Ec cd20 PDF

ENGINE CONTROL SYSTEM
SECTION EC
EC
CONTENTS
CD20T Disassembly and Assembly..................................... 26
ON BOARD DIAGNOSTIC SYSTEM
PRECAUTIONS AND PREPARATION.......................... 3
DESCRIPTION ............................................................. 27
Special Service Tools ................................................ 3
CONSULT-II ............................................................. 27
Engine Fuel & Emission Control System .................. 5
TROUBLE DIAGNOSIS - INTRODUCTION................ 33
Supplemental Restraint System (SRS) AIR
Introduction .............................................................. 33
BAG and SEAT BELT PRE-TENSIONER............. 6
Diagnostic Worksheet.............................................. 34
Precautions for On Board Diagnostic (OBD)
TROUBLE DIAGNOSIS - WORK FLOW .................... 35
System of Engine ...................................................... 6
Work Flow................................................................ 35
Precautions ................................................................ 7
Description for Work Flow ....................................... 36
ENGINE AND EMISSION CONTROL OVERALL
TROUBLE DIAGNOSIS - BASIC INSPECTION......... 37
SYSTEM......................................................................... 9
Basic Inspection....................................................... 37
Engine Control Module Component Parts
TROUBLE DIAGNOSIS - GENERAL
Location ..................................................................... 9
DESCRIPTION ............................................................. 39
Circuit Diagram .........................................................11
Diagnostic Trouble Chart ......................................... 39
System Diagram ...................................................... 12
Symptom Matrix Chart............................................. 47
Vacuum Hose Drawing ............................................ 13
CONSULT-II Reference Value in Data Monitor
System Chart ........................................................... 14
Mode ........................................................................ 50
ENGINE AND EMISSION BASIC CONTROL
Major Sensor Reference Graph in Data Monitor
SYSTEM DESCRIPTION ............................................. 15
Mode ........................................................................ 51
Glow Control System............................................... 15
ECM Terminals and Reference Value ..................... 52
Fuel Injection System .............................................. 15
TROUBLE DIAGNOSIS FOR POWER SUPPLY........ 59
Fuel Injection Timing System .................................. 18
Main Power Supply and Ground Circuit.................. 59
Air Conditioning Cut Control.................................... 20
TROUBLE DIAGNOSIS 1............................................ 62
Cooling Fan Control................................................. 20
Mass Air Flow Sensor (MAFS) ................................ 62
CRANKCASE VENTILATION SYSTEM...................... 21
Description ............................................................... 21
Engine Coolant Temperature (ECT) Sensor ........... 66
Blow-by Control Valve ............................................. 21
Ventilation Hose....................................................... 21
Vehicle Speed Sensor (VSS) .................................. 70
INJECTION NOZZLE................................................... 22
Removal and Installation ......................................... 22
Control Sleeve Position Sensor (CSPS) ................. 74
Test and Adjustment ................................................ 22
ELECTRONIC FUEL INJECTION PUMP.................... 24
Electric Governor ..................................................... 78
Removal................................................................... 24
Installation................................................................ 25
Injection Timing Control Valve ................................. 82 TROUBLE DIAGNOSES 15 ...................................... 126
TROUBLE DIAGNOSIS 7............................................ 86 Air Conditioner Cut Control ................................... 126
Engine Control Module (ECM) ................................ 86 TROUBLE DIAGNOSES 16 ...................................... 129
TROUBLE DIAGNOSIS 8............................................ 87 EGRC-Solenoid Valve ........................................... 129
Cooling Fan (Overheat) ........................................... 87 TROUBLE DIAGNOSES 17 ...................................... 136
TROUBLE DIAGNOSIS 9............................................ 97 Brake Switch.......................................................... 136
Needle Lift Sensor (NLS) ........................................ 97 TROUBLE DIAGNOSES 18 ...................................... 140
TROUBLE DIAGNOSIS 10........................................ 100 ECM Relay............................................................. 140
Fuel Cut Solenoid Valve ........................................ 100 TROUBLE DIAGNOSES 19 ...................................... 141
TROUBLE DIAGNOSIS 11........................................ 104 MI & Data Link Connectors ................................... 141
Fuel Temperature Sensor (FTS)............................ 104 TROUBLE DIAGNOSES 20 ...................................... 145
TROUBLE DIAGNOSIS 12........................................ 108 Start Signal ............................................................ 145
Accelerator Position Sensor & Switch................... 108 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 147
TROUBLE DIAGNOSIS 13.........................................114 General Specifications........................................... 147
Crankshaft Position Sensor (TDC) .........................114 Injection Nozzle ..................................................... 147
TROUBLE DIAGNOSES 14 .......................................118 Inspection and Adjustment .................................... 147
Glow Control System..............................................118
When you read wiring diagrams:

Read GI section, HOW TO READ WIRING DIAGRAMS.
See EL section, POWER SUPPLY ROUTING for power distribution circuit.
See EL section for NATS information and wiring diagram.
When you perform trouble diagnoses, read GI section, HOW TO FOLLOW FLOW CHART
IN TROUBLE DIAGNOSES and HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN
ELECTRICAL INCIDENT.
For clarification of system component abbreviations and terminology read GI section
SAE J1930 TERMINOLOGY LIST.
EC-2
PRECAUTIONS AND PREPARATION CD20T
Special Service Tools

Tool number
Description
Tool name
KV11289004
Nozzle cleaning kit
p1 KV11290012
Box
p2 KV11290110
Brush
p3 KV11290122
Nozzle oil sump
scraper
p4 KV11290140
Nozzle needle tip
cleaner
p5 KV11290150
Nozzle seat scraper
p6 KV11290210
Nozzle holder
p7 KV11290220
Nozzle hole clean-
ing needle
NT296
KV109E0010
Break-out box
NT825
KV109E0050
Y-cable adapter
NT826
KV11292010
Nozzle centering device
NT293
KV11100300
No. 2-4 injection nozzle
holder socket
NT563
EC-3
Special Service Tools (Contd)
Tool number
Description
Tool name
KV119E0030
No. 1 injection nozzle
holder socket
NT648
EC-4
Engine Fuel & Emission Control System
ECM (ECCS-D control module) WIRELESS EQUIPMENT

Do not disassemble ECM. When installing C.B. ham radio or a mobile
If a battery terminal is disconnected, the memory phone, be sure to observe the following as it
will return to the ECM value. may adversely affect electronic control sys-
The ECM will now start to self-control at its initial tems depending on its installation location.
value. Engine operation can vary slightly when 1) Keep the antenna as far as possible away
the terminal is disconnected. However, this is not from the ECM.
an indication of a problem. Do not replace parts 2) Keep the antenna feeder line more than
because of a slight variation. 20 cm (7.9 in) away from the harness of elec-
When ECM is removed for inspection, make sure tronic controls.
to ground the ECM mainframe. Do not let them run parallel for a long dis-
tance.
3) Adjust the antenna and feeder line so that the
BATTERY standing-wave ratio can be kept small.
Always use a 12 volt battery as power 4) Be sure to ground the radio to vehicle body.
source.
Do not attempt to disconnect battery cables
while engine is running.
ECM mainframe
ELECTRONIC FUEL INJECTOR PUMP
Do not disconnect pump harness connectors
with engine running.
Do not disassemble or adjust electronic fuel
injection pump, except for the following
parts.
Camshaft position sensor (pump)
Injection timing control valve
Fuel cut solenoid valve
ECM PARTS HANDLING

Handle mass air flow sensor carefully to avoid
damage.
Do not disassemble mass air flow sensor.
Do not clean mass air flow sensor with any type
of detergent.
Do not disassemble No. 1 injection nozzle (built- WHEN STARTING ECM HARNESS HANDLING
in needle lift sensor). Do not depress accelerator pedal when Connect ECM harness connectors securely.
Even a slight leak in the air intake system can starting. A poor connection can cause an extremely
cause serious problems. Immediately after starting, do not rev up high (surge) voltage to develop in coil and
Do not shock or jar the camshaft position sensor engine unnecessarily. condenser, thus resulting in damage to ICs.
(TDC). Do not rev up engine just prior to shut- Keep ECM harness at least 10 cm (3.9 in)
down. away from adjacent harnesses, to prevent an
ECM system malfunction due to receiving
external noise, degraded operation of ICs,
etc.
Keep ECM parts and harnesses dry.
Before removing parts, turn off ignition
switch and then disconnect battery ground
cable.
NEF390
EC-5
Supplemental Restraint System (SRS) AIR

BAG and SEAT BELT PRE-TENSIONER
NCEC0002
The Supplemental Restraint System AIR BAG and SEAT BELT PRE-TENSIONER, used along with a seat
belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The
Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and
on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning
lamp, wiring harness and spiral cable.
In addition to the supplemental air bag modules for a frontal collision, the supplemental side air bag used
along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a
side collision. The supplemental side air bag consists of air bag modules (located in the outer side of front
seats), satellite sensor, diagnosis sensor unit (one of components of supplemental air bags for a frontal
collision), wiring harness, warning lamp (one of components of supplemental air bags for a frontal collision).
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN dealer.
Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses (except SEAT BELT PRE-TENSIONER connector) can be
identified with yellow harness connector (and with yellow harness protector or yellow insulation
tape before the harness connectors).
Precautions for On Board Diagnostic (OBD)

