric pressure sensor, and repair if necessary. OK Check trouble symptom.

NG

Replace the air flow sensor. NG

Replace the engine-ECU.

13A-23

GDI <4G6> - Troubleshooting Code No.31 Detonation sensor system

Probable cause

Range of check D After 60 seconds have passed since the engine have started Set conditions D Amount of change in the sensor output voltage (detonation sensor peak voltage for each half rotation of the crankshaft) is 0.06 V or less for 200 continuous times.

D D

Measure at the detonation sensor connector A-79. D Disconnect the connector, and measure at the harness side. D Continuity between 2 and earth OK: Continuity NG Check the harness wire between the detonation sensor and the earth, and repair if necessary.

OK

Check the following connector: B-51 OK Check trouble symptom.

D

Malfunction of the detonation sensor Open circuit or short-circuited harness wire of the detonation sensor Malfunction of the engine-ECU

NG

NG

Repair

Check the harness wire between the engine-ECU and the detonation sensor. OK NG Repair Replace the detonation sensor. Check trouble symptom. NG Replace the engine-ECU.

13A-24

GDI <4G6> - Troubleshooting

Code No.41 Injector system

Probable cause

Range of check D Engine: while cranking, or running D Engine speed: 4,000 r/min or less D System voltage: 10 V or more D Fuel shut off, or while forcible activating of injector (actuator test) is in operation. Set conditions D Injector open circuit check signal is not output from the injector predetermined time(s).

D D D D

Check the injector. (Refer to P.13A-111.)

NG

D

Replace

OK

(1) NG Measure at injector driver relay connector A-13X. D Disconnect the connector, and measure at the harness side. (1) Voltage between terminal 4 and earth (Ignition switch: ON) OK: System voltage (2) Voltage between terminal 3 and (2) NG earth OK: System voltage OK

Malfunction of the injector Faulty injector driver relay Faulty injector driver Open circuit or short-circuited harness wire in the injector drive circuit, or poor connector contact Malfunction of the engine-ECU

Check the following connectors: B-28, B-89, B-103

OK

NG

NG

Check the harness wire between the injector driver relay and ignition switch, and repair if necessary.

Repair

Check the following connector: A-28

OK

NG

Check the following connector: A-13X

Check the harness wire between the injector driver relay and battery, and repair if necessary.

(1) NG Measure at injector driver connector A-08. D Disconnect the connector, and measure at the harness side. (1) Voltage between 12, 21 and earth (Ignition switch: ON) OK: System voltage (2) Voltage between 13, 22 and earth (2) NG OK: System voltage (3) Resistance between terminals 14 and 23 Resistance between terminals 15 and 24 Resistance between terminals 16 (3) NG and 25 Resistance between terminals 17 and 26 OK: 0.9 - 1.1 W OK To the next page

OK

Check the harness wire between the injector driver relay and engine-ECU, and repair if necessary.

Repair

Check the following connector: A-13X

Check trouble symptom. NG

NG

OK

Check trouble symptom. NG

NG Repair

Measure at engine-ECU connector B-54. D Disconnect the connector, and measure at the harness side. D Voltage between terminal 20 and earth (Ignition switch: ON) OK: System voltage

Check trouble symptom.

OK

Check trouble symptom. NG

NG

Check the harness wire between the injector driver and injector driver relay, and repair if necessary.

Repair

Check the harness wire between the injector driver and earth, and repair if necessary.

Check the following connectors: A-02, A-03, A-04, A-05, A-06 NG Repair

OK

Check trouble symptom. NG Check the harness wire between the injector driver and injector, and repair if necessary.

13A-25

GDI <4G6> - Troubleshooting From the previous page OK Measure at engine-ECU connector B-52. D Connect the connector. D Voltage between terminal 51 and earth (Ignition switch: ON) OK: 4.0 - 5.2 V D Voltage between terminal 1 and earth Voltage between terminal 2 and earth Voltage between terminal 14 and earth Voltage between terminal 15 and earth (Ignition switch: ON) OK: 8 - 11 V NG Check the following connector: A-08 NG Repair

OK

Check the following connectors: B-52, B-54

NG

Repair

OK Check trouble symptom. NG Replace the injector driver. Check trouble symptom.

OK

Check trouble symptom.

NG

NG

Replace the engine-ECU.

Check the harness wire between the injector driver and engine-ECU, and repair if necessary.

13A-26

GDI <4G6> - Troubleshooting

Code No.44 Abnormal combustion

Probable cause

Range of check D While engine is running during lean fuel combustion Set conditions D Abnormal engine speed due to mis-firing is detected by the crank angle sensor

D D D D

Check the ignition coil (Refer to GROUP 16 - Ignition System).

NG

D D

Malfunction of the ignition coil Malfunction of the spark plug Malfunction of the EGR valve Open circuit or short-circuit in ignition primary circuit Malfunction of the injector system Malfunction of the engine-ECU

Replace

OK

(1) NG Measure at the ignition coil connectors A-74, A-94, A-97, A-98. D Disconnect the connector, and measure at the harness side. (2) NG (1) Voltage between 1 and earth (Ignition switch: ON) OK: System voltage (2) Voltage between 3 and earth (Engine: Cranking) OK: 0.5 - 4.0 V (3) NG (3) Continuity between 2 and earth OK: Continuity OK Check the following connectors: A-74, A-94, A-97, A-98 NG

OK

Check the following connector: B-28, B-89, B-103 OK

Repair Check trouble symptom. NG Check the harness wire between the ignition coil and the ignition switch, and repair if necessary. Check the following connector: B-54 OK

Repair Check trouble symptom. NG Check the following items in the order given. D Spark plugs D Compression pressure OK Check the injector system (Refer to P.13A-24, INSPECTION PROCEDURE FOR DIAGNOSIS CODE No.41) OK Check for air leaking into the air intake system. D Damaged intake manifold gasket D Damaged vacuum hose D Damaged air intake hose D Check the EGR valve.

NG

NG Repair

Check trouble symptom. NG Check the harness wire between the engine-ECU and the ignition coil. OK

NG Repair

Replace the engine-ECU. Check the harness wire between the ignition coil and the earth, and repair if necessary.

GDI <4G6> - Troubleshooting Code No.54 Immobilizer system

Probable cause

Range of Check D Ignition switch: ON Set Conditions D Improper communication between the engine-ECU and immobilizer-ECU

D D D D D

13A-27

Radio interference of encrypted codes Incorrect encrypted code Malfunction of harness or connector Malfunction of immobilizer-ECU Malfunction of engine-ECU

NOTE (1) If the ignition switches are close each other when starting the engine, radio interference may cause this code to be displayed. (2) This code may be displayed when registering the key encrypted code. Is there another ignition key near the ignition key that is inserted in the ignition switch?

Yes

Remove the extra ignition key. NG

No Is a diagnosis code output from the immobilizer-ECU?

Yes

No Check the following connector: B-51

NG

Check trouble symptom. Check the immobilizer system. (Refer to GROUP 54 - Ignition Switch and Immobilizer System.) Repair

OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the immobilizer-ECU. NG Repair

OK

Replace the engine-ECU and immobilizer-ECU.

13A-28

GDI <4G6> - Troubleshooting

Code No.56 Abnormal fuel pressure

Probable cause

Range of check D Ignition switch: ON Set conditions D Sensor output voltage is 4.8 V or more for four seconds. or D Sensor output voltage is 0.2 V or less for four seconds. Range of check D After the engine is started, the following condition has been detected: (1) Engine speed: 1,000 r/min or more (2) Fuel pressure: 2 MPa or more D While engine is running Set conditions D Fuel pressure is 6.9 MPa or more for four seconds. or D Fuel pressure is 2 MPa or less for four seconds.

D D

D

Malfunction of the fuel pressure sensor Open circuit or short-circuited harness wire of the fuel pressure sensor Malfunction of the engine-ECU Malfunction of the fuel pump (high pressure) Malfunction of the fuel pressure regulator (high pressure) Clogged high-pressure fuel line

This diagnosis code is also output when air is sucked in high-pressure fuel line due to no fuel supply. In this case, air can be bled by letting the engine run at 2,000 r/min for at least fifteen seconds. After the air bleeding, the diagnosis code must be erased by the MUT-II.

D

Air sucking due to no fuel supply

MUT-II Data list 74 Fuel pressure sensor D Ignition switch: ON OK: 0 - 8 MPa NG

OK

D D D

MUT-II Data list 74 Fuel pressure sensor D Maintain the engine speed at 2,000 r/min for at least fifteen seconds. OK: 6.9 MPa or less OK MUT-II Data list 74 Fuel pressure sensor D Engine: Idle running for at least three minutes OK: 4 MPa or more

NG

D D

NG

D D

Replace the high-pressure fuel regulator (seized regulator). Replace the high-pressure return pipe (seized pipe).

Replace the fuel pump (high pressure) (poor pump discharge pressure) Replace the high-pressure regulator (fuel leakage at the return side).

OK Erase diagnosis code No.56. (This diagnosis code has been output due to air sucking into high-pressure fuel line. But that problem has been resolved by revving the engine at 2,000 r/min.)

Check trouble symptom. OK Normal To the next page

NG

Check if input voltage from the fuel pressure sensor to engine-ECU changes suddenly by performing an intermittent malfunction simulation test. (Refer to GROUP 00 - Points to Note for Intermittent Malfunction.)

13A-29

GDI <4G6> - Troubleshooting From the previos page

Measure at the fuel pressure sensor connector A-77. D Connect the connector. (Use test harness MB991348) D Voltage between 2 and earth OK: 3 V or less (Engine: Cranking) 0.3 - 4.7 V (Engine: Idling)

NG

OK

Measure at the fuel pressure sensor connector A-77. NG D Disconnect the connector, and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 3 and earth OK: Continuity OK

OK

NG Repair

Check trouble symptom. NG Check the harness wire between the engine-ECU and the fuel pressure sensor.

Check the following connectors: A-77, B-51 OK

Check the following connector: B-51

NG

OK

NG Repair

Repair

Replace the engine-ECU. Check trouble symptom. Measure at the engine-ECU connector B-51. D Connect the connector. D Voltage between 74 and earth (Engine: idling) OK: 0.3 - 4.7 V OK Check the following connectors: A-77, B-51 OK Check trouble symptom. NG Replace the engine-ECU.

NG

Check the harness wire between the engine-ECU and the fuel pressure sensor, and repair if necessary.

NG

Check the harness wire between the engine-ECU and the fuel pressure sensor. OK

NG Repair

Replace the fuel pressure sensor. NG

Repair

13A-30

GDI <4G6> - Troubleshooting

Code No. 59 Oxygen sensor (rear) system

Probable cause

Range of Check D 3 minutes have passed after engine was started. D Engine coolant temperature is approx. 80_C or more. D Idle position switch: OFF D The throttle position sensor output voltage is 4.1 V or more. D Open loop control in operation D 20 seconds have passed after deceleration finished. Set conditions D The oxygen sensor (rear) output voltage is 0.1 V or less. D The difference in the maximum and minimum values for the oxygen sensor (rear) output voltage is 0.08 V or less. D The oxygen sensor (rear) output voltage is 0.5 V or more. D The above conditions continue for a continuous period of 5 seconds.

D D

Check the oxygen sensor (rear). (Refer to P.13A-109.)

NG

D

Malfunction of the oxygen sensor (rear) Improper connector contact, open circuit short-circuited harness wire Malfunction of the engine-ECU

Replace

OK

(1) NG Measure at the oxygen sensor (rear) connector C-29. D Disconnect the connector, and measure at the harness side. (1) Voltage between 3 and earth (Ignition switch: ON) (2) NG OK: System voltage (2) Continuity between 2 and earth OK: Continuity (3) NG (3) Continuity between 4 and earth OK: Continuity

Check the harness wire between the oxygen sensor and the control relay connector, and repair if necessary. Check the following connector: B-52 Check trouble symptom. NG Check the harness wire between the engine-ECU and the oxygen sensor connector. OK Replace the engine-ECU.

Check the harness wire between the oxygen sensor connector and the earth, and repair if necessary. NG

Repair

OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the oxygen sensor connector. OK Replace the oxygen sensor (rear). Check trouble symptom. NG Replace the engine-ECU.

NG

Repair

OK

OK

Check the following connectors: B-52, C-29

NG

Repair

NG

Repair

or

13A-31

GDI <4G6> - Troubleshooting Code No.61 Communication wire with A/T-ECU system

Probable cause

Range of check D After 60 seconds have passed since the engine have started Set conditions D Torque reduction request signal from A/T-ECU is input continuously for 1.5 seconds or more.

D D D

NG

Check the following connectors: B-10, B-52, B-53

Short circuit in ECU communication circuit Malfunction of the engine-ECU Malfunction of the A/T-ECU

Repair

OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the A/T-ECU.

OK

Replace the engine-ECU.

NG Check trouble symptom.

Repair

NG Replace the A/T-ECU.

Code No.64 Alternator FR terminal system

Probable cause

Range of check D Engine speed is 50 r/min or more. Set conditions D Input voltage from the alternator FR terminal is system voltage for 20 seconds.

D D

Measure at the alternator connector A-52. D Connect the connector. (Use test harness MB991519) D Voltage between 4 (blue clip) and earth (Engine: Idling) (Radiator fan: Not operating) (Headlamp: OFF ® ON) (Stop lamp: OFF ® ON) (Rear defogger switch: OFF ® ON) OK: Voltage decreases.

NG

Measure at the alternator connector A-52. D Disconnect the connector, and measure at the harness side. D Voltage between 4 and earth (Ignition switch: ON) OK: System voltage OK

OK

Replace the engine-ECU.

NG Repair

Check trouble symptom.

Check the following connectors: A-30, B-53 OK NG Repair Check trouble symptom.

Check the harness wire between the engine-ECU and the alternator. OK NG Repair Replace the engine-ECU.

NG Check the harness wire between the engine-ECU and the alternator. OK NG Repair Replace the alternator.

NG

NG

Check the following connector: A-52

OK

Open circuit in alternator FR terminal circuit Malfunction of the engine-ECU

13A-32

GDI <4G6> - Troubleshooting

Code No.66 Brake vacuum sensor system

Probable cause

Range of check D Ignition switch: ON Set conditions D Sensor output voltage is 4.8 V or more. or D Sensor output voltage is 0.2 V or less.

D D

Measure at the brake vacuum sensor connector A-09. D Connect the connector. (Use test harness MB991348) D Voltage between 1 and earth (After the engine is turned off from idle speed, turn on the ignition switch, and then depress the brake pedal several times. OK: Voltage increases.

NG

D

Measure at the brake vacuum sensor connector A-09. D Disconnect the connector, and measure at the harness side. D Voltage between 3 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 2 and earth OK: Continuity

Malfunction of the brake vacuum sensor Improper connector contact, open circuit or short-circuited harness wire of the brake vacuum sensor Malfunction of the engine-ECU

NG

OK

NG Repair

Check trouble symptom. NG

OK

OK

Check the following connectors: B-51, B-52, B-53

Check the harness wire between the engine-ECU and the brake vacuum sensor. OK NG

Check the following connector: A-09 OK NG

Repair

Repair

Replace the engine-ECU. Check trouble symptom.

Check the following connectors: A-09, A-27, B-53

NG

Repair

Replace the brake vacuum sensor.

Check trouble symptom. NG

OK Replace the engine-ECU.

Check the harness wire between the engine-ECU and the brake vacuum sensor. OK NG Repair

OK

Check the harness wire between the NG engine-ECU and the brake vacuum sensor.

NG

Repair

13A-33

GDI <4G6> - Troubleshooting Code No.77 Accelerator pedal position sensor (2nd channel) system

Probable cause

Range of check D Accelerator pedal position sensor (1st channel) system is normal. D Communication between the engine-ECU and throttle valve controller is normal. Set conditions D Output voltage of accelerator position sensor (2nd channel) system is 0.2 V or less for one second. or D Output voltage of the accelerator pedal position sensor (1st channel) is 2.5 V or less, and output voltage of the accelerator pedal position sensor (2nd channel) is 4.5 V or more for one second. or D Difference between the accelerator pedal position sensor output voltages (1st and 2nd channels) exceeds 1.0 V (i.e. when the throttle valve opening angle changes slightly).

D

Check the accelerator pedal position sensor (2nd channel). (Refer to P.13A108.)

NG

D D D

Replace the accelerator pedal position sensor assembly (2nd channel).

OK Measure at accelerator pedal position sensor (2nd channel) connector A-63. D Disconnect the connector, and measure at the harness side. D Voltage between terminal 4 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between terminal 1 and earth OK: Continuity

NG

Malfunction of the accelerator pedal position sensor (2nd channel) Open circuit or short-circuited harness wire in the accelerator pedal position sensor (2nd channel) system, or poor connector contact Malfunction of the throttle valve controller Malfunction of the engine-ECU

Check the following connectors: A-27, B-50 OK Check trouble symptom.

NG

NG

OK MUT-II Data list 78 Accelerator pedal position sensor (1st channel). (Refer to P.13A-79.) OK Replace the throttle valve controller.

Check the harness wire between the throttle valve controller and the accelerator pedal position sensor (2nd channel). OK NG Repair

OK

Measure at throttle valve controller connector B-50. D Connect the connector. D Voltage between terminal 20 and earth (Ignition switch: ON) OK: 0.7 - 1.4 V (Accelerator pedal: fully released) 4 V or more (Accelerator pedal: fully depressed)

Repair

Replace the throttle valve controller. NG

Check the following connectors: A-27, A-63 OK Check trouble symptom.

NG

NG

Repair

Check the harness wire between the accelerator pedal position sensor (2nd channel) and throttle valve controller. OK NG Repair

NG

Check the accelerator pedal position sensor (1st channel) system. (Refer to P.13A-34, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 78.)

Adjust the accelerator pedal position sensor (2nd channel). (Refer to P.13A108.) Check trouble symptom. NG Replace the throttle valve controller.

13A-34

GDI <4G6> - Troubleshooting

Code No.78 Accelerator pedal position sensor (1st channel) system

Probable cause

Range of check D Accelerator pedal position sensor (2nd channel) system is normal. D Communication between the engine-ECU and throttle valve controller is normal. Set conditions D Output voltage of accelerator position sensor (1st channel) system is 0.2 V or less for one second. or D Output voltage of the accelerator pedal position sensor (2nd channel) is 2.5 V or less, and (1st channel) output voltage of the accelerator pedal position sensor is 4.5 V or more for one second. or D Difference between the accelerator pedal position sensor (1st and 2nd channels) output voltages exceeds 1.0 V (i.e. when the throttle valve opening angle changes slightly). or D Although the accelerator pedal position switch is on, 1st-channel output voltage of the accelerator pedal position sensor exceeds 1.1 V for one second.

D

MUT-II Data list 26 Accelerator pedal position switch (P.13A-77.) OK Check the accelerator pedal position sensor (1st channel). (Refer to P.13A108.)

NG

NG

D D D D

Check the accelerator pedal position switch system. (Refer to P.13A-67, INSPECTION PROCEDURE 27.) Replace the accelerator pedal position sensor assembly (1st channel).

OK Measure at the accelerator pedal position sensor (1st channel) connector A-62. D Disconnect the connector, and measure at the harness side. D Voltage between terminal 1 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between terminal 4 and earth OK: Continuity

NG

Malfunction of the accelerator pedal position sensor (1st channel) Open circuit or short-circuited harness wire in the accelerator pedal position sensor (1st channel) system, or poor connector contact ON-seizure of the accelerator pedal position switch Malfunction of the throttle valve controller Malfunction of the engine-ECU

Check the following connectors: A-27, B-51 OK Check trouble symptom.

NG

NG

OK MUT-II Data list 78 Accelerator pedal position sensor (2nd channel). (Refer to P.13A-79.) OK Replace the engine-ECU.

Check the harness wire between the accelerator pedal position sensor (1st channel) and engine-ECU. OK NG Repair

OK

Measure at the engine-ECU B-51. D Connect the connector. D Voltage between terminal 87 and earth (Ignition switch: ON) OK: 0.9 - 1.2 V (Accelerator pedal: fully released) 4 V or more (Accelerator pedal: fully depressed)

Repair

Replace the engine-ECU. NG

Check the following connectors: A-27, A-62 OK Check trouble symptom.

NG

NG

Repair

Check the harness wire between the accelerator pedal position sensor (1st channel) and engine-ECU. OK

NG Repair

NG

Check the accelerator pedal position sensor (2nd channel) system. (Refer to P.13A-33, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 77.)

Adjust the accelerator pedal position sensor (1st channel). (Refer to P.13A98.) Check trouble symptom. NG Replace the engine-ECU.

13A-35

GDI <4G6> - Troubleshooting Code No.79 Throttle position sensor (1st channel) system

Probable cause

The throttle valve controller determines a failure, and sends it result to the engine-ECU. Range of check D Ignition switch: ON D System voltage: 8 V or more Set conditions D Output voltage of the sensor remains 0.2 V for one second. or D Output voltage of the sensor remains 4.9 V for one second. or D Output voltage of the throttle position sensor (1st and 2nd channels) remains outside 4 - 6 V for four seconds.

D D

MUT-II Data list Is code No. 14, 91 or 92 output? No Check the throttle position sensor. (Refer to P.13A-107.) OK Measure at throttle position sensor connector A-73. D Disconnect the connector, and measure at the harness side. D Voltage between terminal 1 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between terminal 3 and earth OK: Continuity

Yes

NG

NG

D D

Malfunction of the throttle position sensor (1st channel) Open circuit or short-circuited harness wire in the throttle position sensor (1st channel), or poor connector contact Malfunction of the throttle valve controller Malfunction of the engine-ECU

Follow INSPECTION PROCEDURE FOR DIAGNOSIS CODE.

Replace

Check the following connector: B-50 OK Check trouble symptom.

NG

NG

Check the harness wire between the throttle valve controller and throttle position sensor. OK NG Repair

OK

Measure at throttle valve controller connector B-50. D Connect the connector. D Disconnect the throttle control servo connector (Close the throttle valve fully by finger). D Voltage between terminal 7 and earth (Ignition switch: ON) OK: 0.4 - 0.6 V

Repair

Replace the throttle valve controller. NG

Check the following connector: A-73

NG

Repair

OK Check trouble symptom. NG Check the harness between the throttle position sensor and throttle valve controller.

OK

OK

NG

Adjust the throttle position sensor. (Refer to P.13A-97.) Check trouble symptom.

Repair

NG Replace the throttle valve controller.

Measure at engine-ECU connector B-51. D Connect the connector. D Disconnect the throttle control servo connector (Close the throttle valve fully by finger). D Voltage between terminal 84 and earth (Ignition switch: ON) OK: 4.2 - 4.8 V OK Replace the engine-ECU.

NG

Check the following connectors: A-73, B-50 OK Check trouble symptom.

NG

NG

Repair

Check the harness wire between the throttle position sensor and engineECU, and repair if necessary.

13A-36

GDI <4G6> - Troubleshooting

Code No.89 Abnormal fuel pressure system

Probable cause

Range of check D Engine: Idling (during stoichio-feedback operation) Set conditions D Fuel injection correction value remains excessively low for ten seconds or more. or D Fuel injection correction value remains excessively high for ten seconds or more.

D D D D D

MUT-II Data list 13 Intake air temperature sensor. (Refer to P.13A-75.) OK MUT-II Data list 25 Barometric air temperature sensor. (Refer to P.13A-77.) OK MUT-II Data list 12 Air flow sensor. (Refer to P.13A-75.)

NG

NG

NG

Malfunction Malfunction Malfunction Malfunction Malfunction

of of of of of

the the the the the

fuel pump (high pressure) intake air temperature sensor barometric pressure sensor air flow sensor engine-ECU

Check the intake air temperature sensor system. (Refer to P.13A16, INSPECTION PROCEDURE FOR DIAGNOSIS CODE No.13.) Check the barometric air temperature sensor system. (Refer to P.13A-22, INSPECTION PROCEDURE FOR DIAGNOSIS CODE No.25.) Check the air flow sensor system. (Refer to P.13A-15, INSPECTION PROCEDURE FOR DIAGNOSIS CODE No.12.)

OK Replace the fuel pump (high pressure).

Code No.91 Electronic-controlled throttle valve system

Probable cause

Range of check D Ignition switch: ON D Error in communication between the engine-ECU and throttle valve controller Set conditions D Output voltage of the throttle position sensor (2nd channel) fluctuates significantly (approx. 1 V or more) from an expected value. Range of check D Ignition switch: ON D Error in communication between the throttle valve controller and engine-ECU Set conditions D The throttle valve opening angle (voltage) which the engine-ECU requested of the throttle valve controller is significantly different from output voltage of the (2nd channel) throttle position sensor (approx. one volt).

D D D

MUT-II Self-Diag code Is any other diagnosis code than No.94 output?

Yes

Follow INSPECTION PROCEDURE FOR DIAGNOSIS CODE.

No Check the harness wire between the throttle valve controller and engine-ECU. OK Replace the throttle valve controller.

NG

Short in communication line Malfunction of the engine-ECU Malfunction of the throttle valve controller

Repair

13A-37

GDI <4G6> - Troubleshooting Code No.92 Throttle valve position feedback system

Probable cause

The throttle valve controller determines if a failure is present, and sends its result to the engine-ECU. Range of check D Ignition switch: ON D System voltage: 8 V or more Set condition D Motor position feedback system is defective (System detects a motor overcurrent, or that actual and projected opening angles of the throttle position sensor (1st channel) are different by 1.0 V or more.

D D

Check the throttle valve control servo. (Refer to P.13A-111.)

NG

D

Malfunction of the throttle position sensor (1st channel) Open circuit or short-circuited harness wire in the throttle position sensor system (1st channel), or poor connector contact Malfunction of the throttle valve controller

Replace

OK Check the following connectors:A-99, B-50

NG

Repair

OK Check trouble symptom. NG Check the harness wire between the throttle control servo and throttle valve controller.

NG

Repair

OK Replace the throttle body.

Check trouble symptom. NG Replace the throttle valve controller.

Code No.94 Communication line system with throttle valve controller

Probable cause

Range of check D Ignition switch: ON D System voltage: 8 V or more D Engine: not cranking Set condition D System detects an error in communication line between the engine-ECU and throttle valve controller.

D D D

Check the following connectors: B-50, B-52

NG

Short circuit in communication line Malfunction of the engine-ECU Malfunction of the throttle valve controller

Repair

OK Check trouble symptom. NG Check the harness wire between the engine-ECU and throttle valve controller. NG

OK

Replace the throttle valve controller.

Check trouble symptom.

Repair

NG Replace the engine-ECU.

13A-38

GDI <4G6> - Troubleshooting

Code No.95 Malfunction in throttle valve control servo motor system (1st phase)

Probable cause

Range of check D Throttle valve control servo relay: ON D System voltage: 8 V or more Set conditions D Throttle valve control servo drive circuit is shorted to earth. D Other power source interferences with throttle valve control servo drive circuit. D Throttle valve control servo drive circuit is open circuit.

D D

Check the throttle valve control servo. (Refer to P.13A-111.)

NG

D

Malfunction of the throttle valve control servo Open circuit or short-circuited harness wire in throttle valve control servo system, or poor connector contact Malfunction of the throttle valve controller

Replace

OK Check the following connectors: A-99, B-50 OK

NG

Repair

Check trouble symptom. NG Check the harness wire between the throttle valve control servo and throttle valve controller.

OK

Replace the throttle valve controller.

NG Repair

Code No.99 Malfunction in throttle valve control servo motor system (2nd phase)

Probable cause

Range of check D Throttle valve control servo relay: ON D System voltage: 8V or more Set conditions D Throttle valve control servo drive circuit is shorted to earth. D Other power source interferes with throttle valve control servo drive circuit. D Throttle valve control servo drive circuit is open-circuited.

D D

Check the throttle valve control servo. (Refer to P.13A-111.)

NG

D

Malfunction of the throttle valve control servo Open circuit or short-circuited harness wire in the throttle valve control servo system, or poor connector contact Malfunction of the throttle valve controller

Replace

OK Check the following connectors: A-99, B-50

NG

Repair

OK Check trouble symptom. NG Check the harness wire between the throttle valve control servo and throttle valve controller. NG Repair

OK

Replace the throttle valve controller.

13A-39

GDI <4G6> - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom

Inspection procedure No.

Reference page

Communication with MUT-II II is impossible.

Communication with all systems is not possible.

1

13A-41

Communication with engine-ECU only is not possible.

2

13A-42

Engine warning lamp and related parts

The engine warning lamp does not illuminate right after the ignition switch is turned to the ON position.

3

13A-43

The engine warning lamp remains illuminating and never goes out.

4

13A-43

Starting

No initial combustion (starting impossible)

5

13A-44

Initial combustion but no complete combustion (starting impossible)

6

13A-46

Unstable idling (Rough idling, hunting)

7

13A-48

Idling speed is high. (Improper idling speed)

8

13A-50

When the engine is cold, it stalls at idling. (Die out)

9

13A-51

When the engine is hot, it stalls at idling. (Die out)

10

13A-52

The engine stalls when starting the car. (Pass out)

11

13A-54

The engine stalls when decelerating.

12

13A-55

Hesitation, sag or stumble

13

13A-56

The feeling of impact or vibration when accelerating

14

13A-57

The feeling of impact or vibration when decelerating

15

13A-58

Knocking

16

13A-58

Dieseling

17

13A-58

Too high CO and HC concentration when idling

18

13A-59

Low alternator output voltage (approx. 12.3 V)

19

13A-61

Engine idle speed is incorrect while the A/C is on.

20

13A-61

Fans (radiator fan, A/C condenser fan) are inoperative

21

13A-62

Clutch switch system malfunction

22

13A-63

Long time to start (improper starting) Idling stability (Improper idling)

Idling speed is low. (Improper idling speed) Idling stability (Engine stalls)

Driving

Poor acceleration Surge

13A-40

GDI <4G6> - Troubleshooting

PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) Items Starting

Idling stability

Driving

Symptom Won’t start

The starter is used to crank the engine, but there is no combustion within the cylinders, and the engine won’t start.

Fires up and dies

There is combustion within the cylinders, but then the engine soon stalls.

Hard starting

Engine starts after cranking a while.

Hunting

Engine speed doesn’t remain constant; changes at idle.

Rough idle

Usually, a judgement can be based upon the movement of the tachometer pointer, and the vibration transmitted to the steering wheel, shift lever, body, etc. This is called rough idle.

Incorrect idle speed

The engine doesn’t idle at the usual correct speed.

Engine stall (Die out)

The engine stalls when the foot is taken from the accelerator pedal, regardless of whether the vehicles is moving or not.

Engine stall (Pass out)

The engine stalls when the accelerator pedal is depressed or while it is being used.

Hesitation, Sag

“Hesitation” is the delay in response of the vehicle speed (engine speed) that occurs when the accelerator is depressed in order to accelerate from the speed at which the vehicle is now traveling, or a temporary drop in vehicle speed (engine speed) during such acceleration. Serious hesitation is called “sag”.

Hesitation Normal Vehicle Initial acspeed celerator

pedal depression

Sag

Time

Poor acceleration

Poor acceleration is inability to obtain an acceleration corresponding to the degree of throttle opening, even though acceleration is smooth, or the inability to reach maximum speed.

Stumble

Engine speed increase is delayed when the accelerator pedal is initially depressed for acceleration.

Vehicle speed

Normal Initial accelerator pedal depression

Idling

Stumble Time

13A-41

GDI <4G6> - Troubleshooting Items Driving

Stopping

Symptom Shock

The feeling of a comparatively large impact or vibration when the engine is accelerated or decelerated.

Surge

This is repeated surging ahead during constant speed travel or during variable speed travel.

Knocking

A sharp sound like a hammer striking the cylinder walls during driving and which adversely affects driving.

Run on (“Dieseling”)

The condition in which the engine continues to run after the ignition switch is turned to OFF. Also called “Dieseling”.

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 Communication with MUT-II is not possible. (Communication with all systems is not possible.)

Probable cause

The cause is probably a defect in the power supply system (including earth) for the diagnosis line.

D D

Measure at the diagnostic connector (16-pin) B-25. D Voltage between 16 and earth OK: Battery voltage

NG

OK Check trouble symptom.

OK

Measure at the diagnostic connector (16-pin) B-25. D Continuity between 4 and earth D Continuity between 5 and earth OK: Continuity OK Replace the MUT-II.

Check the following connectors: B-66, B-91, B-92

NG

Check the harness wire between the diagnostic connector (16-pin) and earth, and repair if necessary.

Malfunction of the connector Malfunction of the harness wire NG

NG

Repair

Check the harness wire between the power supply and diagnostic connector (16 pin), and repair if necessary.

13A-42

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE 2 MUT-II communication with engine-ECU is impossible.

Probable cause

One of the following causes may be suspected. D No power supply to engine-ECU. D Defective earth circuit of engine-ECU. D Defective engine-ECU. D Improper communication line between engine-ECU and MUT-II

D D D

Check the following connectors: B-04, B-14, B-25, B-52

NG

Malfunction of engine-ECU power supply circuit Malfunction of engine-ECU Open circuit between the engine-ECU and diagnosis connector

Repair

OK Check trouble symptom. NG Check the harness wire between engine-ECU and diagnosis connector.

NG

Repair

OK Check the engine-ECU power supply and earth circuit system. (Refer to P.13A-64, INSPECTION PROCEDURE 23.)

NOTE On vehicles with multi center display, if a malfunction cannot be resolved after the procedure above, check the multi center display and replace if necessary. (Refer to GROUP 54 - Multi center display.)

13A-43

GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 3 The engine warning lamp does not illuminate right after the ignition switch is turned to the ON position.

Probable cause

Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp to illuminate for five seconds immediately after the ignition switch is turned to ON. If the engine warning lamp does not illuminate immediately after the ignition switch is turned to ON, one of the malfunctions listed at right has probably occurred.

D D D

MUT-II Data list 16 engine-ECU power supply voltage (Refer to P.13A-76.) OK Measure at the engine-ECU connector B-53. D Disconnect the connector, and measure at the harness side. D Earth the terminal No. 36. OK: The engine warning lamp illuminates.

NG

OK

Check the engine-ECU power supply and earth circuit system. (Refer to P.13A-64, INSPECTION PROCEDURE 23.)

Check the following connector: B-53

NG

Repair

OK Check trouble symptom.

NG Check a burnt-out bulb.

Burnt-out bulb Defective warning lamp circuit Malfunction of the engine-ECU

NG

NG

Replace the engine-ECU.

Replace

OK Measure at the combination meter connector B-01. D Disconnect the connector, and measure at the harness side. D Voltage between 42 and earth (Ignition switch: ON) OK: System voltage

NG

Check the engine warning lamp power supply circuit, and repair if necessary.

OK Check the following connectors: B-01, B-02, B-14, B-53 OK

NG

NG

Check trouble symptom.

Repair

Check the harness wire between combination meter and engineECU, and repair if necessary.

INSPECTION PROCEDURE 4 The engine warning lamp remains illuminating and never goes out.

Probable cause

In cases such as the above, the cause is probably that the engine-ECU is detecting a problem in a sensor or actuator, or that one of the malfunctions listed at right has occurred.

D

Yes

MUT-II Self-Diag code Are diagnosis codes displayed? No Measure at the combination meter connector B-02. D Disconnect the connector, and measure at the harness side. D Disconnect the engine-ECU connector D Continuity between 22 and earth OK: No continuity OK Replace the engine-ECU.

NG

D

Short-circuit between the engine warning lamp and engine-ECU Malfunction of the engine-ECU

Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS CODES Check the harness wire between combination meter and engineECU connector, and repair if necessary.

13A-44

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE 5 No initial combustion (starting impossible)

Probable cause

This is caused by incorrect fuel supply into the combustion chamber, and improper ignition circuit. Besides that, foreign material may be contaminated in fuel.

D D D

Check system voltage while the engine is cranking. OK: 8 V or more OK MUT-II Self-Diag code Is a diagnosis code displayed? No MUT-II Data list 16 System voltage (Refer to P.13A-76.) OK Does the camshaft rotate when the engine is cranking? Yes MUT-II Actuator test 07 Fuel pump (low pressure) (Refer to P.13A-81.) OK MUT-II Data list 22 Crank angle sensor (Refer to P.13A-76.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-76.) OK MUT-II Data list 14 Throttle position sensor (2nd channel) (Refer to P.13A-76.) OK Inspect engine start ability by cranking the engine while the accelerator pedal is slightly depressed.

NG

Yes

NG

No NG

NG

NG

NG

OK

Malfunction of the fuel supply system Malfunction of the ignition system Malfunction of the engine-ECU

Check the battery. (Refer to GROUP 55 - Battery.)

Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS CODES. Check the engine control relay and ignition switch-IG system. (Refer to P.13A-65, INSPECTION PROCEDURE 24.)

Check if the timing belt is broken or damaged. Check the fuel pump (low pressure) system. (Refer to P.13A-68, INSPECTION PROCEDURE 28.) Check the crank angle sensor system. (Refer to P.13A-19, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 22.) Check the engine coolant temperature sensor system. (Refer to P.13A-18, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the throttle position sensor (2nd channel) system. (Refer to P.13A-17, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14.) Clean around the throttle valve. (Refer to P.13A-97.)

NG Check fuel leakage. (Refer to P.13A-103.)

NG

Repair

OK Measure low fuel pressure between the fuel pump (low pressure) and fuel pump (high pressure). (Refer to P.13A-99.)

NG

Repair

OK Measure at ignition coil connectors A-74, A-94, A-97, A-98. D Connect the connector. D Connect a timing light to the No.1 terminal of each connector in turn. (Engine cranking) OK: The timing light flashes. OK Check ignition timing while the engine is cranking. OK: Approx. 5_ BTDC OK To the next page

NG

NG

Check abnormal fuel combustion system. (Refer to P.13A-26, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 44.)

Check that the crank angle sensor and timing belt cover are properly installed.

GDI <4G6> - Troubleshooting From the previous page OK Check ignition coil spark for each cylinder. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil. (3) Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx. 100 V is applied to the injector, or you are seriously injured. (4) Earth the spark plug electrode securely. (5) Check that the spark plug ignites when the engine is cranked.

NG

Replace the ignition coil.

OK Check all the following items: D Spark plug D Compression pressure D Foreign material (such as water or kerosine) entered the fuel lines OK Check trouble symptom.

NG

Replace the injector.

13A-45

13A-46

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE 6 Initial combustion takes place, but does not complete (start impossible), too long time to start (poor start)

Probable cause

This may be caused by improper spark plug ignition (poor spark), improper mixture during engine cranking, improper fuel pressure.

D D D D D

Check system voltage while the engine is cranking. OK: 8 V or more OK MUT-II Self-Diag code Is a diagnosis code displayed? No MUT-II Actuator test 07 Fuel pump (low pressure) (Refer to P.13A-81.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-76.) OK MUT-II Data list 18 Cranking signal (Refer to P.13A-76.)

NG

Yes

NG

NG

NG

OK

MUT-II Data list 74 Fuel pressure sensor (Refer to P.13A-79.) OK Check fuel leakage. (Refer to P.13A-103.) OK Is the engine started normally when it is cranked with the accelerator pedal depressed slightly? No MUT-II Data list 14 Throttle position sensor (2nd channel) (Refer to P.13A-76.) OK Check ignition timing when the engine is cranked. OK: approx. 5_ BTDC OK To the next page

NG

NG Yes

NG

NG

Malfunction Malfunction Malfunction Malfunction system Malfunction

of of of of

the fuel supply system the fuel pressure sensor the ignition system the electronic-controlled throttle vale

of the engine-ECU

Check the battery. (Refer to GROUP 55 - Battery.)

Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS CODES. Check the fuel pump (low pressure) system. (Refer to P.13A-68, INSPECTION PROCEDURE 28.) Check the engine coolant temperature system. (Refer to P.13A18, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the ignition switch-ST system . (Refer to P.13A-65, INSPECTION PROCEDURE 25.) Check the ignition switch-ST system and inhibitor switch . (Refer to P.13A-66, INSPECTION PROCEDURE 26.) Check an abnormal fuel pressure system. (Refer to P.13A-28, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 56.)

Repair Clean around the throttle valve. (Refer to P.13A-97.)

Check the throttle position sensor (2nd channel) system. (Refer to P.13A-17, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14.) Check that the crank angle sensor and timing belt cover are properly installed.

GDI <4G6> - Troubleshooting From the previous page OK Check ignition coil spark for each cylinder. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil. (3) Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx. 100 V is applied to the injector, or you are seriously injured. (4) Earth the spark plug electrode securely. (5) Check that the spark plug ignites when the engine is cranked.

NG

Replace the ignition coil.

OK Check all the following items: D Spark plug D Compression pressure D Foreign material (such as water or kerosine) entered the fuel lines OK Check trouble symptom.

NG

Replace the injector.

13A-47

13A-48

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE 7 Unstable idling (rough idle, hunting)

Probable cause

This malfunction is probably caused by a faulty ignition system, improper air/fuel ratio, a faulty electronic-controlled throttle valve system, improper compression pressure, etc. As many causes can be suspected, diagnose from easier items.

D D D D D

Has the battery been disconnected recently?

Yes

No Yes

MUT-II Self-Diag code Is a diagnosis code displayed? No Does the engine idle speed fluctuates excessively (excessive hunting)? No MUT-II Data list 14 Throttle position sensor (2nd channel) (Refer to P.13A-76.)

Yes

NG

OK MUT-II Data list 79 Throttle position sensor (1st channel) (Refer to P.13A-80.)

NG

OK MUT-II Data list 26 Accelerator pedal position switch (Refer to P.13A-77.) OK MUT-II Data list 13 Intake air temperature sensor (Refer to P.13A-75.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13A-77.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-76.) OK MUT-II Actuator test 08 Purge control solenoid valve (Refer to P.13A-81.) OK MUT-II Data list 59 Oxygen sensor (rear) (Refer to P.13A- 79.) D Transmission: 2nd gear , L range D Driving with throttle widely open OK: 600 - 1,000 mV OK MUT-II Data list 11 Oxygen sensor (front) OK: 600 - 1,000 mV when the engine is suddenly raced OK To the next page

NG

NG

NG

NG

NG

NG

NG

Malfunction of the ignition system Malfunction of the air/fuel ratio control system Malfunction of the electronic-control throttle valve system Improper compression pressure Air sucking into the air intake system

Warm up the engine, and then let it run at idle for approx. ten minutes. Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS CODES. Clean around the throttle valve. (Refer to P.13A-97.)

Check the throttle position sensor (2nd channel) system. (Refer to P.13A-17, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14.) Check the throttle valve position feedback system. (Refer to P.13A-37, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 92.) Check the accelerator pedal position switch system. (Refer to P.13A-67, INSPECTION PROCEDURE 27.) Check the intake air temperature sensor system. (Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.) Check the barometric pressure sensor system. (Refer to P.13A-22, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 25.) Check the engine coolant temperature sensor. (Refer to P.13A-18, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the purge control solenoid valve system. (Refer to P.13A-70, INSPECTION PROCEDURE 30.)

Check the oxygen sensor (rear) system. (Refer to P.13A-30, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 59.)

Check the oxygen sensor (front) system. (Refer to P.13A-14, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 11.)

13A-49

GDI <4G6> - Troubleshooting From the previous page OK MUT-II Data list 11 Oxygen sensor (front) OK: 0 - 400 mV and 600 - 1,000 mV alternates when the engine is idling (wait for four minutes after the engine started).

NG

OK

NG

Repair Check that air is sucked in the air intake system. D Broken intake manifold gasket D Damaged vacuum hose D Damaged air intake hose

OK

MUT-II Data list 27 Power steering fluid pressure switch (Refer to P.13A-77.)

Measure fuel high-pressure between the fuel pump (high pressure) and injector. (Refer to P.13A-99.)

NG

Check the power steering fluid pressure switch system. (Refer to P.13A-71, INSPECTION PROCEDURE 31.)

OK MUT-II Data list 28 A/C switch (Refer to P.13A-77.) OK MUT-II Data list 48 M/T oil temperature sensor (Refer to P.13A-78.) OK MUT-II Data list 29 Inhibitor switch (Refer to P.13A-77.) OK MUT-II Data list 67 Stop lamp switch (Refer to P.13A-78.) OK MUT-II Data list 31 Small lamp switch (Refer to P.13A-77.) OK MUT-II Data list 68 EGR valve (Refer to P.13A-79.) OK Check ignition timing. (Refer to GROUP 11A - Engine Adjustment.)

NG

NG

NG

NG

NG

NG

NG

OK Check ignition coil spark for each cylinder. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil. (3) Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx. 100 V is applied to the injector, or you are seriously injured. (4) Earth the spark plug electrode securely. (5) Check that the spark plug ignites when the engine is cranked. OK Clean around the throttle valve. (Refer to P.13A-97.) Check trouble symptom. NG Check all the following items in that order. (1) Spark plugs (2) Exhaust gas emission control system (3) EGR system (4) Compression pressure (5) Foreign material (such as water or kerosine)entered the fuel line. (6) Air is sucked in the air intake system, or EGR gas leaks. D Damaged intake manifold gasket D Damaged air intake hose D Damaged vacuum hose D Faulty EGR valve seat

NG

Check the A/C switch and A/C relay system. (Refer to P.13A-71, INSPECTION PROCEDURE 32.) Check the M/T oil temperature sensor system. (Refer to P.13A-72, INSPECTION PROCEDURE 33.) Check the ignition switch-ST and inhibitor switch. (Refer to P.13A-68, INSPECTION PROCEDURE 28.) Check the stop lamp switch. (Refer to P.13A-73, INSPECTION PROCEDURE 34.) Check the small lamp switch system. (Refer to P.13A-74, INSPECTION PROCEDURE 35.) Check the EGR valve. (Refer to P.13A-69, INSPECTION PROCEDURE 29.) Check that the crank angle sensor and timing belt cover are properly installed. Replace the ignition coil.

13A-50

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE 8 Idle speed is high or low (Improper idling)

Probable cause

The cause is probably that the intake air amount during idling is too great or too small.

D

Yes

MUT-II Self-Diag code Is a diagnosis code displayed? No MUT-II Data list 14 Throttle position sensor (2nd channel) (Refer to P.13A-76.) OK MUT-II Actuator test 08 Purge control solenoid valve (Refer to P.13A-81.) OK MUT-II Data list 26 Accelerator pedal position switch (Refer to P.13A-77.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-76.) OK MUT-II Data list 28 A/C switch (Refer to P.13A-77.) OK MUT-II Data list 48 M/T oil temperature sensor (Refer to P.13A-78.)

NG

NG

NG

NG

NG

NG

D

Malfunction of the electronic-controlled throttle valve system Malfunction of the throttle body

(Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS CODES.) Check the throttle position sensor (2nd channel). (Refer to P.13A-17, INSPECTION PROCEDURE FOR DIAGNOSIS CODES 14.) Check the purge control solenoid valve. (Refer to P.13A-70, INSPECTION PROCEDURE 30.) Check the accelerator pedal position switch system. (Refer to P.13A-67, INSPECTION PROCEDURE 27.) Check the engine coolant temperature sensor. (Refer to P.13A-18, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the A/C switch and A/C relay system. (Refer to P.13A-71, INSPECTION PROCEDURE 32.) Check the M/T oil temperature sensor. (Refer to P.13A-72, INSPECTION PROCEDURE 33.)

OK Check the ignition switch-ST and inhibitor switch. (Refer to P.13A-68, INSPECTION PROCEDURE 28.)

MUT-II Data list 29 Inhibitor switch (Refer to P.13A-77.) OK MUT-II Data list 67 Stop lamp switch (Refer to P.13A-78.) OK D D

Clean around the throttle valve. (Refer to P.13A-97.) Adjust the throttle position sensor. (Refer to P.13A-97.)

NG

Check the stop lamp switch system. (Refer to P.13A-73, INSPECTION PROCEDURE 34.)

13A-51

GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 9 When the engine is cold, it stalls at idling. (Die out)

Probable cause

The cause is probably an incorrect air/fuel ratio or poor intake air amount when the engine is cold.

D

Have the battery terminals been disconnected recently? No MUT-II Self-Diag code Is a diagnosis code displayed?

Yes Yes

D

Malfunction of the electronic-control throttle valve system Malfunction of the throttle body

Warm up the engine, and then let it run at idle for approx. ten minutes. (Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS CODES.)

No Is the engine idling correct after the engine has been warmed up?

Yes

Refer to “Unstable idling (rough idle, hunting).” (Refer to P.13A-48, INSPECTION PROCEDURE 7.)

No MUT-II Data list 22 Crank angle sensor (Refer to P.13A-76.) Check idling speed when the engine is cold. OK MUT-II Data list 26 Accelerator pedal position switch (Refer to P.13A-77.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-76.) OK MUT-II Data list 68 EGR valve (Refer to P.13A-79.) OK Does the engine stall immediately after the accelerator pedal is released?