System of Engine
NCEC0003
The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver
of a malfunction causing emission deterioration.
CAUTION:
Be sure to turn the ignition switch OFF and disconnect the negative battery terminal before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves,
etc. will cause the MI to light up.
Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector
will cause the MI to light up due to the open circuit. (Be sure the connector is free from water,
grease, dirt, bent terminals, etc.)
Certain systems and components, especially those related to OBD, may use a new style slide-
locking type harness connector.
For description and how to disconnect, refer to EL section, Description, HARNESS CONNEC-
TOR.
Be sure to route and secure the harnesses properly after work. The interference of the harness
with a bracket, etc. may cause the MI to light up due to the short circuit.
Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber
tube may cause the MI to light up due to the malfunction of the EGR system or fuel injection
system, etc.
Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM
before returning the vehicle to the customer.
EC-6
Precautions
Before connecting or disconnecting the ECM harness
connector, turn ignition switch OFF and disconnect
negative battery terminal. Failure to do so may damage
the ECM because battery voltage is applied to ECM even
if ignition switch is turned off.
SEF289H
When connecting ECM harness connectors, push in

both sides of the connector until you hear a click.
Maneuver the lever until you hear the three connectors
on the inside click. Refer to the figure at left.
SEF881Y
Before replacing ECM, perform Terminals and Reference

Value inspection and make sure ECM functions properly.
Refer to EC-CD-52.
MEF040D
If MI illuminates or blinks irregularly during engine

running, water may have accumulated in fuel filter. Drain
water from fuel filter. If this does not correct the problem,
perform specified trouble diagnostic procedures.
After performing each TROUBLE DIAGNOSIS, perform
OVERALL FUNCTION CHECK or DTC (Diagnostic
Trouble Code) CONFIRMATION PROCEDURE.
The DTC should not be displayed in the DTC CONFIR-
MATION PROCEDURE if the repair is completed. The
OVERALL FUNCTION CHECK should be a good result
SAT652J if the repair is completed.
EC-7
Precautions (Contd)
When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact.
Accidental contact of probes will cause a short circuit
and damage the ECM power transistor.
SEF348N
EC-8
ENGINE AND EMISSION CONTROL OVERALL SYSTEM CD20T

Location
YEC133A
EC-9
Location (Contd)
YEC134A
EC-10
Circuit Diagram
YEC099A
EC-11
System Diagram
YEC125A
EC-12
Vacuum Hose Drawing
YEC131A
p
1 EGRC-solenoid valves A and B to EGR valve
p
2 EGRC-solenoid valves A and B to air duct
p
3 EGRC-solenoid valve A to vacuum pump
Refer to System Diagram on previous page for vacuum control system.
EC-13
System Chart
Crankshaft position sensor E E Fuel injection control E Electric governor

(TDC)
Control sleeve position sensor E
E Fuel injection timing control E Injection timing control

valve
Fuel temperature sensor E
Mass air flow sensor E

E Fuel cut control E Fuel cut solenoid valve
Engine coolant temperature E

sensor
E Glow control system E Glow relay & glow lamp

Needle lift sensor E
Accelerator position sensor E

E On board diagnostic system E Malfunction indicator
ECM (On the instrument panel)
Accelerator position switch E
Air conditioner switch E

E EGR valve control E EGRC-solenoid valve A & B
Ignition switch (ON & ST POS.) E
E Cooling fan control E Cooling fan relays

Battery voltage E
Vehicle speed sensor or ABS E

actuator and electric unit (con-
trol unit) E Air conditioning cut control E Air conditioner relay
Brake switch E
E Cooling fan motor control E Cooling fan relay

Atmospheric pressure sensor E
EC-14
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION CD20T
Glow Control System

SYSTEM DESCRIPTION
Engine speed
Crankshaft position sensor (TDC) Glow relay Glow plugs
E E E
ECM
Engine coolant temperature
Engine coolant temperature sensor Glow lamp
E E
When coolant temperature is lower than 75C (167F):

Ignition switch ON
After the ignition switch has been turned to ON, the glow
relay turns ON for a period of time depending on the engine
coolant temperature, allowing current to flow through the
glow plugs.
Starting
After starting the engine, current will flow through the glow
plugs for 300 seconds, or until the coolant temperature
exceeds 50C (122F).
Fuel Injection System

SYSTEM DESCRIPTION
Three types of fuel injection control are provided to accommodate the engine operating conditions; normal
control, idle control and start control. The ECM determines the appropriate fuel injection control. Under each
control, the amount of fuel injected is compensated to improve engine performance. The ECM performs duty
cycle control on the electric governor (built into the fuel injection pump) according to sensor signals to com-
pensate the amount of fuel injected to the preset value.
START CONTROL
Input/output signal line
Engine coolant temperature sensor E
Engine speed Electric

Crankshaft position sensor (TDC) E ECM E governor
Control sleeve position
When starting, the ECM adapts the fuel injection system for the
start control. The amount of fuel injected at engine starting is a
Coolant temperature preset program value in the ECM. The program is determined by
Fuel injection volume
getting lower
the engine speed and engine coolant temperature.
For better startability under cool engine conditions, the lower the
coolant temperature becomes, the greater the amount of fuel
injected. The ECM ends the start control when the engine speed
reaches a coolant temperature dependent value.
Engine rpm
SEF648S
EC-15
Fuel Injection System (Contd)
IDLE CONTROL
Engine speed
Crankshaft position sensor (TDC) E
Air conditioner operation

Air conditioner switch E
ECM Electric
Control sleeve position E governor
Idle position
Accelerator position switch E
Vehicle speed
Vehicle speed sensor or ABS actuator E
and electric unit (control unit)
When the ECM determines that the engine speed is at idle, the fuel injection system is adapted for the idle
control. The ECM regulates the amount of fuel injected corresponding to changes in load applied to the
engine to keep engine speed constant. During the first 270s after a cold start, the ECM also provides the
system with a fast idle control in response to the engine coolant temperature.
NORMAL CONTROL
Engine speed

Electric
Accelerator position ECM E governor
Accelerator position sensor E
Vehicle speed
Vehicle speed sensor or ABS actuator E
The amount of fuel injected under normal driving conditions is

determined according to sensor signals. The crankshaft position
sensor (TDC) detects engine speed and the accelerator position
Fuel injection volume
sensor detects accelerator position. These sensors send signals

Accelerator to the ECM.
opening larger
The fuel injection data, predetermined by correlation between
various engine speeds and accelerator positions, are stored in
the ECM memory, forming a map. The ECM determines the
optimal amount of fuel to be injected using the sensor signals in
Engine rpm
comparison with the map.
SEF649S
EC-16
Fuel Injection System (Contd)
FUEL TEMPERATURE COMPENSATION
Fuel temperature
Engine speed ECM Electric

Crankshaft position sensor (TDC) E E governor

The amount of fuel leaking at or around high-pressure parts inside the fuel injection pump varies with fuel
temperature and engine speed. This will result in a difference between the target amount of fuel injected and
the actual amount. The ECM compensates for the actual amount depending on the signal from the fuel
temperature sensor, the control sleeve position sensor and the crankshaft position sensor.
DECELERATION CONTROL
Accelerator position
Accelerator sensor E
Electric
ECM E governor
Engine speed
Camshaft position sensor (PUMP) E
The ECM cuts power supply delivery to the electric governor during deceleration for better fuel efficiency.
The ECM determines the time of deceleration according to signals from the accelerator sensor and cam-
shaft position sensor (PUMP).
EC-17
Fuel Injection Timing System

SYSTEM DESCRIPTION
The fuel injection timing system determines the optimal fuel injection timing, based on engine speed, injec-
tion quantity, engine coolant temperature and atmospheric pressure. The timing is formed by a basic value
(Basic Control) and two correction values. By performing a duty cycle signal on the timing control valve, the
ECM allows the valve to provide optimal injection timing. The ECM also performs feedback control on the
timing control valve using the signal from the needle lift sensor which detects the actual fuel injection tim-
ing.
BASIC CONTROL
Engine speed
Injection timing Injection

Needle lift sensor E ECM E timing con-
trol valve
The optimal fuel injection timing data, predetermined in propor-

BTDC tion to engine speeds and amount of fuel injected, are stored in
(degree) Fuel injection
volume the ECM memory. The ECM uses the data to control the fuel
Large
injection timing.
Fuel injection timing
Small
Engine rpm
SEF650S
HIGH ALTITUDE COMPENSATION

Engine speed
Crankshaft position sensor E

Injection
timing
E control
Atmospheric pressure ECM
Atmospheric pressure sensor E valve
Injection timing
Fuel temperature
For better drivability in high altitude areas, the fuel injection tim-
ing is advanced and the fuel quantity is reduced according to the
atmospheric pressure.
timing compensation
Normal
Fuel injection
High altitude
Engine rpm
NEF771
EC-18
Fuel Injection Timing System (Contd)
ENGINE COOLANT TEMPERATURE COMPENSATION (During driving)
Engine speed

Engine coolant temperature sensor E Injection
ECM timing con-
E
Injection timing trol valve

For better exhaust efficiency under cool engine conditions, the

fuel injection timing is controlled within a compensation range
depending on the engine speed, engine coolant temperature and
Engine coolant
amount of fuel injected.
timing compensation
temperature
Low
Fuel injection
High
Engine rpm
SEF652S
ENGINE COOLANT TEMPERATURE COMPENSATION (When starting)

Engine speed
Injection
Engine coolant temperature ECM
Engine coolant temperature sensor E E timing con-
trol valve
Ignition timing
For better startability under cool engine conditions, the fuel injec-
tion timing is compensated according to the engine coolant tem-
Engine coolant
perature.
timing compensation
temperature
Fuel injection
High
Low
Engine rpm
SEF651S
EC-19
Air Conditioning Cut Control

INPUT/OUTPUT SIGNAL LINE
Air conditioner ON signal
Air conditioner switch or ABS actuator E
Accelerator valve opening angle

Accelerator position sensor E Air
ECM E conditioner
relay
Vehicle speed
Vehicle speed sensor E

SYSTEM DESCRIPTION
This system improves acceleration when the air conditioner is used.
When the accelerator pedal is fully depressed, the air conditioner is turned off for a few seconds.
When engine coolant temperature becomes excessively high, the air conditioner is turned off. This contin-
ues until the coolant temperature returns to normal.
Cooling Fan Control

INPUT/OUTPUT SIGNAL LINE
Vehicle speed sensor or ABS actuator Vehicle speed
E
Engine coolant temperature ECM E Cooling fan relay(s)

Engine coolant temperature sensor
E
Air conditioner switch Air conditioner ON signal

E
The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, and air
conditioner ON signal. The control system has 3-step control [OFF/LOW/HIGH].
Operation
Air conditioner is OFF Air conditioner is ON
temperature C (F)
temperature C (F)
Engine coolant
Engine coolant
. .
102 (216) 102 (216)
. .
96 (205) 96 (205)
. . . .
20 80 20 80
(12) (50) (12) (50)
Vehicle speed km/h (mph) Vehicle speed km/h (mph)
Cooling fans do not operate Cooling fans operate at low speed Cooling fans operate at high speed
NEF772
EC-20
CRANKCASE VENTILATION SYSTEM CD20T
Blow-by control
Description
valve In this system blow-by gas is sucked into the air inlet pipe
through the control valve after oil separation by the oil sepa-
rator in the rocker cover.
Baffle plate
FRESH AIR
BLOW BY
GAS
SEF851S
Blow-by Control Valve

Blow-by control valve Check control valve for clogging and abnormalities.
Intake
manifold
Rocker cover
SEC586B
Ventilation Hose
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air.
If any hose cannot be freed of obstructions, replace.
SEC692
EC-21
INJECTION NOZZLE CD20T
CAUTION:
Do not disassemble injection nozzle assembly. Entrust
disassembly or adjustment to BOSCH service shop.
Plug flare nut with a cap or rag so that no dust enters the
nozzle.
Nozzle side Removal and Installation

1. Remove fuel injection tube and spill tube.
2. Remove injection nozzle assembly.
Also remove gasket from nozzle end.
3. Install injection nozzle in the reverse order of removal.
Injection nozzle to engine:
Combustion
chamber side
: 59 - 69 Nm (6.0 - 7.0 kg-m, 43 - 51 ft-lb)
Injection nozzle to tube:
: 22 - 25 Nm (2.2 - 2.5 kg-m, 16 - 18 ft-lb)
Spill tube:
NEF396
: 39 - 49 Nm (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
No. 1 injection nozzle a. Always clean the nozzle holes.
b. Always use new injection nozzle gasket.
c. Note that small washer should be installed in specified
direction.
d. Bleed air from fuel system.
NEF774
Test and Adjustment

WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to contact your hands or body, and
make sure your eyes are properly protected with goggles.
INJECTION PRESSURE TEST

1. Install nozzle to injection nozzle tester and bleed air from
flare nut.
EF791A
EC-22
INJECTION NOZZLE CD20T
Test and Adjustment (Contd)
2. Pump the tester handle slowly (one time per second) and
watch the pressure gauge.
3. Read the pressure gauge when the injection pressure just
starts dropping.
Initial injection pressure:
Used
14,423 - 15,651 kPa
(144.2 - 156.5 bar,
148 - 159 kg/cm2, 2,091 - 2,269 psi)
New
SEF672A 15,000 - 16,000 kPa
(150.0 - 160.0 bar,
153 - 163 kg/cm2, 2,175 - 2,320 psi)
Always check initial injection pressure using a new nozzle.
If the pressure is not correct, replace nozzle assembly.
LEAKAGE TEST
1. Maintain the pressure at about 981 to 1,961 kPa (9.8 to 19.6
bar, 10 to 20 kg/cm2, 142 to 284 psi) below initial injection
pressure.
2. Check that there is no dripping from the nozzle tip or around
the body.
3. If there is leakage, replace nozzle.
Good Faulty
SEF674A
SPRAY PATTERN TEST

1. Check spray pattern by pumping tester handle one full stroke
per second.
a. If main spray angle is within 30 degrees as shown, injec-
tion nozzle is good.
b. It is still normal even if a thin stream of spray deviates
from the main spray (pattern B).
2. Test again and if spray pattern is not corrected, replace
nozzle.
SEF079S
EC-23
ELECTRONIC FUEL INJECTION PUMP CD20T
6.3 - 8.2 (0.64 - 0.84, 55.6 - 72.9)
16 - 21 (1.6 - 2.1, 12 - 15)
13 - 18
(1.3 - 1.8, 9 - 13)
Front of engine
16 - 21
(1.6 - 2.1, 12 - 15)
31 - 37 (3.2 - 3.8, 23 - 27)
59 - 69 (6.0 - 7.0, 43 - 51) 49 - 59

24 - 27
(2.4 - 2.8, 17 - 20) (5.0 - 6.0, 36 - 43)
: Nm (kg-m, in-lb) 6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
: Nm (kg-m, ft-lb) 24 - 27 (2.4 - 2.8, 17 - 20) NEF777
p
1 Rear back cover p
4 Water connector p
7 Electronic fuel injection pump
p
2 Injection pump sprocket p
5 Bracket p
8 Key
p
3 Injection pump bracket p
6 Bracket
Removal
1. Remove battery.
Disconnect electronic injection pump harness connectors.
2. Set No. 1 piston at TDC on its compression stroke.

Injection timing mark
(Yellow painted mark) TDC: Crankshaft pulley notch without painted mark
3. Remove fuel hoses (supply, return and spill) and injection
tubes.
4. Remove air duct and injection pump timing belt cover.
5. Remove injection pump timing belt.
Refer to EM section (Injection Pump Timing Belt).
TDC (Without painted mark)
SEF655S
6. Remove injection pump sprocket with Tool.

Remove key from injection pump shaft and store safely.
SEF656S
EC-24
Removal (Contd)
7. Remove injection pump assembly.
SEF657S
Injection pump sprocket

Alignment Installation
Key mark
1. Install key on injection pump shaft, then install injection pump
sprocket.
2. Install injection pump timing belt.
Refer to EM section (Injection Pump Timing Belt).
3. Adjust injection timing.
Refer to Basic Inspection, EC-CD-37.
4. Install all parts removed.
NEF866

20 - 25
(2.0 - 2.5, 14 - 18)
O-ring
Washer
20 - 25 (2.0 - 2.5, 14 - 18)

: Do not reuse
: Nm (kg-m, in-lb) 7 - 10 (0.7 - 1.0, 61 - 87)
: Nm (kg-m, ft-lb)
NEF778
EC-25
Disassembly and Assembly

CAUTION:
Do not disassemble the parts not shown in the illustra-
tion above.
Before installing injection timing control valve, apply a
coat of diesel fuel to O-ring and its mating area. Insert
injection timing control valve straight into bore in fuel
pump body. After properly positioning injection timing
control valve, visually check for fuel leaks.
After assembling the parts, erase Diagnostic Trouble
Code (DTC), and perform DTC CONFIRMATION PROCE-
DURE (or OVERALL FUNCTION CHECK).
EC-26
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CD20T
CONSULT-II
Fuse box
CONSULT-II INSPECTION PROCEDURE
1. Turn off ignition switch.
2. Connect CONSULT-II to data link connector for CONSULT-
II.
(Data link connector for CONSULT-II is located behind the
fuse box cover.)
Data link connector

for CONSULT-II
NEF225A
3. Turn on ignition switch.