NG

NG

NG

NG

Yes

Check the throttle valve position feedback system. (Refer to P.13A-37, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 92.) Check the accelerator position switch. (Refer to P.13A-67, INSPECTION PROCEDURE 27.) Check the engine coolant temperature sensor. (Refer to P.13A-18, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the EGR valve system. (Refer to P.13A-70, INSPECTION PROCEDURE 30.)

Clean around the throttle valve. (Refer to P.13A-97.)

No Measure fuel high pressure between the fuel pump (high pressure) NG and injector. (Refer to P.13A-99.) OK Check ignition timing. (Refer to GROUP 11A - Engine Adjustment.) OK Check ignition coil spark for each cylinder. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil. (3) Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx. 100 V is applied to the injector, or you are seriously injured. (4) Earth the spark plug electrode securely. (5) Check that the spark plug ignites when the engine is cranked.

NG NG

Repair

Check that the crank angle sensor and timing belt cover are properly installed. Replace the ignition coil.

OK Check all the following items: D Spark plugs D Compression pressure D Engine oil viscosity

OK

Check trouble symptom. NG Replace the injector.

13A-52

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE 10 When the engine is hot, it stalls at idling. (Die out)

Probable cause

The cause is probably an improper air/fuel ratio, faulty electronic-controlled throttle valve system, compression pressure. In addition, if the engine stalls suddenly, another possible cause might be a poor connector contact.

D D D D D D D

Have the battery terminals been disconnected recently? No MUT-II Self-Diag code Is a diagnosis code displayed? No MUT-II Data list 79 Throttle position sensor (1st channel) (Refer to P.13A-80.)

Yes Yes

NG

OK Is it easy to reproduce the engine stall?

No

Yes

MUT-II Data list 26 Accelerator pedal position switch (Refer to P.13A-77.) OK MUT-II Data list 13 Intake air temperature sensor (Refer to P.13A-75.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13A-77.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-76.)

NG

NG

NG

NG

Malfunction of the ignition system Malfunction of air/fuel ratio control system Malfunction of electronic-controlled throttle valve system Malfunction of the throttle body Poor connector contact Improper compression pressure Air stuck in the air intake system

Warm up the engine, and then let it run at idle for approx. ten minutes. Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS CODES. Check the throttle position sensor (1st channel) system. (Refer to P.13A-35, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 79.) While carrying out an intermittent malfunction simulation test. (Refer to GROUP 00 - Points to Note for Intermittent Malfunction.), check for sudden changes in the following signals. D Crank angle sensor signal D Injector drive signal D Fuel pump (low pressure) drive signal D Air flow sensor D Primary ignition signal D Power supply to the engine-ECU Check the accelerator pedal position switch. (Refer to P.13A-67, INSPECTION PROCEDURE 27.) Check the intake air temperature sensor. (Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)

Check the barometric pressure sensor. (Refer to P.13A-22, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 25.) Check the engine coolant temperature sensor. (Refer to P.13A-18, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.)

OK MUT-II Data list 59 Oxygen sensor (rear) (Refer to P.13A- 78.) D Transmission: 2nd gear , L range D Driving with throttle widely open OK: 600 - 1,000 mV

NG

Check the oxygen sensor (rear) system. (Refer to P.13A-30, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 59.)

OK MUT-II Data list 11 Oxygen sensor (front) OK: 600 - 1,000 mV when the engine is suddenly raced OK MUT-II Data list 11 Oxygen sensor (front) OK: 0 - 400 mV and 600 - 1,000 mV alternates when the engine is idling (wait for four minutes after the engine started). OK To the next page

NG

NG

Check the oxygen sensor (front) system. (Refer to P.13A-14, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 11.)

Measure fuel high-pressure between the fuel pump (high pressure) and injector. (Refer to P.13A-99.) OK

NG Repair

Check that air is sucked in the air intake system. D Broken intake manifold gasket D Damaged vacuum hose D Damaged air intake hose

GDI <4G6> - Troubleshooting

13A-53

From the previous page OK MUT-II Data list 27 Power steering fluid pressure switch (Refer to P.13A-77.)

NG

Check the power steering fluid pressure switch system. (Refer to P.13A-71, INSPECTION PROCEDURE 31.)

OK MUT-II Data list 28 A/C switch (Refer to P.13A-77.)

NG

Check the A/C switch and A/C relay system. (Refer to P.13A-71, INSPECTION PROCEDURE 32.)

OK MUT-II Data list 31 Small lamp switch (Refer to P.13A-77.)

NG

Check the small lamp switch system. (Refer to P.13A-74, INSPECTION PROCEDURE 35.)

OK MUT-II Data list 29 Inhibitor switch (Refer to P.13A-77.)

NG

Check the ignition switch-ST and inhibitor switch. (Refer to P.13A-68, INSPECTION PROCEDURE 28.)

OK MUT-II Data list 34 Air flow sensor reset signal (Refer to P.13A-77.) OK MUT-II Data list 68 EGR valve (Refer to P.13A-79.) OK Does the engine stall immediately after the accelerator pedal is released?

NG

NG

Yes

Check the air flow sensor system. (Refer to P.13A-15, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 12.) Check the EGR valve. (Refer to P.13A-69, INSPECTION PROCEDURE 29.)

Clean around the throttle valve. (Refer to P.13A-97.)

No Check ignition timing. (Refer to GROUP 11A - Engine Adjustment.)

NG

OK Check ignition coil spark for each cylinder. (1) Remove the ignition coil. NG (2) Install a new spark plug to the removed ignition coil. (3) Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx. 100 V is applied to the injector, or you are seriously injured. (4) Earth the spark plug electrode securely. (5) Check that the spark plug ignites when the engine is cranked. OK Check all the following items: D Spark plugs D Compression pressure D Foreign material (such as water or kerosine) entered the fuel lines

Check that the crank angle sensor and timing belt cover are properly installed.

Replace the ignition coil.

13A-54

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE 11 The engine stalls when starting the car. (Pass out)

Probable cause

The cause is probably poor ignition due to a malfunctioning spark plug (weak spark), or an incorrect air/fuel ratio when the accelerator is depressed.

D D D

Yes

MUT-II Self-Diag code Is a diagnosis code displayed? No MUT-II Data list 68 EGR valve (Refer to P.13A-79.) OK MUT-II Actuator test 08 Purge control solenoid valve (Refer to P.13A-81.) OK Check ignition coil spark for each cylinder. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil. (3) Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx. 100 V is applied to the injector, or you are seriously injured. (4) Earth the spark plug electrode securely. (5) Check that the spark plug ignites when the engine is cranked. OK Check all the following items: (1) Spark plug (2) Check if air is stuck in the air intake system. D Damage intake manifold gasket D Damaged or disconnected vacuum hose D Damaged air intake hose

NG

NG

NG

Malfunction of the ignition system Malfunction of the EGR valve Air stuck in the air intake system

(Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS CODES.) Check the EGR valve. (Refer to P.13A-69, INSPECTION PROCEDURE 29.) Check the purge control solenoid valve system. (Refer to P.13A-70, INSPECTION PROCEDURE 30.) Replace the ignition coil.

GDI <4G6> - Troubleshooting

13A-55

INSPECTION PROCEDURE 12 The engine stalls when decelerating.

Probable cause

The cause is probably an improper air/fuel ratio due to a faulty EGR system, or poor intake air volume due to a faulty electronic-controlled throttle valve system.

D

Have the battery terminals been disconnected recently? No MUT-II Self-Diag code Is a diagnosis code displayed? No MUT-II Data list 26 Accelerator pedal position switch (Refer to P.13A-77.) OK MUT-II Data list 79 Throttle position sensor (1st channel) (Refer to P.13A-80.) OK MUT-II Data list 68 EGR valve (Refer to P.13A-79.) OK Check ignition coil spark for each cylinder. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil. (3) Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx. 100 V is applied to the injector, or you are seriously injured. (4) Earth the spark plug electrode securely. (5) Check that the spark plug ignites when the engine is cranked. OK Check all the following items: D Spark plug D Clean around the throttle valve (Refer to P.13A-97.)

Yes Yes

NG

NG

NG

NG

D

Malfunction of the electronic-controlled throttle valve system Malfunction of the EGR valve

Warm up the engine, and then let it run at idle for approx. ten minutes. (Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS CODES.) Check the accelerator pedal position switch. (Refer to P.13A-67, INSPECTION PROCEDURE 27.) Check the throttle valve position feedback system. (Refer to P.13A-37, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 92.) Check the EGR valve system. (Refer to P.13A-69, INSPECTION PROCEDURE 29.) Replace the ignition coil.

13A-56

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE 13 Hesitation, sag, stumble, poor acceleration or surge

Probable cause

The cause is probably a malfunction of the ignition system, electronic-controlled throttle valve system, compression pressure, etc.

D D D D D

Yes

MUT-II Self-Diag code Is a diagnosis code displayed? OK Check ignition timing. (Refer to GROUP 11A - Engine Adjustment.)

NG

OK MUT-II Data list 26 Accelerator pedal position switch (Refer to P.13A-77.) OK MUT-II Data list 13 Intake air temperature sensor (Refer to P.13A-75.)

NG

NG

Malfunction of the ignition system Malfunction of the air/fuel ratio control system Malfunction of the electronic-controlled throttle valve system Improper compression pressure Air stuck in the air intake system

(Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS CODES.)

Check that the crank angle sensor and timing belt cover are properly installed. Check the accelerator pedal position switch. (Refer to P.13A-67, INSPECTION PROCEDURE 27.) Check the intake air temperature sensor. (Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)

OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13A-77.)

NG

Check the barometric pressure sensor. (Refer to P.13A-22, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 25.)

OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-76.)

NG

Check the engine coolant temperature sensor. (Refer to P.13A-18, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.)

OK MUT-II Data list 79 Throttle position sensor (1st channel) (Refer to P.13A-80.) OK MUT-II Data list 59 Oxygen sensor (rear) (Refer to P.13A-78.) D Transmission: 2nd gear , L range D Driving with throttle widely open OK: 600 - 1,000 mV

NG

NG

Check the throttle valve position feedback system. (Refer to P.13A-38, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 99.) Check the oxygen sensor (rear) system. (Refer to P.13A-30, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 59.)

OK MUT-II Data list 11 Oxygen sensor (front) OK: 600 - 1,000 mV when the engine is suddenly raced OK MUT-II Data list 11 Oxygen sensor (front) OK: 0 - 400 mV and 600 - 1,000 mV alternates when the engine is idling (wait for four minutes after the engine started).

NG

NG

OK MUT-II Actuator test 08 Purge control solenoid valve (Refer to P.13A-81.) OK To the next page

Measure fuel high-pressure between the fuel pump (high pressure) and injector. (Refer to P.13A-99.) OK Check that air is sucked in the air intake system. D Broken intake manifold gasket D Damaged vacuum hose D Damaged air intake hose

OK

MUT-II Data list 68 EGR valve (Refer to P.13A-79.)

Check the oxygen sensor (front) system. (Refer to P.13A-14, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 11.)

NG

NG

Check the EGR valve. (Refer to P.13A-69, INSPECTION PROCEDURE 29.) Check the purge control solenoid valve. (Refer to P.13A-70, INSPECTION PROCEDURE 30.)

13A-57

GDI <4G6> - Troubleshooting From the previous page OK Measure high fuel pressure between the fuel pump (high pressure) and injector. (Refer to P.13A-99.)

NG

Repair

OK Check ignition coil spark for each cylinder. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil. (3) Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx. 100 V is applied to the injector, or you are seriously injured. (4) Earth the spark plug electrode securely. (5) Check that the spark plug ignites when the engine is cranked. OK Check all the following items: D Spark plug D EGR system D Compression pressure D Clogged fuel filter, fuel line

NG

OK

Replace the ignition coil.

Check trouble symptom. NG Replace the injector.

INSPECTION PROCEDURE 14 The feeling of impact when accelerating

Probable cause

The cause is probably an ignition leak being generated in line with an increase in the spark plug request voltage during acceleration.

D

Yes

MUT-II Self-Diag code Is a diagnosis code displayed? No MUT-II Data list 79 Throttle position sensor (1st channel) (Refer to P.13A-80.)

NG

OK OK Check ignition coil spark for each cylinder. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil. (3) Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx. 100 V is applied to the injector, or you are seriously injured. NG (4) Earth the spark plug electrode securely. (5) Check that the spark plug ignites when the engine is cranked.

Malfunction of the ignition system

(Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS CODES.) Check the throttle valve position feedback system. (Refer to P.13A-37, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 92.) Check all the following items: D Spark plug D Ignition current leak

Replace the ignition coil.

13A-58

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE 15 The feeling of impact when decelerating

Probable cause

The cause is probably insufficient intake air due to a faulty electronic-controlled throttle valve system.

D

Yes

MUT-II Self-Diag code Is a diagnosis code displayed? No MUT-II Data list 79 Throttle position sensor (1st channel) (Refer to P.13A-80.)

NG

OK MUT-II Data list 26 Accelerator pedal position switch (Refer to P.13A-77.)

NG

Malfunction of the electronic-controlled throttle valve system

(Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS CODES.) Check the throttle valve position feedback system. (Refer to P.13A-37, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 92.) Check the accelerator pedal position switch system. (Refer to P.13A-67, INSPECTION PROCEDURE 27.)

OK Clean around the throttle valve. (Refer to P.13A-97.)

INSPECTION PROCEDURE 16 Knocking

Probable cause

The cause is probably incorrect detonation control or improper heat range of the spark plugs.

D D

Yes

MUT-II Self-Diag code Is a diagnosis code displayed? No Does knocking occur when the vehicle is driven with the detonation sensor disconnected? (At this time, use the MUT-II to check whether the ignition timing is retarded from when the detonation sensor connector is connected.)

No

Malfunction of the detonation sensor Improper heat range of the spark plugs

(Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS CODES.) Check the detonation sensor system. (Refer to P.13A-23, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 31.)

Yes Check all the following items: D Spark plug D Foreign material (such as water or kerosine) entered the fuel lines

INSPECTION PROCEDURE 17 Run-on (dieseling)

Probable cause

The cause is probably fuel leak from injector(s)

D

Replace the injector.

Malfunction of the injector

13A-59

GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 18 Too high CO and HC concentration when idling

Probable cause

The cause is probably an incorrect air/fuel ratio

D D Yes

MUT-II Self-Diag code Is a diagnosis code displayed? No Check ignition timing. (Refer to GROUP 11A - Engine Adjustment.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-76.) OK MUT-II Data list 13 Intake air temperature sensor (Refer to P.13A-75.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13A-77.) OK MUT-II Data list 59 Oxygen sensor (rear) (Refer to P.13A-78.) D Transmission: 2nd gear , L range D Driving with throttle widely open OK: 600 - 1,000 mV

NG NG

NG

NG

NG

Malfunction of air/fuel ratio control system Deterioration of the catalyst

(Refer to P.13A-13, INSPECTION CHART FOR DIAGNOSIS CODES.) Check that the crank angle sensor and timing belt cover are properly installed. Check the engine coolant temperature sensor. (Refer to P.13A-18, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the intake air temperature sensor. (Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.) Check the barometric pressure sensor. (Refer to P.13A-22, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 25.) Check the oxygen sensor (rear) system. (Refer to P.13A-30, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 59.)

OK MUT-II Data list 11 Oxygen sensor (front) OK: 600 - 1,000 mV when the engine is suddenly raced OK MUT-II Data list 11 Oxygen sensor (front) OK: 0 - 400 mV and 600 - 1,000 mV alternates when the engine is idling (wait for four minutes after the engine started).

NG

OK

Check the oxygen sensor (front) system. (Refer to P.13A-14, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 11.)

Replace the oxygen sensor (front).

Check trouble symptom. NG

NG Measure fuel high-pressure between the fuel pump (high pressure) and injector. (Refer to P.13A-99.)

NG

Repair

OK Check ignition coil spark for each cylinder. (1) Remove the ignition coil. (2) Install a new spark plug to the removed ignition coil. (3) Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx. 100 V is applied to the injector, or you are seriously injured. (4) Earth the spark plug electrode securely. (5) Check that the spark plug ignites when the engine is cranked. OK Check all the following items: D Spark plug D EGR system D Compression pressure D Clogged fuel filter or line

Replace the ignition coil.

OK To the next page

NG

13A-60

GDI <4G6> - Troubleshooting

From the previous page OK MUT-II Data list 68 EGR valve (Refer to P.13A-79.) OK MUT-II Actuator test 08 Purge control solenoid valve (Refer to P.13A-81.) OK Check trouble symptom.

NG

NG

NG

Check the EGR valve system. (Refer to P.13A-69, INSPECTION PROCEDURE 29.) Check purge control solenoid valve system. (Refer to P.13A-70, INSPECTION PROCEDURE 30.) Replace the injector. Check trouble symptom. NG Replace the three-way catalytic converter.

13A-61

GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 19 Low alternator output voltage (approx. 12.3 V)

Probable cause

The cause is probably a malfunction of the alternator or one of the problems listed at right.

D D D

Measure at the alternator connector A-52. D Connect the connector. (Use the test harness MB991519) D Voltage between 1 (black clip) and earth (Engine: Idling) (Radiator fan: Not operating) (Headlamp: OFF ® ON) (Stop lamp: OFF ® ON) (Rear defogger switch: OFF ® ON) OK: Voltage increased by 0.2 - 3.5 V.

NG

Measure at the alternator connector A-52. D Disconnect the connector, and measure at the harness side. D Disconnect the engine-ECU connector. D Continuity between 1 and earth OK: No continuity

NG

Check the harness wire between the alternator and the engine-ECU, and repair if necessary.

OK Check the following connectors: A-30, A-52, B-53

NG

Repair

OK

OK Check the alternator. (Refer to GROUP 16 - Charging System.)

Malfunction of the charging system Open circuit between the alternator G terminal and the engine-ECU Malfunction of the engine-ECU

Replace the engine-ECU.

INSPECTION PROCEDURE 20 Idling speed is improper when A/C is operating

Probable cause

If the engine-ECU detects that the air conditioner is on, it activates the idle speed control (ISC) servo to control idle-up operation. The A/C-ECU judges if the load caused by air conditioner operation is high or low, and converts it to voltage signal (high or low voltage) and inputs the signal to the engine-ECU. Based on this voltage signal, the engine-ECU controls the idle-up speed (for high or low load).

D D

Measure at the engine-ECU connector B-51. D Connect the connector. D Voltage between 73 and earth (Engine: at idle, outside air temperature: 25_C or more) OK: 0 - 3 V [When A/C is MAX. COOL condition (when the load by A/C is high)] System voltage [When A/C is MAX. HOT condition (when the load by A/C is low)] NG Check the A/C system. (Refer to GROUP 55 - On-vehicle Service.)

OK

D

Malfunction of the A/C control system Improper connector contact, open short-circuited harness wire Malfunction of the engine-ECU

Check the following connector: B-51 OK

NG Repair

Check trouble symptom. NG Replace the engine-ECU.

circuit

or

13A-62

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE 21 Fans (radiator fan, A/C condenser fan) are inoperative.

Probable cause

The engine-ECU sends a duty signal to the fan controller according to engine coolant temperature, vehicle speed, or A/C switch. The fan controller controls radiator fan and condenser fan speeds, based on this signal. (The closer the terminal voltage comes to 5 V, the higher the fan speed becomes.)

D D D D D

Measure at engine-ECU connector B-54. D Disconnect the connector, measure at the harness side. D Voltage between terminal 21 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V (The fan runs at high speed.) D Earth terminal 21. (Ignition switch: ON) OK: The fan stops.

NG

the fan motor relay the fan motor the fan controller circuit, or poor connector contact the engine-ECU

Check the following connectors: A-28,A-37 OK

NG Repair

Check trouble symptom. NG

OK

Check the harness wire between the engine-ECU and fan controller.

Check the following connector: B-54 OK

Malfunction of Malfunction of Malfunction of Open or short Malfunction of

OK

NG

NG Repair

Repair Check the radiator fan and condenser fan circuit. (Refer to GROUP 14 - Troubleshooting.)

Check trouble symptom. NG MUT-II Data list 21 Engine coolant temperature sensor OK: After the engine has been warmed up, the engine coolant temperature during idling is identical to the MUT-II reading.

NG

Check the engine coolant temperature sensor system. (Refer to P.13A-18, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.)

OK NG

Check the thermostat. OK Replace the engine-ECU.

Replace

13A-63

GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 22 Clutch switch system malfunction

Probable cause

The clutch pedal switch sends a signal indicating clutch pedal depression to the engine-ECU. The engine-ECU controls the fuel injection properly according to this signal, thus prevents the fluctuation of the engine speed during shift change.

D D

Replace the clutch switch. (Refer to NG P.13A-111.)

D

Malfunction of the clutch switch Open circuit or short-circuited harness wire in the clutch switch circuit Malfunction of the engine-ECU

Replace

OK Measure at the clutch switch connector B-67. D Disconnect the connector, and measure at the harness side. (1) Voltage between 2 and earth (Ignition switch: ON) OK: System voltage (2) Continuity between 1 and earth OK: Continuity OK

OK

NG Repair

Check the trouble symptoms.

Replace the engine-ECU.

Check the following connector: B-53

OK

Check the trouble symptoms. NG

NG Repair (2) NG

Check the harness wire between the clutch switch connectorand the earth, and repair if necessary.

Check the harness wire between the engine-ECU and the clutch switch connector. OK

NG Repair

Check the following connector: B-67

NG

(1) NG

Replace the engine-ECU.

13A-64

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE 23 Engine-ECU power supply and earth circuit system

Probable cause

The cause is probably a malfunction of the engine-ECU or one of the problems listed at right.

D D D

(1) NG Measure at the engine-ECU connectors B-51, B-53, B-54. D Disconnect the connector, and measure at the harness side. (1) Voltage between 82 and earth (Ignition switch: ON) OK: System voltage (2),(3) NG (2) Voltage between 38 and earth OK: System voltage (3) Voltage between 12, 25 and earth (Ignition switch: ON) (4) NG OK: System voltage (When terminal 38 is shorted to earth) (4) Continuity between 13, 26 and earth (5) NG OK: Continuity (5) Voltage between 80 and earth OK: System voltage OK Check the following connectors: B-51, B-53, B-54 OK NG Repair Check the trouble symptoms. NG Replace the engine-ECU.

Check the following connector: B-28, B-89, B-103 OK Check the trouble symptoms.

Open circuit or short-circuited harness wire in the engine-ECU power supply circuit Open circuit or short-circuited harness wire in the engine-ECU earth circuit Malfunction of the engine-ECU NG

NG

Check the harness wire between the engine-ECU and engine control relay, and repair if necessary.

Repair

Check the harness wire between the engine-ECU and ignition switch, and repair if necessary. OK NG Repair

Check the harness wire between the engine-ECU and earth, and repair if necessary. Check the following connectors: B-14, B-44, B-66, B-90, B-103 OK Check the trouble symptoms.

Check the ignition switch. (Refer to GROUP 54.) NG

NG

Repair

Check the harness wire between the engine-ECU and the battery, and repair if necessary.

13A-65

GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 24 Engine control relay and ignition switch-IG system

Probable cause

When the ignition switch ON signal is input to the engine-ECU, the engine-ECU turns on the engine control relay. This causes system voltage to be supplied to the engine-ECU and to the sensors and actuators.

D D D

Check the engine control relay. (Refer to P.13A-106.) OK Measure at the engine control relay connector A-14X. D Disconnect the connector, and measure at the harness side. D Voltage between 3, 4 and earth OK: System voltage

NG

NG

D

Malfunction of the ignition switch Malfunction of the engine control relay Open circuit or short-circuited harness wire of the engine control relay circuit Malfunction of the engine-ECU

Replace NG

Check the following connector: A-28 OK

NG

Check the trouble symptoms.

OK

Repair

Check the harness wire between the battery and the engine control relay, and repair if necessary.

Check the engine-ECU power supply and earth circuit system. (Refer to P.13A-64, INSPECTION PROCEDURE 23.)

INSPECTION PROCEDURE 25 Ignition switch-ST system

Probable cause

The ignition switch-ST outputs a HIGH signal to the engine-ECU while the engine is cranking. The engine-ECU uses this signal to carry out functions such as fuel injection control during starting.

D D

(1) NG Measure at the engine-ECU connector B-51. D Disconnect the connector, and measure at the harness side. (1) Voltage between 71 and earth (Ignition switch: START) (2) NG OK: 8 V or more (2) Continuity between 91 and earth OK: Continuity OK Check the following connector: B-51 OK Check the trouble symptoms. NG Replace the engine-ECU.

NG

D

Check the following connectors: A-30, B-13 OK Check the trouble symptoms. Check the harness wire between the engine-ECU connector (terminal No.91) and earth, and repair if necessary. Repair

Malfunction of the ignition switch Open circuit or short-circuited harness wire of the ignition switch circuit Malfunction of the engine-ECU NG

NG

Repair

Check the harness wire between the engine-ECU and the ignition switch. OK NG Repair Check the ignition switch. (Refer to GROUP 54.)

13A-66

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE 26 Ignition switch-ST and inhibitor switch system

Probable cause

The ignition switch-ST outputs a HIGH signal to the engine-ECU while the engine is cranking, and the engine-ECU uses this signal to carry out functions such as fuel injection control during starting. The inhibitor switch inputs the position of the selector lever to the engine-ECU. The engine-ECU uses this signal to carry out idle speed control.

D D D

Check the inhibitor switch (Refer to GROUP 23 - On-vehicle Service.) OK

NG

(1) NG Measure at the inhibitor switch connector A-89. D Disconnect the connector, and measure at the harness side. (1) Voltage between 10 and earth (Ignition switch: ON) OK: System voltage (2) Continuity between 9 and earth (2) NG OK: Continuity (3) Voltage between 10 and earth (Ignition switch: START) Disconnect the engine-ECU (3) NG connector. OK: System voltage

D

Malfunction of the ignition switch Malfunction of the inhibitor switch Open circuit or short-circuited harness wire between ignition switch and inhibitor switch Malfunction of the engine-ECU

Replace

Check the harness wire between the engine-ECU and the inhibitor switch connector.

NG

OK Replace the engine-ECU.

Check the following connectors: A-30, A-39 OK Check the trouble symptoms.

NG

NG

OK Check the following connector: A-89 OK NG Repair Check the trouble symptoms. NG Check the harness wire between the engine-ECU and the inhibitor switch. OK NG Repair Replace the engine-ECU.

Repair

Check the following connector: B-13

NG

Repair

Check the harness wire between the inhibitor switch connector and the starter S terminal, and repair if necessary. Repair

OK Check the trouble symptoms. NG Check the harness wire between the inhibitor switch and the ignition switch connector. OK Check the ignition switch. (Refer to GROUP 54.)

NG

Repair

13A-67

GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 27 Accelerator pedal position switch system

Probable cause

The accelerator pedal position switch detects that the accelerator pedal is fully closed, and sends a signal to the engine-ECU. The engine-ECU controls idle speed, based on this signal.

D D D D

Check the accelerator pedal position switch. (Refer to P.13A-109.) OK Measure at accelerator pedal position sensor (1st channel) connector A-62. D Disconnect the connector, and measure at the harness side. D Voltage between terminal 3 and earth (Ignition switch: ON) OK: 4 V or more D Continuity between terminal 4 and earth OK: Continuity

NG NG

Maladjustment of the accelerator cable Maladjustment of the accelerator pedal position switch Open circuit or short-circuited harness wire in the accelerator pedal position switch system, or poor connector contact Malfunction of the engine-ECU

Replace the accelerator pedal position sensor assembly. Check the following connectors: A-27, B-51, B-52 OK

NG Repair

Check trouble symptom. NG

OK

Check the harness wire between the engine-ECU and accelerator pedal position sensor 1 (1st channel). Check the following connector: A-62 OK Check trouble symptom.

NG NG

OK Repair

Replace the engine-ECU.

NG Repair

13A-68

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE 28 Fuel pump (low pressure) system

Probable cause

The engine-ECU turns on the fuel pump relay while the engine is cranking or running, and supplies power source to the fuel pump (low pressure).

D D D D

MUT-II Actuator test 07 Fuel pump (Refer to P.13A-81.) NG Check the fuel pump relay. (Refer to P.13A-106.) OK Measure at fuel pump relay connector A-15X. D Disconnect the connector, and measure at the harness side. D Voltage between terminals 3, 4 and earth (Ignition switch: ON) OK: System voltage

OK

NG

NG

Malfunction of the fuel pump relay Malfunction of the fuel pump (low pressure) Open circuit or short-circuited harness wire in the fuel pump (low pressure) circuit, or poor connector contact Malfunction of the engine-ECU

Normal

Replace

Check the following connectors: B-28, B-89, B-103 OK

NG

NG

Check trouble symptom.

Repair

Check the harness wire between the fuel pump relay and ignition switch. OK NG

OK Measure at engine-ECU connector B-54. D Disconnect the connector, and measure at the harness side. D Voltage between terminal 22 and earth (Ignition switch: ON) OK: System voltage

NG

Check the following connector: A-15X OK NG

Check the ignition switch. (Refer to GROUP 54 - Ignition Switch.)

Repair NG

Check trouble symptom.

OK Measure at engine-ECU connector B-54. D Disconnect the connector, and measure at the harness side. D Short circuit between terminal 22 and earth (Ignition switch: ON) OK: The fuel pump operates (its operation sound can be heard).

Repair

OK

Check the following connector: B-54 OK

NG

Check trouble symptom.

NG (1) NG Measure at fuel pump (low pressure) connector C-20. D Disconnect the connector, and measure at the harness side. (1) Voltage between terminal 5 and earth (Ignition switch: ON) OK: System voltage (2) Continuity between 4 and earth (2) NG OK: Continuity OK

NG

Check the following connectors: A-15X, B-13, B-65, C-34 OK

NG

NG

Check trouble symptom.

Check the harness wire between the fuel pump relay and engine-ECU, and repair if necessary. Repair

Replace the engine-ECU.

Repair

Check the harness wire between the fuel pump relay and fuel pump (low pressure), and repair if necessary.

Check the following connector: C-34 OK NG Repair Check trouble symptom.

Check the following connector: C-20 OK Check trouble symptom. NG Replace the fuel pump (low pressure).

NG

Repair

NG

Check the harness wire between the fuel pump (low pressure) and earth, and repair if necessary.

13A-69

GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 29 EGR valve (stepper motor) system

Probable cause

The engine-ECU controls the EGR valve (stepper motor) in order to control the amount of exhaust gas mixed in the intake air.

D D D

Check the EGR valve. (Refer to GROUP 17 - Emission Control System.) OK Measure at the EGR valve connector A-91. D Disconnect the connector, and measure at the harness side. D Voltage between 2, 5 and earth (Ignition switch: ON) OK: System voltage

NG

NG

Replace

Check the following connector: A-14X OK Check the trouble symptoms.

OK Measure at the engine-ECU connector B-53. D Disconnect the connector, and measure at the harness side. D Voltage between 31, 32, 39, 40 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: B-53 OK Check the trouble symptoms.

NG

Check the following connector: A-91 OK Check the trouble symptoms.

NG

NG

Malfunction of the EGR valve Open circuit or short-circuited harness wire in the EGR valve circuit Malfunction of the engine-ECU

Repair

Replace the engine-ECU.

NG

NG

NG

NG

Repair

Check the harness wire between the engine control relay and the EGR valve, and repair if necessary. Repair

Check the harness wire between the engine-ECU and EGR valve, and repair if necessary.

13A-70

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE 30 Purge control solenoid valve system

Probable cause

The engine-ECU controls the purge control solenoid valve in order to control the purge air coming from the canister.

D D D

Check the purge control solenoid valve. (Refer to GROUP 17 - On-vehicle Service.) OK Measure at the purge control solenoid valve connector A-76. D Disconnect the connector, and measure at the harness side. D Voltage between 2 and earth (Ignition switch: ON) OK: System voltage

NG

NG

Replace

Check the harness wire between the engine control relay and the purge control solenoid valve, and repair if necessary.

OK Measure at the engine-ECU connector B-54. D Disconnect the connector, and measure at the harness side. D Voltage between 5 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: B-54 OK Check the trouble symptoms.

NG

Check the following connector: A-76 OK Check the trouble symptoms.

NG

NG

Malfunction of the purge control solenoid valve Open circuit or short-circuited harness wire in the purge control solenoid valve circuit Malfunction of the engine-ECU

Repair

Replace the engine-ECU.

NG

NG

Repair

Check the harness wire between the engine-ECU and the purge control solenoid valve, and repair if necessary.

13A-71

GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 31 Power steering fluid pressure switch system

Probable cause

The power steering fluid pressure switch sends a signal to the engine-ECU according to power steering load. Based on this signal, the engine-ECU controls the throttle control servo so that idle speed increases when the power steering is in operation.

D D

Check the power steering fluid pressure switch. (Refer to GROUP 37A - On-vehicle Service.) OK Measure at power steering fluid pressure switch connector A-96. D Disconnect the connector, and measure at the harness side. D Voltage between terminal 1 and earth (Ignition switch: ON) OK: System voltage

NG

NG

Replace

Check the following connector: B-53 OK

NG Repair

OK

Check trouble symptom.

Check the following connector: A-96

NG

NG

OK

D

Malfunction of the power steering fluid pressure switch Open circuit or short-circuited harness wire in the power steering fluid pressure switch circuit, or poor connector contact Malfunction of the engine-ECU

Check the harness wire between the engine-ECU and power steering fluid pressure switch.

Repair

OK

NG Repair

NG

Check trouble symptom.

Replace the engine-ECU.

INSPECTION PROCEDURE 32 A/C switch and A/C relay system

Probable cause

If the engine-ECU receives a ‘A/C on’ signal, it operates the throttle control servo and A/C compressor magnetic clutch so that idle speed increases.

D D D D

Service the A/C compressor relay. (Refer to GROUP 55 - On-vehicle Service.) OK Measure at engine-ECU connectors B-53, B-54. D Disconnect the connector, and measure at the harness side. D Voltage between terminals 8, 45 and earth (Ignition switch: ON) OK: 0 - 3 V (A/C switch: OFF) System voltage (A/C switch: ON) D Connect terminal 8 to earth. (Ignition switch: ON, A/C switch: ON) OK: A/C compressor clutch turns on. NG Check the A/C system. (Refer to GROUP 55 - On-vehicle Service.)

NG

OK

Malfunction of the A/C control system Malfunction of the A/C switch Open circuit or short-circuited harness wire in the A/C switch circuit, or poor connector contact Malfunction of the engine-ECU

Replace

Check the following connectors: B-53, B-54 NG

OK

Repair Check trouble symptom. NG Replace the engine-ECU.

13A-72

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE 33 M/T oil temperature sensor system

Probable cause

This sensor inputs the manual transmission oil temperature to the engine-ECU. The engine-ECU uses this input to control the idle speed control servo so that the idle speed is increased when the manual transmission oil temperature becomes low.

D D

Check the M/T oil temperature sensor. (Refer to GROUP 22 On-vehicle Service.) OK Measure at the M/T oil temperature sensor connector A-87. D Disconnect the connector, and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 2 and earth OK: Continuity

NG

NG

Replace

Check the following connectors: B-51, B-52 NG

OK

Repair Check the trouble symptoms.

OK

NG

Check the following connector: A-87 OK

D

Malfunction of the M/T oil temperature sensor Open circuit or short-circuited harness wire in the M/T oil temperature sensor circuit Malfunction of the engine-ECU

Check the harness wire between the engine-ECU and the M/T oil temperature sensor.

NG

OK

Repair

NG Repair

Check the trouble symptoms.

NG

Replace the engine-ECU.

13A-73

GDI <4G6> - Troubleshooting INSPECTION PROCEDURE 34 Stop lamp switch system

Probable cause

The engine-ECU determines whether the brake pedal is depressed or not, by means of the stop lamp switch input signal.

D D D

Check the stop lamp switch. (Refer to GROUP 35 - Brake Pedal.) OK Measure at stop lamp switch connector B-28. D Disconnect the connector, and measure at the harness side. D Voltage between terminal 2 and earth OK: System voltage

NG NG

Malfunction of the stop lamp switch Open circuit or short-circuited harness wire in the stop lamp circuit, or poor connector contact Malfunction of the engine-ECU

Replace

Check the following connectors: B-65, B-66 OK

NG Repair

OK Check trouble symptom. NG Check the harness wire between the battery and stop lamp switch.

Measure at engine-ECU connector B-53. D Disconnect the connector, and measure at the harness side. D Voltage between terminal 35 and earth (Ignition switch: ON) OK: 0 - 3 V (when the brake pedal is not depressed) System voltage (when the brake pedal is depressed)

NG

Check the following connectors: B-14, B-65 NG

OK

Repair

OK

Check trouble symptom. NG Check the harness wire between the engine-ECU and stop lamp, and repair if necessary.

Check the following connector: B-53 OK Check trouble symptom. NG Replace the engine-ECU.

NG

Repair

13A-74

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE 35 Small lamp switch

Probable cause

The engine-ECU determines whether the small lamp switch is on or off. According to that information, the engine-ECU controls alternator output current when the vehicle is started.

D

Measure at the engine-ECU connector B-52. D Disconnect the connector, and measure at the harness side. D Voltage between 52 and earth (Lighting switch: ON) OK: System voltage

NG

D

Check the taillamp circuit. (Refer to ELECTRICAL WIRING.)

OK Check the following connector: B-52 OK Check the trouble symptoms. NG Replace the engine-ECU.

NG

Improper connector contact, open circuit or short-circuited harness wire in the taillamp circuit Malfunction of the engine-ECU

Repair

13A-75

GDI <4G6> - Troubleshooting DATA LIST REFERENCE TABLE

Caution When shifting the select lever to D range, the brakes should be applied so that the vehicle does not move forward. NOTE *1: Within four minutes after starting the engine *2: In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10% longer than the standard time. *3: The accelerator pedal position switch normally turns off when the voltage of the accelerator pedal position sensor (1st channel) is 50 - 100 mV higher than the voltage at the idle position. If the accelerator pedal position switch turns back on after the accelerator pedal position sensor voltage has risen by 100 mV and the throttle valve has opened, the accelerator pedal position switch and the accelerator pedal position sensor (1st channel) need to be adjusted. Item No.

Check items

Requirements

11

Oxygen sensor

Engine: After warmup

12

Air flow sensor

D D

D

13

Intake air temperature sensor

Normal condition

Inspection procedure No.

Reference page

Idling

0 mV

13A-14

Sudden racing

600 - 1,000 mV

Code No.11

2,500 r/min

400 mV or less and 600 - 1,000 mV alternates. Code No.12

13A-15

Code No.13

13A-16

Engine coolant Idling temperature: 80 - 95_C Lamps, electric 2,500 r/min cooling fan and all accessories: OFF Racing Transmission: Neutral (A/T: P range)

Ignition switch: ON

20 - 55 Hz 70 - 90 Hz Frequency increases in response to racing.

Intake air temperature: - 20_C

- 20_C

Intake air temperature: 0_C

0_C

Intake air temperature: 20_C

20_C

Intake air temperature: 40_C

40_C

Intake air temperature: 80_C

80_C

13A-76

GDI <4G6> - Troubleshooting

Item No.

Check items

Requirements

14

Throttle position sensor (2nd channel)

D D

Engine coolant temperature: 80 - 95_C Ignition switch: ON (Engine stopped)

16

Power supply voltage

Ignition switch: ON

18

Cranking signal (Ignition switch - ST)

Transmission: Neutral (A/T: P range)

21

22

Engine coolant temperature sensor

Crank sensor

angle

Ignition switch: ON

D D D D

Engine: cranking Tachometer: Connected

Normal condition

Inspection procedure No.

Reference page

Release the accelerator pedal.

4,000 - 4,900 mV

Code No.14

13A-17

Depress the accelerator pedal gradually.

Voltage decreases in response to the pedal depression.

Depress the accelerator pedal fully.

100 - 1,100 mV System voltage

Procedure No.24

13A-65

Engine: Stopped

OFF

Engine: Cranking

ON

Procedure No.25 Procedure No.26

13A-65 13A-66

Engine coolant temperature: - 20_C

- 20_C

Code No.21

13A-18

Engine coolant temperature: 0_C

0_C

Engine coolant temperature: 20_C

20_C

Engine coolant temperature: 40_C

40_C

Engine coolant temperature: 80_C

80_C

Compare the engine speed readings on the tachometer and the MUT-II.

Accord

Code No.22

13A-19

Engine: Idling Engine coolant Accelerator temperature: pedal position - 20_C switch: ON Engine coolant temperature: 0_C

1,300 - 1,500 r/min

Engine coolant temperature: 20_C

1,050 - 1,250 r/min

Engine coolant temperature: 40_C

850 - 1,050 r/min

Engine coolant temperature: 80_C

550 - 750 r/min*1

1,200 - 1,400 r/min

13A-77

GDI <4G6> - Troubleshooting Item No.

Check items

Requirements

25

Barometric pressure sensor

Ignition switch: ON

26

27

28

29

31

34

37

Inspection procedure No.

Reference page

Altitude: 0 m

101 kPa

13A-22

Altitude: 600 m

95 kPa

Code No.25

Altitude: 1,200 m

88 kPa

Altitude: 1,800 m

81 kPa Procedure No.27

13A-67

Procedure No.31

13A-71

Procedure No.32

13A-71

Procedure No.26

13A-66

Procedure No.35

13A-74

Code No.12

13A-15

-

-

-

-

Accelerator pedal position switch

Ignition switch: ON (Depress and release the accelerator pedal several times)

Release the accelerator pedal.

ON

Depress the accelerator pedal slightly.

OFF

Power steering fluid pressure switch

Engine: Idling

Steering wheel stationary

OFF

Steering turning

ON

A/C switch

Engine: Idling (The A/C compressor is running when the A/C switch is on.)

A/C switch: OFF

OFF

A/C switch: ON

ON

Ignition switch: ON

Selector lever: P or N

P, N

Selector lever: D, 2, L or R

D, 2, L, R

Lighting OFF

OFF

Inhibitor switch

Small switch

lamp

Engine: Idling

wheel

switch:

Lighting switch: ON

ON

Air flow sensor reset signal

Engine: After having warmed up

Engine is idling

ON

3,000 r/min

OFF

Volumetric efficiency

D

Engine is idling

15 - 35%

2,500 r/min

15 - 35%

Engine is suddenly raced

Volumetric efficiency increases in response to racing

D

D

38

Normal condition

Crank sensor

angle

D D

Engine coolant temperature: 80 - 95_C Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral (A/T: P range)

Engine: Cranking [reading is possible Engine speeds disat 2,000 r/min or less] played on the Tachometer: Connected MUT-II and tachometer are identical.

13A-78

GDI <4G6> - Troubleshooting

Item No.

Check items

Requirements

Normal condition

Inspection procedure No.

Reference page

41

Injector time *2

D

Engine coolant Idling temperature: 80 - 95_C Lamps, electric cooling fan and 2,500 r/min all accessories: OFF Transmission: Sudden racing Neutral (A/T: P range)

0.4 - 0.6 ms*1

-

-

Engine: After Idling warm-up Set a timing 2,500 r/min light.

15 - 25_BTDC *2

Code No.44

13A-26

drive

D

D

44

Ignition advance

D D

0.4 - 0.8 ms

Increases

25 - 35_BTDC

48

M/T oil temperature sensor

Drive after the engine has warmed up.

Drive for 15 minutes or more.

Gradually increases to 50 - 90_C.

Procedure No.33

13A-72

49

A/C relay

Engine: After warmup, idling

A/C switch: OFF

OFF (compressor clutch is not operating)

Procedure No.32

13A-71

A/C switch: ON

ON (compressor clutch is operating)

59

Oxygen sensor (rear)

D

D

66

Brake vacuum sensor

D D

D

67

Stop switch

lamp

Transmission: 3,500 r/min 2nd gear , L range Drive with throttle widely open

600 - 1,000 mV

Code No.59

13A-30

Engine coolant temperature: 80 - 95_C Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral (A/T: P range)

Stop the engine from idling speed, and then depress the brake pedal several times with the ignition switch on.

Displayed pressure increases.

Code No.66

13A-32

Brake pedal: Depressed

OFF

Procedure No.32

13A-71

Brake pedal: Released

ON

Ignition switch: ON

13A-79

GDI <4G6> - Troubleshooting Item No.

Check items

Requirements

Normal condition

Inspection procedure No.

Reference page

68

EGR valve

D

Engine coolant Idling temperature: 80 - 95_C Lamps, electric cooling fan and all accessories: 2,500 r/min OFF Transmission: Neutral

0 - 15 STEP

Procedure No.29

13A-69

Engine coolant Engine: Idling temperature: 80 - 95_C Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral (A/T: P range)

4 - 7.5 MPa

-

-

Release the accelerator pedal.

300 - 1,000 mV

Code No.77

13A-33

Depress the accelerator pedal gradually.

Increases in response to the pedal depression stroke.

Depress the accelerator pedal fully.

4,600 - 5,200 mV

Release the accelerator pedal.

300 - 1,000 mV

Code No.78

13A-34

Depress the accelerator pedal gradually.

Increases in response to pedal depression stroke.

Depress the accelerator pedal fully.

4,600 - 5,200 mV

D

D 74

Fuel pressure sensor

D D

D

77

78

Accelerator pedal position sensor (2nd channel)

Accelerator pedal position sensor *3

Ignition switch: ON

Ignition switch: ON

0 - 10 STEP

13A-80

GDI <4G6> - Troubleshooting

Item No.

Check items

Requirements

79

Throttle position sensor (1st channel)

D D

Engine coolant temperature: 80 - 95_C Ignition switch: ON (Engine stopped)

Engine: After warmup, idling

99

Fuel injection mode

Engine: After warm up

Normal condition

Inspection procedure No.

Reference page

Release the accelerator pedal.

450 - 800 mV

Code No.79

13A-35

Depress the accelerator pedal gradually.

Increases in response to pedal depression stroke.

4,600 - 5,200 mV

3,900 - 4,900 mV

No load

450 - 1,000 mV

A/C switch: OFF ® ON

Increases by 100 600 mV.

Selector lever: N ® D range

Increases by 0 200 mV.

Idling (for several minutes after engine start)

Lean compression

-

-

2,500 r/min

Stoichio feedback

Sudden racing after idle position

Open loop

metric

13A-81

GDI <4G6> - Troubleshooting ACTUATOR TEST REFERENCE TABLE Item No.

Inspection item

Drive contents

Inspection contents

Normal condition

Inspection procedure No.

Reference page

01

Injectors

Cut fuel to No. 1 injector

Engine: After having warmed up/Engine is idling (Cut the fuel supply to each injector in turn and check cylinders which don’t affect idling.)

Idling condition becomes different (becomes unstable).

Code No. 41

13A-24

02

Cut fuel to No. 2 injector

03

Cut fuel to No. 3 injector

04

Cut fuel to No. 4 injector

07

Fuel pump (low pressure)

Fuel pump operates and fuel is recirculated.

Ignition switch: ON

Sound of operation is heard.

Procedure No. 28

13A-68

08

Purge control solenoid valve

Solenoid valve turns from OFF to ON.

Ignition switch: ON

Sound of operation can be heard when solenoid valve is driven.

Procedure No. 30

13A-70

17

Basic ignition timing

Set the engineECU to ignition timing adjustment mode

Idling after engine warm up

5_BTDC

-

-

21

Fan controller

Drive the fan motor

Ignition switch: ON

The fan motor operates

Procedure No.21

13A-62

34

Electroniccontrolled throttle valve system

Close the throttle valve fully

Ignition switch: ON

Operation sound can be heard

Code No.91

13A-36

13A-82

GDI <4G6> - Troubleshooting

CHECK AT THE ENGINE-ECU TERMINALS TERMINAL VOLTAGE CHECK CHART Engine-ECU Connector Terminal Arrangement

Terminal No.

Check item

Check requirements (engine condition)

Normal condition

1

No.1 injector

14

No.2 injector

Engine: Warm up, and then depress the accelerator pedal suddenly from the idle speed.

Decreases slightly for short time from 9 - 13 V.

2

No.3 injector

15

No.4 injector

5

Purge control solenoid valve

D

Engine: stopped

System voltage

Engine: Start the engine, and then increase engine speed up to 3,500 r/min.

Voltage decreases.

D

6

Oxygen sensor heater

Engine coolant temperature: 80 - 95_C Ignition switch: ON

Engine: idling

0 - 3V

Engine: 3,500 r/min

System voltage

8

A/C relay

D D

Engine: idling A/C switch: OFF ® (Compressor is operating)

10

No.1 ignition coil

Engine: 3,000 r/min

0.1 - 2.0 V

11

No.2 ignition coil

23

No.3 ignition coil

24

No.4 ignition coil

12

Power supply

Ignition switch: ON

System voltage

Throttle valve control servo relay

Ignition switch: OFF

0 - 0.3 V

Ignition switch: ON

0.5 - 1.0 V

Air flow sensor reset signal

Engine: idling

0 - 1V

Engine: 3,000 r/min

6 - 9V

ON

System voltage, or changes from momentarily 6 V or more to 0 ® 3 V

25 16

19

13A-83

GDI <4G6> - Troubleshooting Terminal No.