4. Touch START.
5. Touch ENGINE.
6. Perform each diagnostic test mode according to each service
procedure.
For further information, see the CONSULT-II Operation
Manual.
PEF895K
PEF216U
EC-27
CONSULT-II (Contd)
ENGINE CONTROL MODULE COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
DIAGNOSTIC TEST MODE
Item SELF-DIAG-
DATA ACTIVE
NOSTIC
MONITOR TEST
RESULTS
Camshaft position sensor (PUMP) *1 X *2 X
Mass air flow sensor X X
Engine coolant temperature sensor X X
Control sleeve position sensor X X X
Fuel temperature sensor X X
ENGINE CONTROL MODULE COMPONENT PARTS
Vehicle speed sensor or ABS actuator and electric unit

X X
(control unit)
Accelerator position sensor X X
INPUT Accelerator position switch X

Brake lamp switch X *2 X
Crankshaft position sensor (TDC) X X
Needle lift sensor X X
Ignition switch (start signal) X
Ignition switch (ON signal) X
Air conditioner switch X
Brake switch X
Battery voltage X
Injection timing control valve X X X
Fuel cut solenoid valve X X X
Air conditioner relay X
OUTPUT
Glow relay X X
EGRC-solenoid valve X X
Cooling fan relay X X
X: Applicable
*1: Imaginary sensor, which produces secondary engine revolution signal using needle lift sensor pulse.
*2: CONSULT-II may not display, but self-diagnostic results are available with MI.
EC-28
CONSULT-II (Contd)
SELF-DIAGNOSTIC MODE
Regarding items detected in SELF-DIAG RESULTS mode, refer to Diagnostic Trouble chart.
DATA MONITOR MODE
Monitored item ECM
Main
[Unit] input Description Remarks
signals
signals
CKPSRPM The engine speed computed from the
q q

(TDC) [rpm] crankshaft position sensor (TDC) sig-
nal is displayed.
CMPSRPM - The engine speed computed from the
q q

PUMP [rpm] camshaft position sensor (PUMP) sig-
nal is displayed.
COOLAN TEMP/S The engine coolant temperature (deter- When the engine coolant temperature
[C] or [F] mined by the signal voltage of the sensor is open or short-circuited, ECM
q q engine coolant temperature sensor) is
displayed.
enters fail-safe mode. The engine cool-
ant temperature determined by the
ECM is displayed.
VHCL SPEED SE The vehicle speed computed from the
[km/h] or [mph]
q q vehicle speed sensor signal or ABS
actuator and electric unit (control unit)
signal is displayed.
FUEL TEMP SEN The fuel temperature (determined by
q q

[C] or [F] the signal voltage of the fuel tempera-
ture sensor) is displayed.
ACCEL POS SEN
[V] q q The accelerator position sensor signal
voltage is displayed.
OFF ACCEL POS
[ON/OFF] q q Indicates [ON/OFF] condition from the
accelerator position switch signal.
C/SLEEV POS/S [V]
q q The control sleeve position sensor sig-
nal voltage is displayed.
BATTERY VOLT [V]
q q The power supply voltage of ECM is
displayed.
START SIGNAL
[ON/OFF] q q Indicates [ON/OFF] condition from the
starter signal.
After starting the engine, [OFF] is dis-
played regardless of the starter signal.
AIR COND SIG Indicates [ON/OFF] condition of the air
q q

[ON/OFF] conditioner switch as determined by
the air conditioner signal.
BRAKE SW
[ON/OFF] q Indicates [ON/OFF] condition of the
stio lamp switch.
BRAKE SW2
[ON/OFF] q Indicates [ON/OFF] condition of the
stio lamp switch 2.
IGN SW
[ON/OFF] q q Indicates [ON/OFF] condition from igni-
tion switch.
MAS AIR/FL SE [V]
q q The signal voltage of the mass air flow
sensor is displayed.
When the engine is stopped, a certain
value is indicated.
ACT INJ TIMG [] The actual injection timing angle deter-
q mined by the ECM (an approximate

average angle between injection start
and end from TDC) is displayed.
TARGET F/INJ The target fuel injection quantity
q

[mm3/STROKE] (determined by the ECM according to
the input signal) is indicated.
NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.
EC-29
CONSULT-II (Contd)
Monitored item ECM
Main
[Unit] input Description Remarks
signals
signals
FUEL CUT S/V The control condition of the fuel cut When the fuel cut solenoid valve is not
[ON/OFF] solenoid valve (determined by ECM operating, fuel supply is shut off.
according to the input signal) is indi-
cated.
OFF ... Fuel cut solenoid valve is not
operating.
ON ... Fuel cut solenoid valve is oper-
ating.
AIR COND RLY The air conditioner relay control condi-
q

[ON/OFF] tion (determined by ECM according to
the input signal) is indicated.
GLOW RLY The glow relay control condition (deter-
q

[ON/OFF] mined by ECM according to the input
signal) is displayed.
COOLING FAN Indicates the control condition of the
[LOW/HI/OFF] cooling fans (determined by ECM
q
according to the input signal).
LOW ... Operates at low speed.
HI ... Operates at high speed.
OFF ... Stopped.
EGRC SOL/V A The control condition of the EGRC-
[ON/OFF] solenoid valve (determined by ECM
according to the input signal) is indi-
cated.
OFF ... EGRC-solenoid valve is not
operating.
ON ... EGRC-solenoid valve is oper-
ating.
EC-30
CONSULT-II (Contd)
ACTIVE TEST MODE
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
Engine: Return to the original
trouble condition If trouble symptom disappears, see
TARGET F/INJ Control sleeve position sensor
Fix the target injection quantity CHECK ITEM.
using CONSULT-II.
Ignition switch: ON
Operate the cooling fan at LOW, Cooling fan moves at LOW, HI Harness and connector
COOLING FAN
HI speed and turn OFF using speed and stops. Cooling fan motor
CONSULT-II.
Ignition switch: ON
Turn solenoid valve ON and Solenoid valve makes an operating Harness and connector
FUEL CUT SOL/V
OFF with the CONSULT-II and sound. Solenoid valve
listen to operating sound.
Ignition switch: ON
Turn solenoid valve ON and Solenoid valve makes an operating Harness and connector
EGRC SOL/V A
OFF with the CONSULT-II and sound. Solenoid valve
listen to operating sound.
Ignition switch: ON (Engine
stopped)
Glow relay makes the operating Harness and connector
GLOW RLY Turn the glow relay ON and
sound. Fuel pump relay
OFF using CONSULT-II and listen
to operating sound.
Engine: Return to the original
trouble condition If trouble symptom disappears, see
INJ TIMING Adjust initial injection timing
Retard the injection timing using CHECK ITEM.
CONSULT-II.
EC-31
CONSULT-II (Contd)
REAL TIME DIAGNOSIS IN DATA MONITOR MODE
CONSULT-II has two kinds of triggers and they can be selected by touching SETTING in DATA MONI-
TOR mode.
1. AUTO TRIG (Automatic trigger):
The malfunction will be identified on the CONSULT-II screen in real time.
In other words, DTC and malfunction item will be displayed at the moment the malfunction is detected
by ECM.
DATA MONITOR can be performed continuously until a malfunction is detected. However, DATA
MONITOR cannot continue any longer after the malfunction detection.
2. MANU TRIG (Manual trigger):
Malfunction item will not be displayed automatically on CONSULT-II screen even though a malfunc-
tion is detected by ECM.
DATA MONITOR can be performed continuously even though a malfunction is detected.
Use these triggers as follows:
1. AUTO TRIG
While trying to detect the malfunction item by performing the DIAGNOSTIC TROUBLE CONFIR-
MATION PROCEDURE, be sure to select to DATA MONITOR (AUTO TRIG) mode. You can con-
firm the malfunction at the moment it is detected.
While narrowing down the possible causes, CONSULT-II should be set in DATA MONITOR (AUTO
TRIG) mode, especially in case the incident is intermittent.
Inspect the circuit by gently shaking (or twisting) suspicious connectors, components and harness in
the DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE. The moment a malfunction is found
the malfunction item will be displayed. (Refer to GI section, Incident Simulation Tests in HOW TO
PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT.)
2. MANU TRIG
If the malfunction is displayed as soon as DATA MONITOR is selected, reset CONSULT-II to MANU
TRIG. By selecting MANU TRIG you can monitor and store the data. The data can be utilized for
further diagnosis, such as a comparison with the value for the normal operating condition.
SETTING AUTO TRIG MANU TRIG