Check item

Check requirements (engine condition)

Normal condition

20

Injector driver relay

Ignition switch: OFF

0 - 0.1 V

Ignition switch: ON

0.5 - 1.0 V

Radiator and condenser fans are not operating.

0 - 0.3 V

Radiator and condenser fans are operating.

0.7 V or more

Ignition switch: ON

Engine: stopped

System voltage

Engine: Idling

0 - 3V

21

22

Fan controller

Fuel pump relay

31

EGR valve (C)

Ignition switch: Immediately after turning ON

5 - 8 V (fluctuates for approx. three seconds)

32

EGR valve (D)

39

EGR valve (A)

40

EGR valve (B)

33

Alternator G terminal

D D D D D

Engine: Warm up, and then idling Radiator fan: not operating Headlamp: OFF ® ON Stop lamp: OFF ® ON Rear defogger switch: OFF ® ON

Voltage increases by 0.2 - 3.5 V

41

Alternator FR terminal

D D D D D

Engine: Warm up, and then idling Radiator fan: not operating Headlamp: OFF ® ON Stop lamp: OFF ® ON Rear defogger: OFF ® ON

Voltage decreases

34

Oxygen sensor (rear)

D

Transmission: 2nd gear , L range Engine speed: 3,500 r/min or more Driving with the throttle valve widely open

0.6 - 1.0 V

D D 35

Stop lamp switch

Depress the brake pedal.

System voltage

Release the brake pedal.

0 - 3V

36

Engine warning lamp

Ignition switch: OFF ® ON

0 - 3 V ® System voltage (after several seconds)

37

Power steering fluid pressure switch

Engine: Warm up, and then idling

Steering wheel stationary

System voltage

Steering wheel turning

0 - 3V

38

Engine control relay

Ignition switch: OFF

0 - 3V

Ignition switch: ON

System voltage

13A-84

GDI <4G6> - Troubleshooting

Terminal No.

Check item

Check requirements (engine condition)

Normal condition

42

Brake vacuum sensor

Engine: Stop the engine from idle speed, turn the ignition switch ON, and then depress the brake pedal several times.

Voltage increases

44

Clutch switch

Depress the clutch pedal

0 - 3V

Release the clutch pedal

System voltage

Engine: idling

A/C switch: OFF

0 - 3V

A/C switch: ON (Compressor is operating)

System voltage

45

A/C switch (1st channel)

51

Injector open circuit check signal

Engine: Increase engine speed from idle speed to 4,000 r/min.

Decreases slightly (approx.0.7 V) from 4.5 V - 5.0 V.

52

Small lamp switch

Lighting switch: OFF

0 - 3V

Lighting switch: ON (Taillamp: ON)

System voltage

Ignition switch: ON

Release the accelerator pedal.

0 - 1V

Depress the accelerator pedal slightly.

4 V or more

57

Accelerator pedal position switch

58

Tachometer output

Engine: 3,000 r/min

2.0 - 9.0 V

71

Ignition switch - ST

Engine: Cranking

8 V or more

72

Intake air temperature sensor

Ignition switch: ON

Intake air temperature: 0_C

3.2 - 3.8 V

Intake air temperature: 20_C

2.3 - 2.9 V

Intake air temperature: 40_C

1.5 - 2.1 V

Intake air temperature: 80_C

0.4 - 1.0 V

73

A/C switch (2nd channel)

Refer to GROUP 55 - Troubleshooting “Check at the A/C-ECU terminal, engine-ECU output terminals.”

74

Fuel pressure sensor

Engine: Idling

0.3 - 4.7 V

75

M/T oil temperature sensor

M/T oil temperature: 25_C

2.4 - 2.7 V

M/T oil temperature: 80_C

0.5 - 0.8 V

13A-85

GDI <4G6> - Troubleshooting Terminal No.

Check item

Check requirements (engine condition)

Normal condition

76

Oxygen sensor (front)

Engine: Warm up, and then hold the engine speed at 2,500 r/min (Use a digital voltmeter).

0 « 0.8 V alternates.

77

Sensor power supply

Ignition switch: ON

4.5 - 5.5 V

81

Power supply to accelerator pedal position sensor (1st channel)

Ignition switch: ON

4.5 - 5.5 V

80

Back-up power source

Ignition switch: OFF

System voltage

82

Ignition switch - IG

Ignition switch: ON

System voltage

83

Engine coolant temperature sensor

Ignition switch: ON

84

85

Throttle position sensor (2nd channel)

Barometric pressure sensor

Ignition switch: ON

Ignition switch: ON

86

Vehicle speed sensor

D D

87

Accelerator pedal position sensor 1

Ignition switch: ON

88

89

Camshaft position sensor

Crank angle sensor

Engine coolant temperature: 0_C

3.2 - 3.8 V

Engine coolant temperature: 20_C

2.3 - 2.9 V

Engine coolant temperature: 40_C

1.3 - 1.9 V

Engine coolant temperature: 80_C

0.3 - 0.9 V

Release the accelerator pedal.

4.0 - 4.9 V

Depress the accelerator pedal fully.

0.1 - 1.1 V

Altitude: 0 m

3.7 - 4.3 V

Altitude: 1,200 m

3.2 - 3.8 V

Ignition switch: ON Move the vehicle forward.

0 V « system voltage alternates.

Release the accelerator pedal.

0.9 - 1.2 V

Depress the accelerator pedal fully.

4 V or more

Engine: Cranking

0.3 - 3.0 V

Engine: Idling

0.5 - 3.5 V

Engine: Cranking

0.4 - 4.0 V

Engine: Idling

1.5 - 2.5 V

13A-86

GDI <4G6> - Troubleshooting

Terminal No.

Check item

Check requirements (engine condition)

Normal condition

90

Air flow sensor

Engine: Idling

2.2 - 3.2 V

Engine: 2,500 r/min 91

Inhibitor switch

Ignition switch: ON

Selector lever: P or N range

0 - 3V

Selector lever: Other than P or N range

8 - 14 V

CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS 1. Turn the ignition switch to OFF. 2. Disconnect the engine-ECU connector. 3. Measure the resistance and check for continuity between the terminals of the engine-ECU harness-side connector while referring to the check chart. NOTE (1) When measuring resistance and checking continuity, a harness for checking contact pin pressure should be used instead of inserting a test probe. (2) Checking need not be carried out in the order given in the chart. Caution If the terminals that should be checked are mistaken, or if connector terminals are not correctly shorted to earth, damage may be caused to the vehicle wiring, sensors, engine-ECU and/or ohmmeter. Be careful to prevent this! 4. If the ohmmeter shows any deviation from the standard value, check the corresponding sensor, actuator and related electrical wiring, and then repair or replace. 5. After repair or replacement, recheck with the ohmmeter to confirm that the repair or replacement has corrected the problem.

GDI <4G6> - Troubleshooting

13A-87

Engine-ECU Harness Side Connector Terminal Arrangement

Terminal No.

Check item

Standard value, normal condition (check requirements)

5 - 12

Purge control solenoid valve

36 - 44 W (at 20_C)

6 - 12

Oxygen sensor heater control

11 - 18 W (at 20_C)

13 - Body earth

Earth

Continuity (0 W)

31 - 12

EGR valve (C)

15 - 20 W (at 20_C)

32 - 12

EGR valve (D)

39 - 12

EGR valve (A)

40 - 12

EGR valve (B)

57 - 92

Accelerator pedal position switch

26 - Body earth

Continuity (when the accelerator pedal is released) No continuity (when the accelerator pedal is slightly depressed)

72 - 53

Intake air temperature sensor

5.3 - 6.7 kW (when intake air temperature is 0_C) 2.3 - 3.0 kW (when intake air temperature is 20_C) 1.0 - 1.5 kW (when intake air temperature is 40_C) 0.30 - 0.42 kW (when intake air temperature is 80_C)

83 - 53

Engine coolant temperature sensor

5.1 - 6.5 kW (when engine coolant temperature is 0_C) 2.1 - 2.7 kW (when engine coolant temperature is 20_C) 0.9 - 1.3 kW (when engine coolant temperature is 40_C) 0.26 - 0.36 kW (when engine coolant temperature is 80_C)

91 - Body earth

Inhibitor switch

Continuity (when the selector lever is at P or N range) No continuity (when the selector lever is at a range other than P or N)

13A-88

GDI <4G6> - Troubleshooting

CHECK AT THE THROTTLE VALVE CONTROLLER TERMINALS TERMINAL VOLTAGE CHECK CHART Throttle Valve Controller Terminal Arrangement

Terminal No.

Check items

Requirements

Normal value

1

Throttle valve control servo (A+)

D D

Decreases slightly from system voltage.

9

Throttle valve control servo (B+)

Ignition switch: ON Accelerator pedal: Fully opened ® fully closed

14

Throttle valve control servo (A- )

D D

Decreases slightly (approx. 2 V) from system voltage.

15

Throttle valve control servo (B- )

Ignition switch: ON Accelerator pedal: Fully closed ® fully opened

2

Power supply to throttle valve control servo

Ignition switch: ON

System voltage

5

Power supply

Ignition switch: ON

System voltage

6

Sensor voltage

Ignition switch: ON

4.5 - 5.5 V

7

Throttle position sensor (1st channel)

Ignition switch: ON

20

22

Accelerator pedal position sensor (2nd channel)

Ignition switch - IG

Ignition switch: ON

Ignition switch: ON

Release the accelerator pedal.

0.4 - 0.8 V

Depress the accelerator pedal fully.

3.9 - 4.9 V

Release the accelerator pedal.

0.7 - 1.4 V

Depress the accelerator pedal fully.

4 V or more

System voltage

13A-89

GDI <4G6> - Troubleshooting

INSPECTION PROCEDURE USING AN ANALYZER

Analyzer

AIR FLOW SENSOR (AFS) Measurement Method 1. Disconnect the air flow sensor connector, and connect the special tool (test harness: MB991709) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to air flow sensor connector terminal 3.

Special patterns pickup

Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 90. Standard Wave Pattern Observation conditions Function

Special patterns

Pattern height

Low

Pattern selector

Display

Engine r/min

Idle speed

Standard wave pattern (V) 10 T1

0

The time (cycle time) T is reduced when the amount of intake air increases.

T T2

Times T1 and T2 are equal.

Time

Observation conditions (from conditions above engine speed is increased by racing.) (V) 10

0

T

Time

Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased.

13A-90

GDI <4G6> - Troubleshooting Examples of Abnormal Wave Patterns D Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. D

Example 2 Cause of problem Damaged rectifier or vortex generation column Wave pattern characteristics Unstable wave pattern with non-uniform frequency. However, when an ignition leak occurs during acceleration, the wave pattern will be distorted temporarily, even if the air flow sensor is normal.

Camshaft position connector

sensor

Special patterns pick-up

Crank angle sensor connector

Analyzer

CAMSHAFT POSITION SENSOR AND CRANK ANGLE SENSOR Measurement Method 1. Disconnect the camshaft position sensor connector and connect the special tool (test harness: MB991709) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to camshaft position sensor terminal 2. 3. Disconnect the crank angle sensor connector and connect the special tool (test harness: MD998478) in between. 4. Connect the analyzer special patterns pickup to crank angle sensor terminal 2. Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 88. (When checking the camshaft position sensor signal wave pattern.) 2. Connect the analyzer special patterns pickup to engine-ECU terminal 89. (When checking the crank angle sensor signal wave pattern.)

Standard Wave Pattern Observation conditions Function

Special patterns

Pattern height

Low

Pattern selector

Display

Engine r/min

Idle speed

13A-91

GDI <4G6> - Troubleshooting Standard wave pattern 2 engine revolutions (1 camshaft revolution)

(V)

The time (cycle time) T is reduced when the engine speed increases

75_BTDC 5_BTDC Crank angle sensor output wave pattern

0

144°

159°

59°

44°

Camshaft position sensor output wave pattern

Time

0 TDC: Top dead centre

No. 1 TDC

No. 3 TDC

No. 4 TDC

No. 2 TDC

Wave Pattern Observation Points Check that cycle time T becomes shorter when the engine speed increases.

Examples of Abnormal Wave Patterns D Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started.

D

Example 2 Cause of problem Loose timing belt Abnormality in sensor disk Wave pattern characteristics Wave pattern is displaced to the left or right.

13A-92

GDI <4G6> - Troubleshooting

Analyzer

Special patterns pickup

INJECTORS AND INJECTOR OPEN CIRCUIT CHECK SIGNAL Measurement Method 1. Connect the analyzer special patterns pickup to terminal 1 (No.1 injector) of the engine-ECU connector. 2. Connect the analyzer special patterns pickup to terminal 51 (injector open circuit check signal) of the engine-ECU connector. 3. After checking terminal 1, check terminal 14 (No.2 injector), terminal 2 (No.3 injector) and terminal 15 (No.4 injector).

Standard Wave Pattern Observation conditions Function

Special pattern

Pattern height

Low

Pattern selector

Display

Engine r/min

Idle speed

Standard wave pattern (V) Injector open circuit check signal

4

0

8 Injector drive signal 4 0 (ms)

Normal wave pattern

Wave Pattern Observation Points D Check that the injector drive time is identical to the time displayed on the MUT-II. D Check that the injector signals become greatly extended but soon return to their normal wave length when the engine is suddenly raced. D Check that the injector open circuit check signal is synchronized with each rising portion of the injector drive signal.

13A-93

GDI <4G6> - Troubleshooting IGNITION COIL AND POWER TRANSISTOR Power transistor control signal

Analyzer

Measurement Method 1. Disconnect the ignition coil connector, and connect the special tool (test harness: MB991658) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to terminal 3 of each ignition coil connector in turn.

Special patterns pickup

Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 10 (No. 1 ignition coil), terminal 11 (No. 2 ignition coil), terminal 23 (No. 2 ignition coil), terminal 24 (No. 4 ignition coil) respectively.

Standard Wave Pattern Observation condition Function

Special patterns

Pattern height

Low

Pattern selector

Display

Engine r/min

Approx. 1,200 r/min

Standard wave pattern (V) T 6 Crank angle sensor output wave pattern

T: Revolution time corresponding to a crank angle of 180_ Compression top dead center

4 2 0

Power transistor control signal wave pattern

4 2 0

q

Ignition period

q: Spark advance angle

OFF

ON

Dwell section Time

13A-94

GDI <4G6> - Troubleshooting

Wave Pattern Observation Points Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern examples 1 and 2.) Condition of wave pattern build-up section and maximum voltage

Probable cause

Rises from approx. 2V to approx. 4.5V at the top-right

Normal

2V rectangular wave

Open-circuit in ignition primary circuit

Rectangular wave at power voltage

Power transistor malfunction

--- Normal wave pattern

Examples of Abnormal Wave Patterns D Example 1 Wave pattern during engine cranking Cause of problem

2V

Open-circuit in ignition primary circuit Wave pattern characteristics Top-right part of the build-up section cannot be seen, and voltage value is approximately 2V too low.

--- Normal wave pattern VB

D

Example 2 Wave pattern during engine cranking Cause of problem Malfunction in power transistor Wave pattern characteristics Power voltage results when the power transistor is ON.

GDI <4G6> - Troubleshooting

13A-95

EGR VALVE (STEPPER MOTOR) Measurement Method 1. Disconnect the EGR valve connector, and connect the special tool (test harness: MB991658) in between. 2. Connect the analyzer special patterns pickup to the EGR valve-side connector terminal 1, terminal 3, terminal 4 and terminal 6 respectively.

Analyzer

Special patterns pickup

Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 39, connection terminal 40, connection terminal 31, and connection terminal 32 respectively. Standard Wave Pattern Observation conditions Function

Special patterns

Pattern height

High

Pattern selector

Display

Engine condition

When the engine coolant temperature is 20_C or below, turn the ignition switch from OFF to ON (without starting the engine). While the engine is idling, turn the A/C switch to ON. Immediately after starting the warm engine

Standard wave pattern

(V) 30

The wave pattern appears for an instant, but soon disappears.

Point B Coil reverse electromotive force (Approx. 3 ´ 10V)

Point A Induced electromotive force from the motor turning

20

EGR valve control signal wave pattern

10

Time

13A-96

GDI <4G6> - Troubleshooting

Wave Pattern Observation Points Check that the standard wave pattern appears when the EGR control servo is operating. Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal wave pattern.) Contrast with standard wave pattern

Probable cause

Induced electromotive force does not appear or is extremely small.

Motor is malfunctioning

Point B: Height of coil reverse electromotive force Contrast with standard wave pattern

Probable cause

Coil reverse electromotive force does not appear or is extremely small.

Short in the coil

Examples of Abnormal Wave Pattern D Example 1 Cause of problem Motor is malfunctioning. (Motor is not operating.) Wave pattern characteristics Induced electromotive force from the motor turning does not appear.

Open circuit side

D

Example 2 Cause of problem Open circuit in the line between the EGR valve and the engine-ECU Wave pattern characteristics

Normal side

Current is not supplied to the motor coil on the open circuit side. (Voltage does not drop to 0 V.) Furthermore, the induced electromotive force waveform at the normal side is slightly different from the normal waveform.

GDI <4G6> - On-vehicle Service

13A-97

ON-VEHICLE SERVICE

Fixed SAS

Caution (1) Never attempt to tamper the fixed SAS. The fixed SAS is precisely adjusted at factory. (2) Should it be tampered, the full closed position of the throttle valve will be changed. This causes the engine-ECU to learn a wrong position of the throttle valve.

THROTTLE BODY (THROTTLE VALVE ARE) CLEANING 1. Start the engine, and warm it up until engine coolant temperature reaches 80_C. Then stop the engine. 2. Remove the air intake hose at the throttle body side. 3. Apply cleaning agent to the throttle valve through the intake port of the throttle valve, and then leave it for approx. five minutes. 4. Start the engine, race it several times, and then let it run at idle for approx. one minute. 5. If carbon deposits are not removed from the throttle vale area, repeat steps (3) and (4). 6. Install the air intake hose. 7. Use the MUT-II or disconnect the negative battery cable from the battery terminal in order to erase a diagnosis code. Wait for at least ten seconds, and then let the engine run at idle again for approx. ten minutes.

Equipment side connector

Intake manifold

THROTTLE POSITION SENSOR ADJUSTMENT 1. Connect the MUT-II to the diagnosis connector. 2. Disconnect the throttle valve control servo connector. 3. Turn the ignition switch to ON (but do not start the engine).

Throttle position sensor

4. Check the output voltage of the throttle position sensor (1st channel) when the throttle valve is fully closed by your finger. Standard value: 0.4 - 0.6 V 5. If not within the standard value, loosen the throttle position sensor mounting bolts. Then rotate the sensor body to adjust.

13A-98

GDI <4G6> - On-vehicle Service 6. Check the output voltage of the throttle position sensor (2nd channel) when the throttle valve is fully closed by your finger. Standard value: 4.2 - 4.8 V 7. If not within the standard value, replace the throttle position sensor. 8. Turn the ignition switch to OFF. 9. Reconnect the throttle valve control servo connector. 10. Remove the MUT-II. 11. If a diagnosis code is displayed, erase the diagnosis code by using the MUT-II or disconnect the negative battery cable from the battery terminal and then leave it for at least ten seconds. After that, reconnect the battery cable. 12. Turn the ignition switch to ON and return it to OFF, and then leave it for at least ten seconds. In addition, if the battery cable is disconnected at step (11), let the engine run at idle for approx. ten minutes.

Equipment side connector

Accelerator pedal position sensor (1st channel)

ACCELERATOR PEDAL POSITION SWITCH AND ACCELERATOR PEDAL POSITION SENSOR ADJUSTMENT Caution (1) Never attempt to tamper the accelerator pedal position sensor. The sensor position is precisely adjusted at factory. (2) Should it be tampered, follow the procedure below: 1. Connect the MUT-II to the diagnosis connector. 2. Remove the two accelerator pedal position sensor assembly mounting bolts, and then insert a 0.60 mm of thickness gauge blade between the accelerator lever and stopper. 3. Turn the ignition switch to ON (but do not start the engine).

Accelerator pedal position sensor (2nd channel)

A

Accelerator lever

View A

Stopper (full stop position)

Accelerator pedal position sensor (2nd channel)

Accelerator lever Thickness gauge

Stopper (full stop position)

GDI <4G6> - On-vehicle Service

13A-99

4. Loosen the accelerator pedal position sensor (1st channel) mounting bolts, and then rotate it fully anticlockwise. 5. Check that the accelerator pedal position switch is on (there is continuity between terminals). 6. Slowly rotate the accelerator pedal position sensor (1st channel) clockwise, and find the pint where the accelerator pedal position switch is turned off (there will be no continuity). At this point, tighten the accelerator pedal position sensor (1st channel) mounting bolts securely.

Equipment side connector

7. Check output voltage of the accelerator pedal position sensor (1st channel). Standard value: 0.4 - 1.0 V 8. If not within the standard value, check the accelerator pedal position sensor (1st channel) and its related wiring harness. 9. After the adjustment of the accelerator pedal position sensor (1st channel), check that the output voltage of the accelerator pedal position sensor (2nd channel) is identical to that of the sensor (1st channel).

Accelerator pedal position sensor (2nd channel)

10. Loosen the mounting bolts of the accelerator pedal position sensor (2nd channel) if there is a difference between these output voltages, and rotate the sensor body to adjust. 11. Turn the ignition switch to OFF. 12. Remove the thickness gauge blade, and then install the accelerator pedal position sensor assembly. 13. Remove the MUT-II.

Fuel pump (high pressure) High-pressure fuel hose

FUEL PRESSURE TEST MEASUREMENT OF FUEL LOW PRESSURE BETWEEN FUEL PUMP (LOW PRESSURE) AND FUEL PUMP (HIGH PRESSURE) 1. Release residual pressure from the fuel pipe line to prevent fuel gush out. (Refer to P.13A-103.) 2. Disconnect the high-pressure fuel hose at the fuel pump (high pressure) side. Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.

13A-100

GDI <4G6> - On-vehicle Service MB991637

Fuel pump (high pressure)

Gasket MD998709 MD998742 High-pressure fuel hose

Fuel pressure gauge O-ring or gasket Fuel pump (high pressure)

MD998709 MD998742 High-pressure fuel hose

3. Remove the union joint and bolt from the special tool (adapter hose) and instead attach the special tool (hose adapter) to the adapter hose. 4. Install the special tool (for measuring the fuel pressure) that was set up in step 3. (1) Install the special tool (for measuring the fuel pressure) between the high-pressure fuel hose and the fuel pump (high pressure). (2) Install the fuel pressure gauge set (special tool) on the special tool (for measuring the fuel pressure) putting the gasket between them. (3) Connect the lead wire of the fuel pressure gauge set (special tool) to the power supply (cigarette lighter socket) and to the MUT-II.

(1) Install the fuel pressure gauge on the special tool (for measuring the fuel pressure) putting a suitable O-ring or gasket between them. (2) Install the special tool which was set up in step (1) between the high-pressure fuel hose and the fuel pump (high pressure). 5. Connect the MUT-II to the diagnosis connector. 6. Turn the ignition switch to ON. (But do not start the engine.) 7. Select “Item No.07” from the MUT-II Actuator test to drive the fuel pump (low pressure) at the fuel tank side. Check that there are no fuel leaks from any parts. 8. Finish the actuator test or turn the ignition switch to OFF. 9. Start the engine and run at idle. 10. Measure fuel pressure while the engine is running at idle. Standard value: approximately 324 kPa 11. Check to see that fuel pressure at idle does not drop even after the engine has been raced several times. 12. If fuel pressure is out of the standard value, troubleshoot and repair according to the table below.

GDI <4G6> - On-vehicle Service

13A-101

Symptom

Probable cause

Remedy

D D

Clogged fuel filter

Replace fuel filter

Fuel leaking to return side due to poor fuel pressure regulator (low pressure) valve seating or settled spring

Replace fuel pressure regulator (low pressure)

Low fuel pump delivery pressure

Replace the fuel pump (low pressure)

Fuel pressure too low Fuel pressure drops after racing

Fuel pressure too high

(low

Binding valve in fuel regulator (low pressure)

pressure) pressure

Clogged fuel return hose or pipe

Replace fuel pressure regulator (low pressure) Clean or replace hose or pipe

13. Stop the engine and check change of fuel pressure gauge reading. Normal if the reading does not drop within 2 minutes. If it does, observe the rate of drop and troubleshoot and repair according to the table below. Symptom

Probable cause

Remedy

Fuel pressure drops gradually after engine is stopped

Leaky fuel pressure regulator (low pressure) valve seat

Replace fuel pressure regulator (low pressure)

Fuel pressure drops sharply immediately after engine is stopped

Check valve in fuel pump (low pressure) is held open

Replace the fuel pump (low pressure)

14. Release residual pressure from the fuel pipe line. (Refer to P.13A-103.) 15. Remove the fuel pressure gauge and special tools from the fuel pump (high pressure). Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line. 16. Replace the O-ring at the end of the high-pressure fuel hose with a new one. Furthermore, apply engine oil to the new O-ring before replacement. 17. Fit the high-pressure fuel hose to the fuel pump (high pressure) and tighten the mounting bolt to specified torque. 18. Check for any fuel leaks by following the procedure in step 7. 19. Disconnect the MUT-II.

13A-102

GDI <4G6> - On-vehicle Service MEASUREMENT OF FUEL HIGH PRESSURE BETWEEN FUEL PUMP (HIGH PRESSURE) AND INJECTORS Injector intermediate harness

NOTE Measurement of the fuel pressure between the fuel pump (high pressure) and the injectors should be carried out after checking that the fuel pressure between the fuel pump (low pressure) and the fuel pump (high pressure) is normal. 1. 2. 3. 4. 5.

Connect the MUT-II to the diagnosis connector. Disconnect the injector intermediate harness connector. Turn the ignition switch to ON. Select “Item No.74” from the MUT-II Data list. Crank the engine continuously for 2 seconds or more, and visually check that there are no fuel leaks from any parts. Caution If any fuel leaks appear, stop cranking immediately and repair the source of the leak.

6. Check if the fuel pressure is more than 1 MPa immediately after 20 seconds have passed since cranking was finished. 7. If the fuel pressure is lower than 1 MPa, it means that there is likely to be a leak in the high-pressure fuel system, so this system should be checked. 8. Turn the ignition switch to OFF. 9. Connect the injector intermediate harness connector. 10. Start the engine and run at idle. 11. Measure fuel pressure while the engine is running at idle. Standard value: 4 - 7.5 MPa 12. Check to see that fuel pressure at idle does not drop even after the engine has been raced several times. 13. If fuel pressure is out of the standard value, troubleshoot and repair according to the table below. Symptom

Probable cause

Remedy

D D

Fuel leaking to return side due to poor fuel pressure regulator (high pressure) valve seating or settled spring

Replace fuel pressure regulator (high pressure)

Low fuel pump (high pressure) delivery pressure

Replace the fuel pump (high pressure)

Binding valve in fuel regulator (high pressure)

Replace fuel pressure regulator (high pressure)

Fuel pressure too low Fuel pressure drops after racing

Fuel pressure too high

pressure

Clogged fuel return hose or pipe

Clean or replace hose or pipe

14. Stop the engine and turn the ignition switch to OFF. 15. Disconnect the MUT-II.

GDI <4G6> - On-vehicle Service

13A-103

FUEL LEAK CHECK Injector intermediate harness

1. 2. 3. 4. 5.

Connect the MUT-II to the diagnosis connector. Disconnect the injector intermediate harness connector. Turn the ignition switch to ON. Select “Item No.74” from the MUT-II Data list. Crank the engine continuously for two seconds or more, and visually check that there are no fuel leaks from any parts. Caution If any fuel leaks appear, stop cranking immediately and repair the source of the leak.

6. Crank the engine, and then measure fuel pressure immediately after 20 seconds. Limit: Minimum 1 MPa Caution If the fuel pressure is less than 1 MPa, there may be a partial fuel leak in the high-pressure fuel system. 7. Turn off the ignition switch. 8. Reconnect the injector intermediate connector. 9. Remove the MUT-II. Fuel pump relay

FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE FUEL PRESSURE) When removing the fuel pipe, hose, etc., since fuel pressure in the fuel pipe line is high, do the following operation so as to release fuel pressure in the line and prevent fuel from running out. 1. Remove the fuel filler cap to release pressure in the fuel tank. 2. Remove the fuel pump relay. 3. Connect the MUT-II to the diagnosis connector. Caution Turn off the ignition switch before disconnecting or connecting the MUT-II. 4. 5. 6. 7.

Turn off the ignition switch. Select “Item No.74” from the MUT-II Data list. Crank the engine for at least two seconds. If the engine is not be started, use the MUT-II to make sure that the fuel pressure is 0.5 MPa or less. Then turn off the ignition switch.

13A-104

GDI <4G6> - On-vehicle Service 8. If the engine is started, release fuel pressure by the following procedure: (1) Turn off the ignition switch, and then stop the engine. (2) Disconnect one of the ignition coil connectors. (3) Crank the engine for at least two seconds. (4) If the engine is not be started, use the MUT-II to make sure that the fuel pressure is 0.5 MPa or less. Then turn off the ignition switch. (5) If the engine is started, stop it by racing and use the MUT-II to make sure that the fuel pressure is 0.5 MPa or less. Then turn off the ignition switch. (6) Reconnect the ignition coil connector. Caution Clean the spark plug which corresponds to the disconnected ignition coil connector. 9. Remove the MUT-II. 10. Install the fuel pump relay.

Fuel pump relay

FUEL PUMP OPERATION CHECK 1. Check the operation of the fuel pump by using the MUT-II to force-drive the fuel pump. 2. If the fuel pump will not operate, check by using the following procedure, and if it is normal, check the drive circuit. (1) Turn off the ignition switch. (2) Remove the fuel pump relay. Connect the terminal No.1 of the harness-side connector to the battery. Check if the fuel pump operation sound can be heard at this time. NOTE As the fuel pump is an in-tank type, the fuel pump sound is hard to hear, so remove the fuel filler cap and check from the tank inlet. (3) Check the fuel pressure by pinching the fuel hose with the fingertips.

13A-105

GDI <4G6> - On-vehicle Service COMPONENT LOCATION Name

Symbol

Name

Symbol

A/C relay

M

Fuel pressure sensor

F

A/C switch

O

Fuel pump relay

M

Accelerator pedal position sensor (1st and 2nd channels)

A

Ignition coil

K

Inhibitor switch

L

Air flow sensor (with intake air temperature sensor and barometric pressure sensor)

G

Injectors

B

Injector driver

H

Camshaft position sensor

F

Injector driver relay

M

M/T oil temperature sensor

S

Clutch switch

P

Oxygen sensor (front)

T

Crank angle sensor

J

Oxygen sensor (rear)

U

Detonation sensor

C

Power steering fluid pressure switch

I

Diagnosis connector

Q

Purge control solenoid valve

E

EGR valve

D

Throttle position sensor

E

Engine control relay

M

Throttle valve controller

R

Engine coolant temperature sensor

F

Throttle valve control servo

E

Engine-ECU

R

Throttle valve control servo relay

R

Engine warning lamp (CHECK ENGINE lamp)

N

Vehicle speed sensor

L

A

I N

P

B

F

K

J

O

Q

C D E

L S

R

G

H

M T

U

13A-106

GDI <4G6> - On-vehicle Service ENGINE CONTROL RELAY, FUEL PUMP RELAY, INJECTOR DRIVER CONTROL RELAY AND THROTTLE VALVE CONTROL SERVO RELAY CONTINUITY CHECK

Equipment side connector

Fuel pump relay Engine control relay Injector driver relay

Battery voltage

Terminal No. 1

2

3

4

Not supplied Supplied

Equipment side connector

Throttle valve control servo relay

INTAKE AIR TEMPERATURE SENSOR CHECK

Equipment side connector

1. Disconnect the air flow sensor connector. 2. Measure resistance between terminals 5 and 6. Standard value: 2.3 - 3.0 kW (at 20_C) 0.30 - 0.42 kW (at 80_C) Air flow sensor

Intake air temperature sensor

3. Measure resistance while heating the sensor using a hair drier. Normal condition: Temperature (_C)

Resistance (kW)

Higher

Smaller

4. If the value deviates from the standard value or the resistance remains unchanged, replace the air flow sensor assembly.

Equipment side connector

ENGINE COOLANT TEMPERATURE SENSOR CHECK Caution Be careful not to touch the connector (resin section) with the tool when removing and installing. 1. Remove the engine coolant temperature sensor.

Engine coolant temperature sensor

13A-107

GDI <4G6> - On-vehicle Service

2. With temperature sensing portion of engine coolant temperature sensor immersed in hot water, check resistance. Standard value: 2.1 - 2.7 kW (at 20_C) 0.26 - 0.36 kW (at 80_C) 3. If the resistance deviates from the standard value greatly, replace the sensor.

4. Apply sealant to threaded portion. Specified sealant: 3M NUT Locking Part No.4171 or equivalent 5. Install the engine coolant temperature sensor and tighten it to the specified torque. Tightening torque: 29 Nm

Equipment side connector

Intake manifold

THROTTLE POSITION SENSOR CHECK 1. Disconnect the throttle position sensor connector. 2. Measure the resistance between throttle position sensor side connector terminal 1 and terminal 3. Standard value: 1.7 - 3.3 kW

Throttle position sensor

3. Measure resistance between terminal Nos. 1 and 2 as well as 1 and 4 of the throttle position sensor connector, respectively. Normal condition: Throttle valve slowly open until fully open from the idle position

Changes smoothly in proportion to the opening angle of the throttle valve

4. If the resistance is outside the standard value, or if it doesn’t change smoothly, replace the throttle position sensor. NOTE For the throttle position sensor adjustment procedure, refer to P.13A-97.

13A-108

GDI <4G6> - On-vehicle Service Equipment side connector

Accelerator pedal position sensor

ACCELERATOR PEDAL POSITION SENSOR (1ST CHANNEL) CHECK 1. Disconnect the accelerator pedal position sensor (1st channel) connector. 2. Measure resistance between terminal Nos.1 and 4 of the sensor connector. Standard value: 3.5 - 6.5 kW 3. Measure resistance between terminal Nos.1 and 2 of the connector. Normal condition: Depress the accelerator pedal slowly.

Resistance value changes in accordance with the accelerator pedal depression smoothly.

4. If not within the standard value, or resistance value does not change smoothly, replace the accelerator pedal position sensor assembly. NOTE After replacement, adjust the accelerator pedal position sensor (1st channel). (Refer to P.13A-98.) Equipment side connector

Accelerator pedal position sensor (2nd channel)

ACCELERATOR PEDAL POSITION SENSOR (2ND CHANNEL) CHECK 1. Disconnect the accelerator pedal position sensor (2nd channel) connector. 2. Measure resistance between terminal Nos.1 and 4 of the connector. Standard value: 3.5 - 6.5 kW 3. Measure resistance between terminal Nos.4 and 3 of the connector. Normal condition: Depress the accelerator pedal slowly.

Resistance value changes in accordance with the accelerator pedal depression smoothly.

4. If not within the standard value, or resistance value does not change smoothly, replace the accelerator pedal position sensor assembly. NOTE After replacement, adjust the accelerator pedal position sensor (2nd channel). (Refer to P.13A-98.)

13A-109

GDI <4G6> - On-vehicle Service Equipment side connector

Accelerator pedal position sensor

ACCELERATOR PEDAL POSITION SWITCH CHECK 1. Disconnect the accelerator pedal position sensor (1st channel) connector. 2. Check continuity between terminal Nos. 3 (accelerator pedal position switch) and 4 (sensor earth) of the connector. Normal condition Accelerator pedal

Continuity

Depressed

No continuity

Released

Continuity (0 W)

3. If defective, replace the accelerator pedal position sensor assembly. NOTE After replacement, adjust the accelerator pedal position sensor and switch. (Refer to P.13A-98.)

OXYGEN SENSOR CHECK

Equipment side connector

Oxygen sensor

1. Disconnect the oxygen sensor connector and connect the special tool (test harness) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (11 - 18 W at 20_C) between terminal 2 (red clip of special tool) and terminal 4 (blue clip of special tool) on the oxygen sensor connector.

3. If there is no continuity, replace the oxygen sensor. 4. Warm up the engine until engine coolant is 80_C or higher. Red Blue Oxygen sensor equipment side connector

MD998464

5. Use a jumper wire to connect terminal 2 (red clip) of the oxygen sensor connector to the battery (+) terminal and terminal 4 (blue clip) to the battery ( - ) terminal.

Jumper wire

Caution Be very careful when connecting the jumper wire; incorrect connection can damage the oxygen sensor.

White Red Blue

Black

MD998464

6. Connect a digital voltage meter between terminal 1 (black clip) and terminal 3 (white clip).

13A-110

GDI <4G6> - On-vehicle Service 7. While repeatedly racing the engine, measure the oxygen sensor output voltage. Standard value: Engine

Oxygen sensor output voltage

Remarks

When racing the engine

0.6 - 1.0 V

If you make the air/fuel ratio rich by racing the engine repeatedly, a normal oxygen sensor will output a voltage of 0.6 - 1.0 V.

8. If the sensor is defective, replace the oxygen sensor. NOTE For removal and installation of the oxygen sensor, refer to GROUP 15 - Exhaust Pipe and Main Muffler.

Oxygen sensor (rear)

Equipment side connector

MB991223

1. Disconnect the oxygen sensor connector and connect the special tool (test harness set) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (11 - 18 W at 20_C) between terminal 3 and terminal 4 on the oxygen sensor connector. 3. If there is no continuity, replace the oxygen sensor. NOTE (1) If the MUT-II does not display the standard value although no abnormality is found by the above mentioned continuity test and harness check, replace the oxygen sensor (rear). (2) For removal and installation of the oxygen sensor, refer to GROUP 15 - Exhaust Pipe and Main Muffler.

13A-111

GDI <4G6> - On-vehicle Service Injector side connector Injector intermediate harness

INJECTOR CHECK 1. Disconnect the injector intermediate harness connector. 2. Measure the resistance between each of the terminals. Standard value: 0.9 - 1.1 W (at 20_C) Injector

Measurement terminal

No.1 cylinder

1- 2

No.2 cylinder

3- 4

No.3 cylinder

5- 6

No.4 cylinder

7- 8

3. Connect the injector intermediate harness connector.

Throttle valve control servo

Equipment side connector

THROTTLE VALVE CONTROL SERVO CHECK Operation Check 1. Disconnect the air intake hose from the throttle body. 2. Turn on the ignition switch. 3. Check that the throttle valve opens or closes in response to the accelerator pedal depression. Check of Coil Resistance 1. Disconnect the throttle valve control servo connector. 2. Measure resistance between the throttle valve control servo connector terminals. Standard value: Terminals to be measured

Resistance value (W)

1- 3

1.35 - 1.65 (at 20_C)

2- 4

3. Check that there is no continuity between the terminals and body.

CLUTCH SWITCH CHECK 1. Disconnect the connector. 2. Check for continuity between the terminals of the switch. Measurement conditions

Terminal No. 1

When clutch pedal is depressed. When clutch pedal is not depressed.

2

13A-112

GDI <4G6> - On-vehicle Service PURGE CONTROL SOLENOID VALVE CHECK Refer to GROUP 17 - Emission Control System.

EGR VALVE CHECK Refer to GROUP 17 - Emission Control System.

GDI <4G6> -

13A-113

Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure)

FUEL PUMP (HIGH PRESSURE) AND FUEL PRESSURE REGULATOR (HIGH PRESSURE) REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Prevention of fuel discharge (Refer to P.13A-103.) D Engine Cover Removal and Installation

D D

Air Cleaner Assembly Removal and Installation Fuel Leak Check (Refer to P.13A-103.)

19 Nm 19 Nm

1 9

15

6

7

1 8

10 10 - 13 Nm

19 Nm

2

5

9 Nm

9 Nm

3

19

11 Nm

4

24 Nm 10 - 13 Nm

O-ring

14 17

18

19

5 Nm ® 17 Nm

5 Nm

12

13 11

9 Nm

3, 5, 12, 13, 15 Engine oil

13A-114 GDI <4G6> -

"CA "CA

"FA "FA "BA "BA "BA

Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure)

Fuel pressure regulator (High pressure) removal steps 1. Harness connector and clamp 4. Fuel return hose connection 5. Low-pressure fuel pipe 6. Fuel return pipe connection 7. Fuel pressure regulator (high pressure) assembly 8. Fuel pressure sensor assembly 9. O-ring 10. Back-up ring 16. Back-up ring A 17. O-ring 18. Back-up ring Fuel pump (High pressure) removal steps D Intake manifold removal (Refer to GROUP 15.) 2. Fuel pipe clamp

"CA 3. Fuel feed pipe "CA 5. Low-pressure fuel pipe 11. Fuel return hose connection "EA 12. Fuel pressure hose connection 13. Fuel nipple assembly "DA 14. Fuel pump (high pressure) "BA 16. Back-up ring A "BA 17. O-ring "BA 18. Back-up ring Pump camshaft case removal steps 7. Fuel pressure regulator (high pressure) assembly "DA 14. Fuel pump (high pressure) "CA 15. Fuel return pipe "BA 16. Back-up ring A "BA 17. O-ring "BA 18. Back-up ring "AA 19. Pump camshaft case

INSTALLATION SERVICE POINTS

O-ring

Mating marks

"AA PUMP CAMSHAFT CASE ASSEMBLY INSTALLATION 1. Set the No.1 cylinder to the compression top dead centre position. 2. Align the mating mark on the housing of the pump camshaft case assembly with the mating mark on the coupling, and then install the pump camshaft case assembly to the engine. Caution Take care not to drop the O-ring.

GDI <4G6> -

O-ring

Back-up ring A

Cutaway surface Back-up ring B

Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure)

13A-115

"BA BACK-UP RING B/O-RING/BACK-UP RING A INSTALLATION Install the back-up rings and the O-ring as shown in the illustration. Caution 1. Install the back-up ring B facing its cutaway surface toward the opposite side of the O-ring as shown in the illustration. 2. Confirm the outer diameter of the back-up ring A. Take care not to install the back-up ring for the fuel pressure sensor by mistake. (Outer diameter of the back-up ring A: 14.8 mm)

"CA FUEL RETURN PIPE/LOW-PRESSURE FUEL PIPE/FUEL FEED PIPE INSTALLATION Apply a small amount of fresh engine oil to the O-ring. Caution Take care not to let any of the engine oil get inside the fuel pump (high pressure), fuel pressure regulator (high pressure) or the delivery pipe assembly.

Fuel pump (high pressure)

1

3

4

2

"DA FUEL PUMP (HIGH PRESSURE) INSTALLATION Use a torque wrench with a precision of 0.5 Nm to tighten the fuel pump mounting bolts according to the following procedure. 1. Tighten the bolts to 5 Nm in the order shown in the illustration. 2. Tighten the bolts to 17 Nm in the order shown in the illustration. The overall difference in tightening torque between the four bolts should be within 2 Nm.

13A-116 GDI <4G6> -

Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure)

"EA HIGH-PRESSURE FUEL HOSE INSTALLATION 1. Apply a small amount of fresh engine oil to the O-ring. Caution Take care not to let any of the engine oil get inside the fuel pump (high pressure). 2. While being careful not to damage the O-ring, turn the high-pressure fuel hose to the left and right and connect it to the fuel pump (high pressure). After connecting, check that the hose turns smoothly. 3. If the hose does not turn smoothly, the cause may be that the O-ring is getting caught. Disconnect the hose, check the O-ring for damage and re-connect the hose to the fuel pump (high pressure) and then re-check.

Back-up ring

O-ring

"FA BACK-UP RING/O-RING INSTALLATION Install the back-up ring and the O-ring as shown in the illustration. Caution Take care not to install the back-up ring A for the injector, fuel feed pipe or fuel return pipe by mistake. (Outer diameter of the back-up ring for the fuel pressure sensor: 15.1 mm)

Fuel pressure sensor

13A-117

GDI <4G6> - Injector

INJECTOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Prevention of fuel discharge (Refer to P.13A-103.) D Engine Cover Removal and Installation D Air Cleaner Assembly Removal and Installation

D D

Intake Manifold Removal and Installation (Refer to GROUP 15.) Fuel Leak Check (Refer to P.13A-103.)

7

10

10 - 13 Nm

11 8

1

20 - 25 Nm

9 Nm

9 18 17 16 15 14

3

13

12

11 Nm

2

10 - 13 Nm O-ring

14

4 7

16 2, 3

5

Engine oil

AA"

"DA "DA "CA "CA "CA

Removal steps 1. Fuel pipe clamp 2. Fuel feed pipe 3. Fuel return pipe 4. Back-up ring A 5. O-ring 6. Back-up ring B 7. Injector harness connector 8. Washer 9. Injector holder

AB" "BA 10. 11. AB" "BA 12. 13. 14. 15. 16. 17. "AA 18.

Delivery pipe assembly Insulator Fuel injector assembly Back-up ring O-ring Back-up ring Fuel injector Gasket Corrugated washer

13A-118

GDI <4G6> - Injector REMOVAL SERVICE POINTS AA" INJECTOR HARNESS CONNECTOR DISCONNECTION Caution Disconnect the battery ( - ) cable from its terminal before carrying out this operation.

AB" DELIVERY PIPE ASSEMBLY/FUEL INJECTOR ASSEMBLY REMOVAL Remove the delivery pipe assembly with the fuel injector assembly still attached. Caution Be careful not to drop the fuel injector assembly when removing the delivery pipe assembly.

Corrugated washer

f OK

NG

INSTALLATION SERVICE POINTS "AA CORRUGATED WASHER INSTALLATION Caution 1. The corrugated washer should always be replaced with a new part. 2. There should be no scratches or foreign particles on the corrugated washer mounting surface of the injector. 3. Be careful not to mistake the corrugated washer installation direction. "BA FUEL INJECTOR ASSEMBLY/DELIVERY PIPE ASSEMBLY INSTALLATION 1. Apply a small amount of fresh engine oil to the O-ring. Caution Take care not to let any of the engine oil get inside the delivery pipe assembly. 2. While being careful not to damage the O-ring, turn the fuel injector assembly to the left and right and connect it to the delivery pipe assembly. After connecting, check that the fuel injector turns smoothly.

GDI <4G6> - Injector

13A-119

3. If the fuel injector does not turn smoothly, the cause may be that the O-ring is getting caught. Remove the fuel injector, check the O-ring for damage and re-connect the fuel injector to the delivery pipe assembly and then re-check.

Fuel injector

Mating marks

Back-up ring A

Delivery pipe assembly

O-ring

Cutaway surface Back-up ring B

4. Align the mating marks on the delivery pipe assembly and the fuel injector, and then install the delivery pipe assembly with the injector assembly still attached.

"CA BACK-UP RING B/O-RING/BACK-UP RING A INSTALLATION Install the back-up rings and the O-ring as shown in the illustration. Caution 1. Install the back-up ring B facing its cutaway surface toward the opposite side of the O-ring as shown in the illustration. 2. Confirm the outer diameter of the back-up ring A. Take care not to install the back-up ring for the fuel pressure sensor by mistake. (Outer diameter of the back-up ring A: 14.8 mm)

"DA FUEL RETURN PIPE/FUEL FEED PIPE INSTALLATION Apply a small amount of fresh engine oil to the O-ring. Caution Take care not to let any of the engine oil get inside the fuel pump (high pressure), fuel pressure regulator (high pressure) and delivery pipe.

13A-120

GDI <4G6> - Throttle Body

THROTTLE BODY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Engine Coolant Draining and Supplying (Refer to GROUP 14 - On-vehicle Service.) D Engine Cover Removal and Installation D Air Cleaner Assembly Removal and Installation

2

4

10 - 13 Nm

5

3

1

Removal steps 1. Throttle position sensor connector 2. Throttle control servo connector 3. Water hose connection

"BA 4. Throttle body assembly "AA 5. Throttle body gasket

INSTALLATION SERVICE POINT "AA THROTTLE BODY GASKET INSTALLATION Position the projection as shown in the illustration.

Up

Front of vehicle

Projection

GDI <4G6> - Throttle Body "BA THROTTLE BODY INSTALLATION If the throttle body is replaced, electronic-controlled throttle valve system.

13A-121 initialize

the

Initialization Turn on the ignition switch, and turn off it within one second. Then leave it for at least ten seconds with the ignition switch off.