A malfunction can be A malfunction can not be
displayed on DATA displayed on DATA
MONITOR screen MONITOR screen
automatically if detected. automatically even if
detected.
PEF529Q
EC-32
TROUBLE DIAGNOSIS Introduction CD20T
Introduction
The engine has an ECM to control major systems such as fuel
injection control, fuel injection timing control, glow control
system, etc. The ECM accepts input signals from sensors and
instantly drive the electronic fuel injection pump use the data to
based on current ambient conditions. It is essential that both
input and output signals are correct and stable. At the same time,
it is important that there are no problems such as vacuum leaks,
or other problems with the engine.
SEF858S It is much more difficult to diagnose a problem that occurs inter-
mittently rather than catastrophically. Most intermittent problems
are caused by poor electric connections or faulty wiring. In this
case, careful checking of suspected circuits may help prevent the
replacement of good parts.
A visual check only may not be sufficient to determine the cause
of the problems. A road test with CONSULT-II or a circuit tester
connected should be performed. Follow the Work Flow on the
next page.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The
customer can supply good information about such problems,
SEF233G especially intermittent ones. Find out what symptoms are present
and under what conditions they occur. A Diagnostic Worksheet
like the example on next page should be used.
Start your diagnosis by looking for conventional problems first.
This will help troubleshoot driveability problems on a vehicle with
an electronically controlled engine.
SEF234G
EC-33
TROUBLE DIAGNOSIS Introduction CD20T
Diagnostic Worksheet
There are many operating conditions that lead to the malfunction
KEY POINTS
of engine components. A good grasp of such conditions can
WHAT ..... Vehicle & engine model make troubleshooting faster and more accurate.
WHEN ..... Date, Frequencies In general, each customer feels differently about a problem. It is
WHERE ..... Road conditions important to fully understand the symptoms or conditions for a
HOW ..... Operating conditions, customer complaint.
Weather conditions, Utilize a diagnostic worksheet like the one shown below in order
Symptoms to organize all the information for troubleshooting.
SEF907L
WORKSHEET SAMPLE
Customer name MR/MS Model & Year VIN
Engine # Trans. Mileage

Incident Date Manuf. Date In Service Date
l Impossible to start l No combustion l Partial combustion
l Partial combustion when warming-up engine
l Startability l Partial combustion when cooling down engine
l Possible but hard to start l Others
[ ]
l No fast idle l Unstable l High idle l Low idle
Symptoms l Idling
l Others [ ]
l Stumble l Surge l Knock l Lack of power

l Driveability
l Others [ ]
l At the time of start l While idling

l Engine stall l While accelerating l While decelerating
l Just after stopping l While loading
l Just after delivery l Recently

Incident occurrence
l In the morning l At night l In the daytime
Frequency l All the time l Under certain conditions l Sometimes

Weather conditions l Not affected
l Fine l Raining l Snowing l Others
Weather
[ ]
Temperature l Hot l Warm l Cool l Cold l Humid F
l Cold l During warm-up l After warm-up

Engine conditions
Engine speed
0 2,000 4,000 6,000 8,000 rpm
Road conditions l In town l In suburbs l Highway l Off road (up/down)

l Not affected
l At starting l While idling l At racing
l While accelerating l While cruising
Driving conditions l While decelerating l While turning (RH/LH)
Vehicle speed
0 10 20 30 40 50 60 70 80 90 100 mph
Malfunction indicator l Turned on l Not turned on
EC-34
TROUBLE DIAGNOSIS Work Flow CD20T
Work Flow
CHECK IN
H
Listen to customer complaints. (Get symptoms.) .......................................... STEP I
H
Check, print out or write down, and erase Diagnostic Trouble (malfunction item).
..................................... STEP II
Symptoms No symptoms, except MI
collected. lights up, or Malfunction
Code exists at STEP II.
H
Verify the symptom by driving in the condition the
customer described. ....................................................................................*1 STEP III
Normal Code Malfunction Code

(at STEP II) (at STEP II)
H H
Verify the malfunction item by performing the DIAGNOSTIC TROUBLE CON- .....................................*1 STEP IV
FIRMATION PROCEDURE.
H
Choose the appropriate action. ..................................... STEP V
E
*2
Malfunction Code (at STEP II or IV) Normal Code (at both STEP II and IV)
H
BASIC INSPECTION
SYMPTOM BASIS (at STEP I or III)

...........................................................E
H
Perform inspections
according to Symptom
Matrix Chart.
H H
TROUBLE DIAGNOSIS FOR SPECIFIC MAL- STEP VI
FUNCTION ITEM.
H
REPAIR/REPLACE
H
NG FINAL CHECK
Confirm that the incident is completely fixed by performing BASIC INSPECTION
..................................... STEP VII
and DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE (or OVERALL
FUNCTION CHECK). Then, erase the unnecessary (already fixed) Malfunction
Item in ECM.
OK
H
CHECK OUT
*1: If the incident cannot be duplicated, refer to GI section (Incident Simulation Tests, HOW TO PERFORM EFFICIENT
DIAGNOSIS FOR AN ELECTRICAL INCIDENT).
*2: If the on board diagnostic system cannot be performed, check main power supply and ground circuit. Refer to
TROUBLE DIAGNOSIS FOR MAIN POWER SUPPLY AND GROUND CIRCUIT, EC-CD-59.
EC-35
TROUBLE DIAGNOSIS Work Flow CD20T
Description for Work Flow

STEP DESCRIPTION
Get detailed information about the conditions and the environment when the incident/symptom occurred
STEP I
using the DIAGNOSTIC WORKSHEET as shown on the previous page.
Before confirming the concern, check and write down (print out using CONSULT-II) the malfunction item,
then erase the code. The malfunction item can be used when duplicating the incident at STEP III & IV.
STEP II
Study the relationship between the cause, specified by malfunction item, and the symptom described by the
customer. (The Symptom Matrix Chart will be useful. Refer to EC-CD-47.)
Try to confirm the symptom and under what conditions the incident occurs.
The DIAGNOSTIC WORK SHEET is useful to verify the incident. Connect CONSULT-II to the vehicle in
STEP III DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. Refer to GI section.
If the malfunction code is detected, skip STEP IV and perform STEP V.
Try to detect the malfunction item by driving in (or performing) the DIAGNOSTIC TROUBLE CONFIRMA-
TION PROCEDURE. Check and read the malfunction item by using CONSULT-II.
During the malfunction item verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR
(AUTO TRIG) mode and check real time diagnosis results.
STEP IV If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. Refer to GI section.
In case the DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE is not available, perform the OVER-
ALL FUNCTION CHECK instead. The malfunction item cannot be displayed by this check, however, this
simplified check is an effective alternative.
The NG result of the OVERALL FUNCTION CHECK is the same as the DTC detection.
Take the appropriate action based on the results of STEP I through IV.
If the malfunction code is indicated, proceed to specific TROUBLE DIAGNOSIS for the malfunction item.
STEP V
If the normal code is indicated, proceed to the BASIC INSPECTION. Refer to EC-CD-37. Then perform
inspections according to the Symptom Matrix Chart. Refer to EC-CD-47.
Identify where to begin diagnosis based on the relationship study between symptom and possible causes.
Inspect the system for mechanical binding, loose connectors or wiring damage using (tracing) Harness Lay-
outs.
Gently shake the related connectors, components or wiring harness with CONSULT-II set in DATA MONI-
TOR (AUTO TRIG) mode.
Check the voltage of the related ECM terminals or monitor the output data from the related sensors with
STEP VI
CONSULT-II. Refer to EC-CD-52.
The DIAGNOSTIC PROCEDURE in EC section contains a description based on open circuit inspection. A
short circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE. For details,
refer to GI section (Circuit Inspection, HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRI-
CAL INCIDENT).
Repair or replace the malfunctioning parts.
Once you have repaired the circuit or replaced a component, you need to run the engine in the same condi-
tions and circumstances which resulted in the customers initial complaint.
Perform the DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE and confirm the normal code is
STEP VII detected. If the incident is still detected in the final check, perform STEP VI by using a different method from
the previous one.
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) malfunction
item in ECM.
EC-36
TROUBLE DIAGNOSIS Basic Inspection CD20T
Basic Inspection
Precaution:
Perform Basic Inspection without electrical or mechanical
loads applied;
Headlamp switch is off,
Air Conditioner switch is off,
Rear defogger switch is off,
Steering wheel is in the straight-ahead position, etc.
SEF142I BEFORE STARTING

1. Check service records for any
recent repairs that may indicate a
related problem, or the current need
Priming pump
for scheduled maintenance.
2. Open engine hood and check the
following:
Harness connectors for faulty con-
nections
Vacuum hoses for splits, kinks, or
faulty connections
Wiring for faulty connections,
pinches, or cuts
SEF671S
3. Using priming pump, bleed air from
fuel system. Refer to Fuel Filter
. Check in MA section.
Diesel tacho tester
H
. CONNECT CONSULT-II TO THE
Injection tube
VEHICLE.
Connect CONSULT-II to the data link
connector for CONSULT-II and select
ENGINE from the menu. Refer to EC-
CD-27.
SEF689S H
DOES ENGINE START? No Turn ignition switch to
E
the LOCK position, wait
Yes 5 seconds and then start
engine. If engine fails to
start, check malfunction
item.
H
Run engine for 10 minutes.
PEF190P CHECK IDLE SPEED.