13A-122

GDI <4G6> - Throttle Body

DISASSEMBLY AND REASSEMBLY

1 2

Disassembly steps "AA 1. Throttle position sensor 2. Throttle body

REASSEMBLY SERVICE POINTS "AA THROTTLE POSITION SENSOR (1) Position the throttle position sensor on the throttle body along the dotted line as shown in the illustration. (2) Rotate the throttle position sensor anticlockwise as shown in the illustration, and then tighten the screws. (3) Measure resistance value between terminal Nos. 1(sensor power supply) and 2 (throttle position sensor 1st-channel output) as well as 1 (sensor power supply) and 4 (throttle position sensor 2nd-channel output). Normal condition Sensor power supply

Throttle posiEarth tion sensor (2nd channel) output

Open the throttle valve slowly from the idle position to full-open position.

Resistance value changes smoothly in response to throttle valve opening angle.

(4) If the resistance value does not change smoothly, replace the throttle position sensor. Throttle position sensor (1st channel) output

GDI <4G6> - Injector Driver

INJECTOR DRIVER REMOVAL AND INSTALLATION 5 Nm

1

2 5 Nm

44 Nm

AA"

Removal steps 1. Injector driver 2. Bracket

13A-123

13A-124

GDI <4G6> - Injector Driver/Throttle Valve Controller Lock

REMOVAL SERVICE POINT AA" INJECTOR DRIVER REMOVAL Press the injector driver connector in the place shown in the illustration to disconnect the injector driver connector. Caution 1. Disconnect the battery ( - ) cable from its terminal before carrying out this operation. 2. High-tension current is flowing in the harness between the injector driver and the injector while engine is running, and the injector driver will become hot after the vehicle has been driven, so take care when handling it.

THROTTLE VALVE CONTROLLER INSTALLATION SERVICE POINT If the throttle valve controller is replaced, initialize the electronic-controlled throttle valve system. Throttle valve controller

Initialization Turn on the ignition switch, and turn off it within one second. Then leave it for at least ten seconds with the ignition switch off.

13B-1

GASOLINE DIRECT INJECTION (GDI) <4G9> CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . 2

Intake Air Temperature Sensor Check . . . . . . 95

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 6

Engine Coolant Temperature Sensor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Throttle Position Sensor Check . . . . . . . . . . . . 96

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 7 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 8 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 86 Throttle Body (Throttle Valve Area) Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Throttle Position Sensor Adjustment . . . . . . . 86 Basic Idle Speed Adjustment . . . . . . . . . . . . . . 87 Fuel Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 89 Fuel Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . 92

Oxygen Sensor Check . . . . . . . . . . . . . . . . . . . . 97 Injector Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Idle Speed Control (ISC) Servo (Stepper Motor) Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Air By-pass Control Solenoid Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Purge Control Solenoid Valve Check . . . . . . 100 EGR Valve Check . . . . . . . . . . . . . . . . . . . . . . . 100

FUEL PUMP (HIGH PRESSURE) AND FUEL PRESSURE REGULATOR (HIGH PRESSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Fuel Pump Connector Disconnection (How to Reduce the Fuel Pressure) . . . . . . . . . . . . . . . 93

INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Fuel Pump Operation Check . . . . . . . . . . . . . . 93

THROTTLE BODY . . . . . . . . . . . . . . . . . . . . 109

Component Location . . . . . . . . . . . . . . . . . . . . . . 94 Engine Control Relay, Fuel Pump Relay and Injector Driver Control Relay Continuity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

INJECTOR DRIVER . . . . . . . . . . . . . . . . . . . . 111

13B-2

GDI <4G9> - General Information

GENERAL INFORMATION The Gasoline Direct Injection System consists of sensors which detect the engine conditions, the engine-ECU which controls the system based on signals from these sensors, and actuators which operate under the control of the engine-ECU. The engine-ECU carries out FUEL INJECTION CONTROL The injector drive times and injector timing are controlled so that the optimum air/fuel mixture is supplied to the engine to correspond to the continually-changing engine operation conditions. A single injector for each cylinder is mounted at the cylinder head. The fuel is sent under pressure from the fuel tank to the fuel pressure regulator (low pressure) by the fuel pump (low pressure). The pressure is regulated by the fuel pressure regulator (low pressure) and the fuel regulated is then sent to the fuel pump (high pressure). The fuel under increased pressure generated by the fuel pump (high pressure) is then regulated by the fuel pressure regulator (high pressure) and is then distributed to each of the injectors via the delivery pipes.

activities such as fuel injection control, idle speed control and ignition timing control. In addition, the engine-ECU is equipped with several diagnosis modes which simplify troubleshooting when a problem develops.

Fuel injection is normally carried out once for each cylinder for every two rotations of the crankshaft. The firing order is 1-3-4-2. This is called sequential fuel injection. When the engine is cold or under a severe load, the “open-loop” control keeps the air/fuel ratio at a richer than usual level to maintain driveability. When the engine is under low or medium loads, the air/fuel ratio becomes leaner to reduce fuel consumption. When the engine is running at medium or high loads after having warmed up, the “closed-loop” control uses the signal from the oxygen sensor to keep the air/fuel ratio at the optimum theoretical level.

IDLE AIR CONTROL The idle speed is kept at the optimum speed by controlling the amount of air that bypasses the throttle valve in accordance with changes in idling conditions and engine load during idling. The engine-ECU drives the idle speed control (ISC) motor to keep the engine running at the pre-set idle target speed in accordance with the engine coolant temperature and air

conditioner load. In addition, when the air conditioner switch is turned off and on while the engine is idling, the ISC motor operates to adjust the throttle valve bypass air amount in accordance with the engine load conditions in order to avoid fluctuations in the engine speed.

IGNITION TIMING CONTROL The power transistor located in the ignition primary circuit turns ON and OFF to control the primary current flow to the ignition coil. This controls the ignition timing in order to provide the optimum ignition timing with respect to the engine operating conditions. The ignition timing

is determined by the engine-ECU from the engine speed, intake air volume, engine coolant temperature, atmospheric pressure and injection timing (intake stroke or compression stroke).

SELF-DIAGNOSIS FUNCTION D When an abnormality is detected in one of the sensors or actuators related to emission control, the engine warning lamp (check engine lamp) illuminates as a warning to the driver. D When an abnormality is detected in one of the sensors or actuators, a diagnosis

D

code corresponding to the abnormality is output. The RAM data inside the engine-ECU that is related to the sensors and actuators can be read by means of the MUT-II. In addition, the actuators can be force-driven under certain circumstances.

GDI <4G9> - General Information OTHER CONTROL FUNCTIONS 1. Fuel Pump Control Turns the fuel pump relay ON so that current is supplied to the fuel pump while the engine is cranking or running. 2. A/C Relay Control Turns the compressor clutch of the A/C ON and OFF. 3. Fan Relay Control The revolutions of the radiator fan and

13B-3

condenser fan are controlled in response to the engine coolant temperature and vehicle speed. 4. Purge Control Solenoid Valve Control Refer to GROUP 17. 5. EGR Control Servo Control Refer to GROUP 17.

GENERAL SPECIFICATIONS Items Throttle body

Engine-ECU

Sensors

Specifications Throttle bore mm

54

Throttle position sensor

Variable resistor type

Idle speed control servo

Stepper motor type (Stepper motor type by-pass air control system)

Identification model No.

Except vehicles for Germany

E2T72572 , E2T72577

Vehicles for Germany

E2T72573 , E2T72578

Air flow sensor

Karman vortex type

Barometric pressure sensor

Semiconductor type

Intake air temperature sensor

Thermistor type

Engine coolant temperature sensor

Thermistor type

Oxygen sensor

Zirconia type

Vehicle speed sensor

Magnetic resistive element type

Inhibitor switch

Contact switch type

Camshaft position sensor

Magnetic resistive element type

Crank angle sensor

Hall element type

Detonation sensor

Piezoelectric type

Fuel pressure sensor

Metallic membrane type

Power steering fluid pressure switch

Contact switch type

13B-4

GDI <4G9> - General Information

Items Actuators

Specifications Engine control relay type

Contact switch type

Fuel pump relay type

Contact switch type

Injector driver control relay

Contact switch type

Injector type and number

Electromagnetic type, 4

Injector identification mark

DIM 1000G

Air by-pass control solenoid valve (ON/OFF)

ON/OFF type solenoid valve

Air by-pass control solenoid valve (DUTY)

Duty cycle type solenoid valve

EGR valve

Stepper motor type

Purge control solenoid valve

Duty cycle type solenoid valve

Fuel pressure Regulator pressure kPa regulator (low pressure)

329

Fuel pressure regulator (high pressure)

5

Regulator pressure MPa

13B-5

GDI <4G9> - General Information GASOLINE DIRECT INJECTION SYSTEM DIAGRAM *1 *2 *3 *4 *5 *6 *7 *8 *9 *10

Oxygen sensor Air flow sensor Intake air temperature sensor Throttle position sensor Camshaft position sensor Crank angle sensor Barometric pressure sensor Engine coolant temperature sensor Detonation sensor Fuel pressure sensor

D D D D D D D D D D D D D D

Power supply Ignition switch - ST Ignition switch - IG Vehicle speed sensor A/C switch Inhibitor switch Power steering fluid pressure switch Alternator FR terminal M/T oil temperature sensor Small lamp switch Brake vacuum sensor Stop lamp switch Injector open circuit check signal A/T-ECU

Engine-ECU

z1 z2 z3 z4 z5

Injector driver (injector) Idle speed control servo EGR valve (stepper motor) Purge control solenoid valve Air by-pass control solenoid valve (ON/OFF) z6 Air by-pass control solenoid valve (DUTY) D D D D D D D D D D

Fuel pump relay Engine control relay Injector driver relay A/C relay Engine warning lamp Diagnosis output Ignition coil Fan controller Alternator G terminal A/T-ECU

From fuel pump (low pressure) To fuel tank

z5 Air by-pass control solenoid valve (ON/OFF)

*10 Fuel pressure sensor *5 Camshaft position sensor

z6 Air by-pass control solenoid valve (DUTY)

z2 Idle speed control servo

*3 Intake air temperature sensor *2 Air flow sensor *7 Barometric pressure sensor Intake air

*4 Throttle position sensor z3 EGR control servo Fuel pressure regulator (high pressure) Fuel pump (high pressure)

Injector

z1 Injector driver

*8 Engine coolant temperature sensor *9 Detonation sensor *1 Oxygen sensor

*6 Crank angle sensor

z4 Purge control solenoid valve

13B-6

GDI <4G9> - Service Specifications/Sealant

SERVICE SPECIFICATIONS Items

Specifications

Basic idle speed r/min

750 ± 50

Throttle position sensor adjusting voltage mV

535 - 735

Throttle position sensor resistance kW

3.5 - 6.5

Idle speed control servo coil resistance W

28 - 33 (at 20_C)

Intake air temperature sensor resistance kW

20_C

2.3 - 3.0

80_C

0.30 - 0.44

Engine coolant temperature sensor resistance kW

20_C

2.1 - 2.7

80_C

0.26 - 0.36

Oxygen sensor output voltage V

0.6 - 1.0

Fuel pressure

High pressure MPa

4- 7

Low pressure kPa

324 - 343

Injector coil resistance W Air by-pass control solenoid valve coil resistance W

0.9 - 1.1 (at 20_C) ON/OFF

7.7 - 9.3 (at 20_C)

DUTY

7.7 - 9.3 (at 20_C)

SEALANT Item

Specified sealant

Remark

Engine coolant temperature sensor threaded portion

3M Nut Locking Part No. 4171 or equivalent

Drying sealant

GDI <4G9> - Special Tools

13B-7

SPECIAL TOOLS Tool A

Number

Name

Use

MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222

Harness set A: Test harness B: LED harness C: LED harness adapter D: Probe

D A: B: C: D:

Fuel gauge simple inspection Connector pin contact pressure inspection Power circuit inspection Power circuit inspection Commercial tester connection

MB991502

MUT-II sub assembly

D D

Reading diagnosis code GDI system inspection

MB991529

Diagnosis code check harness

Reading diagnosis code

MB991348, MB991658

Test harness set

D

MB991709

Test harness

MB991519

Alternator harness connector

Measurement of voltage during troubleshooting

MD998464

Test harness (4-pin, square)

Inspection of oxygen sensor

B

C

D

D

Measurement of voltage during troubleshooting Inspection using an analyzer

13B-8

GDI <4G9> - Special Tools/Troubleshooting

Tool

Number

Name

Use

MD998478

Test harness (3-pin, triangle)

D

MD998709

Adaptor hose

Measurement of fuel pressure

MD998742

Hose adaptor

MB991637

Fuel pressure gauge set

D

Measurement of voltage during troubleshooting Inspection using an analyzer

TROUBLESHOOTING DIAGNOSIS TROUBLESHOOTING FLOW Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points. NOTE If the engine-ECU is replaced, the steering lock cylinder should be replaced together with it.

DIAGNOSIS FUNCTION ENGINE WARNING LAMP (CHECK ENGINE LAMP) If an abnormality occurs in any of the following items related to the Gasoline Direct Injection (GDI) system, the engine warning lamp will illuminate. If the lamp remains illuminated or if the lamp illuminates while the engine is running, check the diagnosis code output. Engine warning lamp (check engine lamp)

GDI <4G9> - Troubleshooting

13B-9

Engine warning lamp inspection items Engine-ECU Oxygen sensor Air flow sensor Intake air temperature sensor Throttle position sensor Engine coolant temperature sensor Crank angle sensor Camshaft position sensor Barometric pressure sensor Detonation sensor Injector Abnormal combustion Immobilizer system Abnormal fuel pressure Excessive intake air amount Brake vacuum sensor Fuel system malfunction

METHOD OF READING AND ERASING DIAGNOSIS CODES Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points. INSPECTION USING MUT-II DATA LIST AND ACTUATOR TESTING 1. Carry out inspection by means of the data list and the actuator test function. If there is an abnormality, check and repair the chassis harnesses and components. 2. After repairing, re-check using the MUT-II and check that the abnormal input and output have returned to normal as a result of the repairs. 3. Erase the diagnosis code memory. 4. Remove the MUT-II. 5. Start the engine again and carry out a road test to confirm that the problem has disappeared.

13B-10

GDI <4G9> - Troubleshooting

FAIL-SAFE FUNCTION REFERENCE TABLE When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by means of the pre-set control logic to maintain safe conditions for driving. Malfunctioning item

Control contents during malfunction

Air flow sensor

(1) Lean fuel combustion driving and feedback control driving are prevented. (2) Basic injection drive timing and basic ignition timing are set by means of the mapping values from the throttle position sensor signal and the crank angle sensor signal.

Intake air temperature sensor

Control is carried out as if the intake air temperature is 25_C.

Throttle position sensor

(1) Lean fuel combustion driving is prevented. (2) Dashpot compensation for the idle speed control is prevented.

Engine coolant temperature sensor

Control is carried out as if the engine coolant temperature is 80_C. Furthermore, this control will continue until the ignition switch is turned to OFF, even if the sensor signal returns to normal.

Camshaft position sensor

Control is carried out as if the conditions before the failure judgement occurred are continuing.

Vehicle speed sensor

(1) Lean fuel combustion driving is prevented. However, this condition is cleared if the engine speed is continuously at 1,500 r/min or more for a certain length of time. (2) Lean fuel combustion during idling is prevented.

Barometric pressure sensor

Control is carried out as if the barometric pressure is 101 kPa (760 mmHg).

Detonation sensor

Ignition timing is fixed to the timing for standard petrol.

Injector

(1) Lean fuel combustion driving is prevented. (2) EGR operation is cut.

Abnormal combustion

Lean fuel combustion driving is prevented.

Excessive intake air amount

When the air flow sensor output is compared with the throttle position sensor output and the air amount is judged to be excessive, compression stroke fuel injection and lean fuel combustion driving are set.

Communication line with A/T-ECU

Ignition timing retarding control (engine and transmission total control) during transmission gear shifting is prevented.

Alternator FR terminal

Alternator output suppression control under high electrical loads is prevented. (Alternator works as a normal alternator.)

Fuel pressure sensor

(1) Control is carried out as if the fuel pressure is 5 MPa (if there is open or short circuit). (2) Turns off the fuel pump relay (if the fuel pressure is excessively high). (3) Shuts off the fuel injection (If an excessively low pressure is detected or the engine speed exceeds 3,000 r/min).

13B-11

GDI <4G9> - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES Code No.

Diagnosis item

Reference page

11

Oxygen sensor system

13B-12

12

Air flow sensor system

13B-13

13

Intake air temperature sensor system

13B-14

14

Throttle position sensor system

13B-15

21

Engine coolant temperature sensor system

13B-16

22

Crank angle sensor system

13B-17

23

Camshaft position sensor system

13B-18

24

Vehicle speed sensor system

13B-19

25

Barometric pressure sensor system

13B-20

31

Detonation sensor system

13B-21

41

Injector system

13B-22

44

Abnormal combustion

13B-23

54

Immobilizer system

13B-24

56

Abnormal fuel pressure

13B-24

58

Excessive intake air amount

13B-26

61

Communication wire with A/T-ECU system

13B-26

64

Alternator FR terminal system

13B-27

66

Brake vacuum sensor system

13B-28

89

Abnormality in fuel pressure system

13B-29

13B-12

GDI <4G9> - Troubleshooting

INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code No. 11 Oxygen sensor system

Probable cause

Range of check D 3 minutes have passed after engine was started. D Engine coolant temperature is approx. 80_C or more. D Intake air temperature is 20 - 50_C. D Engine speed is approx. 2,000 - 3,500 r/min D Vehicle is moving at constant speed on a flat, level road surface Set conditions D When the engine-ECU has detected that the oxygen sensor output voltage is around 0.6 V for 30 seconds (does not cross 0.6 V for 30 seconds) four times. D When the range of check operations given above which accompany starting of the engine are carried out four times in succession, a problem is detected after each operation.

D D

Check the oxygen sensor. (Refer to P.13B-97.)

NG

D

Malfunction of the oxygen sensor Improper connector contact, open short-circuited harness wire Malfunction of the engine-ECU

circuit

Replace

OK

(1) NG Measure at the oxygen sensor connector B-17. D Disconnect the connector, and measure at the harness side. (1) Voltage between 2 and earth (Ignition switch: ON) (2) NG OK: System voltage (2) Continuity between 4 and earth OK: Continuity

Check the harness wire between the oxygen sensor and the engine control relay connector, and repair if necessary. Check the following connector: B-52

NG

Repair

OK

OK

Check trouble symptom. NG Check the harness wire between the engine-ECU and the oxygen sensor connector.

NG

Repair

OK Replace the engine-ECU.

Measure at the engine-ECU connector B-52. D Disconnect the connector, and measure at the NG harness side. D Voltage between 60 and earth (Ignition switch: ON) OK: System voltage OK Check the following connectors: B-17, B-52

NG

Check the following connector: B-17 OK Repair

OK

Check the harness wire between the engine-ECU and the oxygen sensor connector. OK Replace the engine-ECU.

NG Check the harness wire between the engine-ECU and the oxygen sensor connector, and repair if necessary.

Check trouble symptom. NG

Check trouble symptom.

NG

Repair

NG

Repair

or

13B-13

GDI <4G9> - Troubleshooting Code No.12 Air flow sensor system

Probable cause

Range of check D Engine speed is 500 r/min or more. Set conditions D Sensor output frequency is 3.3 Hz or less for 4 seconds.

D D

(1) NG Measure at the air flow sensor connector A-07. D Connect the connector (Use the test harness MB991709) (1) Voltage between 3 and earth (Engine: Idling) OK: 2.2 - 3.2 V (2) Voltage between 7 and earth (2) NG OK: 0 - 0.1 V (Engine: Idling) OK: 6 - 9 V (Engine speed: 4000 r/min) OK

D

Malfunction of the air flow sensor Open circuit or short-circuited harness wire of air flow sensor circuit Malfunction of the engine-ECU

(1) NG Check the harness wire between the Measure at the air flow sensor connector air flow sensor and the engine control A-07. relay, and repair if necessary. D Disconnect the connector, and measure at the harness side. (2), (3) NG (1) Voltage between 4 and earth Check the following connector: (Ignition switch: ON) B-51 OK: System voltage OK NG (2) Voltage between 3 and earth (Ignition switch: ON) Repair OK: 4.8 - 5.2 V (3) Continuity between 5 and earth OK: Continuity Check trouble symptom. OK NG Check the harness wire between the engine-ECU and the air flow sensor, and repair if necessary. OK NG

Check the following connector: A-07 OK NG Repair

Repair Check trouble symptom.

Replace the engine-ECU.

NG Replace the air flow sensor. Measure at the engine-ECU connector B-54. D Connect the connector D Voltage between 19 and earth (Ignition switch: ON) OK: 6 - 9 V OK

NG Repair

Replace the engine-ECU.

NG Check trouble symptom.

Check the following connector: A-07 OK NG Repair Check trouble symptom.

Check the following connector: B-54 OK

NG

NG Replace the air flow sensor.

13B-14

GDI <4G9> - Troubleshooting

Code No.13 Intake air temperature sensor system

Probable cause

Range of check D After 60 seconds have passed since the engine have started Set conditions D Sensor resistance is 0.14 kW or less for 4 seconds. or D Sensor resistance is 50 kW or more for 4 seconds.

D D

Check the intake air temperature sensor. (Refer to P.13B-95.) OK Measure at the air flow sensor connector A-07. D Disconnect the connector, and measure at the harness side. D Voltage between 6 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 5 and earth OK: Continuity

NG NG

Replace Check the following connector: B-51 OK

Check trouble symptom. NG Check the harness wire between the engine-ECU and the intake air temperature sensor.

Check the following connector: A-07

OK

NG

NG Repair

Repair Check trouble symptom.

NG Repair

OK

OK

D

Malfunction of the intake air temperature sensor Open circuit or short-circuited harness wire of the intake air temperature sensor circuit Malfunction of the engine-ECU

NG

Replace the engine-ECU.

13B-15

GDI <4G9> - Troubleshooting Code No.14 Throttle position sensor system

Probable cause

Range of check D After 60 seconds have passed since the engine have started Set conditions D Sensor output voltage is 0.2 V or less for 4 seconds. or D Idle position switch is ON and sensor output voltage is 2.0 V or more for 4 seconds.

D D

Check the throttle position sensor. (Refer to P.13B-96.) OK Measure at the throttle position sensor connector A-73. D Disconnect the connector, and measure at the harness side. D Voltage between 4 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 1 and earth OK: Continuity

NG

NG

D

Malfunction of the throttle position sensor Open circuit or short-circuited harness wire of the throttle position sensor circuit Malfunction of the engine-ECU

Replace

Check the following connector: B-51

OK

Check trouble symptom. NG

NG

Check the harness wire between the engine-ECU and the throttle position sensor.

Repair

OK

NG Repair

OK

Replace the engine-ECU. NG Measure at the engine-ECU connector B-51. D Connect the connector. D Voltage between 84 and earth (Ignition switch: ON) OK: 0.535 - 0.735 V (Throttle valve: Idle posiOK tion) OK: 4.5 - 5.5 V (Throttle valve: Fully open)

Check the following connector: A-73 NG Repair Replace the engine-ECU.

OK

Check trouble symptom. NG Check the harness wire between the engine-ECU and the throttle position sensor. OK NG Repair Replace the throttle position sensor.

13B-16

GDI <4G9> - Troubleshooting

Code No.21 Engine coolant temperature sensor system

Probable cause

Range of check D After 60 seconds have passed since the engine have started Set conditions D Sensor resistance is 50 W or less for 4 seconds. or D Sensor resistance is 72 kW or more for 4 seconds.

D D D

Malfunction of the engine coolant temperature sensor Open circuit or short-circuited harness wire of the engine coolant temperature sensor circuit Malfunction of the engine-ECU

Range of check D After engine starts Set conditions D After 5 minutes or more have passed since the engine coolant temperature after filtering has dropped from 40_C or more to less than this temperature

Check the engine coolant temperature sensor. (Refer to P.13B-95.) OK Measure at the engine coolant temperature sensor connector A-80. D Disconnect the connector, and measure st the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 2 and earth OK: Continuity

NG NG

Check the following connector: B-51 OK

Check trouble symptom. NG Check the harness wire between the engine-ECU and the engine coolant temperature sensor.

Check the following connector: A-80

OK

NG

NG Repair

Repair Check trouble symptom.

NG Repair

OK

OK

Replace

NG

Replace the engine-ECU.

13B-17

GDI <4G9> - Troubleshooting Code No.22 Crank angle sensor system

Probable cause

Range of check D Engine: During cranking Set conditions D Sensor output voltage does not change for 4 seconds (no pulse signal is being input).

D D

Measure at the crank angle sensor connector A-71. D Connect the connector (Use the test harness MD998478) D Voltage between 2 (black clip) and earth (Engine: Cranking) OK: 0 - 4.0 V D Voltage between 2 (black clip) and earth (Engine: Idling) OK: 1.5 - 2.5 V OK Replace the engine-ECU.

NG

D

Malfunction of the crank angle sensor Open circuit or short-circuited harness wire of the crank angle sensor circuit Malfunction of the engine-ECU

(1) NG Measure at the crank angle sensor connector A-71. D Disconnect the connector, and measure at the harness side. (2) NG (1) Voltage between 3 and earth (Ignition switch: ON) OK: System voltage (2) Voltage between 2 and earth (3) NG (Ignition switch: ON) OK: 4.8 - 5.2 V (3) Continuity between 1 and earth OK: Continuity OK

Check the harness wire between the crank angle sensor and the engine control relay, and repair if necessary. Check the following connector: B-51 OK NG Repair Check trouble symptom. NG

Check the following connector: A-71 OK NG Repair

Check the harness wire between the engine-ECU and the crank angle sensor. OK NG Repair

Check trouble symptom. NG

Replace the engine-ECU.

Replace the crank angle sensor. Check the harness wire between the crank angle sensor and the earth, and repair if necessary.

13B-18

GDI <4G9> - Troubleshooting

Code No.23 Camshaft position sensor system

Probable cause

Range of check D While engine is cranking or running Set conditions D Sensor output voltage does not change for 4 seconds (no pulse signal is being input). or D Abnormal pulse signal pattern is output.

D D

Measure at the camshaft position sensor connector A-78. D Connect the connector (Use the test harness MB991709) D Voltage between 2 and earth (Engine: Cranking) OK: 0 - 4.0 V D Voltage between 2 and earth (Engine: Idling) OK: 0.5 - 2.0 V OK Replace the engine-ECU.

NG

D

Malfunction of the camshaft position sensor Open circuit or short-circuited harness wire of the camshaft position sensor Malfunction of the engine-ECU

(1) NG Measure at the camshaft position sensor connector A-78. D Disconnect the connector, and measure at the harness side. (2) NG (1) Voltage between 3 and earth (Ignition switch: ON) OK: System voltage (3) NG (2) Voltage between 2 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V (3) Continuity between 1 and earth OK: Continuity OK

Check the following connector: B-51 OK NG Repair Check trouble symptom. NG

Check the following connector: A-78 OK

Check the harness wire between the camshaft position sensor and the engine control relay, and repair if necessary.

NG Repair

Check the harness wire between the engine-ECU and the camshaft position sensor. OK NG Repair

Check trouble symptom. NG

Replace the engine-ECU.

Replace the camshaft position sensor. Check the harness wire between the camshaft position sensor and the earth, and repair if necessary.

13B-19

GDI <4G9> - Troubleshooting Code No. 24 Vehicle speed sensor system

Probable cause

Range of check D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. D Engine speed is 3,000 r/min or more. D Driving under high engine load conditions. Set conditions D Sensor output voltage does not change for 4 seconds (no pulse signal input).

D D

No

Does the speedometer operate normally? Yes Measure at engine-ECU connector B-51. D Connect the connector. D Voltage between terminal 86 and earth (Ignition switch: ON) OK: If the vehicle is moved forward without starting the engine, 0 V and system voltage alternates. NG

Check the vehicle speed sensor circuit. (Refer to GROUP 54 Combination Meter.) Check the following connector: B-51 NG

OK

Repair Check trouble symptom. NG

Check the following connector: B-14, A-81 OK

OK

D

Malfunction of the vehicle speed sensor Improper connector contact, open circuit or short-circuited harness wire of the vehicle speed sensor circuit Malfunction of the engine-ECU

NG Repair

Check trouble symptom. NG Check the harness wire between the vehicle speed sensor and engine-ECU.

Replace the engine-ECU.

13B-20

GDI <4G9> - Troubleshooting

Code No.25 Barometric pressure sensor system

Probable cause

Range of check D After 60 seconds have passed since the engine have started D Battery voltage is 8 V or more. Set conditions D Sensor output voltage is 0.2 V or less for 4 seconds. or D Sensor output voltage is 4.5 V or more for 4 seconds.

D D

Measure at the air flow sensor connector A-07. D Connect the connector. (Use test harness MB991709) D Voltage between 2 and earth (Ignition switch: ON) OK: 3.9 - 4.1 V (at altitude of 0 m) 3.3 - 3.6 V (at altitude of 1,200 m) OK

NG

D

Measure at the air flow sensor connector A-07. D Disconnect the connector, and measure at the harness side. (1) Voltage between 1 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V (2) Continuity between 5 and earth OK: Continuity

Malfunction of the barometric pressure sensor Open circuit or short-circuited harness wire of the barometric pressure sensor Malfunction of the engine-ECU

NG

OK

Check trouble symptom. NG Check the harness wire between the engine-ECU and the barometric pressure sensor. OK NG

Check the following connector: A-07 OK NG

Repair Replace the engine-ECU.

Repair

OK Check the following connector: B-51 NG Repair

OK

Check trouble symptom.

NG Repair

OK

Measure at the engine-ECU connector B-51. D Connect the connector. D Voltage between 85 and earth (Ignition switch: ON) OK: 3.9 - 4.1 V NG (at altitude of 0 m) 3.3 - 3.6 V (at altitude of 1,200 m)

Check the following connector: B-51

NG

Check the harness wire between the engine-ECU and the barometric pressure sensor. OK

Repair

Check the harness wire between the engine-ECU and the barometric pressure sensor, and repair if necessary. OK Check trouble symptom.

NG

Replace the air flow sensor. NG

Replace the engine-ECU.

13B-21

GDI <4G9> - Troubleshooting Code No.31 Detonation sensor system

Probable cause

Range of check D After 60 seconds have passed since the engine have started Set conditions D Amount of change in the sensor output voltage (detonation sensor peak voltage for each half rotation of the crankshaft) is 0.06 V or less for 200 continuous times.

D D

Measure at the detonation sensor connector A-79. D Disconnect the connector, and measure at the harness side. D Continuity between 2 and earth OK: Continuity NG Check the harness wire between the detonation sensor and the earth, and repair if necessary.

OK

Check the following connector: B-51 OK Check trouble symptom.

D

Malfunction of the detonation sensor Open circuit or short-circuited harness wire of the detonation sensor Malfunction of the engine-ECU

NG

NG

Repair

Check the harness wire between the engine-ECU and the detonation sensor. OK NG Repair Replace the detonation sensor. Check trouble symptom. NG Replace the engine-ECU.

13B-22

GDI <4G9> - Troubleshooting

Code No.41 Injector system

Probable cause

Range of check D While engine is cranking or running D Engine speed is 4,000 r/min or less. D System voltage is 10 V or more. D While fuel cut and injector forced drive (actuator test) are not being carried out Set conditions D Injector open circuit check signal is not output by the injector driver for a set number of times.

D D D D

Check the injector. (Refer to P.13B-98.)

NG

OK

D

Check the following connectors: A-02, A-03, A-04, A-05

Malfunction of the injector Malfunction of the injector driver control relay Malfunction of the injector driver Open circuit or short-circuited harness wire of the injector drive circuit Malfunction of the engine-ECU

OK

Check the harness wire between the intermediate connector and the injector. OK

NG

NG

Repair

Repair Replace the injector.

(1) NG Measure at the injector driver connector A-08. D Disconnect the connector, and (2) NG measure at the harness side. (1) Voltage between 12 and earth Voltage between 21 and earth (Ignition switch: ON) OK: System voltage (2) Continuity between 13 and earth Continuity between 22 and earth OK: Continuity (3) Continuity between 17 and 26 Continuity between 16 and 25 Continuity between 15 and 24 Continuity between 14 and 23 (3) NG OK: 0.9 - 1.1 W OK

Check the injector driver control relay. (Refer to P.13B-95.) OK

Check the harness wire between the injector driver and the earth, and repair if necessary.

NG Replace

Check the following connectors: A-08, A-13X, A-28 OK NG Repair Check the harness wire between the injector driver and the injector driver control relay. Check the harness wire between the injector driver control relay and the battery.

Check the following connector: A-06 OK NG

OK

Repair

NG Repair

Check the harness wire between the injector driver and the intermediate connector, and repair if necessary. OK

Check trouble symptom. NG Replace the engine-ECU. Measure at the engine-ECU connectors NG B-52, B-54. D Connect the connector. (1) Voltage between 51 and earth (Ignition switch: ON) OK: 4.0 - 5.0 V (2) Voltage between 1 and earth Voltage between 2 and earth Voltage between 14 and earth Voltage between 15 and earth (Ignition switch: ON) OK: 8 - 11 V

NG

Check the following connector: A-08 NG

Check the following connectors: A-13X, B-13, B-103 OK NG

OK Repair

Repair

Check the harness wire between the engine-ECU and the injector driver, and repair if necessary.

Check the harness wire between the engine-ECU and the injector driver control relay. Check the harness wire between the injector driver control relay and the ignition switch.

OK

NG

Check trouble symptom.

Repair

NG Replace the injector driver.

Measure at the engine-ECU connector B-54. D Connect the harness D Voltage between 20 and earth (Ignition switch: ON) OK: System voltage

Check trouble symptom.

NG

Replace the engine-ECU.

13B-23

GDI <4G9> - Troubleshooting Code No.44 Abnormal combustion

Probable cause

Range of check D While engine is running during lean fuel combustion Set conditions D Abnormal engine speed due to mis-firing is detected by the crank angle sensor

D D D

Check the ignition coil (Refer to GROUP 16 - Ignition System).

NG

D D

Malfunction of the ignition coil Malfunction of the spark plug Open circuit or short-circuit in ignition primary circuit Malfunction of the injector system Malfunction of the engine-ECU

Replace

OK

(1) NG Measure at the ignition coil connectors A-74, A-94, A-97, A-98. D Disconnect the connector, and measure at the harness side. (2) NG (1) Voltage between 1 and earth (Ignition switch: ON) OK: System voltage (2) Voltage between 3 and earth (Engine: Cranking) OK: 0.5 - 4.0 V (3) NG (3) Continuity between 2 and earth OK: Continuity OK Check the following connectors: A-74, A-94, A-97, A-98 NG

OK

Check the following connectors: B-13, B-103, B-89 OK

Repair Check trouble symptom. NG Check the harness wire between the ignition coil and the ignition switch, and repair if necessary. Check the following connector: B-54 OK

Repair Check trouble symptom. NG Check the following items in the order given. D Spark plugs D Compression pressure OK

Check for air D Damaged D Damaged D Damaged

leaking into the air intake system. intake manifold gasket vacuum hose air intake hose

NG Repair

Check trouble symptom. NG Check the harness wire between the engine-ECU and the ignition coil. OK

NG Repair

Check the injector system (Refer to P.13B-22, Code No.41) OK

NG

Replace the engine-ECU. Check the harness wire between the ignition coil and the earth, and repair if necessary.

13B-24

GDI <4G9> - Troubleshooting

Code No.54 Immobilizer system

Probable cause

Range of Check D Ignition switch: ON Set Conditions D Improper communication between the engine-ECU and immobilizer-ECU

D D D D D

Radio interference of encrypted codes Incorrect encrypted code Malfunction of harness or connector Malfunction of immobilizer-ECU Malfunction of engine-ECU

NOTE (1) If the ignition switches are close each other when starting the engine, radio interference may cause this code to be displayed. (2) This code may be displayed when registering the key encrypted code.

Is there another ignition key near the ignition key that is inserted in the ignition switch?

Yes NG

No

Is a diagnosis code output from the immobilizer-ECU?

Remove the extra ignition key.

Yes

No Check the following connectors: B-52, B-14, B-82

NG

Check trouble symptom. Check the immobilizer system. (Refer to GROUP 54 - Ignition Switch and Immobilizer System.) Repair

OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the immobilizer-ECU.

OK

Replace the engine-ECU and immobilizer-ECU.

NG Repair

Code No.56 Abnormal fuel pressure

Probable cause

Range of check D Ignition switch: ON Set conditions D Sensor output voltage is 4.8 V or more for four seconds. or D Sensor output voltage is 0.2 V or less for four seconds. Range of check D After the engine is started, the following condition has been detected: (1) Engine speed: 1,000 r/min or more (2) Fuel pressure: 2 MPa or more D While engine is running Set conditions D Fuel pressure is 6.9 MPa or more for four seconds. or D Fuel pressure is 2 MPa or less for four seconds.

D D

D

Malfunction of the fuel pressure sensor Open circuit or short-circuited harness wire of the fuel pressure sensor Malfunction of the engine-ECU Malfunction of the fuel pump (high pressure) Malfunction of the fuel pressure regulator (high pressure) Clogged high-pressure fuel line

This diagnosis code is also output when air is sucked in high-pressure fuel line due to no fuel supply. In this case, air can be bled by letting the engine run at 2,000 r/min for at least fifteen seconds. After the air bleeding, the diagnosis code must be erased by the MUT-II.

D

Air sucking due to no fuel supply

D D D

13B-25

GDI <4G9> - Troubleshooting MUT-II Data list 74 Fuel pressure sensor D Ignition switch: ON OK: 0 - 8 MPa NG

OK

MUT-II Data list 74 Fuel pressure sensor D Maintain the engine speed at 2,000 r/min for at least fifteen seconds. OK: 6.9 MPa or less OK MUT-II Data list 74 Fuel pressure sensor D Engine: Idle running for at least three minutes OK: 4 MPa or more

NG

D D

NG

D D

Replace the high-pressure fuel regulator (seized regulator). Replace the high-pressure return pipe (seized pipe).

Replace the fuel pump (high pressure) (poor pump discharge pressure) Replace the high-pressure regulator (fuel leakage at the return side).

OK Erase diagnosis code No.56. (This diagnosis code has been output due to air sucking into high-pressure fuel line. But that problem has been resolved by revving the engine at 2,000 r/min.) NG

Check trouble symptom. OK Normal

Measure at the fuel pressure sensor connector A-77. D Connect the connector. (Use test harness MB991348) D Voltage between 2 and earth OK: 3 V or less (Engine: Cranking) 0.3 - 4.7 V (Engine: Idling)

NG

OK

Measure at the fuel pressure sensor connector A-77. D Disconnect the connector, and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 3 and earth OK: Continuity

NG

Check if input voltage from the fuel pressure sensor to engine-ECU changes suddenly by performing an intermittent malfunction simulation test. (Refer to GROUP 00 - Points to Note for Intermittent Malfunction.)

Check the following connector: B-51 OK NG Repair Check trouble symptom. NG

OK

Check the harness wire between the engine-ECU and the fuel pressure sensor. OK NG

Check the following connectors: A-77, B-51 OK NG

Repair

Repair

Replace the engine-ECU. Check trouble symptom. Measure at the engine-ECU connector B-51. D Connect the connector. D Voltage between 74 and earth (Engine: idling) OK: 0.3 - 4.7 V OK Check the following connectors: A-77, B-51 OK Check trouble symptom. NG Replace the engine-ECU.

NG

Check the harness wire between the engine-ECU and the fuel pressure sensor, and repair if necessary.

NG

Check the harness wire between the engine-ECU and the fuel pressure sensor. OK

NG Repair

Replace the fuel pressure sensor. NG

Repair

13B-26

GDI <4G9> - Troubleshooting

Code No.58 Excessive intake air amount

Probable cause

Range of check D While engine is running in lean compression mode D Engine speed is 3,000 r/min or less. D Throttle position sensor output voltage is 1 V or less. Set conditions D Air flow sensor output frequency is 100 Hz or more for 1 second.

D D

Range of check D While engine is not running in lean compression mode Set conditions D Air flow sensor output frequency is higher than the map value specified by the engine speed for 1 second.

D

MUT-II Actuator test 18 Air by-pass control solenoid valve (ON/OFF) 32 Air by-pass control solenoid valve (DUTY) (Refer to P.13B-68.) OK MUT-II Data list 45 Idle speed control servo (Refer to P.13B-66.)

NG

NG

D D

Malfunction of the idle speed control servo Open circuit or short-circuited harness wire of the idle speed control servo Malfunction of the air by-pass control solenoid valve (ON/OFF, DUTY) Short-circuited harness wire of the air by-pass control solenoid valve (ON/OFF, DUTY) Malfunction of the engine-ECU

Check the air by-pass control solenoid valve system (Refer to P.13B-54, INSPECTION PROCEDURE 27.)

Check the idle speed control servo system (Refer to P.13B-53, INSPECTION PROCEDURE 26.)

OK Check the air by-pass control solenoid valve system (Refer to P.13B-54, INSPECTION PROCEDURE 27.) OK Check trouble symptom.

NG

Replace the engine-ECU.

Code No.61 Communication wire with A/T-ECU system

Probable cause

Range of check D After 60 seconds have passed since the engine have started Set conditions D Torque reduction request signal from A/T-ECU is input continuously for 1.5 seconds or more.

D D D

Check the following connectors: B-52, B-54, B-10

NG

Short circuit in ECU communication circuit Malfunction of the engine-ECU Malfunction of the A/T-ECU

Repair

OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the A/T-ECU.

OK

Replace the engine-ECU.

NG Repair

Check trouble symptom. NG Replace the A/T-ECU.

13B-27

GDI <4G9> - Troubleshooting Code No.64 Alternator FR terminal system

Probable cause

Range of check D Engine speed is 50 r/min or more. Set conditions D Input voltage from alternator FR terminal is system voltage for 20 seconds.

D D

Measure at the alternator connector A-52. D Connect the connector. (Use test harness MB991519) D Voltage between 4 (blue clip) and earth (Engine: Idling) (Radiator fan: Not operating) (Headlamp: OFF ® ON) (Stop lamp: OFF ® ON) (Rear defogger switch: OFF ® ON) OK: Voltage decreases.

NG

Measure at the alternator connector A-52. D Disconnect the connector, and measure at the harness side. D Voltage between 4 and earth (Ignition switch: ON) OK: System voltage OK

OK

Replace the engine-ECU.

NG Repair

Check trouble symptom.

Check the following connectors: A-30, B-53 OK

NG Repair

Check trouble symptom.

Check the harness wire between the engine-ECU and the alternator. OK NG Repair Replace the engine-ECU.

NG Check the harness wire between the engine-ECU and the alternator. OK NG Repair Replace the alternator.

NG

NG

Check the following connector: A-52

OK

Open circuit in alternator FR terminal circuit Malfunction of the engine-ECU

13B-28

GDI <4G9> - Troubleshooting

Code No.66 Brake vacuum sensor system

Probable cause

Range of check D Ignition switch: ON Set conditions D Sensor output voltage is 4.8 V or more. or D Sensor output voltage is 0.2 V or less.

D D

Measure at the brake vacuum sensor connector A-09. D Connect the connector. (Use test harness MB991348) D Voltage between 1 and earth OK: Voltage increases when the ignition switch is turned on and the brake pedal is depressed several times after the warmed engine is turned off from the idle speed.

NG

D

Measure at the brake vacuum sensor connector A-09. D Disconnect the connector, and measure at the harness side. D Voltage between 3 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 2 and earth OK: Continuity

Malfunction of the brake vacuum sensor Improper connector contact, open circuit or short-circuited harness wire of the brake vacuum sensor Malfunction of the engine-ECU

NG

OK

NG Repair

Check trouble symptom. NG

OK

Check the harness wire between the engine-ECU and the brake vacuum sensor. OK NG

Check the following connector: A-09 OK NG

OK

Check the following connector: B-51

Repair

Repair

Replace the engine-ECU. Check trouble symptom.

Check the following connectors: A-09, A-27, B-53

NG

Repair

Check trouble symptom.

Replace the brake vacuum sensor.

NG

Replace the engine-ECU.

Check the harness wire between the engine-ECU and the brake vacuum sensor. OK NG Repair

OK

Check the harness wire between the NG engine-ECU and the brake vacuum sensor. OK

NG

Repair

13B-29

GDI <4G9> - Troubleshooting Code No.89 Abnormal fuel pressure

Probable cause

Range of check D Engine: Idling (during stoichio-feedback operation) Set conditions D Fuel injection correction value remains excessively low for ten seconds or more. or D Fuel injection correction value remains excessively high for ten seconds or more.

D D D D D

MUT-II Data list 13 Intake air temperature sensor. (Refer to P.13B-62.) OK MUT-II Data list 25 Barometric air temperature sensor. (Refer to P.13B-64.) OK MUT-II Data list 12 Air flow sensor. (Refer to P.13B-62.) OK Replace the fuel pump (high pressure).

NG

NG

NG

Malfunction Malfunction Malfunction Malfunction Malfunction

of of of of of

the the the the the

fuel pump (high pressure) intake air temperature sensor barometric pressure sensor air flow sensor engine-ECU

Check the intake air temperature sensor system. (Refer to P.13B14, CODE No.13.) Check the barometric pressure sensor system. (Refer to P.13B-20, CODE No.25.) Check the air flow sensor system. (Refer to P.13B-13, CODE No.12.)

13B-30

GDI <4G9> - Troubleshooting

INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom

Inspection procedure No.

Reference page

Communication with MUT-II II is impossible.

Communication with all systems is not possible.

1

13B-32

Communication with engine-ECU only is not possible.

2

13B-33

Engine warning lamp and related parts

The engine warning lamp does not illuminate right after the ignition switch is turned to the ON position.

3

13B-34

The engine warning lamp remains illuminating and never goes out.

4

13B-34

Starting

No initial combustion (starting impossible)

5

13B-35

Initial combustion but no complete combustion (starting impossible)

6

13B-36

Unstable idling (Rough idling, hunting)

7

13B-37

Idling speed is high. (Improper idling speed)

8

13B-39

When the engine is cold, it stalls at idling. (Die out)

9

13B-40

When the engine is hot, it stalls at idling. (Die out)

10

13B-41

The engine stalls when starting the car. (Pass out)

11

13B-43

The engine stalls when decelerating.

12

13B-44

Hesitation, sag or stumble

13

13B-44

The feeling of impact or vibration when accelerating

14

13B-46

The feeling of impact or vibration when decelerating

15

13B-46

Knocking

16

13B-46

Dieseling

17

13B-47

Too high CO and HC concentration when idling

18

13B-47

Low alternator output voltage (approx. 12.3 V)

19

13B-48

Idling speed is improper when A/C is operating

20

13B-48

Fans (radiator fan, A/C condenser fan) are inoperative

21

13B-49

Long time to start (improper starting) Idling stability (Improper idling)

Idling speed is low. (Improper idling speed) Idling stability (Engine stalls)

Driving

Poor acceleration Surge

13B-31

GDI <4G9> - Troubleshooting PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) Items Starting

Idling stability

Driving

Symptom Won’t start

The starter is used to crank the engine, but there is no combustion within the cylinders, and the engine won’t start.

Fires up and dies

There is combustion within the cylinders, but then the engine soon stalls.

Hard starting

Engine starts after cranking a while.

Hunting

Engine speed doesn’t remain constant; changes at idle.

Rough idle

Usually, a judgement can be based upon the movement of the tachometer pointer, and the vibration transmitted to the steering wheel, shift lever, body, etc. This is called rough idle.

Incorrect idle speed

The engine doesn’t idle at the usual correct speed.

Engine stall (Die out)

The engine stalls when the foot is taken from the accelerator pedal, regardless of whether the vehicles is moving or not.

Engine stall (Pass out)

The engine stalls when the accelerator pedal is depressed or while it is being used.

Hesitation, Sag

“Hesitation” is the delay in response of the vehicle speed (engine speed) that occurs when the accelerator is depressed in order to accelerate from the speed at which the vehicle is now traveling, or a temporary drop in vehicle speed (engine speed) during such acceleration. Serious hesitation is called “sag”.

Hesitation Normal Vehicle Initial acspeed celerator

pedal depression

Sag

Time

Poor acceleration

Poor acceleration is inability to obtain an acceleration corresponding to the degree of throttle opening, even though acceleration is smooth, or the inability to reach maximum speed.

Stumble

Engine speed increase is delayed when the accelerator pedal is initially depressed for acceleration.

Vehicle speed

Normal Initial accelerator pedal depression

Idling

Stumble Time

13B-32

GDI <4G9> - Troubleshooting

Items Driving

Stopping

Symptom Shock

The feeling of a comparatively large impact or vibration when the engine is accelerated or decelerated.

Surge

This is repeated surging ahead during constant speed travel or during variable speed travel.

Knocking

A sharp sound like a hammer striking the cylinder walls during driving and which adversely affects driving.

Run on (“Dieseling”)

The condition in which the engine continues to run after the ignition switch is turned to OFF. Also called “Dieseling”.

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS INSPECTION PROCEDURE 1 Communication with MUT-II is not possible. (Communication with all systems is not possible.)

Probable cause

The cause is probably a defect in the power supply system (including earth) for the diagnosis line.

D D

Measure at the diagnostic connector (16-pin) B-25. D Voltage between 16 and earth OK: Battery voltage

NG

OK Check trouble symptom.

OK

Measure at the diagnostic connector (16-pin) B-25. D Continuity between 4 and earth D Continuity between 5 and earth OK: Continuity OK Replace the MUT-II.

Check the following connectors: B-91, B-92, B-66

NG

Check the harness wire between the diagnostic connector (16-pin) and earth, and repair if necessary.

Malfunction of the connector Malfunction of the harness wire NG

NG

Repair

Check the harness wire between the power supply and diagnostic connector (16 pin), and repair if necessary.

GDI <4G9> - Troubleshooting

13B-33

INSPECTION PROCEDURE 2 MUT-II communication with engine-ECU is impossible.

Probable cause

One of the following causes may be suspected. D No power supply to engine-ECU. D Defective earth circuit of engine-ECU. D Defective engine-ECU. D Improper communication line between engine-ECU and MUT-II

D D D

Check the following connectors: B-25, B-102, B-04, B-14, B-52

NG

Malfunction of engine-ECU power supply circuit Malfunction of engine-ECU Open circuit between the engine-ECU and diagnosis connector

Repair

OK Check trouble symptom. NG Check the harness wire between engine-ECU and diagnosis connector.

NG

Repair

OK Check the engine-ECU power supply and earth circuit system. (Refer to P.13B-50, INSPECTION PROCEDURE 22.)

NOTE On vehicles with multi-display, if a malfunction cannot be resolved after the procedure above, check the multi-display and replace if necessary. (Refer to GROUP 54 - Multi-display.)

13B-34

GDI <4G9> - Troubleshooting

INSPECTION PROCEDURE 3 The engine warning lamp does not illuminate right after the ignition switch is turned to the ON position.

Probable cause

Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp to illuminate for five seconds immediately after the ignition switch is turned to ON. If the engine warning lamp does not illuminate immediately after the ignition switch is turned to ON, one of the malfunctions listed at right has probably occurred.

D D D

MUT-II Data list 16 engine-ECU power supply voltage (Refer to P.13B-63.) OK Measure at the engine-ECU connector B-53. D Disconnect the connector, and measure at the harness side. D Earth the terminal No. 36. OK: The engine warning lamp illuminates.

NG

OK

Check the engine-ECU power supply and earth circuit system. (Refer to P.13B-50, INSPECTION PROCEDURE 22.)

Check the following connector: B-53

NG

Repair

OK Check trouble symptom.

NG Check a burnt-out bulb.

Burnt-out bulb Defective warning lamp circuit Malfunction of the engine-ECU

NG

NG

Replace the engine-ECU.

Replace

OK Measure at the combination meter connector B-01. D Disconnect the connector, and measure at the harness side. D Voltage between 42 and earth (Ignition switch: ON) OK: System voltage

NG

Check the engine warning lamp power supply circuit, and repair if necessary.

OK Check the following connectors: B-02, B-14, B-53 OK

NG

NG

Check trouble symptom.

Repair

Check the harness wire between combination meter and engineECU, and repair if necessary.

INSPECTION PROCEDURE 4 The engine warning lamp remains illuminating and never goes out.

Probable cause

In cases such as the above, the cause is probably that the engine-ECU is detecting a problem in a sensor or actuator, or that one of the malfunctions listed at right has occurred.

D

Yes

MUT-II Self-Diag code Are diagnosis codes displayed? No Measure at the combination meter connector B-02. D Disconnect the connector, and measure at the harness side. D Disconnect the engine-ECU connector D Continuity between 22 and earth OK: No continuity OK Replace the engine-ECU.

NG

D

Short-circuit between the engine warning lamp and engine-ECU Malfunction of the engine-ECU

Refer to P.13B-30, INSPECTION CHART FOR DIAGNOSIS CODES Check the harness wire between combination meter and engineECU connector, and repair if necessary.

GDI <4G9> - Troubleshooting

13B-35

INSPECTION PROCEDURE 5 No initial combustion (starting impossible)

Probable cause

The cause is probably a problem with the supply of fuel to the combustion chambers or a malfunction of the ignition circuit. Furthermore, there is a slight possibility that the fuel is contaminated.

D D D

Check the battery voltage during cranking. OK: 8 V or more OK MUT-II Self-Diag code Is a diagnosis code displayed? NO MUT-II Data list 16 System voltage (Refer to P.13B-63.) OK Is the camshaft rotating while the engine is cranking? YES MUT-II Actuator test 07 Fuel pump (low pressure) (Refer to P.13B-68.) OK MUT-II Data list 22 Crank angle sensor (Refer to P.13B-64.) OK Can the sound of the injectors operating be heard while the engine is cranking? (Using a soundscope) OK Check for fuel leaks. (Refer to P.13B-92.)

NG

YES

NG

NO NG

NG

NG

NG

Malfunction of the fuel supply system Malfunction of the ignition system Malfunction of the engine-ECU

Check the battery. (Refer to GROUP 54.)

Refer to P.13B-11, INSPECTION CHART FOR DIAGNOSIS CODES. Check the engine control relay and ignition switch-IG system. (Refer to P.13B-51, INSPECTION PROCEDURE 23.) Check for a broken timing belt. Check the fuel pump (low pressure) system. (Refer to P.13B-55, INSPECTION PROCEDURE 28.) Check the crank angle sensor system. (Refer to P.13B-17, Code No.22.) Check the injector system. (Refer to P.13B-22, Code No.41.)

Replace the fuel pump (high pressure).

OK Measure the fuel pressure between the fuel pump (low pressure) and the fuel pump (high pressure). (Refer to P.13B-89.) OK Check the ignition timing during cranking. OK: Approx. 5_ BTDC

NG

Check that the crank angle sensor and timing belt cover are installed properly.

OK

NG Measure at the ignition coil connectors A-74, A-94, A-97, A-98. D Connect the connector. (Use test harness MB991658) D Check while connecting a primary voltage detection-type OK tachometer to terminal 1 of each connector. OK: For all terminals, the engine tachometer indication is 1/2 of the cranking speed.

Check the abnormal combustion. (Refer to P.13B-23, Code No.44.) Contamination (water, kerosene, etc.) in the fuel

13B-36

GDI <4G9> - Troubleshooting

INSPECTION PROCEDURE 6 Initial combustion but no complete combustion (starting impossible) Long time to start (improper starting)

Probable cause

The cause is probably poor ignition due to a malfunctioning spark plug (weak spark), an incorrect air/fuel ratio when starting or incorrect fuel pressure switching.

D D D D D D

Check the battery voltage during cranking. OK: 8 V or more OK MUT-II Self-Diag code Is a diagnosis code displayed? NO MUT-II Data list 18 Cranking signal (Refer to P.13B-63.)

OK

YES

NG

OK

MUT-II Data list 74 Fuel pressure sensor (Refer to P.13B-67.) OK MUT-II Actuator test 18 Air by-pass control solenoid valve (ON/OFF) (Refer to P.13B-68.) 32 Air by-pass control solenoid valve (DUTY) (Refer to P.13B-68.) OK Can the sound of the injectors operating be heard while the engine is cranking? (Using a soundscope) OK Check for fuel leaks. (Refer to P.13B-92.)

NG

NG

NG

NG

Malfunction Malfunction Malfunction Malfunction Malfunction Malfunction

of of of of of of

the the the the the the

fuel supply system fuel pressure sensor ignition system idle speed control system air by-pass control system engine-ECU

Check the battery. (Refer to GROUP 54.)

Refer to P.13B-11, INSPECTION CHART FOR DIAGNOSIS CODES. Check the ignition switch-ST system . (Refer to P.13B-51, INSPECTION PROCEDURE 24.) Check the ignition switch-ST and inhibitor switch system . (Refer to P.13B-52, INSPECTION PROCEDURE 25.) Check the fuel pressure sensor system. (Refer to P.13B-24, Code No.56.) Check the air by-pass control solenoid valve system. (Refer to P.13B-54, INSPECTION PROCEDURE 27.)

Check the injector system. (Refer to P.13B-22, Code No.41.)

Replace the fuel pump (high pressure).

OK Is starting performance good when the accelerator pedal is depressed slightly during cranking?

YES

NO

Check for sound of idle speed control servo operation. (Refer to P.13B-99.)

NG

Check the idle speed control servo system. (Refer to P.13B-53, INSPECTION PROCEDURE 26.)

OK Clean around the throttle valve. (Refer to P.13B-86.)

Check the ignition timing during cranking. OK: Approx. 5_ BTDC NG Check that the crank angle sensor and timing belt cover are installed properly.

OK

Check the following items in the order given. D Ignition coil, spark plug D Compression pressure D Fuel line clogging D Contamination (water, kerosene, etc.) in the fuel

13B-37

GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 7 Unstable idling (Rough idling, hunting)

Probable cause

The cause is probably a malfunction of the ignition system, or incorrect air/fuel ratio, idle speed control, air by-pass control or compression pressure. Because the probable range of causes is so wide, checking starts from those items which are most likely to be the cause.

D D D D D D

Have the battery terminals been disconnected recently?

YES

NO YES

MUT-II Self-Diag code Is a diagnosis code displayed? NO Check for sound of idle speed control servo operation. (Refer to P.13B-99.) OK Check the injector operation sound. OK MUT-II Data list 14 Throttle position sensor (Refer to P.13B-63.) OK MUT-II Data list 13 Intake air temperature sensor (Refer to P.13B-62.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13B-64.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13B-63.) OK MUT-II Actuator test 08 Purge control solenoid valve (Refer to P.13B-68.) OK MUT-II Data list 11 Oxygen sensor (Refer to P.13B-62.) OK: 700 - 900 mV when the engine is suddenly raced OK MUT-II Data list 11 Oxygen sensor (Refer to P.13B-62.) OK: Changes between 0 mV and 700 - 900 mV at 2,500 r/min.

NG

NG NG

NG

NG

NG

NG

NG

NG

OK

MUT-II Data list 27 Power steering fluid pressure switch (Refer to P.13B-64.) OK MUT-II Data list 28 A/C switch (Refer to P.13B-64.) OK To next page

NG

NG

Malfunction of the ignition system Malfunction of air/fuel ratio control system Malfunction of the idle speed control system Malfunction of the air by-pass control system Incorrect compression pressure Air leaking into air intake system

After the engine has warmed up, run it at idle for approximately 10 minutes. Refer to P.13B-11, INSPECTION CHART FOR DIAGNOSIS CODES. Check the idle speed control servo system. (Refer to P.13B-53, INSPECTION PROCEDURE 26.) Check the injector system. (Refer to P.13B-22, Code No.41.) Check the throttle position sensor system. (Refer to P.13B-15, Code No.14.) Check the intake air temperature sensor system. (Refer to P.13B-14, Code No.13.) Check the barometric pressure sensor system. (Refer to P.13B-20, Code No.25.) Check the engine coolant temperature sensor system. (Refer to P.13B-16, Code No.21.) Check the purge control solenoid valve. (Refer to P.13B-57, INSPECTION PROCEDURE 30.) Check the oxygen sensor system. (Refer to P.13B-12, Code No.11)

Check the fuel pressure. (Refer to P.13B-89.)

OK

Check for air leaking into the air intake system. D Damaged intake manifold gasket D Damaged vacuum hose D Damaged air intake hose

Check the power steering fluid pressure switch system. (Refer to P.13B-58, INSPECTION PROCEDURE 31.) Check the A/C switch and A/C relay system. (Refer to P.13B-58, INSPECTION PROCEDURE 32.)

13B-38

GDI <4G9> - Troubleshooting

From previous page

MUT-II Data list 29 Inhibitor switch (Refer to P.13B-64.) OK MUT-II Data list 48 M/T oil temperature sensor (Refer to P.13B-66.) OK MUT-II Data list 67 Stop lamp switch (Refer to P.13B-66.) OK MUT-II Data list 31 Small lamp switch (Refer to P.13B-64.) OK MUT-II Data list 45 Idle speed control servo (Refer to P.13B-66.) OK MUT-II Data list 68 EGR valve (Refer to P.13B-66.) OK MUT-II Actuator test 18 Air by-pass control solenoid valve (ON/OFF) (Refer to P.13B-68.) 32 Air by-pass control solenoid valve (DUTY) (Refer to P.13B-68.) OK Check the ignition timing. (Refer to GROUP 11A - On-vehicle Service)

NG

NG

NG

NG

NG

NG

NG

OK

NG Check that the crank angle sensor and timing belt cover are installed properly.

Check the ignition switch-ST and inhibitor switch system. (Refer to P.13B-52, INSPECTION PROCEDURE 25.) Check the M/T oil temperature sensor system. (Refer to P.13B-59, INSPECTION PROCEDURE 33.)

Check the stop lamp switch system. (Refer to P.13B-60, INSPECTION PROCEDURE 34.) Check the small lamp switch system. (Refer to P.13B-61, INSPECTION PROCEDURE 35.) Adjust the basic idle speed. (Refer to P.13B-87.)

Check the EGR valve system. (Refer to P.13B-56, INSPECTION PROCEDURE 29.) Check the air by-pass control solenoid valve system. (Refer to P.13B-54, INSPECTION PROCEDURE 27.)

Check the following items in the order given. D Ignition coil, spark plug D Evaporative Emission Control System D EGR system D Compression pressure D Contamination (water, kerosene, etc.) in the fuel

OK Clean the throttle body. (Refer to P.13B-86.) Check the trouble symptoms.

NG

Check for air D Damaged D Damaged D Damaged

leaking into the air intake system. intake manifold gasket air intake hose vacuum hose

GDI <4G9> - Troubleshooting

13B-39

INSPECTION PROCEDURE 8 Idling speed is high, Idling speed is low (Improper idling speed)

Probable cause

The cause is probably that the intake air amount during idling is too great or too small.

D D D

YES

MUT-II Self-Diag code Is a diagnosis code displayed? NO Check for sound of idle speed control servo operation. (Refer to P.13B-97.) OK MUT-II Actuator test 18 Air by-pass control solenoid valve (ON/OFF) (Refer to P.13B-68.) 32 Air by-pass control solenoid valve (DUTY) (Refer to P.13B-68.) OK MUT-II Actuator test 08 Purge control solenoid valve (Refer to P.13B-68.) OK MUT-II Data list 14 Throttle position sensor (Refer to P.13B-63.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13B-63.) OK MUT-II Data list 28 A/C switch (Refer to P.13B-64.) OK MUT-II Data list 29 Inhibitor switch (Refer to P.13B-64.) OK MUT-II Data list 48 M/T oil temperature sensor (Refer to P.13B-66.) OK MUT-II Data list 67 Stop lamp switch (Refer to P.13B-66.)

NG

NG

NG

NG

NG

NG

NG

NG

NG

Malfunction of the idle speed control system Malfunction of the air by-pass control system Malfunction of the throttle body

Refer to P.13B-11, INSPECTION CHART FOR DIAGNOSIS CODES. Check the idle speed control servo system. (Refer to P.13B-53, INSPECTION PROCEDURE 26.) Check the air by-pass control solenoid valve system. (Refer to P.13B-54, INSPECTION PROCEDURE 27.)

Check the purge control solenoid valve system. (Refer to P.13B-57, INSPECTION PROCEDURE 30.) Check the throttle position sensor system. (Refer to P.13B-15, Code No.14.) Check the engine coolant temperature sensor system. (Refer to P.13B-16, Code No.21.) Check the A/C switch and A/C relay system. (Refer to P.13B-58, INSPECTION PROCEDURE 32.) Check the ignition switch-ST and inhibitor switch system . (Refer to P.13B-52, INSPECTION PROCEDURE 25.) Check the M/T oil temperature sensor system. (Refer to P.13B-59, INSPECTION PROCEDURE 33.) Check the stop lamp switch system. (Refer to P.13B-60, INSPECTION PROCEDURE 34.)

Adjust the basic idle speed. (Refer to P.13B-87.) Check the trouble symptoms.

NG

Clean around the throttle valve. (Refer to P.13B-86.)

13B-40

GDI <4G9> - Troubleshooting

INSPECTION PROCEDURE 9 When the engine is cold, it stalls at idling. (Die out)

Probable cause

The cause is probably an incorrect air/fuel ratio when the engine is cold, or insufficient intake air.

D D D

Have the battery terminals been disconnected recently?

YES

NO YES

MUT-II Self-Diag code Is a diagnosis code displayed? NO Is the engine idling correct after the engine has warmed up? YES Check for sound of idle speed control servo operation. (Refer to P.13B-99.) OK Check the injector operation sound. OK MUT-II Data list 14 Throttle position sensor (Refer to P.13B-63.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13B-63.) OK MUT-II Data list 48 M/T oil temperature sensor (Refer to P.13B-66.) OK MUT-II Data list 68 EGR valve (Refer to P.13B-65.) OK MUT-II Actuator test 18 Air by-pass control solenoid valve (ON/OFF) (Refer to P.13B-68.) 32 Air by-pass control solenoid valve (DUTY) (Refer to P.13B-68.) OK Does the engine stall soon after the accelerator pedal is released?

NO NG

NG NG

NG

NG

NG

NG

YES

Malfunction of the idle speed control system Malfunction of the air by-pass control system Malfunction of the throttle body

After the engine has warmed up, run it at idle for approximately 10 minutes. Refer to P.13B-11, INSPECTION CHART FOR DIAGNOSIS CODES. Refer to P.13B-37, INSPECTION PROCEDURE 7, Unstable idle (rough idle, hunting) Check the idle speed control servo system. (Refer to P.13B-53, INSPECTION PROCEDURE 26.) Check the injector system. (Refer to P.13B-22, Code No.41.) Check the throttle position sensor system. (Refer to P.13B-15, Code No.14.) Check the engine coolant temperature sensor system. (Refer to P.13B-16, Code No.21.) Check the M/T oil temperature sensor system. (Refer to P.13B-59, INSPECTION PROCEDURE 33.) Check the EGR valve system. (Refer to P.13B-56, INSPECTION PROCEDURE 29.) Check the air by-pass control solenoid valve system. (Refer to P.13B-54, INSPECTION PROCEDURE 27.)

Clean around the throttle valve. (Refer to P.13B-86.)

NO Check the fuel pressure. (Refer to P.13B-89.) Check the ignition timing. (Refer to GROUP 11B - On-vehicle Service) OK Check the following items in the order given. D Ignition coil, spark plug D Compression pressure D Engine oil viscosity

NG

Check that the crank angle sensor and timing belt cover are installed properly.

13B-41

GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 10 When the engine is hot, it stalls at idling. (Die out)

Probable cause

The cause is probably a malfunction of the ignition system, or incorrect air/fuel ratio, idle speed control, air by-pass control or compression pressure. In addition, if the engine suddenly stalls, another possible cause might be a poor connector contact.

D D D D D D D

Have the battery terminals been disconnected recently?

YES

NO YES

MUT-II Self-Diag code Is a diagnosis code displayed? NO Check for sound of idle speed control servo operation. (Refer to P.13B-99.) OK Check the injector operation sound. OK Is it easy to reproduce the stalling?

NG

NG NO

YES

MUT-II Data list 14 Throttle position sensor (Refer to P.13B-63.) OK MUT-II Data list 13 Intake air temperature sensor (Refer to P.13B-62.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13B-64.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13B-63.) OK MUT-II Data list 11 Oxygen sensor (Refer to P.13B-62.) OK: 700 - 900 mV when the engine is suddenly raced

NG

NG

NG

NG

NG

Malfunction of the ignition system Malfunction of the air/fuel ratio control system Malfunction of the idle speed control system Malfunction of the air by-pass control system Malfunction of the throttle body Poor connector contact Air leaking into air intake system

After the engine has warmed up, run it at idle for approximately 10 minutes. Refer to P.13B-11, INSPECTION CHART FOR DIAGNOSIS CODES. Check the idle speed control servo system. (Refer to P.13B-53, INSPECTION PROCEDURE 26.) Check the injector system. (Refer to P.13B-22, Code No.41.) While carrying out an intermittent malfunction simulation test. (Refer to GROUP 00 - Points to Note for Intermittent Malfunctions.), check for sudden changes in the following signals. D Crank angle sensor signal D Injector drive signal D Fuel pump (low pressure) drive signal D Air flow sensor signal D Engine-ECU power supply voltage

Check the throttle position sensor system. (Refer to P.13B-15, Code No.14.) Check the intake air temperature sensor system. (Refer to P.13B-14, Code No.13.) Check the barometric pressure sensor system. (Refer to P.13B-20, Code No.25.) Check the engine coolant temperature sensor system. (Refer to P.13B-16, Code No.21.) Check the oxygen sensor system. (Refer to P.13B-12, Code No.11.)

OK MUT-II Data list 11 Oxygen sensor (Refer to P.13B-62.) OK: Changes between 0 mV and 700 - 900 mV at 2,500 r/min. OK To next page

NG

Check the fuel pressure. (Refer to P.13B-89.)

OK

Check for air leaking into the air intake system. D Damaged intake manifold gasket D Damaged vacuum hose D Damaged air intake hose

13B-42

GDI <4G9> - Troubleshooting

From previous page

MUT-II Data list 27 Power steering fluid pressure switch (Refer to P.13B-64.) OK MUT-II Data list 28 A/C switch (Refer to P.13B-64.) OK MUT-II Data list 29 Inhibitor switch (Refer to P.13B-64.) OK MUT-II Data list 31 Small lamp switch (Refer to P.13B-64.) OK MUT-II Data list 12 Air flow sensor (Refer to P.13B-62.) OK MUT-II Data list 45 Idle speed control servo (Refer to P.13B-66.) OK MUT-II Data list 68 EGR valve (Refer to P.13B-66.) OK MUT-II Actuator test 18 Air by-pass control solenoid valve (ON/OFF) (Refer to P.13B-68.) 32 Air by-pass control solenoid valve (DUTY) (Refer to P.13B-68.) OK Does the engine stall soon after the accelerator pedal is released?

NG

NG

NG

NG

NG

NG

NG

NG

YES

Check the power steering fluid pressure switch. (Refer to P.13B-58, INSPECTION PROCEDURE 31.) Check the A/C switch. (Refer to P.13B-58, INSPECTION PROCEDURE 32.) Check the ignition switch-ST and inhibitor switch system. (Refer to P.13B-52, INSPECTION PROCEDURE 25.) Check the small lamp switch system. (Refer to P.13B-61, INSPECTION PROCEDURE 35.) Check the air flow sensor system. (Refer to P.13B-13, Code No.12)

Adjust the basic idle speed. (Refer to P.13B-87.)

Check the EGR valve system. (Refer to P.13B-56, INSPECTION PROCEDURE 29.) Check the air by-pass control solenoid valve system. (Refer to P.13B-54, INSPECTION PROCEDURE 27.)

Clean around the throttle valve. (Refer to P.13B-86.)

NO Check the ignition timing. (Refer to GROUP 11B - On-vehicle Service.) NG Check that the crank angle sensor and timing belt cover are installed properly.

OK

Check the following items in the order given. D Ignition coil, spark plug D Compression pressure D Contamination (water, kerosene, etc.) in the fuel

GDI <4G9> - Troubleshooting

13B-43

INSPECTION PROCEDURE 11 The engine stalls when starting the car. (Pass out)

Probable cause

The cause is probably poor ignition due to a malfunctioning spark plug (weak spark), or an incorrect air/fuel ratio when the accelerator is depressed.

D D D D

YES

MUT-II Self-Diag code Is a diagnosis code displayed? NO MUT-II Data list 68 EGR valve (Refer to P.13B-66.) OK MUT-II Actuator test 18 Air by-pass control solenoid valve (ON/OFF) (Refer to P.13B-68.) 32 Air by-pass control solenoid valve (DUTY) (Refer to P.13B-68.) OK MUT-II Actuator test 08 Purge control solenoid valve (Refer to P.13B-68.) OK Check the following items in the order given. D Ignition coil, spark plug D Check for air leaking into the air intake system. Damaged intake manifold gasket Damaged or disconnected vacuum hose Damaged air intake hose

NG

NG

NG

Malfunction of the ignition system Malfunction of the air by-pass control system Malfunction of the EGR valve Air leaking into air intake system

Refer to P.13B-11, INSPECTION CHART FOR DIAGNOSIS CODES. Check the EGR valve system. (Refer to P.13B-56, INSPECTION PROCEDURE 29.) Check the air by-pass control solenoid valve system. (Refer to P.13B-54, INSPECTION PROCEDURE 27.)

Check the purge control solenoid valve system. (Refer to P.13B-57, INSPECTION PROCEDURE 30.)

13B-44

GDI <4G9> - Troubleshooting

INSPECTION PROCEDURE 12 The engine stalls when decelerating

Probable cause

The cause is probably insufficient intake air due to an idle speed control malfunction, or incorrect air/fuel ratio due to an air by-pass control or EGR malfunction.

D D D

Have the battery terminals been disconnected recently? NO MUT-II Self-Diag code Is a diagnosis code displayed? NO MUT-II Data list 14 Throttle position sensor (Refer to P.13B-63.) OK MUT-II Data list 45 Idle speed control servo D Does the idle speed control servo position drop to steps 0 - 2 during deceleration (when engine speed is 1,000 r/min or more)? NO MUT-II Data list 68 EGR valve (Refer to P.13B-66.) OK MUT-II Actuator test 18 Air by-pass control solenoid valve (ON/OFF) (Refer to P.13B-68.) 32 Air by-pass control solenoid valve (DUTY) (Refer to P.13B-68.) OK

YES YES

NG

YES

NG

NG

Malfunction of the idle speed control system Malfunction of the air by-pass control system Malfunction of the EGR valve

After the engine has warmed up, run it at idle for approximately 10 minutes. Refer to P.13B-11, INSPECTION CHART FOR DIAGNOSIS CODES. Check the throttle position sensor system (Refer to P.13B-15, Code No.14.) Check the vehicle speed sensor system. (Refer to P.13B-19, Code No.24.)

Check the EGR valve system. (Refer to P.13B-56, INSPECTION PROCEDURE 29.) Check the air by-pass control solenoid valve system. (Refer to P.13B-54, INSPECTION PROCEDURE 27.)

Check the following items in the order given. D Ignition coil, spark plug D Clean around the throttle valve. (Refer to P.13B-86.)

INSPECTION PROCEDURE 13 Hesitation, sag, stumble, poor acceleration or surge

Probable cause

The cause is probably a malfunction of the ignition system, or incorrect air/fuel ratio, air by-pass control or compression pressure.

D D D D D

YES

MUT-II Self-Diag code Is a diagnosis code displayed? NO Check the injector operation sound. NO To next page

NG

Malfunction of the ignition system Malfunction of the air/fuel ratio control system Malfunction of the air by-pass control system Poor compression pressure Air leaking into air intake system

Refer to P.13B-11, INSPECTION CHART FOR DIAGNOSIS CODES. Check the injector system. (Refer to P.13B-22, Code No.41.)

13B-45

GDI <4G9> - Troubleshooting From previous page Check the ignition timing. (Refer to GROUP 11B - On-vehicle Service) OK MUT-II Data list 13 Intake air temperature sensor (Refer to P.13B-62.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13B-64.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13B-63.) OK MUT-II Data list 14 Throttle position sensor (Refer to P.13B-63.) OK MUT-II Data list 11 Oxygen sensor OK: 700 - 900 mV when the engine is suddenly raced OK MUT-II Data list 11 Oxygen sensor OK: Changes between 0 mV and 700 - 900 mV at 2,500 r/min.

NG

NG

NG

NG

NG

NG

NG

OK MUT-II Actuator test 18 Air by-pass control solenoid valve (ON/OFF) (Refer to P.13B-68.) 32 Air by-pass control solenoid valve (DUTY) (Refer to P.13B-68.) OK MUT-II Actuator test 08 Purge control solenoid valve (Refer to P.13B-68.) OK Check the fuel pressure. (Refer to P.13B-89.)

Check the intake air temperature sensor system. (Refer to P.13B-14, Code No.13.) Check the barometric pressure sensor system. (Refer to P.13B-20, Code No.25.) Check the engine coolant temperature sensor system. (Refer to P.13B-16, Code No.21.) Check the throttle position sensor system. (Refer to P.13B-15, Code No.14.) Check the oxygen sensor system. (Refer to P.13B-12, Code No.11.)

Check the fuel pressure. (Refer to P.13B-89.) OK Check for air D Damaged D Damaged D Damaged

OK

MUT-II Data list 68 EGR valve (Refer to P.13B-66.)

Check that the crank angle sensor and timing belt cover are installed properly.

NG

NG

NG

OK

leaking into the air intake system. intake manifold gasket vacuum hose air intake hose

Check the EGR valve system. (Refer to P.13B-56, INSPECTION PROCEDURE 29.) Check the air by-pass control solenoid valve system. (Refer to P.13B-54, INSPECTION PROCEDURE 27.)

Check the purge control solenoid valve system. (Refer to P.13B-57, INSPECTION PROCEDURE 30.) Check the following items in the order given. D Ignition coil, spark plug D EGR system D Compression pressure D Fuel filter and fuel line clogging

13B-46

GDI <4G9> - Troubleshooting

INSPECTION PROCEDURE 14 The feeling of impact when accelerating

Probable cause

The cause is probably an ignition leak being generated in line with an increase in the spark plug demand voltage during acceleration.

D

YES

MUT-II Self-Diag code Is a diagnosis code displayed?

Malfunction of the ignition system

Refer to P.13B-11, INSPECTION CHART FOR DIAGNOSIS CODES.

NO Check the following items in the order given. D Ignition coil, spark plug D Ignition leak.

INSPECTION PROCEDURE 15 The feeling of impact when decelerating

Probable cause

The cause is probably insufficient intake air due to an idle speed control malfunction.

D

YES

MUT-II Self-Diag code Is a diagnosis code displayed? NO Check for sound of idle speed control servo operation. (Refer to P.13B-99.) OK MUT-II Data list 14 Throttle position sensor (Refer to P.13B-63.) OK

NG

NG

Malfunction of the idle speed control system

Refer to P.13B-11, INSPECTION CHART FOR DIAGNOSIS CODES. Check the idle speed control servo system. (Refer to P.13B-53, INSPECTION PROCEDURE 26.) Check the throttle position sensor system. (Refer to P.13B-15, Code No.14.)

Clean around the throttle valve. (Refer to P.13B-86.)

INSPECTION PROCEDURE 16 Knocking

Probable cause

The cause is probably incorrect detonation control or an incorrect heating value for the spark plugs.

D D

YES

MUT-II Self-Diag code Is a diagnosis code displayed? NO Does knocking occur when driving while the detonation sensor connector is disconnected? (At this time, use the MUT-II to check whether the ignition timing is retarded from when the detonation sensor connector is connected.) YES Check the following items in the order given. D Spark plug D Contamination (water, kerosene, etc.) in the fuel

NO

Malfunction of the detonation sensor Incorrect heat value of the spark plug

Refer to P.13B-11, INSPECTION CHART FOR DIAGNOSIS CODES. Check the idle speed control servo system. (Refer to P.13B-53, INSPECTION PROCEDURE 26.)

13B-47

GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 17 Run-on (Dieseling)

Probable cause

The cause is probably a leaking injector.

D

Malfunction of the injector

Replace the injector.

INSPECTION PROCEDURE 18 Too high CO and HC concentration when idling

Probable cause

The cause is probably an incorrect air/fuel ratio.

D D

YES

MUT-II Self-Diag code Is a diagnosis code displayed? NO Check the ignition timing. (Refer to GROUP 11A - On-vehicle Service.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13B-63.) OK MUT-II Data list 13 Intake air temperature sensor (Refer to P.13B-62.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13B-64.) OK MUT-II Data list 11 Oxygen sensor OK: 700 - 900 mV when the engine is suddenly raced OK MUT-II Data list 11 Oxygen sensor OK: Changes between 0 mV and 700 - 900 mV at 2,500 r/min.

NG

NG

NG

NG

NG

OK

Malfunction of the air/fuel ration control system Deterioration of the catalyst

Refer to P.13B-11, INSPECTION CHART FOR DIAGNOSIS CODES. Check that the crank angle sensor and timing belt cover are installed properly. Check the engine coolant temperature sensor system. (Refer to P.13B-16, Code No.21.) Check the intake air temperature sensor system. (Refer to P.13B-14, Code No.13.) Check the barometric pressure sensor system. (Refer to P.13B-20, Code No.25.) Check the oxygen sensor system. (Refer to P.13B-12, Code No.11.)

Replace the oxygen sensor. Check the trouble symptoms.

NG

NG

Check the fuel pressure. (Refer to P.13B-87.) OK Check the following items in the order given. D Ignition coil, spark plug D Compression pressure D Positive crankcase ventilation system OK MUT-II Data list 68 EGR valve (Refer to P.13B-66.) OK MUT-II Actuator test 08 Purge control solenoid valve (Refer to P.13B-68.) OK Check the trouble symptoms. NG Replace the three-way catalytic converter.

NG

NG

Check the EGR valve system. (Refer to P.13B-56, INSPECTION PROCEDURE 29.) Check the purge control solenoid valve system. (Refer to P.13B-57, INSPECTION PROCEDURE 30.)

13B-48

GDI <4G9> - Troubleshooting

INSPECTION PROCEDURE 19 Low alternator output voltage (approx. 12.3 V)

Probable cause

The cause is probably a malfunction of the alternator or one of the problems listed at right.

D D D

Measure at the alternator connector A-52. D Connect the connector. (Use the test harness MB991519) D Voltage between 1 (black clip) and earth (Engine: Idling) (Radiator fan: Not operating) (Headlamp: OFF ® ON) (Stop lamp: OFF ® ON) (Rear defogger switch: OFF ® ON) OK: Voltage increased by 0.2 - 3.5 V.

NG

Measure at the alternator connector A-52 D Disconnect the connector, and measure at the harness side. D Disconnect the engine-ECU connector. D Continuity between 1 and earth OK: No continuity

Malfunction of the charging system Open circuit between the alternator G terminal and the engine-ECU Malfunction of the engine-ECU NG

Check the harness wire between the alternator and the engine-ECU, and repair if necessary.

OK Check the following connectors: A-52, A-30, B-53 OK NG

OK

Repair

Check the alternator. (Refer to GROUP 16 - Charging System.)

Replace the engine-ECU.

INSPECTION PROCEDURE 20 Idling speed is improper when A/C is operating

Probable cause

If the engine-ECU detects that the air conditioner is on, it activates the idle speed control (ISC) servo to control idle-up operation. The A/C-ECU judges if the load caused by air conditioner operation is high or low, and converts it to voltage signal (high or low voltage) and inputs the signal to the engine-ECU. Based on this voltage signal, the engine-ECU controls the idle-up speed (for high or low load).

D D

Measure at the engine-ECU connector B-51. D Connect the connector. D Voltage between 73 and earth (Engine: at idle, outside air temperature: 25_C or more) OK: 0 - 3 V [When A/C is MAX. COOL condition (when the load by A/C is high)] System voltage [When A/C is MAX. HOT condition (when the load by A/C is low)] NG Check the A/C system. (Refer to GROUP 55 - On-vehicle Service.)

OK

D

Malfunction of the A/C control system Improper connector contact, open short-circuited harness wire Malfunction of the engine-ECU

Check the following connector: B-51 OK

NG Repair

Check trouble symptom. NG Replace the engine-ECU.

circuit

or

13B-49

GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 21 Fans (radiator fan, A/C condenser fan) are inoperative.

Probable cause

The engine-ECU sends a duty signal to the fan controller according to engine coolant temperature, vehicle speed, or A/C switch. The fan controller controls radiator fan and condenser fan speeds, based on this signal. (The closer the terminal voltage comes to 5 V, the higher the fan speed becomes.)

D D D D D

Measure at engine-ECU connector B-54. D Disconnect the connector, measure at the harness side. D Voltage between terminal 21 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V (The fan runs at high speed.) D Earth terminal 21. (Ignition switch: ON) OK: The fan stops.

NG

the fan motor relay the fan motor the fan controller circuit, or poor connector contact the engine-ECU

Check the harness wire between the engine-ECU and fan controller. OK

NG Repair

Check the radiator fan and condenser fan circuit. (Refer to GROUP 14 - Troubleshooting.)

OK Check the following connector: B-54

Malfunction of Malfunction of Malfunction of Open or short Malfunction of

NG

Repair

OK Check trouble symptom. NG MUT-II Data list 21 Engine coolant temperature sensor OK: After the engine has been warmed up, the engine coolant temperature during idling is identical to the MUT-II reading.

NG

Check the engine coolant temperature sensor system. (Refer to P.13B-16, Code No.21.)

OK NG

Check the thermostat. OK Replace the engine-ECU.

Replace

13B-50

GDI <4G9> - Troubleshooting

INSPECTION PROCEDURE 22 Engine-ECU power supply and earth circuit system

Probable cause

The cause is probably a malfunction of the engine-ECU or one of the problems listed at right.

D D D

1. NG Measure at the engine-ECU connectors B-51, B-53, B-54. D Disconnect the connector, and measure at the harness side. 1. Voltage between 82 and earth (Ignition switch: ON) OK: System voltage 2,3. NG 2. Voltage between 38 and earth OK: System voltage 3. Voltage between 12, 25 and earth (Ignition switch: ON) 4. NG OK: System voltage (When terminal 38 is shorted to earth) 4. Continuity between 13, 26 and earth 5. NG OK: Continuity 5. Voltage between 80 and earth OK: System voltage OK Check the following connectors: B-51, B-53, B-54 OK NG Repair Check the trouble symptoms. NG Replace the engine-ECU.

Check the following connectors: B-13, B-103, B-89 OK Check the trouble symptoms.

Open circuit or short-circuited harness wire in the engine-ECU power supply circuit Open circuit or short-circuited harness wire in the engine-ECU earth circuit Malfunction of the engine-ECU NG

NG

Check the harness wire between the engine-ECU and engine control relay, and repair if necessary.

Repair

Check the harness wire between the engine-ECU and ignition switch, and repair if necessary. OK NG Repair

Check the harness wire between the engine-ECU and earth, and repair if necessary. Check the following connectors: B-14, B-44, B-90, B-103, B-66 OK Check the trouble symptoms.

Check the ignition switch. (Refer to GROUP 54.) NG

NG

Repair

Check the harness wire between the engine-ECU and the battery, and repair if necessary.

13B-51

GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 23 Engine control relay and ignition switch-IG system

Probable cause

When the ignition switch ON signal is input to the engine-ECU, the engine-ECU turns on the engine control relay. This causes system voltage to be supplied to the engine-ECU and to the sensors and actuators.

D D D

Check the engine control relay. (Refer to P.13B-95.) OK Measure at the engine control relay connector A-14X. D Disconnect the connector, and measure at the harness side. D Voltage between 3, 4 and earth OK: System voltage

NG

NG

D

Malfunction of the ignition switch Malfunction of the engine control relay Open circuit or short-circuited harness wire of the engine control relay circuit Malfunction of the engine-ECU

Replace NG

Check the following connector: A-28 OK

NG

Check the trouble symptoms.

OK

Repair

Check the harness wire between the battery and the engine control relay, and repair if necessary.

Check the engine-ECU power supply and earth circuit system. (Refer to P.13B-50, INSPECTION PROCEDURE 22.)

INSPECTION PROCEDURE 24 Ignition switch-ST system

Probable cause

The ignition switch-ST outputs a HIGH signal to the engine-ECU while the engine is cranking. The engine-ECU uses this signal to carry out functions such as fuel injection control during starting.

D D

(1) NG Measure at the engine-ECU connector B-51. D Disconnect the connector, and measure at the harness side. (1) Voltage between 71 and earth (Ignition switch: START) (2) NG OK: 8 V or more (2) Continuity between 91 and earth OK: Continuity OK Check the following connector: B-51 OK Check the trouble symptoms. NG Replace the engine-ECU.

NG

D

Check the following connectors: A-30, B-13 OK Check the trouble symptoms. Check the harness wire between the engine-ECU connector (terminal No.91) and earth, and repair if necessary. Repair

Malfunction of the ignition switch Open circuit or short-circuited harness wire of the ignition switch circuit Malfunction of the engine-ECU NG

NG

Repair

Check the harness wire between the engine-ECU and the ignition switch. OK NG Repair Check the ignition switch. (Refer to GROUP 54.)

13B-52

GDI <4G9> - Troubleshooting

INSPECTION PROCEDURE 25 Ignition switch-ST and inhibitor switch system

Probable cause

The ignition switch-ST outputs a HIGH signal to the engine-ECU while the engine is cranking, and the engine-ECU uses this signal to carry out functions such as fuel injection control during starting. The inhibitor switch inputs the position of the selector lever to the engine-ECU. The engine-ECU uses this signal to carry out idle speed control.

D D D

Check the inhibitor switch (Refer to GROUP 23 - On-vehicle Service.) OK

NG

(1) NG Measure at the inhibitor switch connector A-89. D Disconnect the connector, and measure at the harness side. (1) Voltage between 10 and earth (Ignition switch: ON) OK: System voltage (2) Continuity between 9 and earth (2) NG OK: Continuity (3) Voltage between 10 and earth (Ignition switch: START) Disconnect the engine-ECU (3) NG connector. OK: System voltage

D

Malfunction of the ignition switch Malfunction of the inhibitor switch Open circuit or short-circuited harness wire between ignition switch and inhibitor switch Malfunction of the engine-ECU

Replace

Check the harness wire between the engine-ECU and the inhibitor switch connector.

NG

OK Replace the engine-ECU.

Check the following connectors: A-30, A-39 OK Check the trouble symptoms.

NG

NG

OK Check the following connector: A-89 OK NG Repair Check the trouble symptoms. NG Check the harness wire between the engine-ECU and the inhibitor switch. OK NG Repair Replace the engine-ECU.

Repair

Check the following connector: B-13

NG

Repair

Check the harness wire between the inhibitor switch connector and the starter S terminal, and repair if necessary. Repair

OK Check the trouble symptoms. NG Check the harness wire between the inhibitor switch and the ignition switch connector. OK Check the ignition switch. (Refer to GROUP 54.)

NG

Repair

13B-53

GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 26 Idle speed control servo (ISC) system

Probable cause

The engine-ECU controls the amount of intake air during idling by opening and closing the servo valve which is located in the air by-pass passage.

D D D

Check the idle speed control servo. (Refer to P.13B-99.) OK Measure at the idle speed control servo connector A-75. D Disconnect the connector, and measure at the harness side. D Voltage between 2, 5 and earth (Ignition switch: ON) OK: System voltage

NG

NG

Replace

Check the harness wire between the engine control relay and the idle speed control servo, and repair if necessary.

OK Measure at the engine-ECU connector B-54. D Disconnect the connector, and measure at the harness side. D Voltage between 4, 5, 17, 18 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: B-54 OK Check the trouble symptoms.

NG

Check the following connector: A-75 OK Check the trouble symptoms.

NG

NG

Malfunction of the idle speed control servo Open circuit or short-circuited harness wire in the idle speed control servo circuit Malfunction of the engine-ECU

Repair

Replace the engine-ECU.

NG

NG

Repair

Check the harness wire between the engine-ECU and the idle speed control servo, and repair if necessary.

13B-54

GDI <4G9> - Troubleshooting

INSPECTION PROCEDURE 27 Air by-pass control solenoid valve system

Probable cause

The engine-ECU controls the two ON/OFF and DUTY solenoid valves in order to adjust the by-pass air amount.

D D D

Check the air by-pass control solenoid valves (ON/OFF, DUTY) (Refer to P.13B-100.) OK Measure at the air by-pass control solenoid valve (ON/OFF) connector A-93. Measure at the air by-pass control solenoid valve (DUTY) connector A-92. D Disconnect the connector, and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: System voltage

NG

NG

Replace

Check the following connector: A-72 OK Check the trouble symptoms.

OK

(1) NG Measure at the engine-ECU connector B-54. (2) NG D Disconnect the connector, and measure at the harness side. (1) Voltage between 3 and earth (Ignition switch: ON) OK: System voltage (2) Voltage between 16 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: B-54 OK Check the trouble symptoms. NG Replace the engine-ECU.

Malfunction of the air by-pass control solenoid valves (ON/OFF, DUTY) Open circuit or short-circuited harness wire in the air by-pass control solenoid valves (ON/OFF, DUTY) Malfunction of the engine-ECU

NG

NG

Repair

Check the harness wire between the engine control relay and the air by-pass control solenoid valve (ON/OFF), and repair if necessary. Check the harness wire between the engine control relay and the air by-pass control solenoid valve (DUTY), and repair if necessary.

Check the following connectors: A-72, A-93 Check the following connectors: A-72, A-92 OK NG Repair Check the trouble symptoms. NG Check the harness wire between the engine-ECU and the air by-pass control solenoid valve (DUTY), and repair if necessary.

OK

NG Repair

Check the trouble symptoms. NG Check the harness wire between the engine-ECU and the air by-pass control solenoid valve (ON/OFF), and repair if necessary.

13B-55

GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 28 Fuel pump (low pressure) system

Probable cause

The engine-ECU turns on the fuel pump relay while the engine is cranking or running, and supplies power source to the fuel pump (low pressure).

D D D D

MUT-II Actuator test 07 Fuel pump (Refer to P.13B-68.) NG Check the fuel pump relay. (Refer to P.13B-95.) OK Measure at fuel pump relay connector A-15X. D Disconnect the connector, and measure at the harness side. D Voltage between terminals 3, 4 and earth (Ignition switch: ON) OK: System voltage

OK

NG

NG

Malfunction of the fuel pump relay Malfunction of the fuel pump (low pressure) Open circuit or short-circuited harness wire in the fuel pump (low pressure) circuit, or poor connector contact Malfunction of the engine-ECU

Normal

Replace

Check the following connectors: B-13, B-103, B-89 OK

NG

NG

Check trouble symptom.

Repair

Check the harness wire between the fuel pump relay and ignition switch. OK NG

OK Measure at engine-ECU connector B-54. D Disconnect the connector, and measure at the harness side. D Voltage between terminal 22 and earth (Ignition switch: ON) OK: System voltage

NG

Check the following connector: A-15X OK NG

Check the ignition switch. (Refer to GROUP 54 - Ignition Switch.)

Repair NG

Check trouble symptom.

OK Measure at engine-ECU connector B-54. D Disconnect the connector, and measure at the harness side. D Short circuit between terminal 22 and earth (Ignition switch: ON) OK: The fuel pump operates (its operation sound can be heard).

Repair

OK

Check the following connector: B-54 OK

NG

Check trouble symptom.

NG (1) NG Measure at fuel pump (low pressure) connector C-20. D Disconnect the connector, and measure at the harness side. (1) Voltage between terminal 5 and earth (Ignition switch: ON) OK: System voltage (2) Continuity between 4 and earth (2) NG OK: Continuity OK

NG

Check the following connectors: C-34, B-13, A-15X OK

NG

NG

Check trouble symptom.

Check the harness wire between the fuel pump relay and engine-ECU, and repair if necessary. Repair

Replace the engine-ECU.

Repair

Check the harness wire between the fuel pump relay and fuel pump (low pressure), and repair if necessary.

Check the following connector: C-34 OK NG Repair Check trouble symptom.

Check the following connector: C-20 OK Check trouble symptom. NG Replace the fuel pump (low pressure).

NG

Repair

NG

Check the harness wire between the fuel pump (low pressure) and earth, and repair if necessary.

13B-56

GDI <4G9> - Troubleshooting

INSPECTION PROCEDURE 29 EGR valve (stepper motor) system

Probable cause

The engine-ECU controls the EGR valve (stepper motor) in order to control the amount of exhaust gas mixed in the intake air.

D D D

Check the EGR valve. (Refer to GROUP 17 - Emission Control System.)

NG

Replace

OK Measure at the EGR valve connector A-91. D Disconnect the connector, and measure at the harness side. D Voltage between 2, 5 and earth (Ignition switch: ON) OK: System voltage

NG

Check the following connector: A-72 OK Check the trouble symptoms.

OK Measure at the engine-ECU connector B-53. D Disconnect the connector, and measure at the harness side. D Voltage between 31, 32, 39, 40 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: B-53 OK Check the trouble symptoms.

NG

Check the following connector: A-91 OK Check the trouble symptoms.

NG

NG

Malfunction of the EGR valve Open circuit or short-circuited harness wire in the EGR valve circuit Malfunction of the engine-ECU

Repair

Replace the engine-ECU.

NG

NG

NG

NG

Repair

Check the harness wire between the engine control relay and the EGR valve, and repair if necessary. Repair

Check the harness wire between the engine-ECU and EGR valve, and repair if necessary.