Read engine idle speed in
DATA MONITOR mode with
CONSULT-II.
825 rpm 25 (in N position)
----------------------------------------------------------------- OR -----------------------------------------------------------------
Check idle speed using tachom-
eter tester.
825 rpm 25 (in N position)
H
(Go to p
A on next page.)
EC-37
TROUBLE DIAGNOSIS Basic Inspection CD20T
Basic Inspection (Contd)
p
A
H
OK
CHECK INJECTION TIMING. E Bleed air from fuel sys-
1. Set No. 1 piston at TDC on its com- tem.
pression stroke. After this inspection,
TDC: Without painted mark unnecessary diagnostic
2. Remove injection tubes and air trouble code No. might
bleeder on the back of injection be displayed.
pump. Erase the stored
3. Set dial gauge so its indicator points memory in ECM.
SEF661S
to somewhere between 1.0 and 2.0 Refer to ON BOARD
mm (0.039 and 0.079 in) on the DIAGNOSTIC SYSTEM
Plunger lift timing mark scale. DESCRIPTION.
(Yellow painted mark) 4. Turn crankshaft 2 turns clockwise
and check that dial gauge indicates OK
the same value again.
5. Turn crankshaft counterclockwise H
about 100 degrees, then turn crank-
shaft slowly clockwise, and set dial INSPECTION END
gauge indicator to 0 mm at the posi-
tion it stops.
TDC (Without painted mark)
6. Turn crankshaft clockwise and set it
at plunger lift timing mark using the
mark on the crankshaft pulley.
SEF655S
plunger lift timing mark: Yellow
painted mark
7. Read plunger lift.
Plunger lift:
0.89 0.08 mm (0.0350 0.0031
in) at plunger lift timing mark
Increase When repeating the checking,
Decrease
start with step 5.
NG
H
Adjusting E Go to
1. If plunger lift is not within the speci-
SEF662S fied value, adjust by turning injec-
tion pump.
If indication is smaller than the
specified value, turn pump body
away from engine.
If indication is larger than the
specified value, turn pump body
towards engine.
2. Tighten injection pump securing
bolts and nuts.
Nut:
: 20 - 25 Nm
(2.0 - 2.6 kg-m, 15 - 18 ft-lb)
Bolt:
SEF657S : 25 - 35 Nm
(2.6 - 3.6 kg-m, 18 - 26 ft-lb)
3. Remove dial gauge and install air
bleeder with new washer.
4. Install injection tubes.
Flare nut:
: 14 - 20 Nm
(1.4 - 2.0 kg-m, 10 - 15 ft-lb)
5. Bleed air from fuel system.
Refer to Water Draining, Fuel Filter
Check and Replacement of
ENGINE MAINTENANCE in MA
section.
EC-38
TROUBLE DIAGNOSIS General Description CD20T
Diagnostic Trouble Chart

ENGINE RELATED ITEMS
Detected items
Malfunction is detected when ...

(Screen terms for CONSULT-II,
SELF-DIAG RESULTS mode)
Mass air flow sensor circuit An excessively high or low voltage from the sensor is detected by the ECM.
(MASS AIR FLOW SEN)
Engine coolant temperature An excessively high or low voltage from the sensor is detected by the ECM.
sensor circuit
(COOLANT TEMP SEN)
Vehicle speed sensor circuit or The almost 0 km/h (0 mph) signal from the sensor is detected by the ECM even when
ABS actuator and electric unit vehicle is being driven.
(control unit) circuit
(VEHICLE SPEED SEN)
Control sleeve position sensor An excessively high or low voltage from the sensor is detected by the ECM.
circuit An incorrect voltage signal from the sensor is detected by the ECM during engine run-
(CONT SLEEV POS SEN) ning.
Fuel injection feedback 2 The fuel injection feedback system (consists of the ECM, electric governor and control
(F/INJ F/B 2) sleeve position sensor) does not operate properly.
Fuel injection timing feedback The fuel injection timing feedback system (consists of the ECM, fuel injection timing con-
(F/INJ TIMG F/B) trol valve and needle lift sensor) does not operate properly.
Abbreviations for Quick Reference of DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE

IGN: ON : Turning the ignition switch ON is required for checking the function of the sensor, switch, solenoid and circuit.
RUNNING : Running engine is required for checking the function of the sensor, switch, solenoid and circuit.
LIFTING : Lifting up the vehicle, running engine and spinning wheels are required.
DRIVING : Driving the vehicle in the specified pattern is required.
Abbreviations for Quick Reference of OVERALL FUNCTION CHECK

IGN: ON : Turning the ignition switch ON is required for the ECM to detect a malfunction (if one exists).
RUNNING : Running engine is required for the ECM to detect a malfunction (if one exists).
LIFTING : Lifting up the vehicle, running engine and spinning wheels are required for the ECM to detect a malfunction (if one
exists).
DRIVING : Driving the vehicle in the specified pattern is required for the ECM to detect a malfunction (if one exists).
EC-39
Diagnostic Trouble Chart (Contd)
: Not applicable
*1 *2
Confirmation Overall MI Reference
Check Items
Procedure Function Illumination Page
(Possible Cause)
Quick Ref. Check
Harness or connectors
(The sensor circuit is open or shorted.) IGN: ON EC-CD-62
Mass air flow sensor
(The sensor circuit is open or shorted.) IGN: ON Lighting up EC-CD-66
(The sensor circuit is open or shorted.)
LIFTING EC-CD-70
Vehicle speed sensor or ABS actuator and electric unit
(control unit)
(The sensor circuit is open or shorted.) RUNNING Lighting up EC-CD-74
Control sleeve position sensor
Main power supply circuit (ECM terminals 23 , 45 ),
68 and fuse
(Electric governor and control sleeve position sensor cir- RUNNING
Lighting up EC-CD-78
cuit) (DRIVING)
Electronic fuel injection pump
ECM
Electric governor
(Injection timing control valve, Needle lift sensor and
Crankshaft position sensor (TDC) circuit]
RUNNING
Injection timing control valve Lighting up EC-CD-82
(DRIVING)
Needle lift sensor
Crankshaft position sensor
Air in fuel line
*1: This is Quick Reference of DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE.
Details are described in each TROUBLE DIAGNOSIS.
*2: The OVERALL FUNCTION CHECK is a simplified and effective way to inspect a component or circuit.
In some cases, the OVERALL FUNCTION CHECK is used rather than a DIAGNOSTIC TROUBLE CONFIRMATION PRO-
CEDURE.
When no DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE is available, the NG result of the OVERALL FUNCTION
CHECK can be considered to mean the same as a malfunction item detection.
During an NG OVERALL FUNCTION CHECK, the malfunction item might not be confirmed.
This is Quick Reference of OVERALL FUNCTION CHECK.
Details are described in each TROUBLE DIAGNOSIS.
EC-40

Detected items
(Screen terms for Malfunction is detected when ...

CONSULT-II, SELF-DIAG
RESULTS mode)
Cooling fan An excessive high engine coolant temperature sensor signal is detected by the ECM. (Over-
(OVER HEAT) heat)
ECM2 ECM calculation function is malfunctioning.

(ECM2)
Needle lift sensor circuit An incorrect signal from the sensor is detected by the ECM during engine running.
(NEEDLE LIFT SEN)
Fuel cut solenoid valve 1 Fuel cut solenoid valve circuit is malfunctioning.
(FUEL CUT S/V 1)
Fuel temperature sensor An excessively high or low voltage from the sensor is detected by the ECM.
circuit
(FUEL TEMP SENSOR)
Accelerator position sensor An excessively high or low voltage from the sensor is detected by the ECM.
circuit
(ACCEL POS SENSOR)
Crankshaft position sensor An incorrect signal from the sensor is detected by the ECM during engine running and
(TDC) cranking.
[CRANK POS SEN (TDC)]
No failure No malfunction is detected by the ECM.
(NO SELF DIAGNOSTIC
FAILURE INDICATED)

exists).
EC-41
: Not applicable
*1 *2
Confirmation Overall MI Reference
Check Items
Procedure Function Illumination Page
(Possible Cause)
Quick Ref. Check
(The cooling fan circuit is open or shorted.)
Cooling fan
Radiator hose
Radiator
Radiator cap IGN: ON
Lighting up EC-CD-78
Water pump (RUNNING)
Thermostat
Fan belt

For more information, refer to 12 MAIN CAUSES OF
OVERHEATING. (EC-CD-95)
ECM
IGN: ON Lighting up EC-CD-86
Needle lift sensor RUNNING Lighting up EC-CD-97
Air in fuel line
Clogging No. 1 injection nozzle
(The solenoid valve circuit is open or shorted.) RUNNING Lighting up EC-CD-100
(The sensor circuit is open or shorted.) IGN: ON EC-CD-104
Fuel temperature sensor
Accelerator position sensor
Accelerator position switch
(The sensor circuit is open or shorted.) RUNNING Lighting up EC-CD-114
Crankshaft position sensor (TDC)
No failure


Details are described in each specific TROUBLE DIAGNOSIS.
CEDURE.
EC-42

Detected items

RESULTS mode)
Atmospheric pressure An excessively high or low voltage from the sensor is detected by the ECM.
sensor *5
() *3
Glow relay circuit Glow relay circuit is open or shorted.
(GLOW RELAY)
ECM ECM reference voltage (2.5V) is excessively high or low.