13B-57

GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 30 Purge control solenoid valve system

Probable cause

The engine-ECU controls the purge control solenoid valve in order to control the purge air coming from the canister.

D D D

Check the purge control solenoid valve. (Refer to GROUP 17 - On-vehicle Service.) OK Measure at the purge control solenoid valve connector A-76. D Disconnect the connector, and measure at the harness side. D Voltage between 2 and earth (Ignition switch: ON) OK: System voltage

NG

NG

Replace

Check the harness wire between the engine control relay and the purge control solenoid valve, and repair if necessary.

OK Measure at the engine-ECU connector B-52. D Disconnect the connector, and measure at the harness side. D Voltage between 57 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: B-52 OK Check the trouble symptoms.

NG

Check the following connector: A-76 OK Check the trouble symptoms.

NG

NG

Malfunction of the purge control solenoid valve Open circuit or short-circuited harness wire in the purge control solenoid valve circuit Malfunction of the engine-ECU

Repair

Replace the engine-ECU.

NG

NG

Repair

Check the harness wire between the engine-ECU and the purge control solenoid valve, and repair if necessary.

13B-58

GDI <4G9> - Troubleshooting

INSPECTION PROCEDURE 31 Power steering fluid pressure switch system

Probable cause

This switch inputs the amount of power steering load to the engine-ECU. The engine-ECU uses this input to control the idle speed control servo so that the idle speed is increased when the power steering is operating.

D D D

Check the power steering fluid pressure switch. (Refer to GROUP 37A - On-vehicle Service.) OK Measure at the power steering fluid pressure switch connector A-96. D Disconnect the connector, and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: A-96 OK Check the trouble symptoms.

NG

NG

Replace

NG

Check the following connector: B-53 OK

NG

Check the trouble symptoms.

NG

NG

Malfunction of the power steering fluid pressure switch Open circuit or short-circuited harness wire in the power steering fluid pressure switch circuit Malfunction of the engine-ECU

Repair

Check the harness wire between the engine-ECU and the power steering fluid pressure switch. NG

Repair

Repair

Replace the engine-ECU.

INSPECTION PROCEDURE 32 A/C switch and A/C relay system

Probable cause

When an A/C ON signal is input to the engine-ECU, the engine-ECU controls the idle speed control servo to increase the idle speed, and also operates the A/C compressor magnetic clutch.

D D D D

Check A/C compressor relay. (Refer to GROUP 55 - On-vehicle Service.) OK Measure at the engine-ECU connectors B-53, B-54. D Disconnect the connector, and measure at the harness side. D Voltage between 8, 45 and earth Ignition switch: ON A/C switch: ON OK: System voltage D Short circuit between 8 and earth Ignition switch: ON A/C switch: ON OK: A/C compressor clutch turns on. NG Check A/C system. (Refer to GROUP 55 - On-vehicle Service.)

NG

OK

Malfunction of the A/C control system Malfunction of the A/C switch Open circuit or short-circuited harness wire in the A/C switch circuit Malfunction of the engine-ECU

Replace

Check the following connectors: B-53, B-54 OK Check the trouble symptoms.

NG

NG

Repair

Replace the engine-ECU.

13B-59

GDI <4G9> - Troubleshooting INSPECTION PROCEDURE 33 M/T oil temperature sensor system

Probable cause

This sensor inputs the manual transmission oil temperature to the engine-ECU. The engine-ECU uses this input to control the idle speed control servo so that the idle speed is increased when the manual transmission oil temperature becomes low.

D D

Check the M/T oil temperature sensor. (Refer to GROUP 22 - On-vehicle Service.) OK Measure at the M/T oil temperature sensor connector A-87. D Disconnect the connector, and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 2 and earth OK: Continuity OK

NG

NG

Check the following connector: B-51 OK NG Check the harness wire between the engine-ECU and the M/T oil temperature sensor.

NG

Check the trouble symptoms.

Replace

NG

Repair

Check the trouble symptoms.

Check the following connector: A-87 OK

D

Malfunction of the M/T oil temperature sensor Open circuit or short-circuited harness wire in the M/T oil temperature sensor circuit Malfunction of the engine-ECU

NG

Repair

OK

Replace the engine-ECU.

NG

Repair

13B-60

GDI <4G9> - Troubleshooting

INSPECTION PROCEDURE 34 Stop lamp switch system

Probable cause

This switch inputs the brake pedal depression amount to the engine-ECU. The engine-ECU uses this input to detect brake operation in order to switch the fuel injection mode.

D D

Check the stop lamp switch. (Refer to GROUP 35 - Brake Pedal.) OK Measure at stop lamp switch connector B-28. D Disconnect the connector, and measure at the harness side. D Voltage between terminal 2 and earth OK: System voltage

NG NG

D

Malfunction of the stop lamp switch Open circuit or short-circuited harness wire in the stop lamp switch circuit Malfunction of the engine-ECU

Replace

Check the following connectors: B-65, B-66 OK

NG Repair

OK Check trouble symptom. NG Check the harness wire between the battery and stop lamp switch.

Measure at engine-ECU connector B-53. D Disconnect the connector, and measure at the harness side. D Voltage between terminal 35 and earth (Ignition switch: ON) OK: 0 - 3 V (when the brake pedal is not depressed) System voltage (when the brake pedal is depressed)

NG

Check the following connectors: B-28, B-65, B-14 NG

OK

Repair

OK

Check trouble symptom. NG Check the harness wire between the engine-ECU and stop lamp, and repair if necessary.

Check the following connector: B-53 OK Check trouble symptom. NG Replace the engine-ECU.

NG

Repair

GDI <4G9> - Troubleshooting

13B-61

INSPECTION PROCEDURE 35 Small lamp switch

Probable cause

The engine-ECU determines whether the small lamp switch is ON or OFF. According to that information, the engine-ECU controls alternator output current when the vehicle is started.

D

Measure at the engine-ECU connector B-52. D Disconnect the connector, and measure at the harness side. D Voltage between 52 and earth (Lighting switch: ON) OK: System voltage

NG

D

Check the taillamp relay circuit. (Refer to ELECTRICAL WIRING.)

OK Check the following connector: B-52 OK Check the trouble symptoms. NG Replace the engine-ECU.

NG

Improper connector contact, open circuit or short-circuited harness wire in the taillamp circuit Malfunction of the engine-ECU

Repair

13B-62

GDI <4G9> - Troubleshooting

DATA LIST REFERENCE TABLE Caution When shifting the select lever to D range, the brakes should be applied so that the vehicle does not move forward. NOTE *1. In a new vehicle [driven approximately 500 km or less], the air flow sensor output frequency is sometimes 10% higher than the standard frequency. *2. In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10% longer than the standard time. *3. In a new vehicle [driven approximately 500 km or less], the step of the stepper motor is sometimes 30 steps greater than the standard value. Item No.

Inspection item

Inspection contents

11

Oxygen sensor

Engine: After having warmed up

12

Air flow sensor*1

D D D

13

Intake air temperature sensor

Normal condition

Inspection procedure No.

Reference page

Engine is idling (within 4 minutes after engine start)

0 mV

Code No.11

13B-12

When engine is suddenly raced

600 - 1,000 mV

2,500 r/min

0 mV and 600 1,000 mV alternates. -

-

Code No. 13

13B-15

Engine coolant Engine is idling temperature: 80 95_C 2,500 r/min Lamps, electric cooling fan and all accessories: OFF Engine is raced Transmission: Neutral (A/T: P range)

Ignition switch: ON or with engine running

20 - 55 Hz 65 - 85 Hz Frequency increases in response to racing

When intake air temperature is - 20_C

- 20_C

When intake air temperature is 0_C

0_C

When intake air temperature is 20_C

20_C

When intake air temperature is 40_C

40_C

When intake air temperature is 80_C

80_C

13B-63

GDI <4G9> - Troubleshooting Item No.

Inspection item

Inspection contents

14

Throttle position sensor

Ignition switch: ON

16

Power supply voltage

Ignition switch: ON

18

Cranking signal (ignition switch-ST)

Ignition switch: ON

Engine coolant temperature sensor

Ignition switch: ON or with engine running

21

Normal condition

Inspection procedure No.

Reference page

Release the accelerator pedal.

535 - 735 mV

Code No. 14

13B-15

Depress the accelerator pedal gradually.

Increases in proportion to throttle opening angle

Depress the accelerator pedal fully.

4,500 - 5,500 mV System voltage

Procedure No. 22

13B-50

Engine: Stopped

OFF

Engine: Cranking

ON

Procedure No. 24 Procedure No. 25

13B-51 13B-52

When engine coolant temperature is - 20_C

- 20_C

Code No. 21

13B-16

When engine coolant temperature is 0_C

0_C

When engine coolant temperature is 20_C

20_C

When engine coolant temperature is 40_C

40_C

When engine coolant temperature is 80_C

80_C

13B-64

GDI <4G9> - Troubleshooting

Item No.

Inspection item

Inspection contents

22

Crank angle sensor

D D

Engine: Cranking Tachometer: Connected

D D

Engine: Idling Idle position switch: ON

25

27

28

29

31

Normal condition

Inspection procedure No.

Reference page

Compare the engine speed readings on the tachometer and the MUT-II.

Accord

Code No. 22

13B-17

When engine coolant temperature is - 20_C

1,200 - 1,400 r/min

When engine coolant temperature is 0_C

1,100 - 1,300 r/min

When engine coolant temperature is 20_C

1,000 - 1,200 r/min

When engine coolant temperature is 40_C

900 - 1,100 r/min

When engine coolant temperature is 80_C

550 - 850 r/min

At altitude of 0 m

101 kPa

13B-20

At altitude of 600 m

95 kPa

Code No. 25

At altitude of 1,200 m

88 kPa

At altitude of 1,800 m

81 kPa

Power Engine: Idling steering fluid pressure switch

Steering wheel stationary

OFF

Procedure No. 31

13B-58

Steering wheel turning

ON

A/C switch

Engine: Idling (when A/C switch is ON, A/C compressor should be operating.)

A/C switch: OFF

OFF

Procedure No. 32

13B-58

A/C switch: ON

ON

Inhibitor switch

Ignition switch: ON

P or N

P or N

13B-52

D, 2, L or R

D, 2, L or R

Procedure No. 25

Small lamp switch

Engine: Idling

Lighting switch: OFF

OFF

13B-61

Lighting switch: ON

ON

Procedure No.35

Barometric pressure sensor

Ignition switch: ON

13B-65

GDI <4G9> - Troubleshooting Item No.

Inspection item

Inspection contents

34

Air flow sensor reset signal

Engine: After having warmed up

Volumetric efficiency

D

37

D D

38

41

Crank angle sensor

D

Injectors

D D

Injectors*2

D

D D D

44

Ignition coils and power transistors

D D

Normal condition

Inspection procedure No.

Reference page

Engine is idling

ON

13B-13

3,000 r/min

OFF

Code No.12

Engine is idling

15 - 35%

-

-

2,500 r/min

15 - 35%

Engine is suddenly raced

Volumetric efficiency increases in response to racing

Engine: Cranking [reading is possible at Engine speeds 2,000 r/min or less] displayed on the Tachometer: Connected MUT-II and tachometer are identical.

-

-

Engine: Idling Transmission: Neutral (A/T: P range)

-

-

-

-

-

-

Engine coolant temperature: 80 95_C Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral (A/T: P range)

Engine coolant temperature: 80–95_C Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral (A/T : P range)

When engine coolant temperature is 0_C

0.9 - 1.1 ms

When engine coolant temperature is 20_C

0.8 - 1.0 ms

When engine coolant temperature is 50_C

0.7 - 0.9 ms

When engine coolant temperature is 80_C

0.5 - 0.7 ms

Engine is idling (within 4 minutes after engine start)

0.5 - 0.7 ms

2,500 r/min

0.6 - 0.8 ms

When engine is suddenly raced

Increases

Engine: After Engine is idling having warmed up Timing lamp is set. (The timing lamp is set in order to 2,500 r/min check actual ignition timing.)

12 - 20_BTDC

20 - 40_BTDC

13B-66

GDI <4G9> - Troubleshooting

Item No.

Inspection item

Inspection contents

45

ISC (stepper) motor position *3

D D D D D

Engine coolant temperature: 80 - 95_C Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral (A/T : P range) Engine: Idling When A/C switch is ON, A/C compressor should be operating

Normal condition

Inspection procedure No.

Reference page

A/C switch: OFF

10 - 55 STEP

-

-

A/C switch: OFF ® ON

Increases by 15 - 55 steps

D D

Increases by 10 - 40 steps

A/C switch: OFF Select lever: N range ® D range

48

M/T oil temperature sensor

Drive after the engine has warmed up.

Drive for 15 minutes or more.

Gradually increases to 50_ - 90_C.

Procedure No. 33

13B-59

49

A/C relay

Engine: After having warmed up/Engine is idling

A/C switch: OFF

OFF (Compressor clutch is not operating)

Procedure No. 32

13B-58

A/C switch: ON

ON (Compressor clutch is operating)

When the engine is running at idle, stop the engine, and then turn the ignition switch to ON and depress the brake pedal several times.

Displayed pressure increases.

Code No. 66

13B-28

Brake pedal: Depressed

OFF

Procedure No. 34

13B-60

Brake pedal: Released

ON

Engine is idling

5 - 15 STEP

Procedure No. 29

13B-56

2,500 r/min

0 - 5 STEP

66

Brake vacuum sensor

D D

D

67

68

Stop lamp switch

EGR valve

Engine coolant temperature: 80 - 95_C Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral (A/T: P range)

Ignition switch: ON

D D

D

Engine coolant temperature: 80 - 95_C Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral (A/T: P range)

13B-67

GDI <4G9> - Troubleshooting Item No.

Inspection item

Inspection contents

74

Fuel pressure sensor

D D

D

99

Fuel injection mode

Engine coolant temperature: 80 - 95_C Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral (A/T: P range)

Engine: After warmed-up

Normal condition

Inspection procedure No.

Reference page

Engine; Idling

4 - 7 MPa

Code No. 56

13B-24

Engine: Idling (several minutes after engine starts)

Lean compression

-

-

2,500 r/min

Stoichiometric feedback

When engine is idling and then suddenly raced

Open-loop

13B-68

GDI <4G9> - Troubleshooting

ACTUATOR TEST REFERENCE TABLE Item No.

Inspection item

Drive contents

Inspection contents

Normal condition

Inspection procedure No.

Reference page

01

Injectors

Cut fuel to No. 1 injector

Engine: After having warmed up/Engine is idling (Cut the fuel supply to each injector in turn and check cylinders which don’t affect idling.)

Idling condition becomes different (becomes unstable).

Code No. 41

13B-22

02

Cut fuel to No. 2 injector

03

Cut fuel to No. 3 injector

04

Cut fuel to No. 4 injector

07

Fuel pump (low pressure)

Fuel pump operates and fuel is recirculated.

Ignition switch: ON

Sound of operation is heard.

Procedure No. 28

13B-55

08

Purge control solenoid valve

Solenoid valve turns from OFF to ON.

Ignition switch: ON

Sound of operation can be heard when solenoid valve is driven.

Procedure No. 30

13B-57

17

Basic ignition timing

Set the engineECU to ignition timing adjustment mode

Idling after engine warm up

5_BTDC

-

-

18

Air by-pass control solenoid valve (ON/OFF)

Solenoid valve turns from OFF to ON.

Ignition switch: ON

Sound of operation can be heard when solenoid valve is driven.

Procedure No. 27

13B-54

21

Fan controller

Drive the fan motor

Ignition switch: ON

Fan motor operates at low speed.

Procedure No.21

13B-49

30

SAS adjustment mode

Set the engineECU to SAS adjustment mode

Engine: Idling

Idle speed control (ISC) servo is fixed at step 6.

-

-

32

Air by-pass control solenoid valve (DUTY)

Solenoid valve turns from OFF to ON.

Ignition switch: ON

Sound of operation can be heard when solenoid valve is driven.

Procedure No. 27

13B-54

13B-69

GDI <4G9> - Troubleshooting CHECK AT THE ENGINE-ECU TERMINALS TERMINAL VOLTAGE CHECK CHART Engine-ECU Connector Terminal Arrangement

Terminal No.

Check item

Check condition (Engine condition)

Normal condition

1

No.1 injector

14

No.2 injector

Engine: Warm up the engine, and then depress the accelerator pedal suddenly from the idle speed.

Decreases slightly for short time from 9 - 13 V.

2

No.3 injector

15

No.4 injector

3

Air by-pass control solenoid valve (ON/OFF)

Engine: Idling after having warmed up

System voltage

Engine: 2,500 r/min

System voltage

Air by-pass control solenoid valve (DUTY)

Engine: Idling after having warmed up

System voltage

Engine: 2,500 r/min

System voltage

4

Idle speed control servo (A)

17

Idle speed control servo (B)

Engine: Immediately after the warm engine has been started

System voltage « 0 - 0.5 V (changes repeatedly)

5

Idle speed control servo (C)

18

Idle speed control servo (D)

8

A/C relay

Engine: idling A/C switch: OFF ® ON (Compressor is operating)

System voltage, or changes from momentarily 6 V or more to 0 ® 3 V

10

No.1 ignition coil

Engine: 3,000 r/min

0.1 - 2.0 V

11

No.2 ignition coil

23

No.3 ignition coil

24

No.4 ignition coil

12

Power supply

Ignition switch: ON

System voltage

16

25

13B-70

GDI <4G9> - Troubleshooting

Terminal No.

Check item

Check condition (Engine condition)

Normal condition

19

Air flow sensor reset signal

Engine: Idling

0 - 0.1 V

Engine: 3,000 r/min

6 - 9V

Engine: Idling

2.2 - 3.2 V

90

Air flow sensor

Engine: 2,500 r/min 20

21

22

Injector driver control relay

Fan controller

Fuel pump relay

39

EGR valve (A)

40

EGR valve (B)

31

EGR valve (C)

32

EGR valve (D)

33

Ignition switch: OFF

0 - 0.1 V

Ignition switch: ON

0.5 - 1 V

Radiator fan is not operating (Engine coolant temperature is 80_C or less)

0 - 0.1 V

Radiator fan is operating (Engine coolant temperature is 80_C or more)

1V

Ignition switch: ON

Engine: Stopped

System voltage

Engine: Idling

0 - 3V

Ignition switch: Immediately after turning ON

5 - 8 V (fluctuates for approx. three seconds)

Alternator G terminal

Engine: Idling after having warmed up Radiator fan: Not operating Headlamp: OFF ® ON Stop lamp: OFF ® ON Rear defogger switch: OFF ® ON

Voltage increases by 0.2 3.5 V

41

Alternator FR terminal

Engine: Idling after having warmed up Radiator fan: Not operating Headlamp: OFF ® ON Stop lamp: OFF ® ON Rear defogger switch: OFF ® ON

Voltage decreases

35

Stop lamp switch

Brake pedal: Depressed

System voltage

Brake pedal: Released

0 - 0.1 V

36

Engine warning lamp

Ignition switch: OFF ® ON

0 - 3 V ® System voltage (after several seconds have passed)

37

Power steering fluid pressure switch

Engine: Idling after having warmed up

Steering wheel: Neutral position

System voltage

Steering wheel: Turned

0 - 3V

13B-71

GDI <4G9> - Troubleshooting Terminal No.

Check item

Check condition (Engine condition)

Normal condition

38

Engine control relay

Ignition switch: OFF

0 - 3V

Ignition switch: ON

System voltage

42

Brake vacuum sensor

When the engine is running at idle, stop the engine, and then turn the ignition switch to ON and depress the brake pedal several times.

Voltage increases

45

A/C switch 1

Engine: Idling

A/C switch: OFF

0 - 3V

A/C switch: ON (Compressor is operating)

System voltage

51

Injector open circuit check signal

Engine: Increase engine speed from idle speed to 4,000 r/min.

Decreases slightly (approx.0.7 V) from 4.5 V 5.0 V.

52

Small lamp switch

Engine: Idling

Lighting switch: OFF

0 - 3V

Lighting switch: ON

System voltage

Engine: Stopped

System voltage

Engine: Start the engine, and then increase engine speed to 3,500 r/min.

Voltage decreases.

57

Purge control solenoid valve

Engine coolant temperature: 80 - 95_C Ignition switch: ON

58

Tachometer

Engine: 3,000 r/min

0.3 - 3.0 V

60

Oxygen sensor heater control

Engine: Idling

0 - 3V

Engine: 5,000 r/min

System voltage

76

Oxygen sensor

Engine: Running at 2,500 r/min after having warmed up

0«1V (changes repeatedly)

71

Ignition switch-ST

Engine: Cranking

8 V or more

13B-72

GDI <4G9> - Troubleshooting

Terminal No.

Check item

Check condition (Engine condition)

Normal condition

72

Intake air temperature sensor

Ignition switch: ON

Intake air temperature: 0_C

3.2 - 3.8 V

Intake air temperature: 20_C

2.3 - 2.9 V

Intake air temperature: 40_C

1.5 - 2.0 V

Intake air temperature: 80_C

0.4 - 1.0 V

73

A/C switch 2

Refer to GROUP 55 - Troubleshooting “Check at the A/C-ECU terminal, engine-ECU output terminals.”

74

Fuel pressure sensor

Engine: Idling

0.3 - 4.7 V

75

M/T oil temperature sensor

M/T oil temperature: 25_C

2.4 - 2.7 V

M/T oil temperature: 80_C

0.5 - 0.8 V

Sensor power supply (5 V)

Ignition switch: ON

4.5 - 5.5 V

80

Back-up power supply

Ignition switch: OFF

System voltage

82

Ignition switch- IG

Ignition switch: ON

System voltage

83

Engine coolant temperature sensor

Ignition switch: ON

77 81

84

85

86

Throttle position sensor

Barometric pressure sensor

Vehicle speed sensor

Ignition switch: ON

Ignition switch: ON

Engine coolant temperature: 0_C

3.2 - 3.8 V

Engine coolant temperature: 20_C

2.3 - 2.9 V

Engine coolant temperature: 40_C

1.3 - 1.9 V

Engine coolant temperature: 80_C

0.3 - 0.9 V

Release the accelerator pedal.

0.535 - 0.735 V

Depress the accelerator pedal fully.

4.5 - 5.5 V

Altitude: 0 m

3.7 - 4.3 V

Altitude: 1,200 m

3.2 - 3.8 V

Ignition switch: ON Move the vehicle slowly forward

0«5V (changes repeatedly)

13B-73

GDI <4G9> - Troubleshooting Terminal No.

Check item

Check condition (Engine condition)

Normal condition

88

Camshaft position sensor

Engine: Cranking

0.4 - 3.0 V

Engine: Idling

0.5 - 2.0 V

Engine: Cranking

0.4 - 4.0 V

Engine: Idling

1.5 - 2.5 V

89

91

Crank angle sensor

Inhibitor switch

Ignition switch: ON

Selector lever position: N or P

0 - 3V

Selector lever position: Except N and P

System voltage

CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS 1. Turn the ignition switch to OFF. 2. Disconnect the engine-ECU connector. 3. Measure the resistance and check for continuity between the terminals of the engine-ECU harness-side connector while referring to the check chart. NOTE (1) When measuring resistance and checking continuity, a harness for checking contact pin pressure should be used instead of inserting a test probe. (2) Checking need not be carried out in the order given in the chart. Caution If the terminals that should be checked are mistaken, or if connector terminals are not correctly shorted to earth, damage may be caused to the vehicle wiring, sensors, engine-ECU and/or ohmmeter. Be careful to prevent this! 4. If the ohmmeter shows any deviation from the standard value, check the corresponding sensor, actuator and related electrical wiring, and then repair or replace. 5. After repair or replacement, recheck with the ohmmeter to confirm that the repair or replacement has corrected the problem.

13B-74

GDI <4G9> - Troubleshooting

Engine-ECU Harness Side Connector Terminal Arrangement

Terminal No.

Check item

Standard value, normal value (Check condition)

3 - 12

Air by-pass control solenoid valve (ON/OFF)

8 - 11 W (At 20_C)

16 - 12

Air by-pass control solenoid valve (DUTY)

8 - 11 W (At 20_C)

4 - 12

Idle speed control servo (A)

28 - 33 W (At 20_C)

17 - 12

Idle speed control servo (B)

5 - 12

Idle speed control servo (C)

18 - 12

Idle speed control servo (D)

13 - Body earth

Engine-ECU earth

26 - Body earth

Engine-ECU earth

39 - 12

EGR valve (A)

40 - 12

EGR valve (B)

31 - 12

EGR valve (C)

32 - 12

EGR valve (D)

57 - 12

Purge control solenoid valve

36 - 44 W (At 20_C)

60 - 12

Oxygen sensor heater

11 - 18 W (At 20_C)

72 - 92

Intake air temperature sensor

5.3 - 6.7 W (When intake air temperature is 0_C)

Continuity (0 W)

15 - 20 W (At 20_C)

2.3 - 3.0 W (When intake air temperature is 20_C) 1.0 - 1.5 W (When intake air temperature is 40_C) 0.26 - 0.36 kW (When intake air temperature is 80_C)

GDI <4G9> - Troubleshooting

13B-75

Terminal No.

Check item

Standard value, normal value (Check condition)

83 - 92

Engine coolant temperature sensor

5.1 - 6.5 kW (When coolant temperature is 0_C) 2.1 - 2.7 kW (When coolant temperature is 20_C) 0.9 - 1.3 kW (When coolant temperature is 40_C) 0.26 - 0.36 kW (When coolant temperature is 80_C)

91 - Body earth

Inhibitor switch

Continuity (0 W) (When selector lever position is N or P) No continuity (When selector lever position is except N and P)

13B-76

GDI <4G9> - Troubleshooting INSPECTION PROCEDURE USING AN ANALYZER

Analyzer

AIR FLOW SENSOR (AFS) Measurement Method 1. Disconnect the air flow sensor connector, and connect the special tool (test harness: MB991709) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to air flow sensor connector terminal 3.

Special patterns pickup

Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 90. Standard Wave Pattern Observation conditions Function

Special patterns

Pattern height

Low

Pattern selector

Display

Engine r/min

Idle speed

Standard wave pattern (V) 10 T1

0

The time (cycle time) T is reduced when the amount of intake air increases.

T T2

Times T1 and T2 are equal.

Time

Observation conditions (from conditions above engine speed is increased by racing.) (V) 10

0

T

Time

Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased.

GDI <4G9> - Troubleshooting

13B-77

Examples of Abnormal Wave Patterns D Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. D

Example 2 Cause of problem Damaged rectifier or vortex generation column Wave pattern characteristics Unstable wave pattern with non-uniform frequency. However, when an ignition leak occurs during acceleration, the wave pattern will be distorted temporarily, even if the air flow sensor is normal.

Camshaft position connector

sensor

Special patterns pick-up

Crank angle sensor connector

Analyzer

CAMSHAFT POSITION SENSOR AND CRANK ANGLE SENSOR Measurement Method 1. Disconnect the camshaft position sensor connector and connect the special tool (test harness: MB991709) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to camshaft position sensor terminal 2. 3. Disconnect the crank angle sensor connector and connect the special tool (test harness: MD998478) in between. 4. Connect the analyzer special patterns pickup to crank angle sensor terminal 2. Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 88. (When checking the camshaft position sensor signal wave pattern.) 2. Connect the analyzer special patterns pickup to engine-ECU terminal 89. (When checking the crank angle sensor signal wave pattern.)

Standard Wave Pattern Observation conditions Function

Special patterns

Pattern height

Low

Pattern selector

Display

Engine r/min

Idle speed

13B-78

GDI <4G9> - Troubleshooting

Standard wave pattern 2 engine revolutions (1 camshaft revolution)

(V) 75_BTDC

The time (cycle time) T is reduced when the engine speed increases

5_BTDC

Crank angle sensor output wave pattern

0 131°

49°

56° 34°

Camshaft position sensor output wave pattern

Time

0 No. 1 TDC

No. 3 TDC

No. 4 TDC

No. 2 TDC

TDC: Top dead centre

Wave Pattern Observation Points Check that cycle time T becomes shorter when the engine speed increases.

Examples of Abnormal Wave Patterns D Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started.

D

Example 2 Cause of problem Loose timing belt Abnormality in sensor disk Wave pattern characteristics Wave pattern is displaced to the left or right.

GDI <4G9> - Troubleshooting

Analyzer

Special patterns pickup

13B-79

INJECTORS AND INJECTOR OPEN CIRCUIT CHECK SIGNAL Measurement Method 1. Connect the analyzer special patterns pickup to terminal 1 (No.1 injector) of the engine-ECU connector. 2. Connect the analyzer special patterns pickup to terminal 51 (injector open circuit check signal) of the engine-ECU connector. 3. After checking terminal 1, check terminal 14 (No.2 injector), terminal 2 (No.3 injector) and terminal 15 (No.4 injector).

Standard Wave Pattern Observation conditions Function

Special pattern

Pattern height

Low

Pattern selector

Display

Engine r/min

Idle speed

Standard wave pattern

(V) Injector open circuit check signal

4 0 8

Injector drive signal

4 0 (ms)

Normal wave pattern

Wave Pattern Observation Points D Check that the injector drive time is identical to the time displayed on the MUT-II. D Check that the injector signals become greatly extended but soon return to their normal wave length when the engine is suddenly raced. D Check that the injector open circuit check signal is synchronized with each rising portion of the injector drive signal.

13B-80

GDI <4G9> - Troubleshooting Analyzer

Special patterns pickup

IDLE SPEED CONTROL (ISC) SERVO (STEPPER MOTOR) Measurement Method 1. Disconnect the ISC servo connector and connect the special tool (test harness: MB991709) in between. 2. Connect the analyzer special patterns pickup to the ISC servo-side connector terminal 1, terminal 3, terminal 4 and terminal 6 respectively.

Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 4, connection terminal 5, connection terminal 17, and connection terminal 18 respectively. Standard Wave Pattern Observation conditions Function

Special patterns

Pattern height

High

Pattern selector

Display

Engine condition

When the engine coolant temperature is 20_C or below, turn the ignition switch from OFF to ON (without starting the engine). While the engine is idling, turn the A/C switch to ON. Immediately after starting the warm engine

Standard wave pattern

(V) 30

The wave pattern appears for an instant, but soon disappears.

Point B Coil reverse electromotive force (Approx. 3 ´ 10V)

Point A Induced electromotive force from the motor turning

20

ISC servo control signal wave pattern

10

Time

GDI <4G9> - Troubleshooting

13B-81

Wave Pattern Observation Points Check that the standard wave pattern appears when the ISC servo is operating. Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal wave pattern.) Contrast with standard wave pattern

Probable cause

Induced electromotive force does not appear or is extremely small.

Motor is malfunctioning

Point B: Height of coil reverse electromotive force Contrast with standard wave pattern

Probable cause

Coil reverse electromotive force does not appear or is extremely small.

Short in the coil

Examples of Abnormal Wave Pattern D Example 1 Cause of problem Motor is malfunctioning. (Motor is not operating.) Wave pattern characteristics Induced electromotive force from the motor turning does not appear.

Open circuit side

D

Example 2 Cause of problem Open circuit in the line between the ISC servo and the engine-ECU Wave pattern characteristics

Normal side

Current is not supplied to the motor coil on the open circuit side. (Voltage does not drop to 0 V.) Furthermore, the induced electromotive force waveform at the normal side is slightly different from the normal waveform.

13B-82

GDI <4G9> - Troubleshooting IGNITION COIL AND POWER TRANSISTOR Power transistor control signal

Analyzer

Measurement Method 1. Disconnect the ignition coil connector, and connect the special tool (test harness: MB991658) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to terminal 3 of each ignition coil connector in turn.

Special patterns pickup

Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 10 (No. 1 ignition coil), terminal 11 (No. 2 ignition coil), terminal 23 (No. 2 ignition coil), terminal 24 (No. 4 ignition coil) respectively.

Standard Wave Pattern Observation condition Function

Special patterns

Pattern height

Low

Pattern selector

Display

Engine r/min

Approx. 1,200 r/min

Standard wave pattern (V) T 6 Crank angle sensor output wave pattern

T: Revolution time corresponding to a crank angle of 180_ Compression top dead center

4 2 0

Power transistor control signal wave pattern

4 2 0

q

Ignition period

q: Spark advance angle

OFF

ON

Dwell section Time

GDI <4G9> - Troubleshooting

13B-83

Wave Pattern Observation Points Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern examples 1 and 2.) Condition of wave pattern build-up section and maximum voltage

Probable cause

Rises from approx. 2V to approx. 4.5V at the top-right

Normal

2V rectangular wave

Open-circuit in ignition primary circuit

Rectangular wave at power voltage

Power transistor malfunction

--- Normal wave pattern

Examples of Abnormal Wave Patterns D Example 1 Wave pattern during engine cranking Cause of problem

2V

Open-circuit in ignition primary circuit Wave pattern characteristics Top-right part of the build-up section cannot be seen, and voltage value is approximately 2V too low.

--- Normal wave pattern VB

D

Example 2 Wave pattern during engine cranking Cause of problem Malfunction in power transistor Wave pattern characteristics Power voltage results when the power transistor is ON.

13B-84

GDI <4G9> - Troubleshooting EGR VALVE (STEPPER MOTOR) Measurement Method 1. Disconnect the EGR valve connector, and connect the special tool (test harness: MB991658) in between. 2. Connect the analyzer special patterns pickup to the EGR valve-side connector terminal 1, terminal 3, terminal 4 and terminal 6 respectively.

Analyzer

Special patterns pickup

Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 39, connection terminal 40, connection terminal 31, and connection terminal 32 respectively. Standard Wave Pattern Observation conditions Function

Special patterns

Pattern height

High

Pattern selector

Display

Engine condition

When the engine coolant temperature is 20_C or below, turn the ignition switch from OFF to ON (without starting the engine). While the engine is idling, turn the A/C switch to ON. Immediately after starting the warm engine

Standard wave pattern

(V) 30

The wave pattern appears for an instant, but soon disappears.

Point B Coil reverse electromotive force (Approx. 3 ´ 10V)

Point A Induced electromotive force from the motor turning

20

EGR valve control signal wave pattern

10

Time

GDI <4G9> - Troubleshooting

13B-85

Wave Pattern Observation Points Check that the standard wave pattern appears when the EGR valve is operating. Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal wave pattern.) Contrast with standard wave pattern

Probable cause

Induced electromotive force does not appear or is extremely small.

Motor is malfunctioning

Point B: Height of coil reverse electromotive force Contrast with standard wave pattern

Probable cause

Coil reverse electromotive force does not appear or is extremely small.

Short in the coil

Examples of Abnormal Wave Pattern D Example 1 Cause of problem Motor is malfunctioning. (Motor is not operating.) Wave pattern characteristics Induced electromotive force from the motor turning does not appear.

Open circuit side

D

Example 2 Cause of problem Open circuit in the line between the EGR valve and the engine-ECU Wave pattern characteristics

Normal side

Current is not supplied to the motor coil on the open circuit side. (Voltage does not drop to 0 V.) Furthermore, the induced electromotive force waveform at the normal side is slightly different from the normal waveform.

13B-86

GDI <4G9> - On-vehicle Service

ON-VEHICLE SERVICE THROTTLE BODY (THROTTLE VALVE AREA) CLEANING 1. Start the engine and warm it up until the coolant is heated to 80_C or higher and then stop the engine. 2. Remove the air intake hose from the throttle body.

3. Plug the bypass passage inlet of the throttle body. Caution Do not allow cleaning solvent to enter the bypass passage. 4. Spray cleaning solvent into the valve through the throttle body intake port and leave it for about 5 minutes.

5. Start the engine, race it several times and idle it for about 1 minute. If the idling speed becomes unstable (or if the engine stalls) due to the bypass passage being plugged, slightly open the throttle valve to keep the engine running. 6. If the throttle valve deposits are not removed, repeat steps 4 and 5. 7. Unplug the bypass passage inlet. 8. Attach the air intake hose. 9. Use the MUT-II to erase the self-diagnosis code. 10. Adjust the basic idle speed. (Refer to P.13B-87.) NOTE If the engine hunts while idling after adjustment of the basic idle speed, disconnect the (–) cable from the battery for 10 seconds or more, and then reconnect it and run the engine at idle for about 10 minutes.

THROTTLE POSITION SENSOR ADJUSTMENT Throttle position sensor

1. Connect the MUT-II to the diagnosis connector.

GDI <4G9> - On-vehicle Service

13B-87

2. Turn the ignition switch to ON (but do not start the engine). 3. Check the throttle position sensor output voltage. Standard value: 535 - 735 mV

4. If not within the standard value, loosen the throttle position sensor mounting bolts, and then rotate the sensor body to adjust the output voltage. 5. Turn the ignition switch to OFF. 6. Remove the MUT-II. 7. If a diagnosis code is displayed, erase the diagnosis code by using the MUT-II or disconnect the negative battery cable from the battery terminal and then leave it for at least ten seconds. After that, reconnect the battery cable, and then let the engine run at idle for approx. 10 minutes.

BASIC IDLE SPEED ADJUSTMENT Caution (1) The standard idling speed has been adjusted by the speed adjusting screw (SAS) by the manufacturer, and there should usually be no need for readjustment. (2) If the adjustment has been changed by mistake, the idle speed may become too high or the idle speed may drop too low when loads from components such as the A/C are placed on the engine. If this occurs, adjust by the following procedure. (3) The adjustment, if made, should be made after first confirming that the spark plugs, the injectors, the idle speed control servo, the compression pressure, etc., are all normal. 1. Before inspection and adjustment, set the vehicle to the pre-inspection condition. 2. Connect the MUT-II to the diagnosis connector. NOTE When the MUT-II is connected, the diagnosis control terminal should be earthed. 3. Start the engine and run it at idle.

13B-88

GDI <4G9> - On-vehicle Service 4. Select the item No.30 of the MUT-II Actuator test. NOTE This holds the idle speed control servo at the basic step to adjust the basic idle speed. 5. Check the basic idle speed. Standard value: 750 ± 50 r/min NOTE (1) The engine speed may be 20 to 100 r/min lower than indicated above for a new vehicle [driven approximately 500 km or less], but no adjustment is necessary. (2) If the engine stalls or the engine speed is low even though the vehicle has been driven approximately 500 km or more, it is probable that deposits are adhered to the throttle valve, so clean it.

6. If not within the standard value range, turn the speed adjusting screw (SAS) to make the necessary adjustment.

SAS

Throttle body

NOTE (1) Use a screwdriver which is shorter than 30 mm to turn the SAS. (2) If the idling speed is higher than the standard value range even when the SAS is fully closed, check whether or not there is any indication that the fixed SAS has been moved. If there is an indication that it has been moved, adjust the fixed SAS. 7. Press the MUT-II clear key, and release the idle speed control servo from the Actuator test mode. NOTE Unless the idle speed control servo is released, the Actuator test mode will continue 27 minutes. 8. Turn the ignition switch to OFF. 9. Disconnect the MUT-II. 10. Start the engine again and let it run at idle speed for about 10 minutes; check that the idling condition is normal.

GDI <4G9> - On-vehicle Service

13B-89

FUEL PRESSURE TEST

Fuel pump (high pressure)

MEASUREMENT OF FUEL LOW PRESSURE BETWEEN FUEL PUMP (LOW PRESSURE) AND FUEL PUMP (HIGH PRESSURE) 1. Release residual pressure from the fuel pipe line to prevent fuel gush out. (Refer to P.13B-93.) 2. Disconnect the high-pressure fuel hose at the fuel pump (high pressure) side.

High-pressure fuel hose

Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.

MB991637 Fuel pump (high pressure)

Gasket MD998709 MD998742 High-pressure fuel hose

Fuel pressure gauge O-ring or gasket Fuel pump (high pressure)

MD998709 MD998742 High-pressure fuel hose

3. Remove the union joint and bolt from the special tool (adapter hose) and instead attach the special tool (hose adapter) to the adapter hose. 4. Install the special tool (for measuring the fuel pressure) that was set up in step 3. (1) Install the special tool (for measuring the fuel pressure) between the high-pressure fuel hose and the fuel pump (high pressure). (2) Install the fuel pressure gauge set (special tool) on the special tool (for measuring the fuel pressure) putting the gasket between them. (3) Connect the lead wire of the fuel pressure gauge set (special tool) to the power supply (cigarette lighter socket) and to the MUT-II.

(1) Install the fuel pressure gauge on the special tool (for measuring the fuel pressure) putting a suitable O-ring or gasket between them. (2) Install the special tool which was set up in step (1) between the high-pressure fuel hose and the fuel pump (high pressure).

13B-90

GDI <4G9> - On-vehicle Service 5. Connect the MUT-II to the diagnosis connector. 6. Turn the ignition switch to ON. (But do not start the engine.) 7. Select “Item No.07” from the MUT-II Actuator test to drive the fuel pump (low pressure) at the fuel tank side. Check that there are no fuel leaks from any parts. 8. Finish the actuator test or turn the ignition switch to OFF. 9. Start the engine and run at idle. 10. Measure fuel pressure while the engine is running at idle. Standard value: 324 - 343 kPa at kerb idle 11. Check to see that fuel pressure at idle does not drop even after the engine has been raced several times. 12. If fuel pressure is out of the standard value, troubleshoot and repair according to the table below.

Symptom

Probable cause

Remedy

D D

Clogged fuel filter

Replace fuel filter

Fuel leaking to return side due to poor fuel pressure regulator (low pressure) valve seating or settled spring

Replace fuel pressure regulator (low pressure)

Low fuel pump delivery pressure

Replace the fuel pump (low pressure)

Fuel pressure too low Fuel pressure drops after racing

Fuel pressure too high

(low

Binding valve in fuel regulator (low pressure)

pressure) pressure

Clogged fuel return hose or pipe

Replace fuel pressure regulator (low pressure) Clean or replace hose or pipe

13. Stop the engine and check change of fuel pressure gauge reading. Normal if the reading does not drop within 2 minutes. If it does, observe the rate of drop and troubleshoot and repair according to the table below. Symptom

Probable cause

Remedy

Fuel pressure drops gradually after engine is stopped

Leaky fuel pressure regulator (low pressure) valve seat

Replace fuel pressure regulator (low pressure)

Fuel pressure drops sharply immediately after engine is stopped

Check valve in fuel pump (low pressure) is held open

Replace the fuel pump (low pressure)

14. Release residual pressure from the fuel pipe line. (Refer to P.13B-93.) 15. Remove the fuel pressure gauge and special tools from the fuel pump (high pressure). Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.

GDI <4G9> - On-vehicle Service

13B-91

16. Replace the O-ring at the end of the high-pressure fuel hose with a new one. Furthermore, apply engine oil to the new O-ring before replacement. 17. Fit the high-pressure fuel hose to the fuel pump (high pressure) and tighten the mounting bolt to specified torque. 18. Check for any fuel leaks by following the procedure in step 7. 19. Disconnect the MUT-II.

Injector intermediate harness

MEASUREMENT OF FUEL HIGH PRESSURE BETWEEN FUEL PUMP (HIGH PRESSURE) AND INJECTORS NOTE Measurement of the fuel pressure between the fuel pump (high pressure) and the injectors should be carried out after checking that the fuel pressure between the fuel pump (low pressure) and the fuel pump (high pressure) is normal. 1. 2. 3. 4. 5.

Connect the MUT-II to the diagnosis connector. Disconnect the injector intermediate harness connector. Turn the ignition switch to ON. Select “Item No.74” from the MUT-II Data list. Crank the engine continuously for 2 seconds or more, and visually check that there are no fuel leaks from any parts. Caution If any fuel leaks appear, stop cranking immediately and repair the source of the leak.

6. Check if the fuel pressure is more than 1 MPa immediately after 20 seconds have passed since cranking was finished. 7. If the fuel pressure is lower than 1 MPa, it means that there is likely to be a leak in the high-pressure fuel system, so this system should be checked. 8. Turn the ignition switch to OFF. 9. Connect the injector intermediate harness connector. 10. Start the engine and run at idle.

13B-92

GDI <4G9> - On-vehicle Service 11. Measure fuel pressure while the engine is running at idle. Standard value: 4 - 7 MPa 12. Check to see that fuel pressure at idle does not drop even after the engine has been raced several times. 13. If fuel pressure is out of the standard value, troubleshoot and repair according to the table below.

Symptom

Probable cause

Remedy

D D

Fuel leaking to return side due to poor fuel pressure regulator (high pressure) valve seating or settled spring

Replace fuel pressure regulator (high pressure)

Low fuel pump (high pressure) delivery pressure

Replace the fuel pump (high pressure)

Binding valve in fuel regulator (high pressure)

Replace fuel pressure regulator (high pressure)

Fuel pressure too low Fuel pressure drops after racing

Fuel pressure too high

pressure

Clogged fuel return hose or pipe

Clean or replace hose or pipe

14. Stop the engine and turn the ignition switch to OFF. 15. Disconnect the MUT-II.

FUEL LEAK CHECK Injector intermediate harness

1. 2. 3. 4. 5.

Connect the MUT-II to the diagnosis connector. Disconnect the injector intermediate harness connector. Turn the ignition switch to ON. Select “Item No.74” from the MUT-II Data list. Crank the engine continuously for 2 seconds or more, and visually check that there are no fuel leaks from any parts. Caution If any fuel leaks appear, stop cranking immediately and repair the source of the leak.

6. Stop cranking and measure fuel pressure immediately after 20 seconds. Limit: Minimum 1 MPa

GDI <4G9> - On-vehicle Service

13B-93

Caution If the fuel pressure is less than 1 MPa, there may be a partial fuel leak in the high-pressure fuel system. Check this system. 7. Turn the ignition switch to OFF. 8. Reconnect the injector intermediate connector. 9. Remove the MUT-II.

FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE THE FUEL PRESSURE) Refer to GROUP 13A - On-vehicle Service.

FUEL PUMP OPERATION CHECK Refer to GROUP 13A - On-vehicle Service.

13B-94

GDI <4G9> - On-vehicle Service

COMPONENT LOCATION Name

Symbol

Name

Symbol

A/C relay

K

Engine warning lamp (check engine lamp)

R

A/C switch

S

Fuel pressure sensor

H

Air by-pass control solenoid valve (DUTY)

B

Idle speed control (ISC) servo

F

Air by-pass control solenoid valve (ON/OFF)

B

Ignition coil

N

Air flow sensor (with intake air temperature sensor and barometric pressure sensor)

I

Inhibitor switch

Q

Injectors

C

Camshaft position sensor

G

Injector driver

J

Control relay and fuel pump relay

K

Injector driver control relay

K

Crank angle sensor

A

M/T oil temperature sensor

V

Detonation sensor

M

Oxygen sensor

W

Diagnosis connector

T

Power steering fluid pressure switch

L

EGR valve

D

Purge control solenoid valve

D

Engine coolant temperature sensor

O

Throttle position sensor

E

Engine-ECU

U

Vehicle speed sensor

P

A

B

L R

C

D

M

N

S

T

E F G H I

O

P V

U

J K

Q W

13B-95

GDI <4G9> - On-vehicle Service Fuel pump relay Equipment side connector

ENGINE CONTROL RELAY, FUEL PUMP RELAY AND INJECTOR DRIVER CONTROL RELAY CONTINUITY CHECK Battery voltage

Terminal No. 1

2

3

4

Not supplied Supplied

Engine control relay

Injector driver control relay Equipment side connector

Equipment side connector

INTAKE AIR TEMPERATURE SENSOR CHECK Air flow sensor

1. Disconnect the air flow sensor connector. 2. Measure resistance between terminals 5 and 6. Standard value: 2.3 - 3.0 kW (at 20_C) 0.26 - 0.36 kW (at 80_C)

Intake air temperature sensor

3. Measure resistance while heating the sensor using a hair drier. Normal condition: Temperature (_C)

Resistance (kW)

Higher

Smaller

4. If the value deviates from the standard value or the resistance remains unchanged, replace the air flow sensor assembly.

Engine coolant temperature sensor

ENGINE COOLANT TEMPERATURE SENSOR CHECK Caution Be careful not to touch the connector (resin section) with the tool when removing and installing. 1. Remove the engine coolant temperature sensor.

13B-96

GDI <4G9> - On-vehicle Service 2. With temperature sensing portion of engine coolant temperature sensor immersed in hot water, check resistance. Standard value: 2.1 - 2.7 kW (at 20_C) 0.26 - 0.36 kW (at 80_C) 3. If the resistance deviates from the standard value greatly, replace the sensor.

4. Apply sealant to threaded portion. Specified sealant: 3M NUT Locking Part No.4171 or equivalent 5. Install the engine coolant temperature sensor and tighten it to the specified torque. Tightening torque: 29 Nm

Throttle position sensor

THROTTLE POSITION SENSOR CHECK 1. Disconnect the throttle position sensor connector. 2. Measure the resistance between the throttle position sensor side connector terminal 1 and terminal 4. Standard value: 3.5 - 6.5 kW 3. Measure the resistance between the throttle position sensor side connector terminal 3 and terminal 4.