()*3
Air conditioner relay circuit Air conditioner relay circuit is shorted.
()*3
EGRC-solenoid valve A EGRC-solenoid valve A is open or shorted.

(EGR SYS)
Brake switch circuits Brake switch circuits are open or shorted.

()*3
ECM ECM version number or switching function is not plausible.

()*3
ECCS-D relay circuit ECCS-D relay shut-off time is too late.
()*3
Ignition switch ON signal Ignition switch ON signal evaluation circuit in ECM is malfunctioning.
circuit
()*3
Injection timing control Injection timing control valve circuit is open or shorted.
valve circuit
(INJ TIMING CONT/V)
Camshaft position sensor An improper signal is calculated by the ECM.

(PUMP)*4
()*3
exists).
EC-43
: Not applicable
*1 *2
Confirmation Overall Func- MI Reference
Check Items
Procedure tion Check Illumination Page
(Possible Cause)
Quick Ref.
ECM
IGN: ON EC-CD-86
(The glow relay circuit is open or shorted.) IGN: ON EC-CD-118
Glow relay
ECM
IGN: ON EC-CD-86
(The air conditioner relay circuit is open or shorted.) IGN: ON EC-CD-126
Air conditioner relay
(The EGRC-solenoid valve A circuit is open or shorted.) RUNNING Lighting up EC-CD-129
EGRC-solenoid valve
(Brake switch circuits are open or shorted.)
RUNNING Lighting up EC-CD-136
Brake lamp switch
RDNT brake switch
ECM
IGN: ON EC-CD-86
(The ECCS-D relay circuit is shorted.)
ECCS-D relay
ECM
ECM
(The injection timing control valve circuit is open or
shorted.)
ECM
Needle lift sensor RUNNING Lighting up EC-CD-97
Low battery voltage
CEDURE.
*3: CONSULT-II may not detect, but self-diagnostic results are available with MI.
*4: Imaginary sensor, which produces secondary engine revolution signal using needle lift sensor pulse.
*5: The atmospheric pressure sensor is located inside the ECM and is not replaceable.
EC-44

Detected items

RESULTS mode)
MI MI (malfunction indicator) circuit is open or shorted.
()*3
GLOW LAMP CIRCUIT Glow lamp circuit is open or shorted.

()*3

exists).
EC-45
: Not applicable
*1 *2
Confirmation Overall Func- MI Reference
Check Items
Procedure tion Check Illumination Page
(Possible Cause)
Quick Ref.
(The MI circuit is open or shorted.)
IGN: ON EC-CD-141
MI lamp
ECM
(The glow indicator lamp circuit is open or shorted.) IGN: ON EC-CD-118
Glow lamp

CEDURE.
*3: CONSULT-II may not detect, but self-diagnostic results are available with MI.
EC-46
Symptom Matrix Chart

SYMPTOM
HARD/NO START/RESTART (EXCP. HA)
ENGINE STALL
ABNORMAL SMOKE COLOR

OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
SYSTEM
Basic engine
control system
HARD TO START WHEN ENGINE IS COLD
HARD TO START WHEN ENGINE IS HOT
DEAD BATTERY (UNDER CHARGE)

HESITATION/SURGING/FLAT SPOT
EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION
SPARK KNOCK/DETONATION
NO START (without first firing)
SLOW/NO RETURN TO IDLE
Can be detected by CONSULT-II?
Feature of symptom, Check point

Malfunction indicator illuminates.
NO START (with first firing)
ROUGH IDLE/HUNTING
WHEN DECELERATING
POOR ACCELERATION
IDLING VIBRATION
DURING DRIVING
LACK OF POWER
BLACK SMOKE
WHITE SMOKE
Reference page
LOW IDLE
AT IDLE
HI IDLE
Fuel cut
New CT/CS AA AB AC AD AE AF AG AH AJ AK AL AM AP HA
Injec- Advanced q q q q q q EC-CD-38
tion
timing Retarded q q q q q q EC-CD-38
Electric injection
q q q q q q q q q q q q q q *1
pump mainframe
Injection nozzle q q q q q q q q q q EC-CD-22 *2
Glow system q q EC-CD-118
EM-
Engine body q q q q q q q q q q q *3
section
EGR system EC-CD-129
Air cleaner and MA-
q *4
ducts section
; High Possibility Item

q; Low Possibility Item
*1: Insufficient or excess amount. Governor malfunction may be the cause.
*2: Depends on open-valve pressure and spray pattern.
*3: Caused mainly by insufficient compression pressure.
*4: Symptom varies depending on off-position of air duct, etc.
EC-47
SYMPTOM
HI IDLE
Fuel cut
LOW IDLE
ENGINE STALL
HARD/NO START/
LACK OF POWER
IDLING VIBRATION
RESTART (EXCP. HA)

POOR ACCELERATION
ROUGH IDLE/HUNTING
AT IDLE
Malfunction
Check point
Reference page
DURING DRIVING
Feature of symptom
WHEN DECELERATING
SYSTEM Engine control module system


WHITE SMOKE
BLACK SMOKE

open, ground short q q q q
Mass air flow sensor circuit EC-CD-62
short q q q
EC-48
Compensation according to
open, short q q q q q q q q EC-CD-66 engine coolant temperature
circuit
does not function.
Vehicle speed sensor circuit or ABS
actuator and electric unit (control open, short q q EC-CD-70
unit) circuit
Control sleeve position sensor cir-
open, short q q q q q q EC-CD-74
cuit
open, ground short q q q q q q q
Electric governor circuit EC-CD-78
short q q
Injection timing cannot be
open, short q q q q
Injection timing control valve circuit EC-CD-82 controlled.
ground short q q q
Needle lift sensor circuit open, short q q q q EC-CD-97
Engine control module

open, ground short q q q q q q q
TROUBLE DIAGNOSIS General Description
Symptom Matrix Chart (Contd)
Fuel cut solenoid valve circuit EC-CD-100 Engine runs on after turning
short q q q
ignition switch OFF.
Compensation for amount
fuel injected according
Fuel temperature sensor circuit open, short q q q q q q q q q q EC-CD-104 of
to fuel temperature does
not function.
Accelerator position sensor circuit open, short q q q q q EC-CD-108
Crankshaft position sensor (TDC) open, short q q q q
EC-CD-114
circuit noise q q q q q
CD20T
SYMPTOM
HI IDLE
Fuel cut
LOW IDLE
ENGINE STALL
HARD/NO START/
LACK OF POWER
IDLING VIBRATION
RESTART (EXCP. HA)

POOR ACCELERATION
ROUGH IDLE/HUNTING
AT IDLE
Malfunction
Check point
Reference page
DURING DRIVING
Feature of symptom
WHEN DECELERATING
SYSTEM Engine control module system


WHITE SMOKE
BLACK SMOKE

Start signal circuit open, short q q EC-CD-145 Start control does not function.
Air conditioner does not stop
open, ground short
Air conditioner switch circuit EC-CD-126 operating.
EC-49
short Air conditioner does not work.
open, ground short q q q q q
Accelerator position switch (Idle)
EC-CD-108 Accelerator position sensor NG
circuit short q q q q q
signal is output.
open q q q q
Ignition switch circuit (ON signal) EC-CD-59
short Engine does not stop.
open q q q
Power supply for ECM circuit EC-CD-59
short q q
open, short q q
EGRC-solenoid valve circuit EC-CD-129
ground short q q Does not stop operating. q
open q q q q q q Glow lamp does not turn on. q
Glow relay circuit EC-CD-118
short q Glow lamp does not turn off. q
open
Engine control module

q q q q
Engine control module relay (Self-
EC-CD-59 Ground short makes engine
shutoff) circuit
TROUBLE DIAGNOSIS General Description
short q q q unable to stop.