Equipment side connector

Normal condition: Throttle valve slowly open until fully open from the idle position

Changes smoothly in proportion to the opening angle of the throttle valve

4. If the resistance is outside the standard value, or if it doesn’t change smoothly, replace the throttle position sensor. NOTE For the throttle position sensor adjustment procedure, refer to P.13B-86.

13B-97

GDI <4G9> - On-vehicle Service Oxygen sensor

Equipment side connector

OXYGEN SENSOR CHECK 1. Disconnect the oxygen sensor connector and connect the special tool (test harness) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (11 - 18 W at 20_C) between terminal 2 (red clip) and terminal 4 (blue clip) on the oxygen sensor connector.

3. If there is no continuity, replace the oxygen sensor. 4. Warm up the engine until engine coolant is 80_C or higher. Red Blue

Oxygen sensor equipment side connector

MD998464

5. Use a jumper wire to connect terminal 2 (red clip) of the oxygen sensor connector to the battery (+) terminal and terminal 4 (blue clip) to the battery ( - ) terminal.

Jumper wire Black

Caution Be very careful when connecting the jumper wire; incorrect connection can damage the oxygen sensor.

Red

White

MD998464

Blue

6. Connect a digital voltage meter between terminal 1 (black clip) and terminal 3 (white clip). 7. While repeatedly racing the engine, measure the oxygen sensor output voltage. Standard value: Engine

Oxygen sensor output voltage

Remarks

When racing the engine

0.6 - 1.0 V

If you make the air/fuel ratio rich by racing the engine repeatedly, a normal oxygen sensor will output a voltage of 0.6 - 1.0 V.

8. If the sensor is defective, replace the oxygen sensor. NOTE For removal and installation of the oxygen sensor, refer to GROUP 15 - Exhaust Pipe and Main Muffler.

13B-98

GDI <4G9> - On-vehicle Service INJECTOR CHECK Injector intermediate harness

1. Disconnect the injector intermediate harness connector. 2. Measure the resistance between each of the terminals. Standard value: 0.9 - 1.1 W (at 20_C)

Injector side connector

Injector

Measurement terminal

No.1 cylinder

1- 2

No.2 cylinder

3- 4

No.3 cylinder

5- 6

No.4 cylinder

7- 8

3. Connect the injector intermediate harness connector.

GDI <4G9> - On-vehicle Service

13B-99

IDLE SPEED CONTROL (ISC) SERVO (STEPPER MOTOR) CHECK

Idle speed control servo

Checking the Operation Sound 1. Check that the engine coolant temperature is 20_C or below. Throttle body

NOTE Disconnecting the engine coolant temperature sensor connector and connecting the harness-side of the connector to another engine coolant temperature sensor that is at 20_C or below is also okay. 2. Check that the operation sound of the stepper motor can be heard after the ignition is switched ON. (but without starting the motor.) 3. If the operation sound cannot be heard, check the stepper motor’s activation circuit. If the circuit is normal, it is probable that there is a malfunction of the stepper motor or of the engine control unit.

Checking the Coil Resistance 1. Disconnect the idle speed control servo connector. 2. Measure the resistance between terminal 2 and either terminal 1 or terminal 3 of the connector at the idle speed control servo side. Standard value: 28 - 33 W (at 20_C) 3. Measure the resistance between terminal 5 and either terminal 6 or terminal 4 of the connector at the idle speed control servo side. Standard value: 28 - 33 W (at 20_C)

13B-100

GDI <4G9> - On-vehicle Service Operation Check 1. Remove the throttle body. 2. Remove the stepper motor. 3. Connect the special tool (test harness: MB991709) to the idle speed control servo connector. 4. Connect the positive (+) terminal of a power supply (approx. 6 V) to the terminals 2 and 5. 5. With the idle speed control servo as shown in the illustration, connect the negative ( - ) terminal of the power supply to each clip as described in the following steps, and check whether or not a vibrating feeling (a feeling of very slight vibration of the stepper motor) is generated as a result of the activation of the stepper motor. (1) Connect the negative ( - ) terminal of the power supply to the red and black clip. (2) Connect the negative ( - ) terminal of the power supply to the blue and black clip. (3) Connect the negative ( - ) terminal of the power supply to the blue and yellow clip. (4) Connect the negative ( - ) terminal of the power supply to the red and yellow clip. (5) Connect the negative ( - ) terminal of the power supply to the red and black clip. (6) Repeat the tests in sequence from (5) to (1). 6. If, as a result of these tests, vibration is detected, the stepper motor can be considered to be normal.

Equipment side connector

Air by-pass control solenoid valve (ON/OFF)

AIR BY-PASS CONTROL SOLENOID VALVE CHECK 1. Measure the resistance between the terminals of the air by-pass control solenoid valve (DUTY). Standard value: 7.7 - 9.3 W (at 20_C) 2. Measure the resistance between the terminals of the air by-pass control solenoid valve (ON/OFF).

Air by-pass control solenoid valve (DUTY)

Standard value: 7.7 - 9.3 W (at 20_C)

PURGE CONTROL SOLENOID VALVE CHECK Refer to GROUP 17 - Emission Control System.

EGR VALVE CHECK Refer to GROUP 17 - Emission Control System.

GDI <4G9> -

Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure)

13B-101

FUEL PUMP (HIGH PRESSURE) AND FUEL PRESSURE REGULATOR (HIGH PRESSURE) REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Prevention of fuel discharge (Refer to P.13B-93.) D Engine Cover Removal and Installation

1

D D

Air Cleaner Assembly Removal and Installation Fuel Leak Check (Refer to P.13B-92.)

19 Nm

O-ring

17

8 9

19

1

10

18

22 - 25 Nm

11

3, 5, 6, 13, 14, 16

7

Engine oil 10 - 13 Nm

19 Nm

2

4 5

16 9 Nm

10 - 13 Nm

4 9 Nm

13 6 2 20

24 Nm

15

3

10 - 13 Nm

5 Nm ® 17 Nm

14 5 Nm

13

12

9 Nm

13B-102 GDI <4G9> -

Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure)

Fuel pressure regulator (High pressure) removal steps 1. Harness connector and clamp 4. Fuel return hose connection "CA 5. Low-pressure fuel pipe "CA 6. Fuel return pipe connection 7. Fuel pressure regulator (high pressure) assembly AA" "GA 8. Flange "GA 9. Fuel pressure sensor "FA 10. O-ring "FA 11. Back-up ring "BA 17. Back-up ring A "BA 18. O-ring "BA 19. Back-up ring B Fuel pump (High pressure) removal steps D Throttle body removal (Refer to P.13B-109.)

2. Fuel pipe clamp "CA 3. Fuel feed pipe "CA 5. Low-pressure fuel pipe 12. Fuel return hose connection "EA 13. Fuel pressure hose connection "CA 14. Fuel nipple assembly "DA 15. Fuel pump (high pressure) "BA 17. Back-up ring A "BA 18. O-ring "BA 19. Back-up ring Pump camshaft case removal steps 7. Fuel pressure regulator (high pressure) assembly "DA 15. Fuel pump (high pressure) "CA 16. Fuel return pipe "BA 17. Back-up ring A "BA 18. O-ring "BA 19. Back-up ring B "AA 20. Pump camshaft case

REMOVAL SERVICE POINT Fuel pressure sensor Flange

Mating marks

AA" FLANGE REMOVAL If reusing the fuel pressure sensor, make the mating marks on the sensor and the flange before removing the flange. NOTE The flange will be bent when it is installed to the engine. Because of this, the sealing condition and installation condition of the fuel pressure sensor will be maintained in good condition. Therefore, the mating marks should be made in order to install the flange in the original condition. If replacing the fuel pressure sensor with a new part, the sensor and flange should be replaced together.

GDI <4G9> -

Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure)

13B-103

INSTALLATION SERVICE POINTS

O-ring

Mating marks

"AA PUMP CAMSHAFT CASE ASSEMBLY INSTALLATION 1. Set the No.1 cylinder to the compression top dead centre position. 2. Align the mating mark on the housing of the pump camshaft case assembly with the mating mark on the coupling, and then install the pump camshaft case assembly to the engine. Caution Take care not to drop the O-ring.

Back-up ring A

O-ring

Cutaway surface Back-up ring B

"BA BACK-UP RING B/O-RING/BACK-UP RING A INSTALLATION Install the back-up rings and the O-ring as shown in the illustration. Caution 1. Install the back-up ring B facing its cutaway surface toward the opposite side of the O-ring as shown in the illustration. 2. Confirm the outer diameter of the back-up ring A. Take care not to install the back-up ring for the fuel pressure sensor by mistake. (Outer diameter of the back-up ring A: 14.8 mm)

"CA FUEL RETURN PIPE/LOW-PRESSURE FUEL PIPE/FUEL FEED PIPE INSTALLATION Apply a small amount of fresh engine oil to the O-ring. Caution Take care not to let any of the engine oil get inside the fuel pump (high pressure), fuel pressure regulator (high pressure) or the delivery pipe assembly.

13B-104 GDI <4G9> -

1

3

4

2

Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure)

"DA FUEL PUMP (HIGH PRESSURE) INSTALLATION Use a torque wrench with a precision of 0.5 Nm to tighten the fuel pump mounting bolts according to the following procedure. 1. Tighten the bolts to 5 Nm in the order shown in the illustration. 2. Tighten the bolts to 17 Nm in the order shown in the illustration. The overall difference in tightening torque between the four bolts should be within 2 Nm.

"EA HIGH-PRESSURE FUEL HOSE INSTALLATION 1. Apply a small amount of fresh engine oil to the O-ring. Caution Take care not to let any of the engine oil get inside the fuel pump (high pressure). 2. While being careful not to damage the O-ring, turn the high-pressure fuel hose to the left and right and connect it to the fuel pump (high pressure). After connecting, check that the hose turns smoothly. 3. If the hose does not turn smoothly, the cause may be that the O-ring is getting caught. Disconnect the hose, check the O-ring for damage and re-connect the hose to the fuel pump (high pressure) and then re-check.

Back-up ring

O-ring

"FA BACK-UP RING/O-RING INSTALLATION Install the back-up ring and the O-ring as shown in the illustration. Caution Take care not to install the back-up ring A for the injector, fuel feed pipe or fuel return pipe by mistake. (Outer diameter of the back-up ring for the fuel pressure sensor: 15.1 mm)

Fuel pressure sensor

GDI <4G9> -

Fuel Pump (High Pressure) and Fuel Pressure Regulator (High Pressure)

13B-105

"GA FUEL PRESSURE SENSOR/FLANGE INSTALLATION 1. Apply a small amount of fresh engine oil to the O-ring. Caution Take care not to let any of the engine oil get inside the fuel pressure regulator (high pressure) assembly. 2. Align the mating marks which were made at the time of removal, and then install the fuel pressure sensor and flange to the fuel pressure regulator (high pressure) assembly. Caution If replacing the fuel pressure sensor with a new part, the sensor and flange should be replaced together.

13B-106

GDI <4G9> - Injector

INJECTOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Prevention of fuel discharge (Refer to P.13B-93.) D Engine Cover Removal and Installation D Air Cleaner Assembly Removal and Installation

D D

Intake Manifold Removal and Installation (Refer to GROUP 15.) Fuel Leak Check (Refer to P.13B-92.)

7

10

11

10 - 13 Nm

8 1 20 - 25 Nm

18 17 16

3

9

15 14 13

12

O-ring

4

O-ring

2 6

12

1 2, 3

5

Engine oil

AA"

"DA "DA "CA "CA "CA

Removal steps 1. Fuel pipe clamp 2. Fuel feed pipe 3. Fuel return pipe 4. Back-up ring A 5. O-ring 6. Back-up ring B 7. Injector harness connector 8. Washer 9. Injector holder

AB" "BA 10. 11. AB" "BA 12. 13. 14. 15. 16. 17. "AA 18.

Delivery pipe assembly Insulator Fuel injector assembly Back-up ring O-ring Back-up ring Fuel injector Gasket Corrugated washer

10 13 Nm

GDI <4G9> - Injector

13B-107

REMOVAL SERVICE POINTS AA" INJECTOR HARNESS CONNECTOR DISCONNECTION Caution Disconnect the battery ( - ) cable from its terminal before carrying out this operation.

AB" DELIVERY PIPE ASSEMBLY/FUEL INJECTOR ASSEMBLY REMOVAL Remove the delivery pipe assembly with the fuel injector assembly still attached. Caution Be careful not to drop the fuel injector assembly when removing the delivery pipe assembly.

Corrugated washer

OK

NG

INSTALLATION SERVICE POINTS "AA CORRUGATED WASHER INSTALLATION Caution 1. The corrugated washer should always be replaced with a new part. 2. There should be no scratches or foreign particles on the corrugated washer mounting surface of the injector. 3. Be careful not to mistake the corrugated washer installation direction. "BA FUEL INJECTOR ASSEMBLY/DELIVERY PIPE ASSEMBLY INSTALLATION 1. Apply a small amount of fresh engine oil to the O-ring. Caution Take care not to let any of the engine oil get inside the delivery pipe assembly. 2. While being careful not to damage the O-ring, turn the fuel injector assembly to the left and right and connect it to the delivery pipe assembly. After connecting, check that the fuel injector turns smoothly.

13B-108

GDI <4G9> - Injector 3. If the fuel injector does not turn smoothly, the cause may be that the O-ring is getting caught. Remove the fuel injector, check the O-ring for damage and re-connect the fuel injector to the delivery pipe assembly and then re-check.

Fuel injector

Mating marks

Back-up ring A

Delivery pipe assembly

O-ring

Cutaway surface Back-up ring B

4. Align the mating marks on the delivery pipe assembly and the fuel injector, and then install the delivery pipe assembly with the injector assembly still attached.

"CA BACK-UP RING B/O-RING/BACK-UP RING A INSTALLATION Install the back-up rings and the O-ring as shown in the illustration. Caution 1. Install the back-up ring B facing its cutaway surface toward the opposite side of the O-ring as shown in the illustration. 2. Confirm the outer diameter of the back-up ring A. Take care not to install the back-up ring for the fuel pressure sensor by mistake. (Outer diameter of the back-up ring A: 14.8 mm)

"DA FUEL RETURN PIPE/FUEL FEED PIPE INSTALLATION Apply a small amount of fresh engine oil to the O-ring. Caution Take care not to let any of the engine oil get inside the fuel pump (high pressure), fuel pressure regulator (high pressure) and delivery pipe.

13B-109

GDI <4G9> - Throttle Body

THROTTLE BODY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Engine Coolant Draining and Supplying (Refer to GROUP 14 - On-vehicle Service.) D Accelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle Service.)

D D

Engine Cover Removal and Installation Air Cleaner Assembly Removal and Installation

5 1

2

19 Nm

3 6

4

4

Removal steps 1. Accelerator cable 2. Throttle position sensor connector 3. Idle speed control servo connector 4. Water hose connection

Up

7

5. Vacuum hose connection 6. Throttle body assembly "AA 7. Throttle body gasket

INSTALLATION SERVICE POINT "AA THROTTLE BODY GASKET INSTALLATION Position the projection as shown in the illustration.

Front of vehicle

13B-110

GDI <4G9> - Throttle Body

DISASSEMBLY AND REASSEMBLY

5 6 4

2

3

1

Disassembly steps "AA 1. Throttle position sensor 2. Idle speed control servo 3. O-ring 4. Throttle body 5. Speed adjusting screw 6. O-ring

NOTE 1. The speed adjusting screw is correctly adjusted at the factory and should not be removed. 2. If the speed adjusting screw has been removed, carry out fixed SAS adjustment. 3. If the speed adjusting screw should happen to have been removed, carry out speed adjusting screw adjustment.

GDI <4G9> - Throttle Body/Injector Driver

13B-111

CLEANING THROTTLE BODY PARTS 1. Clean all throttle body parts. Do not use solvent to clean the following parts: D Throttle position sensor D Accelerator pedal position sensor D Idle speed control body assembly If these parts are immersed in solvent, their insulation will deteriorate. Wipe them with cloth only. 2. Check if the vacuum port or passage is clogged. Use compressed air to clean the vacuum passage.

REASSEMBLY SERVICE POINT "AA THROTTLE POSITION SENSOR (TPS) INSTALLATION 1. Position the throttle position sensor on the throttle body along the dotted line as shown in the illustration. 2. Rotate the throttle position sensor clockwise as shown in the illustration, and then tighten the screws. Throttle position sensor

Not used Earth

TPS power supply

3. Connect a multimeter between terminal (4) (TPS power supply) and terminal (3) (TPS output) of the TPS connector, and check that the resistance increases gradually as the throttle valve is opened slowly to the fully-open position. 4. If there is an abnormality, replace the TPS.

TPS output

INJECTOR DRIVER Refer to GROUP 13A.

NOTES

13C-1

FUEL SUPPLY CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2

13509000197

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

13C-2

FUEL SUPPLY - General Information

GENERAL INFORMATION D

D

The steel fuel tank is located under the floor of the rear seats to provide increased safety and increase the amount of luggage compartment space. The fuel tank has been equipped with a valve assembly which incorporates a fuel cut-off valve to prevent fuel from leaking out in the event of a collision and a two-way valve for adjusting the pressure inside the fuel tank.

13500010120

D

D

A plastic snap-fitting hose (high-pressure fuel hose) has been adopted between the fuel pump assembly and the fuel filter assembly in petrol-powered vehicles in order to improve ease of maintenance. A fuel pump module with an electric fuel pump (low-pressure), fuel gauge unit, fuel filter and fuel pressure regulator (low-pressure) integrated has been used to reduce the weight and enhance the collision safety.

13C-3

FUEL SUPPLY - Fuel Tank

FUEL TANK

13500190244

REMOVAL AND INSTALLATION Pre-removal Operation D Fuel Draining D Reduce the Inner Pressure of Fuel Line and Hose (Refer to GROUP 13A - On-vehicle Service.) D Center Exhaust Pipe Removal (Refer to GROUP 15.) D Propeller Shaft Removal <4WD> (Refer to GROUP 25.) 2 - 3 Nm

13 2 - 3 Nm

15 14

18

4

16

17

7 12

2 - 3 Nm

11

10

5

2 - 3 Nm

10

8

Post-installation Operation D Fuel Supplying. D Checking for Fuel Leaks D Propeller Shaft Installation <4WD> (Refer to GROUP 25.) D Center Exhaust Pipe Installation (Refer to GROUP 15.)

9

12

21

20 5 7

9

2

6 1 3 Removal steps 1. Fuel hose protector 2. Vapour hose 3. Filler hose 4. Harness connector connection 5. Vapour hose connection "AA 6. Pressure tube connectionlink=IA 7. Return hose connection 8. Fuel tank assembly 9. Vapour tube 10. Vapour hose 11. Fuel check valve assembly

12. "AA 13. 14. 15. "AA 16. 17. 18. 19. 20. 21.

Valve assembly Suction tube Return hose Pipe and gauge assembly Pressure tube Return hose Fuel pump module Fuel filler cap Filler neck assembly Packing

19

13C-4

FUEL SUPPLY - Fuel tank INSTALLATION SERVICE POINT spot=IA"AA

PRESSURE TUBE/SUCTION TUBE

CONNECTION Caution After the connection, pull the pressure tube and suction tube gently in the direction of removal to check that they are firmly connected.

INSPECTION

13500300104

VALVE CHECK If the sound of the float valve moving (knocking sound) can be heard when the valve assembly is gently shaken up and down, then the valve is okay.

FUEL GAUGE UNIT CHECK Refer to GROUP 54 - Combination Meter.

Fuel hose

Fuel tube

Pipe and gauge assembly

Harness connector

FUEL GAUGE UNIT REPLACEMENT 1. Remove the rear seat, rear seat rail cover, rear scuff plate and center pillar lower trim and turn over the carpet. 2. Remove the service hose cover. 3. Disconnect the harness connector, fuel hose and fuel tube. 4. Unscrew the mounting nuts to remove the pipe and gauge assembly and fuel pump module. 5. Install the pipe and gauge assembly and fuel pump module. Tighten the mounting nuts to the specified torque. Specified torque: 2 - 3 Nm

Harness connector Fuel tube

Fuel hose Fuel pump module

6. Connect the fuel hose, fuel tube and harness connector. Caution After the connection, pull the pressure tube and suction tube gently in the direction of removal to check that they are firmly connected. 7. Install the service hole cover. 8. Turn back the carpet and install the rear seat, rear seat rail cover, rear scuff plate and center pillar lower trim.

14-1

ENGINE COOLING CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2

14109000208

Engine Coolant Replacement . . . . . . . . . . . . . . . . . . 9 Concentration Measurement . . . . . . . . . . . . . . . . . . 10 Fan Controller Check . . . . . . . . . . . . . . . . . . . . . . . . 10

LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Fan Control Relay Continuity Check . . . . . . . . . . 11

SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

WATER PUMP

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 3 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 8 Engine Coolant Leak Checking . . . . . . . . . . . . . . . . 8 Radiator Cap Opening Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

<4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 <4G9> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 WATER HOSE AND WATER PIPE . . . . . . . . 16 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

14-2

ENGINE COOLING -

General Information/Service Specifications/Lubricant/Sealants

GENERAL INFORMATION

14100010217

The cooling system is designed to keep every part of the engine at appropriate temperature in whatever condition the engine may be operated. The cooling method is of the water-cooled, pressure forced circulation type in which the water pump pressurizes coolant and circulates it throughout the engine. If the coolant temperature exceeds the prescribed temperature, the thermostat opens to circulate the coolant through the radiator as well so that the heat absorbed by the coolant may be radiated into the air.

The water pump is of the centrifugal type and is driven by the timing belt or drive belt from the crankshaft. The radiator is the corrugated fin, down flow type and is cooled by the electrical radiator fan. The cooling fans are controlled by a fan controller and the engine-ECU depending on driving conditions.

Items

Specifications

Radiator

Performance kJ/h

A/T oil cooler

4G6

205,116

4G9

171,628

Performance kJ/h

5,860

SERVICE SPECIFICATIONS

14100030091

Items

Standard value

Limit

Radiator cap opening pressure kPa

74 - 103

64

Range of coolant antifreeze concentration of radiator %

30 - 60

-

Valve opening temperature of thermostat _C

85 ± 1.5

-

Full-opening temperature of thermostat _C

98

-

Valve lift (at 95_C) mm

8.5 or more

-

Thermostat

LUBRICANT

14100040148

Items MITSUBISHI GENUINE COOLANT!or equivalent

Quantity L 4G6

7

4G9

6

SEALANTS

14100050172

Items

Specified sealant

Remarks

Cylinder block drain plug

3M Nut Locking Part No. 4171 or equivalent

Drying sealant

Water pump <4G9> Thermostat case assembly

Mitsubishi Genuine Parts No. MD970389 or equivalent

Semi-drying sealant

14-3

ENGINE COOLING - Special Tool/Troubleshooting

SPECIAL TOOL Tool A

14100060038

Number

Name

Use

MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222

Harness set A: Test harness B: LED harness C: LED harness adapter D: probe

Measurement of terminal voltage A: Connector pin contact pressure inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection

B

C

D

TROUBLESHOOTING

14100560019

INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptoms

Inspection procedure No.

Reference page

Radiator fan and condenser fan do not operate. Radiator fan does not operate.

1

14-3

Radiator fan and condenser fan do not change speed or stop. Radiator fan does not change speed or stop.

2

14-6

Radiator fan does not operate.

3

14-7

Condenser fan does not operate.

4

14-7

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 Radiator fan and condenser fan do not operate. Radiator fan does not operate.

Probable cause

The cause could be a malfunction of the fan controller power supply or earth circuit. The cause could also be a malfunction of the fan controller or the engine-ECU.

D D D D D

Malfunction Malfunction Malfunction Malfunction Malfunction

of of of of of

fusible link fan control relay fan controller engine-ECU wiring harness or connector

14-4

ENGINE COOLING - Troubleshooting

D D

Fusible link (7) check Fan control relay check (Refer to P.14-11.)

NG

Replace

OK

(1) NG Measure at the fan control relay connector A-20X. D Remove the relay, and measure at the harness side connector. (1) Voltage between 4 and body earth (2) NG OK: Battery voltage (2) Voltage between 3 and body earth (Ignition switch: ON) OK: Battery voltage (3) NG (3) Continuity between 1 and body earth OK: Continuity OK

(1) NG Measure at the fan controller connector A-37. D Disconnect the connector, and measure at the harness side connector. (2) NG (1). Voltage between 3 and body earth (Ignition switch: ON) OK: Battery voltage (2). Continuity between 1 and body earth OK: Continuity OK Measure at the engine-ECU connector B- 54. D Connect the connector. D Voltage between 21 and body earth (Engine: idling, A/C switch: ON) OK: 0.7 V or more (When A/C compressor is operating)

NG

OK

Check the harness wire between fan control relay and fusible link (7), and repair if necessary. Check the harness wire between fan control relay and engine control relay, and repair if necessary. Check the harness wire between fan control relay and body earth, and repair if necessary. Check the harness wire between fan controller and fan control relay, and repair if necessary. Check the harness wire between fan controller and body earth, and repair if necessary.

Check the harness wire between fan controller and engine-ECU. OK

NG Repair

Engine-ECU terminal voltage check (Refer to GROUP 13 - Troubleshooting.) NG

OK

Replace Check the automatic compressor-ECU, and repair if necessary. (Refer to GROUP 55 - Troubleshooting.) Measure at the engine-ECU connector B- 54. D Connect the connector. D Pull out the terminal No.21 to disconnect it (Ignition switch: ON) OK: The radiator fan motor and condenser fan motor operate. YES Engine-ECU terminal voltage check (Refer to GROUP 13 - Troubleshooting.)

NO Replace the radiator fan motor and fan controller assembly.

14-5

ENGINE COOLING - Troubleshooting D D

Fusible link (7) check Fan control relay check (Refer to P.14-11.) OK

NG

(1) NG Measure at the fan control relay connector A-20X. D Remove the relay, and measure at the harness side connector. (1) Voltage between 4 and body earth (2) NG OK: Battery voltage (2) Voltage between 3 and body earth (Ignition switch: ON) OK: Battery voltage (3) NG (3) Continuity between 1 and body earth OK: Continuity OK

(1) NG Measure at the fan controller connector A-37. D Disconnect the connector, and measure at the harness side connector. (2) NG (1) Voltage between 3 and body earth (Ignition switch: ON) OK: Battery voltage (2) Continuity between 1 and body earth OK: Continuity OK Measure at the engine-ECU connector B-54. D Connect the connector. D Voltage between 21 and body earth (Engine: idling) OK: 0.7 V or more (When radiator fan is operating)

NG

OK

Measure at the engine-ECU connector B-54. D Connect the connector. D Pull out the terminal No.21 to disconnect it (Ignition switch: ON) OK: The radiator fan motor operates. YES Engine-ECU terminal voltage check (Refer to GROUP 13 - Troubleshooting.)

Replace

Check the harness wire between fan control relay and fusible link (7), and repair if necessary. Check the harness wire between fan control relay and engine control relay, and repair if necessary. Check the harness wire between fan control relay and body earth, and repair if necessary. Check the harness wire between fan controller and fan control relay, and repair if necessary. Check the harness wire between fan controller and body earth, and repair if necessary.

Check the harness wire between fan controller and engine-ECU. OK NG Repair Engine-ECU terminal voltage check (Refer to GROUP 13 - Troubleshooting.)

NO Replace the radiator fan motor and fan controller assembly.

14-6

ENGINE COOLING - Troubleshooting

Inspection Procedure 2 Radiator fan and condenser fan do not change speed or stop. Radiator fan does not change speed or stop.

Probable cause

The fan controller carries out step-free control of the radiator fan motor and the condenser fan motor speeds using signals transmitted from the engine-ECU.

D D D D

Malfunction Malfunction Malfunction Malfunction

of of of of

fan control relay fan controller engine-ECU wiring harness or connector

Fan control relay check (Refer to P.14-11.) OK D D D

Check the harness wire between fan control relay and engine control relay. Check the harness wire between fan control relay and body earth. Check the harness wire between fan control relay and fan controller. OK

Measure at the engine-ECU connector B-54. D Connect the connector. D Voltage between 21 and body earth (Engine: idling, engine coolant temperature: 80_C or less) OK: 0 - 0.3 V (Engine: idling, A/C switch: ON) OK: 0.7 V or more (When A/C compressor is operating)

NG NG

NG

Replace

Repair

Check the harness wire between fan controller and engine-ECU. NG OK

Repair

Engine-ECU terminal voltage check (Refer to GROUP 13 - Troubleshooting.)

OK

NG OK

Replace

Check the automatic compressor-ECU, and repair if necessary. (Refer to GROUP 55 - Troubleshooting.)

Fan controller check (Refer to P.14-10.) OK

NG

Replace the radiator fan motor and fan controller assembly.

Measure at the engine-ECU connector B-54. D Connect the connector. D Pull out the terminal No.21 to disconnect it (Ignition switch: ON) OK: The radiator fan motor and condenser fan motor operate. D Connect the terminal No.21 to the body earth (Ignition switch: ON) OK: The radiator fan motor and condenser fan motor stop. YES Engine-ECU terminal voltage check (Refer to GROUP 13 - Troubleshooting.)

NO Replace the radiator fan motor and fan controller assembly.

14-7

ENGINE COOLING - Troubleshooting NG

Fan control relay check (Refer to P.14-11.) OK D D D

Check the harness wire between fan control relay and engine control relay. Check the harness wire between fan control relay and body earth. Check the harness wire between fan control relay and fan controller. OK

Measure at the engine-ECU connector B-54. D Connect the connector. D Voltage between 21 and body earth (Engine: idling, engine coolant temperature: 80_C or less) OK: 0 - 0.3 V (Engine: idling) OK: 0.7 V or more (When radiator fan is operating)

Replace

NG

Repair

NG

Check the harness wire between fan controller and engine-ECU. OK

Repair Engine-ECU terminal voltage check (Refer to GROUP 13 - Troubleshooting.)

OK NG

Fan controller check (Refer to P.14-10.)

NG

Replace the radiator fan motor and fan controller assembly.

OK Measure at the engine-ECU connector B-54. D Connect the connector. D Pull out the terminal No.21 to disconnect it (Ignition switch: ON) OK: The radiator fan motor operates. D Connect the terminal No.21 to the body earth (Ignition switch: ON) OK: The radiator fan motor stops. NO

YES Engine-ECU terminal voltage check (Refer to GROUP 13 - Troubleshooting.)

Replace the radiator fan motor and fan controller assembly.

Inspection Procedure 3 Radiator fan does not operate.

Probable cause

The cause could be a malfunction of the radiator fan motor or an open circuit between the fan controller and the radiator fan motor.

D D

Malfunction of radiator fan motor Open circuit between fan controller and radiator fan motor

Replace the radiator fan motor and fan controller assembly.

Inspection Procedure 4 Condenser fan does not operate.

Probable cause

The cause could be a malfunction of the condenser fan motor or of the fan controller.

D D D

Condenser fan motor check (Refer to GROUP 55.) OK Replace the radiator fan motor and fan controller assembly.

NG

Condenser fan motor connector OK Check the trouble symptom.

Malfunction of condenser fan motor Malfunction of fan controller Malfunction of wiring harness or connector NG NG

Repair

Replace the condenser fan motor.

14-8

ENGINE COOLING - On-vehicle Service

ON-VEHICLE SERVICE Cap adapter Adapter

14100100136

ENGINE COOLANT LEAK CHECKING 1. Confirm that the coolant level is up to the filler neck. Install a radiator cap tester and apply 160 kPa pressure, and then check for leakage from the radiator hose or connections. Caution (1) Be sure to completely clean away any moisture from the places checked. (2) When the tester is taken out, be careful not to spill any coolant from it. (3) Be careful, when installing and removing the tester and when testing, not to deform the filler neck of the radiator. 2. If there is leakage, repair or replace the appropriate part.

RADIATOR CAP OPENING PRESSURE CHECK 14100130159

Cap adapter

1. Use a cap adapter to attach the cap to the tester. 2. Increase the pressure until the indicator of the gauge stops moving. Limit: 64 kPa Standard value: 74 - 103 kPa 3. Replace the radiator cap if the reading does not remain at or above the limit. NOTE Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an improper indication.

ENGINE COOLING - On-vehicle Service ENGINE COOLANT REPLACEMENT

<4G6>

14-9 14100120231

1. Drain the engine coolant by removing the drain plug and then the radiator cap. 2. Remove the drain plug from the cylinder block to drain the engine coolant. 3. Remove the reserve tank to drain the engine coolant. 4. When the engine coolant has drained, pour in water from the radiator cap to clean the engine coolant line.

<4G9>

<4G6>

<4G9>

5. Coat the thread of the cylinder block drain plug with the specified sealant and tighten to the specified torque. Specified sealant: 3M Nut Locking Part No. 4171 or equivalent 6. Securely tighten the radiator drain plug. 7. Install the reserve tank.

44 Nm

39 Nm

8. Slowly pour the engine coolant into the mouth of the radiator until the radiator is full, and pour also into the reserve tank up to the FULL line. Recommended antifreeze: MITSUBISHI GENUINE COOLANT or equivalent Quantity: <4G6> 7 L <4G9> 6 L Caution Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol anti-freeze. The use of an improper anti-freeze can cause the corrosion of the aluminium components. NOTE For Norway, the non-amine type of antifreeze should be used. 9. Install the radiator cap securely.

14-10

ENGINE COOLING - On-vehicle Service 10. Start the engine and warm the engine until the thermostat opens. (Touch the radiator hose with your hand to check that warm water is flowing.) 11. After the thermostat opens, race the engine several times, and then stop the engine. 12. Cool down the engine, and then pour engine coolant into the reserve tank until the level reaches the FULL line. If the level is low, repeat the operation from step 9.

CONCENTRATION MEASUREMENT

14100110146

Measure the temperature and specific gravity of the engine coolant to check the antifreeze concentration. Standard value: 30 - 60 % (allowable concentration range) RECOMMENDED ANTIFREEZE Antifreeze

Allowable concentration

MITSUBISHI GENUINE COOLANT or equivalent

30 - 60 %

Caution If the concentration of the antifreeze is below 30 %, the anti-corrosion property will be adversely affected. In addition, if the concentration is above 60 %, both the anti-freezing and engine cooling properties will decrease, affecting the engine adversely. For these reasons, be sure to maintain the concentration level within the specified range.

FAN CONTROLLER CHECK Fan controller

14100610011

1. Remove the fan controller mounting bolt, and then disconnect the condenser fan motor connector. 2. Start the engine and run it at idle. 3. Turn the A/C switch to ON and maintain the coolant temperature at 80_C or less. 4. When measuring the voltage between the fan controller-side connector terminals, check that the value changes repeatedly as indicated by (1) - (3) below. (1) 0 V (2) 8.2 ± 2.6 V (3) Battery voltage ± 2.6 V 5. If the voltage does not repeatedly change as indicated, replace the radiator fan motor and the fan controller assembly.

14-11

ENGINE COOLING - On-vehicle Service

FAN CONTROL RELAY CONTINUITY CHECK 14100620014

Battery voltage

Terminal No. 1

Fan control relay

When current is not supplied When current supplied

is

2

3

4

14-12

ENGINE COOLING - Thermostat

THERMOSTAT

14100240265

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Engine Coolant Draining and Supplying (Refer to P.14-9.) D Air Intake Duct Removal and Installation

<4G6>

3

2

1 13 Nm

<4G9>

3 2 13 Nm

1

Removal steps AA" "BA 1. Radiator lower hose connection 2. Water inlet fitting

"AA 3. Thermostat

ENGINE COOLING - Thermostat

14-13

REMOVAL SERVICE POINT AA" RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose.

INSTALLATION SERVICE POINTS Jiggle valve

"AA THERMOSTAT INSTALLATION Install the thermostat so that the jiggle valve is facing straight up. Caution Make absolutely sure that no oil is adhering to the rubber ring of the thermostat. In addition, be careful not to fold over or scratch the rubber ring when inserting. If the rubber ring is damaged, replace the thermostat.

Rubber ring

"BA RADIATOR LOWER HOSE CONNECTION 1. Insert each hose as far as the projection of the water inlet fitting. 2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

INSPECTION

14100250275

THERMOSTAT CHECK 1. Immerse the thermostat in water, and heat the water while stirring. Check the thermostat valve opening temperature. Standard value: Valve opening temperature: 85 ± 1.5_C

2. Check that the amount of valve lift is at the standard value when the water is at the full-opening temperature. Standard value: Full-opening temperature: 98_C Amount of valve lift: 8.5 mm or more Valve lift

NOTE Measure the valve height when the thermostat is fully closed, and use this measurement to calculate the valve height when the thermostat is fully open.

14-14

ENGINE COOLING - Water Pump <4G6>

WATER PUMP <4G6>

14100270363

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Engine Coolant Draining and Supplying (Refer to P.14-9.) D Engine Cover Removal D Timing Belt Removal and Installation (Refer to GROUP 11A.)

4 2 1

Bolt specifications 8 ´ 80

3 24 Nm 13 Nm

8 ´ 14

2 8 ´ 25 8 ´ 22 Screw diameter ´ length mm

Removal steps 1. Alternator brace 2. Water pump 3. Water pump gasket "AA 4. O-ring

INSTALLATION SERVICE POINT Water pump

O-ring

Water inlet pipe assembly

"AA O-RING INSTALLATION Insert the O-ring to the water inlet pipe assembly, and coat the outer circumference of the O-ring with water or engine coolant. Caution Do not allow engine oil or other greases to adhere to the O-ring

14-15

ENGINE COOLING - Water Pump <4G9>

WATER PUMP <4G9>

14100270370

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Engine Coolant Draining and Supplying (Refer to P.14-9.) D Timing Belt Removal and Installation (Refer to GROUP 11B.)

D

Idler Pulley Removal and Installation (Refer to GROUP 11B - Timing Belt.)

1

10 - 12 Nm

Sealant: Mitsubishi Genuine Part MD970389 or equivalent 24 Nm

No.

2

Removal steps 1. Timing belt rear left cover "AA 2. Water pump

INSTALLATION SERVICE POINT "AA WATER PUMP INSTALLATION Squeeze out the sealant from the tube evenly and apply it so that there is not too much sealant and no places without sealant. Specified Sealant: Mitsubishi Genuine Part No. MD970389 or equivalent

14-16

ENGINE COOLING - Water Hose and Water Pipe

WATER HOSE AND WATER PIPE

14100330306

REMOVAL AND INSTALLATION <4G6> Pre-removal and Post-installation Operation D Engine Coolant Draining and Supplying (Refer to P.14-9.)

13 Nm

D D

Engine Cover Removal and Installation Air Cleaner Assembly Removal and Installation

1

7

2 6

3

24 Nm

5

4 9

9

10 8

13 Nm

Sealant: Mitsubishi Genuine Part No. MD970389 or equivalent Removal steps AA" "CA 1. Radiator upper hose connection AA" "CA 2. Radiator lower hose connection 3. Water hose 4. Water hose 5. Water hose

6. "BA 7. 8. "AA 9. 10.

Water inlet fitting Thermostat case assembly Heater hose connection O-ring Water inlet pipe

14-17

ENGINE COOLING - Water Hose and Water Pipe <4G9> Pre-removal and Post-installation Operation D Engine Coolant Draining and Suppling (Refer to P.14-9.) D Engine Cover Removal and Installation D Air Cleaner Assembly and Air Intake Hose Removal and Installation

6

2

5

22 - 25 Nm

3 14 Nm

6

4 6 1

14 Nm

7 8

Sealant: Mitsubishi Genuine Part No. MD970389 or equivalent Removal steps AA" "CA 1. Radiator lower hose connection 2. Water temperature gauge unit connector "BA 3. Thermostat case assembly "AA 4. O-ring 5. Heater hose connection

D Intake manihold

(Refer to GROUP 15) 6. Water hose 7. Water inlet pipe assembly "AA 8. O-ring

14-18

ENGINE COOLING - Water Hose and Water Pipe REMOVAL SERVICE POINT AA" RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose.

Thermostat case assembly, water pump or cylinder block

O-ring

Water inlet pipe assembly or heater pipe assembly

INSTALLATION SERVICE POINTS "AA O-RING INSTALLATION Insert the O-ring to the water inlet pipe assembly or the heater pipe assembly and coat the outer circumference of the O-ring with water or engine coolant. Caution Do not allow engine oil or other greases to adhere to the O-ring

"BA THERMOSTAT CASE ASSEMBLY INSTALLATION Squeeze out the sealant from the tube evenly and apply it so that there is not too much sealant and no places without sealant. Specified Sealant: Mitsubishi Genuine Parts No. MD970389 or equivalent

"CA RADIATOR LOWER HOSE/RADIATOR UPPER HOSE CONNECTION 1. Insert each hose as far as the projection of the water inlet fitting or water outlet fitting. 2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

INSPECTION

14100340118

WATER PIPE AND HOSE CHECK Check the water pipe and hose for cracks, damage, clog and replace them if necessary.

14-19

ENGINE COOLING - Radiator

RADIATOR

14100150285

REMOVAL AND INSTALLATION Pre-removal operation D Engine Coolant Draining (Refer to P.14-9.) D Air Intake Duct Assembly Removal D Battery and Battery Cover Removal

Post-installation Operation D Air Intake Duct Assembly Installation D Engine Coolant Supplying (Refer to P.14-9.) D A/T Fluid Supplying and Checking (Refer to GROUP 23 - On-vehicle Service.) D Battery and Battery Cover Installation

12 Nm

9

2

9 14 15 10

17

16

5 3 1

7

12

11 4

5 Nm

11

8

13 6

Radiator removal steps 1. Drain plug 2. Radiator cap 3. Overflow hose 4. Reserve tank AA" "AA 5. Radiator upper hose AA" "AA 6. Radiator lower hose AB" 7. Transmission fluid cooler hose connection 8. Condenser fan motor assembly 9. Upper insulator 10. Radiator assembly 11. Lower insulator 12. Bolt

AB"

13. Transmission fluid cooler hose and pipe assembly 14. Radiator fan motor assembly Radiator fan motor and fan controller assembly removal steps AA" "AA 5. Radiator upper hose 12. Bolt 8. Condenser fan motor assembly 14. Radiator fan motor assembly 15. Fan 16. Radiator fan motor and fan controller assembly 17. Shroud

14-20

ENGINE COOLING - Radiator REMOVAL SERVICE POINTS AA" RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose. AB" TRANSMISSION FLUID COOLER HOSE AND PIPE ASSEMBLY REMOVAL After disconnecting the hoses from the radiator and the transmission, plug all of the pipes and hoses to prevent dirt and other foreign objects from getting inside.

INSTALLATION SERVICE POINT "AA RADIATOR LOWER HOSE/RADIATOR UPPER HOSE CONNECTION 1. Insert each hose as far as the projection of the water inlet fitting. 2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

15-1

INTAKE AND EXHAUST CONTENTS

15109000250

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2

INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE SPECIFICATION . . . . . . . . . . . . . . . . . . 2

EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 6

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

EXHAUST PIPE AND MAIN MUFFLER . . . . . . 8

15-2

INTAKE AND EXHAUST -

General Information/Service Specification/Special Tool

GENERAL INFORMATION

15100010061

The intake manifold is made of an aluminium alloy, and the shape provides an increased intake inertia effect and has a good volumetric efficiency.

The exhaust manifold is made of stainless steel. The exhaust pipe is divided into three parts; the front pipe, the centre pipe, and the main muffler.

SERVICE SPECIFICATION

15100030197

Items

Standard value

Limit

Manifold distortion of the installation surface mm

0.15 or less

0.20

SPECIAL TOOL Tool

15100060066

Number

Name

Use

MD998770

Oxygen sensor wrench

Removal/Installation of oxygen sensor

15-3

INTAKE AND EXHAUST - Intake Manifold

INTAKE MANIFOLD

15100300441

REMOVAL AND INSTALLATION <4G6> Pre-removal and Post - installation Operation D Engine Coolant Draining and Supplying (Refer to GROUP 14 - On-vehicle Service.) D Engine Cover Removal and Installation D Air Cleaner Assembly Removal and Installation

D D

Ignition Coil Removal and Installation (Refer to GROUP 16.) Throttle Body Removal and Installation (Refer to GROUP 13A.)

20 Nm

2

3

10 - 12 Nm

6

20 Nm

8

15

8

4 13

7

18

12

14 5 10

9 Nm

1 30 Nm

9 11 30 Nm

9 Nm

16 24 Nm

17

Removal steps 1. Engine harness connector and clamp 2. Earth cable connection 3. PCV hose 4. Brake booster vacuum hose connection 5. Vacuum hose connection 6. Purge solenoid valve 7. Vacuum pipe and hose assembly 8. Intake manifold and air intake plenum resonator assembly connecting bolt 9. Intake manifold stay and air intake plenum resonator assembly connecting bolt

10. Intake manifold and stay connecting bolt 11. Intake manifold and EGR valve support connecting bolt 12. Intake manifold 13. Intake manifold gasket 14. Gasket 15. Air intake plenum resonator assembly 16. Power steering hose clamp 17. Alternator harness clamp 18. Intake manifold stay

15-4

INTAKE AND EXHAUST - Intake Manifold

<4G9> Pre-removal and Post - installation Operation D Engine Coolant Draining and Supplying (Refer to GROUP 14 - On-vehicle Service.) D Engine Cover Removal and Installation D Ignition Coil Removal and Installation (Refer to GROUP 16.)

D D

Air Cleaner Assembly Removal and Installation Throttle Body Removal and Installation (Refer to GROUP 13B.)

10 - 12 Nm

7 9 Nm

20 Nm

3

9 Nm

3

8

10

1

26 9 2 25 24

6

16

14

9 Nm

4

19 Nm 9 Nm

22 5

23

11

3

13

15

24 Nm

3

25 - 32 Nm

18

21

17 19 Nm

12 10 - 12 Nm 25 - 32 Nm

19

19 20 19 Nm

INTAKE AND EXHAUST - Intake Manifold Intake manifold removal steps 1. Brake booster vacuum pipe 2. Brake booster vacuum hose 3. Harness connector 4. Vacuum hose 5. Vacuum pipe and pipe 6. Purge control solenoid valve 7. Harness clamp 8. PCV hose connection 9. Water hose connection D Front exhaust pipe assembly (Refer to P.15-8.) 10. Intake manifold and air intake plenum resonator assembly connecting bolt 11. Intake manifold and stay connecting bolt 12. Intake manifold and EGR valve support connecting bolt 13. EGR pipe gasket 14. Intake manifold assembly 15. Intake manifold gasket

15-5

16. Air intake plenum resonator assembly 17. Harness connector clamp 18. Intake manifold stay EGR valve removal steps 3. Harness connector 12. Intake manifold and EGR valve support connecting bolt 13. EGR valve gasket 19. Water hose connection 20. EGR valve 21. EGR valve gasket 22. EGR valve support 23. EGR valve gasket Air bypass valve removal steps 14. Intake manifold assembly 24. Water hose connection 25. Air bypass valve 26. Air bypass valve gasket

INSPECTION

15100310161

Check the following points; replace the part if a problem is found. INTAKE MANIFOLD CHECK 1. Check for damage or cracking of any part. 2. Check for obstruction of the negative pressure (vacuum) outlet port, and for obstruction of the water passage or gas passage. 3. Using a straight edge and thickness gauge, check for distortion of the cylinder head installation surface. Standard value: 0.15 mm or less Limit: 0.20 mm

15-6

INTAKE AND EXHAUST - Exhaust Manifold

EXHAUST MANIFOLD

15100330440

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation

<4G6> 49 Nm

7

12 - 15 Nm

6 29 Nm 49 Nm 34 Nm

2

4

1

44 Nm

7

<4G9>

18 Nm

6

29 Nm

13 Nm

29 Nm

5

12 - 15 Nm

4 35 Nm

5 3 34 Nm

19 Nm

2 1

44 Nm

Removal steps 1. Front exhaust pipe connection 2. Gasket 3. Oil level gauge assembly <4G9> 4. Heat protector

5. Exhaust manifold bracket <4G9> 6. Exhaust manifold 7. Exhaust manifold gasket

INTAKE AND EXHAUST - Exhaust Manifold INSPECTION

15-7 15100340061

EXHAUST MANIFOLD CHECK 1. Check for damage or cracking of any part. 2. Using a straight edge and thickness gauge, check for distortion of the cylinder head installation surface. Standard value: 0.15 mm or less Limit: 0.20 mm

15-8

INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler

EXHAUST PIPE AND MAIN MUFFLER

15100540355

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Under Cover Removal and Installation

Hanger installation bolt tightening torque

5, 8, 13 13 Nm

1 5

13 Nm

14 34 Nm

12

5

13 15

7

54 Nm

3

54 Nm

2

9

44 Nm

4

49 Nm

8 10

49 Nm

11

6

49 Nm

Main muffler removal steps 1. Main muffler assembly 2. Gasket 3. Hanger Center exhaust pipe removal steps AA" "AA 2. Oxygen sensor <4G6> 3. Center exhaust pipe 4. Gasket 7. Gasket 8. Hanger

Catalytic converter removal steps 6. Catalytic converter 7. Gasket 11. Gasket Front exhaust pipe removal steps AA" "AA 9. Oxygen sensor 10. Front exhaust pipe 11. Gasket 12. Gasket 13. Hanger 14. Front hanger bracket 15. Front exhaust pipe bracket

REMOVAL SERVICE POINT AA" OXYGEN SENSOR REMOVAL

INSTALLATION SERVICE POINT "AA OXYGEN SENSOR INSTALLATION

MD998770

16-1

ENGINE ELECTRICAL CONTENTS CHARGING SYSTEM . . . . . . . . . . . . . . . . 2

IGNITION SYSTEM . . . . . . . . . . . . . . . . . 25

GENERAL INFORMATION . . . . . . . . . . . . . . . . 2

GENERAL INFORMATION . . . . . . . . . . . . . . 25

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 3

SERVICE SPECIFICATIONS . . . . . . . . . . . . 26

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 3

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 26

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 4

Ignition Coil (With Built-in Power Transistor) Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Alternator Output Line Voltage Drop Test . . . . 4

Spark Plug Check and Cleaning . . . . . . . . . . . 27

Output Current Test . . . . . . . . . . . . . . . . . . . . . . . 5

Camshaft Position Sensor Check

Regulated Voltage Test . . . . . . . . . . . . . . . . . . . . 7

Crank Angle Sensor Check . . . . . . . . . . . . . . . 28

Waveform Check Using An Analyzer . . . . . . . . 9

Detonation Sensor Check . . . . . . . . . . . . . . . . . 28

Alternator Relay Continuity Check . . . . . . . . . 10

. . . . . . . . . 28

IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . 29

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CRANK ANGLE SENSOR . . . . . . . . . . . . . . 29

STARTING SYSTEM . . . . . . . . . . . . . . . . 17 GENERAL INFORMATION . . . . . . . . . . . . . . 17 SERVICE SPECIFICATIONS . . . . . . . . . . . . 17 STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . 18

CAMSHAFT POSITION SENSOR . . . . . . . 30 DETONATION SENSOR . . . . . . . . . . . . . . . . 31

16-2

ENGINE ELECTRICAL - Charging System

CHARGING SYSTEM GENERAL INFORMATION The charging system uses the alternator output to keep the battery charged at a constant level under various electrical loads.

Voltage

OPERATION

Approx. 14.4 V

Rotation of the excited field coil generates AC voltage in the stator. This alternating current is rectified through diodes to DC voltage having a waveform shown in the illustration at left. The average output voltage fluctuates slightly with the alternator load condition.

Time

When the ignition switch is turned on, current flows in the field coil and initial excitation of the field coil occurs. When the stator coil begins to generate power after the engine is started, the field coil is excited by the output current of the stator coil. The alternator output voltage rises as the field current increases and it falls as the field current decreases. When the battery voltage (alternator S terminal voltage) reaches a regulated voltage

of approx. 14.4 V, the field current is cut off. When the battery voltage drops below the regulated voltage, the voltage regulator regulates the output voltage to a constant level by controlling the field current. In addition, when the field current is constant, the alternator output voltage rises as the engine speed increases.

SYSTEM DIAGRAM <4G9>

Stator coil

B Engine-ECU

Field coil Voltage regulator

G S L FR

+ Ignition Charging switch warning lamp

Battery

-

16-3

ENGINE ELECTRICAL - Charging System <4G6>

B Stator coil Engine-ECU

Field coil

G S L FR

Voltage regulator

+ Ignition switch

Charging warning lamp

Battery

-

ALTERNATOR SPECIFICATIONS Items

4G9

4G6

Type

Battery voltage sensing

Battery voltage sensing

Rated output V/A

12/85 12/100

12/100

Voltage regulator

Electronic built-in type

Electronic built-in type

SERVICE SPECIFICATIONS Items

Standard value

Limit

Alternator output line voltage drop (at 30A) V

-

max. 0.3

Regulated voltage ambient temp. at voltage regulator V

- 20_C

14.2 - 15.4

-

20_C

13.9 - 14.9

-

60_C

13.4 - 14.6

-

80_C

13.1 - 14.5

-

Output current

-

70% of normal output current

Rotor coil resistance W

Approx. 2 - 5

-

SPECIAL TOOL Tool

Number

Name

Use

MB991519

Alternator test harness

Checking the alternator (S terminal voltage)

16-4

ENGINE ELECTRICAL - Charging System

ON-VEHICLE SERVICE ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST

+ Alternator

Terminal B

Ammeter

Voltmeter

+

This test determines whether the wiring from the alternator “B” terminal to the battery (+) terminal (including the fusible line) is in a good condition or not. 1. Always be sure to check the following before the test. D Alternator installation D Alternator drive belt tension D Fusible link D Abnormal noise from the alternator while the engine is running 2. Turn the ignition switch off. 3. Disconnect the negative battery cable. 4. Disconnect the alternator output wire from the alternator “B” terminal and connect a DC test ammeter with a range of 0 - 100 A in series between the “B” terminal and the disconnected

-

Battery

output wire. (Connect the (+) lead of the ammeter to the “B” terminal, and then connect the ( - ) lead of the ammeter to the disconnected output wire.) NOTE An inductive-type ammeter which enables measurements to be taken without disconnecting the alternator output wire should be recommended. Using this equipment will lessen the possibility of a voltage drop caused by a loose “B” terminal connection. 5. Connect a digital-type voltmeter between the alternator “B” terminal and the battery (+) terminal. (Connect the (+) lead of the voltmeter to the “B” terminal and the connect the ( - ) lead of the voltmeter to the battery (+) cable.)

16-5

ENGINE ELECTRICAL - Charging System 6. 7. 8. 9. 10.

Reconnect the negative battery cable. Connect a tachometer or the MUT-II. Leave the hood open. Start the engine. With the engine running at 2,500 r/min, turn the headlamps and other lamps on and off to adjust the alternator load so that the value displayed on the ammeter is slightly above 30 A. Adjust the engine speed by gradually decreasing it until the value displayed on the ammeter is 30 A. Take a reading of the value displayed on the voltmeter at this time. Limit: max. 0.3 V NOTE When the alternator output is high and the value displayed on the ammeter does not decrease until 30 A, set the value to 40 A. Read the value displayed on the voltmeter at this time. When the value range is 40 A, the limit is max. 0.4 V.

11. If the value displayed on the voltmeter is above the limit value, there is probably a malfunction in the alternator output wire, so check the wiring between the alternator “B” terminal and the battery (+) terminal (including fusible link). If a terminal is not sufficiently tight or if the harness has become discolored due to overheating, repair and then test again. 12. After the test, run the engine at idle. 13. Turn off all lamps and the ignition switch. 14. Remove the tachometer or the MUT-II. 15. Disconnect the negative battery cable. 16. Disconnect the ammeter and voltmeter. 17. Connect the alternator output wire to the alternator “B” terminal. 18. Connect the negative battery cable.

OUTPUT CURRENT TEST Load Voltmeter Ammeter Charging warning lamp Ignition switch Alternator relay

-

+

+

B

FR L S G

Battery Engine -ECU

Alternator

16-6

ENGINE ELECTRICAL - Charging System

This test determines whether the alternator output current is normal. 1. Before the test, always be sure to check the following. D Alternator installation D Battery NOTE The battery should be slightly discharged. The load needed by a fully-charged battery is insufficient for an accurate test. D Alternator drive belt tension D Fusible link D Abnormal noise from the alternator while the engine is running. 2. Turn the ignition switch off. 3. Disconnect the negative battery cable. 4. Disconnect the alternator output wire from the alternator “B” terminal. Connect a DC test ammeter with a range of 0 - 100 A in series between the “B” terminal and the disconnected output wire. (Connect the (+) lead of the ammeter to the “B” terminal. Connect the ( - ) lead of the ammeter to the disconnected output wire.)

10. Turn the light switch on to turn on headlamps and then start the engine. 11. Immediately after setting the headlamps to high beam and turning the heater blower switch to the high revolution position, increase the engine speed to 2,500 r/min and read the maximum current output value displayed on the ammeter. Limit: 70% of normal current output

Caution Never use clips but tighten bolts and nuts to connect the line. Otherwise loose connections (e.g. using clips) will lead to a serious accident because of high current. NOTE An inductive-type ammeter which enables measurements to be taken without disconnecting the alternator output wire should be recommended. 5. Connect a voltmeter with a range of 0 - 20 V between the alternator “B” terminal and the earth. (Connect the (+) lead of the voltmeter to the “B” terminal, and then connect the ( - ) lead of the voltmeter to the earth.) 6. Connect the negative battery cable. 7. Connect a tachometer or the MUT-II. 8. Leave the hood open. 9. Check that the reading on the voltmeter is equal to the battery voltage. NOTE If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the alternator “B” terminal and the battery (+) terminal.

12.

13. 14. 15. 16. 17. 18. 19.

NOTE D For the nominal current output, refer to the Alternator Specifications. D Because the current from the battery will soon drop after the engine is started, the above step should be carried out as quickly as possible in order to obtain the maximum current output value. D The current output value will depend on the electrical load and the temperature of the alternator body. D If the electrical load is small while testing, the specified level of current may not be output even though the alternator is normal. In such cases, increase the electrical load by leaving the headlamps turned on for some time to discharge the battery or by using the lighting system in another vehicle, and then test again. D The specified level of current also may not be output if the temperature of the alternator body or the ambient temperature is too high. In such cases, cool the alternator and then test again. The reading on the ammeter should be above the limit value. If the reading is below the limit value and the alternator output wire is normal, remove the alternator from the engine and check the alternator. Run the engine at idle after the test. Turn the ignition switch off. Remove the tachometer or the MUT-II. Disconnect the negative battery cable. Disconnect the ammeter and voltmeter. Connect the alternator output wire to the alternator “B” terminal. Connect the negative battery cable.

16-7

ENGINE ELECTRICAL - Charging System REGULATED VOLTAGE TEST Ignition switch

Load

Charging warning lamp

MB991519

Alternator FR L S

Alternator relay

G

B Yellow

EngineECU

Battery

Ammeter Voltmeter

-

+

This test determines whether the voltage regulator is correctly controlling the alternator output voltage. 1. Always be sure to check the following before the test. D Alternator installation D Check that the battery installed in the vehicle is fully charged. D Alternator drive belt tension D Fusible link D Abnormal noise from the alternator while the engine is running 2. Turn the ignition switch off. 3. Disconnect the negative battery cable. 4. Use the special tool (Alternator test harness: MB991519) to connect a digital voltmeter between the alternator S terminal and earth. (Connect the (+) lead of the voltmeter to the ”S” terminal, and then connect the (-) lead of the voltmeter to a secure earth or to the battery (-) terminal.) 5. Disconnect the alternator output wire from the alternator “B” terminal.

+

-

6. Connect a DC test ammeter with a range of 0 - 100 A in series between the “B” terminal and the disconnected output wire. (Connect the (+) lead of the ammeter to the “B” terminal. Connect the ( - ) lead of the ammeter to the disconnected output wire.) 7. Reconnect the negative battery cable. 8. Connect a tachometer or the MUT-II. 9. Turn the ignition switch to the ON position and check that the reading on the voltmeter is equal to the battery voltage. NOTE If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the alternator “S” terminal and the battery (+) terminal. 10. 11. 12. 13.

Turn all lamps and accessories off. Start the engine. Increase the engine speed to 2,500 r/min. Read the value displayed on the voltmeter when the alternator output current alternator becomes 10 A or less.

16-8

ENGINE ELECTRICAL - Charging System

14. If the voltage reading conforms to the value in the voltage regulation, then the voltage regulator is operating normally. If the voltage is not within the standard value, there is a malfunction of the voltage regulator or of the alternator. 15. After the test, lower the engine speed to the idle speed. 16. Turn the ignition switch off.

17. 18. 19. 20.

Remove the tachometer or the MUT-II. Disconnect the negative battery cable. Disconnect the ammeter and voltmeter. Connect the alternator output wire to the alternator “B” terminal. 21. Remove the special tool, and return the connector to the original condition. 22. Connect the negative battery cable.

Voltage Regulation Table Standard value: Inspection terminal

Voltage regulator ambient temperature _C

Voltage V

Terminal “S”

- 20

14.2 - 15.4

20

13.9 - 14.9

60

13.4 - 14.6

80

13.1 - 14.5

16-9

ENGINE ELECTRICAL - Charging System Special patterns pickup

Alternator

Analyzer

WAVEFORM CHECK USING AN ANALYZER MEASUREMENT METHOD Connect the analyzer special patterns pick-up to the alternator B terminal.

B terminal

STANDARD WAVEFORM Observation Conditions FUNCTION

SPECIAL PATTERNS

PATTERN HEIGHT

VARIABLE

VARIABLE knob

Adjust while viewing the waveform.

PATTERN SELECTOR

RASTER

Engine speed

Curb idle speed

0.4 0.2 Voltage at alternator B terminal

0 - 0.2 - 0.4

Time

NOTE The voltage waveform of the alternator B terminal can undulate as shown at left. This waveform is produced when the regulator operates according to fluctuations in the alternator load (current), and is normal for the alternator. In addition, when the voltage waveform reaches an excessively high value (approx. 2 V or higher at idle), it often indicates an open circuit due to a brown fuse between alternator B terminal and battery, but not a defective alternator.

16-10

ENGINE ELECTRICAL - Charging System

EXAMPLES OF ABNORMAL WAVEFORMS NOTE 1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the analyzer. 2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not operating). (Waveforms can be observed when the headlamps are illuminated.) 3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging system totally. Abnormal waveforms

Problem cause

Abnormal waveforms

Problem cause

Example 1

D

Open diode

Example 4

D

Short in stator coil

Example 2

D

Short in diode

Example 5

D

Open supplementary diode

Example 3

D

Broken wire in stator coil

At this time, the charging warning lamp is illuminated.

Alternator relay

1

2

3

4

ALTERNATOR RELAY CONTINUITY CHECK 1. Remove the alternator relay from the relay box inside the engine compartment. 2. Set the analogue-type circuit tester to the W range and check that there is continuity when the (+) terminal of the tester is connected to terminal 2 of the alternator relay and the ( - ) terminal is connected to terminal 4. 3. Next, check that there is no continuity when the (+) terminal is connected to terminal 4 and the ( - ) terminal is connected to terminal 2. 4. If defect is found in steps 2 and 3 above, replace the alternator relay.

ENGINE ELECTRICAL - Charging System

ALTERNATOR

16-11 16100140286

REMOVAL AND INSTALLATION Pre-removal Operation Under Cover and Side Cover (R.H. side) Removal

Post-installation Operation D Drive Belt Tension Adjustment (Refer to GROUP 11 - On-vehicle Service.) D Under Cover and Side Cover (R.H. side) Installation

<4G6>

5

3

20 - 25 Nm

1 2

24 Nm

4 49 Nm

<4G9> 20 - 25 Nm

5

1

3

2

49 Nm

4 44 Nm

Removal steps 1. Drive belt (Power steering, A/C) 2. Drive belt (Alternator) 3. Alternator connector

4. Alternator 5. Alternator brace

16-12

ENGINE ELECTRICAL - Charging System

DISASSEMBLY AND REASSEMBLY

1 4

3

5 7

6

2

12 10 9 8

14 13 11

AA" AB"

Disassembly steps 1. Front bracket assembly 2. Alternator pulley AB" 3. Rotor 4. Rear bearing 5. Bearing retainer 6. Front bearing 7. Front bracket

AC"

8. 9. AC" "AA 10. 11. 12. 13. 14.

Startor Plate Regulator assembly Brush Slinger Rectifier Rear bracket

ENGINE ELECTRICAL - Charging System

16-13

DISASSEMBLY SERVICE POINTS AA" FRONT BRACKET ASSEMBLY REMOVAL Insert flat tip screwdrivers or the like in the clearance between the front bracket assembly and stator core, to pry open and separate the stator and front bracket. Caution Do not insert the screwdriver too far, or the stator coil gets damaged.

AB" ALTERNATOR PULLEY REMOVAL Face the pulley side upward, fix the rotor with a work bench and remove the pulley. Caution Use care not to damage the rotor.

Soldered

AC" STATOR/REGULATOR ASSEMBLY REMOVAL 1. Unsolder the stator with a soldering iron (180 to 250W). Complete this work within four seconds not to transfer heat to the diode. 2. When removing the rectifier from the regulator assembly, remove the soldered sections of the rectifier. Caution (1) Use care to make sure that the heat of the soldering iron is not transmitted to the diodes for a long period. (2) Use care that no undue force is exerted to the lead wires of the diodes.

16-14

ENGINE ELECTRICAL - Charging System REASSEMBLY SERVICE POINTS Wire

"AA REGULATOR ASSEMBLY INSTALLATION After installing the regulator assembly, insert a wire into the hole provided on the rear bracket while pressing in the brush to fix the brush. NOTE The brush is fixed when a wire is inserted, making rotor installation easier.

Rear bracket Brush Wire

Wire

"BA ROTOR INSTALLATION After installing the rotor, remove the wire used to fix the brush.

INSPECTION

16100170216

ROTOR CHECK 1. Check the continuity between the rotor coil slip rings, and replace the rotor if the resistance value is not at the standard value. Standard value: 3 - 5 W

2. Check the continuity between the slip ring and core, and if there is continuity, replace the rotor.

ENGINE ELECTRICAL - Charging System

16-15

STATOR CHECK 1. Check the continuity between the coil leads, and if there is continuity, replace the stator.

2. Check the continuity between the coil and core, and if there is continuity, replace the stator.

RECTIFIER CHECK 1. Inspect the (+) heat sink by checking the continuity between the (+) heat sink and stator coil lead wire connection terminal using a tester probe. If there is a continuity at both, the diode is short circuited, so replace the rectifier.

2. Inspect the ( - ) heat sink by checking the continuity between the ( - ) heat sink and stator coil lead wire connection terminal using a tester probe. If there is a continuity at both, the diode is short circuited, so replace the rectifier.

3. Check the diode trio by connecting an ohmmeter to both ends of each diode and check the continuity of the three diodes. If there is a continuity at both ends, or if there is no continuity, the diode is damaged so replace the rectifier.

16-16

ENGINE ELECTRICAL - Charging System BRUSH CHECK 1. Measure the length of the brush protrusion shown in the illustration, and replace the brush if the measured value is below the limit value. Limit: 2 mm or less

Protrusion length

Soldered

2. The brush can be removed if the solder of the brush lead wire is removed. 3. When installing a new brush, insert the brush into the holder as shown in the illustration, and then solder the lead wires.

16-17

ENGINE ELECTRICAL - Starting System

STARTING SYSTEM GENERAL INFORMATION If the ignition switch is turned to the ”START” position, current flows in the pull-in and holding coils provided inside magnetic switch, attracting the plunger. When the plunger is attracted, the lever connected to the plunger is actuated to engage the starter clutch. On the other hand, attracting the plunger will turn on the magnetic switch, allowing the B terminal

and M terminal to conduct. Thus, current flows to engage the starter motor. When the ignition switch is returned to the “ON” position after starting the engine, the starter clutch is disengaged from the ring gear. An overrunning clutch is provided between the pinion and the armature shaft, to prevent damage to the starter.

SYSTEM DIAGRAM Pull-in coil

Holding coil Plunger Lever Over-running clutch Pinion shaft

Ignition switch Armature Battery

Brush

Yoke

STARTER MOTOR SPECIFICATIONS Items

4G9

4G6

Type

Reduction drive with planetary gear

Reduction drive with planetary gear

Rated output kW/V

1.2/12

1.4/12

No. of pinion teeth

8

8

SERVICE SPECIFICATIONS Items

Standard value

Limit

Pinion gap mm

0.5 - 2.0

-

Commutator outer diameter mm

29.4

28.8

Commutator runout mm

0.05

0.1

Commutator undercut mm

0.5

0.2

16-18

ENGINE ELECTRICAL - Starting System

STARTER MOTOR

Switch

<4G9>

INSPECTION

S B

M

PINION GAP ADJUSTMENT 1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect a 12V battery between S-terminal and M-terminal. 3. Set switch to “ON”, and pinion will move out.

Battery

Wire

<4G6>

Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning.

Switch S

Battery

M

B

Wire

4. Check pinion to stopper clearance (pinion gap) with a thickness gauge. Pinion gap: 0.5 - 2.0 mm

Stopper Pinion gap Pinion

5. If pinion gap is out of specification, adjust by adding or removing gaskets between magnetic switch and front bracket.

ENGINE ELECTRICAL - Starting System <4G9> S M

Battery

16-19

MAGNETIC SWITCH PULL-IN TEST 1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect a 12V battery between S-terminal and M-terminal. Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning.

Wire

3. If pinion moves out, then pull-in coil is good. If it doesn’t, replace magnetic switch. <4G6> S Battery

M

Wire

<4G9> S Battery

Wire

MAGNETIC SWITCH HOLD-IN TEST 1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect a 12V battery between S-terminal and body. Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning. 3. Manually pull out the pinion as far as the pinion stopper position. 4. If pinion remains out, everything is in order. If pinion moves in, hold-in circuit is open. Replace magnetic switch.

<4G6> S Battery

Wire

16-20

ENGINE ELECTRICAL - Starting System

<4G9>

Carbon-pile rheostat

S

Ammeter

M

B

A

Starter motor

Battery

V Voltmeter

Carbon-pile rheostat

<4G6> S

Ammeter

B

M

Battery Starter motor

Voltmeter

<4G9>

M

Battery

Wire

FREE RUNNING TEST 1. Place starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter motor as follows: 2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat in series with battery positive post and starter motor terminal. 3. Connect a voltmeter (15-volt scale) across starter motor. 4. Rotate carbon pile to full-resistance position.

5. Connect battery cable from battery negative post to starter motor body. 6. Adjust the rheostat until the battery voltage shown by the voltmeter is 11 V. 7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely. Current: max. 90 Amps

MAGNETIC SWITCH RETURN TEST 1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect a 12V battery between M-terminal and body. Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning. 3. Pull pinion out and release. If pinion quickly returns to its original position, everything is in order. If it doesn’t, replace magnetic switch. Caution Be careful not to get your fingers caught when pulling out the pinion.

<4G6>

Battery

M

Wire

16-21

ENGINE ELECTRICAL - Starting System DISASSEMBLY AND REASSEMBLY 2

13 16

14

12

11

15 21

1

4

18

19

20 3

17

8

22

5

7 6 9

10

AA"

AB" AB"

Disassembly steps 1. Screw 2. Magnetic switch 3. Screw 4. Through bolt 5. Rear bracket 6. Brush holder 7. Brush 8. Rear bearing 9. Armature 10. Yoke assembly 11. Ball

12. 13. 14. 15. 16. AC" "AA 17. AC" "AA 18. 19. 20. 21. 22.

Packing A Packing B Plate Planetary gear Lever Snap ring Stop ring Overrunning clutch Internal gear Planetary gear holder Front bracket

16-22 Magnetic switch

ENGINE ELECTRICAL - Starting System S terminal M terminal

DISASSEMBLY SERVICE POINTS AA" MAGNETIC SWITCH REMOVAL Disconnect the field coil wire from terminal M of the magnetic switch.

Field coil wire

AB" ARMATURE AND BALL REMOVAL When removing the armature, do not lose the ball placed at the end as a bearing.

Socket Stop ring

AC" SNAP RING/STOP RING REMOVAL 1. Using an appropriate wrench socket, push the stop ring toward the overrunning clutch.

Pinion gear Overrunning clutch

Snap ring

Snap ring pliers

2. Remove the snap ring with snap ring pliers and then remove the stop ring and overrunning clutch.

Pinion gear Overrunning clutch

STARTER MOTOR PARTS CLEANING 1. Do not immerse the parts in cleaning solvent. Immersing the yoke and field coil assembly and/or armature will damage insulation. Wipe these parts with a cloth only. 2. Do not immerse the drive unit in cleaning solvent. The overrunning clutch is pre-lubricated at the factory and solvent will wash lubrication from clutch. 3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.

ENGINE ELECTRICAL - Starting System

16-23

REASSEMBLY SERVICE POINTS "AA STOP RING/SNAP RING INSTALLATION Using an appropriate tool, pull the stop ring over the snap ring. Stop ring Stop ring

Overrunning clutch Snap ring

INSPECTION COMMUTATOR 1. Place the armature in a pair of “V” blocks and check the runout with a dial indicator. Standard value: 0.05 mm Limit: 0.1 mm

2. Measure the commutator outer diameter. Standard value: 29.4 mm Limit: 28.8 mm

3. Check the undercut depth between segments. Undercut Segment

Mica

Free Lock

Standard value: 0.5 mm Limit: 0.2 mm

OVERRUNNING CLUTCH 1. Check that the pinion locks when it is turned counterclockwise and moves smoothly when it is turned clockwise. 2. Check the pinion for wear or damage.

16-24

ENGINE ELECTRICAL - Starting System BRUSH 1. Check the brush for roughness of the surface that contacts the commutator and check the brush length.

Wear limit line

Growler

Limit: Wear limit line 2. In case the contacting surface has been corrected or the brush has been replaced, correct the contacting surface by winding sandpaper around the commutator.

ARMATURE COIL SHORT-CIRCUIT TEST 1. Place armature in a growler. 2. Hold a thin steel blade parallel and just above while rotating armature slowly in growler. A shorted armature will cause blade to vibrate and be attracted to the core. Replace shorted armature. Caution Clean the armature checking.

surface

thoroughly before

3. Check the insulation between each commutator segment and armature coil core. If there is no continuity, the insulation is in order.

ARMATURE COIL OPEN-CIRCUIT INSPECTION Check the continuity between segments. If there is continuity, the coil is in order.

16-25

ENGINE ELECTRICAL - Ignition System

IGNITION SYSTEM GENERAL INFORMATION This system is equipped with four ignition coils with built-in power transistors for each of the cylinders. Interruption of the primary current flowing in the primary side of an ignition coil generates a high voltage in the secondary side of the ignition coil. The high voltage thus generated is applied to the spark plugs to generate sparks. The engine-ECU turns the power transistors inside the ignition coils alternately on and off. This causes the primary currents in the ignition coils to be alternately interrupted and allowed to flow to fire the cylinders in the order 1 - 3 - 4 - 2.

The engine-ECU determines which ignition coil should be controlled by means of the signals from the camshaft position sensor and the crank angle sensor. It also detects the crankshaft position, in order to provide ignition at the most appropriate timing in response to the engine operation conditions. When the engine is cold or running at high altitudes, the ignition timing is slightly advanced to provide optimum performance. Furthermore, if knocking occurs, the ignition timing is gradually retarded until knocking ceases.

SYSTEM DIAGRAM Ignition switch

Air flow sensor

Battery

Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Accelerator pedal position switch <4G6>

EngineECU

Camshaft position sensor Crank angle sensor

Ignition coil

Ignition switch-ST Detonation sensor Vehicle speed sensor Inhibitor switch

Spark plug

To tachometer

Cylinder No.

1

2

IGNITION COIL SPECIFICATION Items

Specification

Type

Molded 4-coil

SPARK PLUG SPECIFICATION Items

4G6

4G9

NGK

IZFR5B

IZFR6B

3

4

16-26

ENGINE ELECTRICAL - Ignition System

SERVICE SPECIFICATIONS SPARK PLUG Items

Standard value

Limit

Spark plug gap mm

0.5 - 0.6

0.75

Spark plug insulation resistance MW

-

1

ON-VEHICLE SERVICE + -

+

1.5 V

-

IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK PRIMARY COIL AND POWER TRANSISTOR CONTINUITY CHECK NOTE 1. An analogue-type circuit tester should be used. 2. Connect the negative ( - ) prove of the circuit tester to terminal 1. Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning and power transistor from breakage. Voltage: 1.5V

Terminal No. 1

2

3

When current is flowing When current is not flowing

SECONDARY COIL CHECK NOTE It is impossible to check the secondary coil through the continuity check as a diode is integrated in the secondary coil circuit of this ignition coil. So, check the secondary coil in the following procedure. 1. Disconnect the ignition coil connector. 2. Remove the ignition coil and install a new spark plug to the ignition coil. 3. Connect the ignition coil connector. 4. Earth the side electrode of the spark plug and crank the engine.

ENGINE ELECTRICAL - Ignition System

16-27

5. Check that spark is produced between the electrodes of the spark plug. 6. If no spark is produced, replace the ignition coil with a new one and recheck. 7. If spark is produced with the new ignition coil, replace the old one as it is faulty. If no spark is produced again, the ignition circuit is suspected as faulty. Check the ignition circuit.

SPARK PLUG CHECK AND CLEANING Caution 1. The spark plug gap for iridium plugs should not be adjusted. 2. Cleaning iridium plugs may result in damage to the iridium tip. Therefore, if cleaning is necessary because the plug is sooty, use a plug cleaner, and do not clean the plug for more than 20 seconds in order to preserve the electrodes. A wire brush should never be used. 3. The spark plugs in GDI engines are special iridium plugs in which the electrodes can become black even when the plugs are working normally. Carbon which may become deposited on these plugs burns off more readily than with conventional plugs, and so should not cause any problems with spark plug performance. Judgement of whether a spark plug is operating normally or not should be made by checking the insulation resistance.

1. Remove the ignition coils. 2. Remove the spark plugs. 3. Check the spark plug gap. Replace the spark plug if the gap exceeds the limit. Limit: 0.75 mm Standard value: 0.5 - 0.6 mm 4. Measure the spark plug insulation resistance. Replace the spark plug if the measured value is lower than the limit value. Limit: 1 MW 5. Clean the spark plug holes. 6. Install the spark plugs. 7. Install the ignition coils.

16-28

ENGINE ELECTRICAL - Ignition System CAMSHAFT POSITION SENSOR CHECK Refer to GROUP 13A - Troubleshooting <4G6> or GROUP 13B - Troubleshooting <4G9>.

CRANK ANGLE SENSOR CHECK Refer to GROUP 13A - Troubleshooting <4G6> or GROUP 13B - Troubleshooting <4G9>.

DETONATION SENSOR CHECK Check the detonation sensor circuit if self-diagnosis code, No. 31 is shown. NOTE For information concerning the self-diagnosis codes, refer to GROUP 13A - Troubleshooting <4G6> or GROUP 13B - Troubleshooting <4G9>.

ENGINE ELECTRICAL - Ignition System

IGNITION COIL

16-29 16300320174

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation

10 Nm

2

1 3 25 Nm

Removal steps 1. Ignition coil connector 2. Ignition coil 3. Spark plug

CRANK ANGLE SENSOR

16300350036

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Timing Belt Removal and Installation <4G6> (Refer to GROUP 11A.)

<4G6> 10 - 12 Nm

Crank angle sensor

9 Nm

D

Timing Belt Front Lower Cover Removal and Installation <4G9> (Refer to GROUP 11B.)

<4G9> 10 - 12 Nm

Crank angle sensor

9 Nm

16-30

ENGINE ELECTRICAL - Ignition System

CAMSHAFT POSITION SENSOR

16300340026

REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Engine Cover Removal and Installation

<4G6>

9 Nm

Camshaft position sensor

<4G9> 9 Nm

Camshaft position sensor

16-31

ENGINE ELECTRICAL - Ignition System

DETONATION SENSOR

16300280144

REMOVAL AND INSTALLATION Caution Do not subject the detonation sensor to any shocks. Pre-removal and Post-installation Operation D Engine Cover Removal and Installation D Air Cleaner Assembly Removal and Installation

D

Intake Manifold Stay Removal and Installation (Refer to GROUP 15.)

<4G6>

1 20 - 25 Nm

<4G9>

10 - 12 Nm

1 20 - 25 Nm

AA" "AA 1. Detonation sensor

REMOVAL SERVICE POINT AA" DETONATION SENSOR REMOVAL

INSTALLATION SERVICE POINT "AA DETONATION SENSOR INSTALLATION MD998773

NOTES

17-1

ENGINE AND EMISSION CONTROL CONTENTS ENGINE CONTROL SYSTEM . . . . . . . . 2

CRANKCASE EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

GENERAL INFORMATION . . . . . . . . . . . . . . . . 2

General Information . . . . . . . . . . . . . . . . . . . . . . 10

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 2 Accelerator Cable Check and Adjustment . . . . 2

System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 10 Component Location . . . . . . . . . . . . . . . . . . . . . . 10 Positive Crankcase Ventilation System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Accelerator Pedal Position Sensor Check . . . . 3

PCV Valve Check . . . . . . . . . . . . . . . . . . . . . . . . 11

ACCELERATOR CABLE AND PEDAL . . . . 4

EVAPORATIVE EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

ACCELERATOR PEDAL POSITION SENSOR <4G6> . . . . . . . . . . . . . . . . . . . . . . . . . 5

General Information . . . . . . . . . . . . . . . . . . . . . . 12

EMISSION CONTROL SYSTEM . . . . . . 6

System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 12 Component Location . . . . . . . . . . . . . . . . . . . . . . 12 Purge Control System Check . . . . . . . . . . . . . . 13

GENERAL INFORMATION . . . . . . . . . . . . . . . . 6

Purge Port Vacuum Check . . . . . . . . . . . . . . . . 13

Emission Control Device Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Purge Control Solenoid Valve Check . . . . . . . 14

SERVICE SPECIFICATION . . . . . . . . . . . . . . . 7 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 7

EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 General Information . . . . . . . . . . . . . . . . . . . . . . 15 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

VACUUM HOSE . . . . . . . . . . . . . . . . . . . . . . . . . 7

System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 15

Vacuum Hose Piping Diagram . . . . . . . . . . . . . . 7

Component Location . . . . . . . . . . . . . . . . . . . . . . 15

Vacuum Circuit Diagram . . . . . . . . . . . . . . . . . . . 9

Exhaust Gas Recirculation (EGR) Control System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Vacuum Hose Check . . . . . . . . . . . . . . . . . . . . . . 9 Vacuum Hose Installation . . . . . . . . . . . . . . . . . . 9

EGR Valve (Stepper Motor) Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

CATALYTIC CONVERTER . . . . . . . . . . . . . . 17

17-2

ENGINE AND EMISSION CONTROL - Engine Control System

ENGINE CONTROL SYSTEM

17100010102

GENERAL INFORMATION A cable-type accelerator mechanism and a suspended-type pedal have been adopted.

Accelerator pedal position sensor is used for vehicles with 4G6 engine which is equipped with the electronically-controlled fuel injection system.

SERVICE SPECIFICATION

17100030139

Items

Standard value

Accelerator cable play mm

1- 2

ON-VEHICLE SERVICE

17100090243

ACCELERATOR CABLE CHECK AND ADJUSTMENT 1. Turn A/C and lamps OFF. Inspect and adjust at no load. 2. Warm engine until stabilized at idle. 3. Confirm idle speed is at prescribed value. (Refer to GROUP 11 - On-vehicle Service.) 4. Stop engine (ignition switch OFF). 5. Confirm there are no sharp bends in accelerator cable. 6. Check inner cable for correct slack. Standard value: 1 - 2 mm

<4G6>

Adjusting nut Accelerator pedal position sensor

Lock nut

Lever

<4G9>

Adjusting bolt or adjusting nut

Plate

7. If there is too much slack or no slack, adjust play by the following procedures. <4G6> (1) Loosen the adjusting nut, and then move the lever to throttle fully-closed position. (2) Tighten the adjusting nut until the lever start to move, turn back one turn, and then tighten the lock nut to the specified torque. <4G9> (1) Loosen the adjusting bolt or adjusting nut to release the cable. (2) Move the plate until the inner cable play is at the standard value, and then tighten the adjusting bolt or adjusting nut. (3) After adjusting, check that the throttle lever is touching the stopper.

ENGINE AND EMISSION CONTROL - Engine Control System

17-3

ACCELERATOR PEDAL POSITION SENSOR 17100190011 CHECK Refer to GROUP 13A - On-vehicle Service.

17-4

ENGINE AND EMISSION CONTROL - Engine Control System

ACCELERATOR CABLE AND PEDAL

17100120256

REMOVAL AND INSTALLATION Post-installation Operation Adjusting the Accelerator P.17-2plink=17100090052.)

Cable

(Refer

to

<4G6> <4G9 - R.H. drive vehicles>

2

1

<4G9 - L.H. drive vehicles> 4

10 Nm 5 Nm

1

4

4

5 Nm

2

1

2 12 Nm

3 9

<4G6>

10

3

10 5

6

12 Nm

6 7

<4G9>

3

8 6

Removal steps 1. Adjusting bolt or adjusting nut 2. Inner cable connection (Engine side) 3. Inner cable connection (Pedal side) 4. Accelerator cable 5. Snap ring

11

6. 7. 8. 9. 10. 11.

Accelerator arm assembly Spring Pedal pad Accelerator pedal bracket Bushing Accelerator pedal stopper sub=

ENGINE AND EMISSION CONTROL - Engine Control System

ACCELERATOR PEDAL POSITION SENSOR <4G6>

17-5 17100180018

REMOVAL AND INSTALLATION Post-installation Operation Adjusting the Accelerator Cable (Refer to P.17-2.)

2

10 - 13 Nm

1

2 10 Nm

3

10 - 13 Nm

10 - 13 Nm

4

Removal steps 1. Inner cable connection 2. Accelerator pedal position sensor connector 3. Accelerator pedal position sensor assembly

4. Accelerator pedal position sensor bracket

17-6

ENGINE AND EMISSION CONTROL -

Emission Control System

EMISSION CONTROL SYSTEM GENERAL INFORMATION The emission control system consists of the following subsystems: D Crankcase emission control system D Evaporative emission control system D Exhaust emission control system Items

Name

Specification

Crankcase emission control system

Positive crankcase ventilation (PCV) valve

Variable flow type (Purpose: HC reduction)

Evaporative emission control system

Canister Purge control solenoid valve

Equipped Duty cycle type solenoid valve (Purpose: HC reduction)

Exhaust emission control system

Air-fuel ratio control device- GDI system

Oxygen sensor feedback type (Purpose: CO, HC, NOx reduction)

Exhaust gas recirculation system D EGR valve

Equipped Stepper motor type (Purpose: NOx reduction)

Catalytic converter

Monolith type (Purpose: CO, HC, NOx reduction)

EMISSION CONTROL DEVICE REFERENCE TABLE Related parts

PCV valve

Crankcase emission control system

Evaporative emission control system

Exhaust gas recirculation system

Reference page

17-11 ´

GDI system component

´

EGR valve

Catalytic converter

´

Purge control solenoid valve

Catalytic converter

Air/fuel ratio control system

17-14 ´

GROUP 13A <4G6> GROUP 13B <4G9> ´

17-17 ´

17-16

ENGINE AND EMISSION CONTROL -

Emission Control System

SERVICE SPECIFICATIONS Items

Standard value

Purge control solenoid valve coil resistance (at 20_C) W

36 - 44

EGR valve coil resistance (at 20_C) W

10 - 20

SPECIAL TOOL Tool

Number

Name

Use

MB991658

Test harness set

Inspection of EGR valve

VACUUM HOSE VACUUM HOSE PIPING DIAGRAM <4G9> From fuel pump (low-pressure) To fuel tank

P

Fuel pressure regulator (highpressure)

PCV valve

EGR valve (stepper motor) Canister Injector

Fuel pump (highpressure) Oxygen sensor

Catalytic converter

Purge control solenoid valve

17-7

17-8

ENGINE AND EMISSION CONTROL -

Emission Control System

<4G6> From fuel pump (low-pressure) To fuel tank

Fuel pressure regulator (high-pressure)

P EGR valve (stepper motor) Canister

PCV valve Injector Purge control solenoid valve

Fuel pump (high-pressure) Oxygen sensor

Catalytic converter

ENGINE AND EMISSION CONTROL -

Emission Control System

17-9

VACUUM CIRCUIT DIAGRAM

Intake manifold

Throttle body

To combustion chamber

Vacuum hose colour B: Black R: Red

From air cleaner

Purge control solenoid valve (ON: OPEN)

Canister

VACUUM HOSE CHECK 1. Using the piping diagram as a guide, check to be sure that the vacuum hoses are correctly connected. 2. Check the connection condition of the vacuum hoses, (removed, loose, etc.) and check to be sure that there are no bends or damage.

VACUUM HOSE INSTALLATION 1. When connecting the vacuum hoses, they should be securely inserted onto the nipples. 2. Connect the hoses correctly, using the vacuum hose piping diagram as a guide.

17-10

ENGINE AND EMISSION CONTROL -

Emission Control System

CRANKCASE EMISSION CONTROL SYSTEM GENERAL INFORMATION The crankcase emission control system prevents blow-by gases from escaping inside the crankcase into the atmosphere. Fresh air is sent from the air cleaner into the crankcase through the breather hose. The air becomes mixed with the blow-by gases inside the crankcase. The blow-by gas inside the crankcase is drawn into the intake manifold through the positive crankcase ventilation (PCV) valve.

The PCV valve lifts the plunger according to the intake manifold vacuum so as to regulate the flow of blow-by gas properly. In other words, the blow-by gas flow is regulated during low load engine operation to maintain engine stability, while the flow is increased during high load operation to improve the ventilation performance.

SYSTEM DIAGRAM

Ventilation hose

PCV valve

Breather hose

COMPONENT LOCATION PCV valve <4G9>

PCV valve <4G6>

ENGINE AND EMISSION CONTROL -

Emission Control System

17-11

POSITIVE CRANKCASE VENTILATION SYSTEM CHECK 1. 2. 3. 4.

Remove the ventilation hose from the PCV valve. Remove the PCV valve from the rocker cover. Reinstall the PCV valve at the ventilation hose. Start the engine and run at idle.

5. Place a finger at the opening of the PCV valve and check that vacuum of the intake manifold is felt. PCV valve

NOTE At this moment, the plunger in the PCV valve moves back and forth. 6. If vacuum is not felt, clean the PCV valve or replace it.

PCV VALVE CHECK 1. Insert a thin rod into the PCV valve from the side shown in the illustration (rocker cover installation side), and move the rod back and forth to check that the plunger moves. 2. If the plunger does not move, there is clogging in the PCV valve. In this case, clean or replace the PCV valve.

17-12

ENGINE AND EMISSION CONTROL -

Emission Control System

EVAPORATIVE EMISSION CONTROL SYSTEM GENERAL INFORMATION The evaporative emission control system prevents fuel vapours generated in the fuel tank from escaping into the atmosphere. Fuel vapours from the fuel tank flow through the fuel tank pressure control valve and vapour pipe/hose to be stored temporarily in the canister. When driving the vehicle, fuel vapours stored in the canister flow through the purge solenoid and purge port and go into the intake manifold to be

sent to the combustion chamber. When the engine coolant temperature is low or when the intake air quantity is small (when the engine is at idle, for example), the engine control unit turns the purge solenoid off to shut off the fuel vapour flow to the intake manifold. This does not only insure the driveability when the engine is cold or running under low load but also stabilize the emission level.

SYSTEM DIAGRAM Throttle body

Engine-ECU Canister

Air flow sensor

From fuel tank

Engine coolant temperature sensor Purge control solenoid valve (ON: Open) Control relay

Intake air temperature sensor Barometric pressure sensor

COMPONENT LOCATION Purge control solenoid valve <4G9>

Purge control solenoid valve<4G6>

ENGINE AND EMISSION CONTROL -

17-13

PURGE CONTROL SYSTEM CHECK

<4G9> Vacuum hose (red stripe)

1. Disconnect the vacuum hose (red stripe) from the throttle body <4G9>, intake manifold <4G6>, and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3. When the engine is cold or hot, apply a vacuum of 53 kPa, and check the condition of the vacuum. When engine is cold (Engine coolant temperature: 40_C or less)

Plug

<4G6>

Emission Control System

Plug

Vacuum hose (red stripe)

Engine condition

Normal condition

At idle

Vacuum is maintained

3,000 r/min

When engine is hot (Engine coolant temperature: 80_C or higher) Engine condition

Normal condition

At idle

Vacuum is maintained

3,000 r/min (fore approximately 3 minutes after the engine is started.)

Vacuum will leak.

PURGE PORT VACUUM CHECK

<4G9>

1. Disconnect the vacuum hose (red stripe) from the throttle body <4G9>, intake manifold <4G6> purge vacuum nipple and connect a hand vacuum pump to the nipple.

Vacuum hose (red stripe)

<4G6>

Vacuum hose (red stripe)

17-14

ENGINE AND EMISSION CONTROL -

Emission Control System

2. Start the engine and check that the vacuum remains fairly constant after racing the engine.

Vacuum

NOTE If vacuum changes, it is possible that the throttle body purge port may be clogged and require cleaning.

Engine speed (r/min)

PURGE CONTROL SOLENOID VALVE CHECK

A

B

Battery

NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (black stripe, red stripe) from the solenoid valve. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to nipple (A) of the solenoid valve (refer to the illustration at left). 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve and without applying voltage. Battery voltage

Normal condition

Applied

Vacuum leaks

Not applied

Vacuum maintained

5. Measure the resistance between the terminals of the solenoid valve. Standard value: 36 - 44 W (at 20_C)

ENGINE AND EMISSION CONTROL -

17-15

Emission Control System

EXHAUST GAS RECIRCULATION (EGR) SYSTEM GENERAL INFORMATION The exhaust gas recirculation (EGR) system lowers the nitrogen oxide (NOx) emission level. When the air/fuel mixture combustion temperature is high, a large quantity of nitrogen oxides (NOx) is generated in the combustion chamber. Therefore, this system recirculates part of emission gas from

the exhaust port of the cylinder head to the combustion chamber through the intake manifold to decrease the air/fuel mixture combustion temperature, resulting in reduction of NOx. The EGR flow rate is controlled by the EGR valve so as not to decrease the driveability.

OPERATION The EGR valve is being closed and dose not recirculate exhaust gases under one of the following conditions. Otherwise, the EGR valve is opened and recirculate exhaust gases.

D D D

The engine coolant temperature is low. The engine is at idle. The throttle valve is widely opened.

SYSTEM DIAGRAM Throttle body

EGR valve

Engine-ECU

Air flow sensor Engine control relay Battery

Engine coolant temperature sensor

Crank angle sensor Throttle position sensor

COMPONENT LOCATION EGR valve <4G6>

EGR valve <4G9>

Throttle body

Intake manifold

17-16

ENGINE AND EMISSION CONTROL -

Emission Control System

EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM CHECK Refer to GROUP 13 - Troubleshooting.

EGR VALVE (STEPPER MOTOR) CHECK

<4G9>

Checking the Operation Sound 1. Check that the operation sound of the stepper motor can be heard from the EGR valve when the ignition switch is turned to ON (without starting the engine). 2. If the operation sound cannot be heard, check the stepper motor drive circuit. Intake manifold EGR valve

NOTE If the circuit is normal, the cause is probably a malfunction of the stepper motor or of the engine-ECU.

<4G6> Throttle body

Checking the Coil Resistance 1. Disconnect the EGR valve connector. 2. Measure the resistance between the EGR valve-side connector terminal No.2 and terminal No.1 or terminal No.3. Standard value: 10 - 20 W (at 20_C) 3. Measure the resistance between the EGR valve-side connector terminal No.5 and terminal No.4 or terminal No.6. Standard value: 10 - 20 W (at 20_C)

ENGINE AND EMISSION CONTROL -

17-17

Operation Check 1. Remove the EGR valve. 2. Connect the special tool (test harness set) to the EGR valve-side connector. 3. Connect terminal No.2 and terminal No.5 to the positive (+) terminal of power supply of approximately 6 V. 4. Connect each clip to the negative ( - ) terminal of power supply in the order given below to test if any vibration occurs (as though the stepper motor is shaking slightly) due to the operation of the stepper motor.

EGR valve

Battery

Emission Control System

MB991658

(1) Connect terminal No.1 and terminal No.4 to negative ( - ) terminal of the power supply. (2) Connect terminal No.3 and terminal No.4 to negative ( - ) terminal of the power supply. (3) Connect terminal No.3 and terminal No.6 to negative ( - ) terminal of the power supply. (4) Connect terminal No.1 and terminal No.6 to negative ( - ) terminal of the power supply. (5) Connect terminal No.1 and terminal No.4 to negative ( - ) terminal of the power supply. (6) Repeat the test in the order from (5) to (1).

the the the the the

5. If the results of testing show that the vibration could be felt, the stepper motor is normal.

CATALYTIC CONVERTER

17500270021

REMOVAL AND INSTALLATION

Catalytic converter

49 Nm 49 Nm

NOTES