Symptom Matrix Chart (Contd)
Air conditioner does not oper-

open ate.
Air conditioner relay circuit EC-CD-126
Air conditioner does not stop
short q q operating.
open q
Brake switch circuits EC-CD-136
short q
ECM, Connector circuit open, short q q q q q q q q q q q q q q q q q q q q q q q q q EC-CD-86
CD20T
CONSULT-II Reference Value in Data Monitor

Mode
Remarks:
Specification data are reference values.
Specification data are output/input values which are detected or supplied by the ECM at the connector.
* Specification data may not be directly related to their components signals/values/operations.
MONITOR ITEM CONDITION SPECIFICATION
CKPSRPM (TDC) Tachometer: Connect Almost the same speed as the CON-
CKPSRPM-PUMP Run engine and compare tachometer indication with the CONSULT-II value. SULT-II value.
COOLAN TEMP/S Engine: After warming up More than 70C (158F)

Turn drive wheels and compare speedometer indication with the CON- Almost the same speed as
VHCL SPEED SE
SULT-II value the CONSULT-II value
FUEL TEMP SEN Engine: After warming up More than 40C (104 F)
Ignition switch: ON Accelerator pedal: release Approx. 0.40V

ACCEL POS SEN
(Engine stopped) Accelerator pedal: depress Approx. 3.3V
Ignition switch: ON Accelerator pedal: release ON

OFF ACCEL POS
(Engine stopped) Accelerator pedal: slightly open OFF
C/SLEEV POS/S Engine: After warming up Approx. 2.5V
BATTERY VOLT Ignition switch: ON (Engine stopped) 11 - 14V
START SIGNAL Ignition switch: ON , START , ON OFF , ON , OFF
Air conditioner switch: OFF OFF
Engine: After warming up, idle the
AIR COND SIG Air conditioner switch: ON
engine ON
(Compressor operates.)
IGN SW Ignition switch: ON , OFF ON , OFF
Engine: After warming up Idle 0.8 - 2.7V
Air conditioner switch: OFF
MAS AIR/FL SE
Shift lever: N
No-load 2,000 rpm 2.2 - 2.8V
Engine: After warming up

Air conditioner switch: OFF Idle -0.5 to -1.5
ACT INJ TIMG Shift lever: N
No-load 2,000 rpm +2.5 to +3.5
At sea level
Air conditioner switch: OFF Idle 8.0 - 8.8 mm3/stroke
TARGET F/INJ Shift lever: N
No-load 2,000 rpm Approx. 7.6 mm3/stroke
At sea level
Brake pedal: released OFF
BRAKE SW Ignition switch: ON
Brake pedal: depressed ON
Brake pedal: released OFF
BRAKE SW 2 Ignition switch: ON
Brake pedal: depressed ON
FUEL CUT S/V Ignition switch: ON , OFF ON , OFF
AIR COND RLY Air conditioner switch: OFF , ON OFF , ON
GLOW RLY Refer to EC-CD-124.
When cooling fan is stopped. OFF
COOLING FAN When cooling fan operates at low speed. LOW
When cooling fan operates at high speed. HI
Air conditioner switch: OFF Idle OFF
EGRC SOL/V A Shift lever: N
No-load 2,800 rpm ON
At sea level
EC-50
Major Sensor Reference Graph in Data

Monitor Mode
The following are the major sensor reference graphs in DATA MONITOR mode.
(Select HI SPEED in DATA MONITOR with CONSULT-II.)
ACCEL POS SEN, C/SLEEV POS/S, ACT INJ TIMG

Below is the data for ACCEL POS SEN, C/SLEEV POS/S and ACT INJ TIMG when revving engine
quickly up to 3,000 rpm under no load after warming up engine sufficiently.
Each value is for reference, the exact value may vary.
+0495
-0009
ACCEL POS SEN should increase

x0.1V
while depressing the accelerator

pedal and should decrease while
releasing it.
+049516:06
-0009
C/SLEEV POS/S should increase

x0.1V
when depressing the accelerator

pedal and should decrease when the pedal is
released.
+049516:06
-0009
ACT INJ TIMG should increase

when depressing the accelerator
pedal and should decrease when
the pedal is released.
ACT INJ TIMG
13:22
NEF780
EC-51
ECM Terminals and Reference Value

PREPARATION
The ECM is located beneath the heater unit. To access the ECM,
remove the center console under cover at the passenger side.
Perform all voltage measurements with all connectors con-
nected. Since the ECM harness connector cannot be accessed
from the backside, voltages should be measured by connecting
a break out box (SST) between ECM and ECM harness connec-
tor.
SEF883Y
ECM
When measuring:
Use extreme care not to touch 2 pins at the same time.
Note that the data is for comparison and may not be exact.
Be sure ECM unit is properly grounded before checking.
Y-adapter
Breakout box
To ECM har-
ness connec-
tor
Y-adapter NEF162A
EC-52
ECM Terminals and Reference Value (Contd)
ECM INSPECTION TABLE
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in
damage to the ECMs transistor. Use a ground other than ECM terminals, such as the ground.
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and
COLOR
NO. Pulse Signal)
qApproximately 10.5V
Engine is running. (Warm-up condition)
Idle speed
101 SEF562S
102 B/L Electric governor ground
103 Approximately 10.5

Engine speed is 2,000 rpm
SEF563S
Engine ground
104 Engine is running. (Probe this terminal with
105 B ECM ground
Idle speed @ tester probe when
106
measuring.)
107
BATTERY VOLTAGE
108 R Power supply for ECM Ignition switch ON
(11 - 14V)
109
Approximately 9V
Idle speed
Injection timing control SEF564S

202 B/W
valve Approximately 8V
SEF565S
EC-53
TER- DATA
WIRE
COLOR
NO. Pulse Signal)
Engine is running.
Both A/C switch and blower switch are Approximately 0.4V
204 L/W Air conditioner relay ON
Engine is running. BATTERY VOLTAGE

A/C switch is OFF (11 - 14V)
Engine is running. (Warm-up condition) BATTERY VOLTAGE (11

Idle speed - 14V)
208 P EGRC-solenoid valve A
Approximately 0.3V
214 W/R Glow relay Refer to Glow control System.
Ignition switch ON Approximately 1.0V
215 OR/L Malfunction indicator Engine is running. BATTERY VOLTAGE

Idle speed (11 - 14V)
Mass air flow sensor Engine is running.

218 OR Approximately 0V
ground Idle speed

Cooling fan is not operating. (11 - 14V)
Cooling fan relay
219 LG/R
(Low speed) Engine is running.
Approximately 0.4V
Cooling fan is operating.
Engine is running.
BATTERY VOLTAGE
Cooling fan is not operating. (11 - 14V)
Cooling fan relay Cooling fan is operating at low speed.
220 LG
(High speed)
Engine is running.
Approximately 0.5V
Cooling fan is operating at high speed.
Ignition switch ON
Approximately 1.0V
Glow lamp is ON.
221 P/L Glow lamp
Ignition switch ON BATTERY VOLTAGE
Glow lamp is OFF (11 - 14V)

223 W/L Ignition switch ON Approximately 5V
power supply

1.9 - 2.3V
Idle speed
224 L/W Mass air flow sensor
2.5 - 2.9V
EC-54
TER- DATA
WIRE
COLOR
NO. Pulse Signal)
Approximately 2.6V
Control sleeve position Engine is running.

320 W
sensor power supply Idle speed
SEF559S
Approximately 2.6V
Control sleeve position Engine is running.

321 B
sensor ground Idle speed
SEF560S
Approximately 2.6V
Control sleeve position Engine is running. (Warm-up condition)

322 R sensor (Reference sig-
nal) Idle speed
SEF561S
Engine is running.
Ignition switch LOCK 0 - 1V
Engine control module For a few seconds after turning ignition

325 W/G switch to the LOCK position
relay (Self-shutoff)
Ignition switch LOCK
BATTERY VOLTAGE
Following a few seconds delay after turning (11 - 14V)
ignition switch to the LOCK position
Crankshaft position sen- Engine is running.

331 OR Approximately 0V
sor (TDC) ground Idle speed
Needle lift sensor

333 B Ignition switch ON Approximately 0V
ground
334 Engine is running.

335 B Sensors ground Approximately 0V
436 Idle speed
EC-55
TER- DATA
WIRE
COLOR
NO. Pulse Signal)
Approximately 0V
Idle speed
Crankshaft position sen- NEF867

344 W
sor (TDC) (Signal) Approximately 0V
Engine is running.
NEF868
Approximately 3.8 - 4.0V

Idle speed
NEF869
345 W Needle lift sensor
NEF870
0.6 - 4.8V
Engine coolant tempera- Output voltage varies
347 L/B Engine is running.
ture sensor with engine coolant tem-
perature.
0.6 - 4.8V
348
R/Y Fuel temperature sensor Engine is running. Output voltage varies
411
with fuel temperature.
Ignition switch LOCK Approximately 0V

349 SB Fuel cut solenoid valve
BATTERY VOLTAGE
Ignition switch ON
(11 - 14V)
EC-56
TER- DATA
WIRE
COLOR
NO. Pulse Signal)
Engine is running.
Both air conditioner switch and blower Approximately 0V
403 GY Air conditioner switch switch are ON (Compressor operates)

Air conditioner switch is OFF (11 - 14V)
Ignition switch ON
0V
Brake pedal released
405 R/G Stop lamp switch
Ignition switch ON Battery voltage
Brake pedal depressed (11 - 14V)
Immobilizer communica- BATTERY VOLTAGE

410 OR Ignition switch ON
tion (4 - 14V)
Ignition switch ON Battery voltage

Brake pedal released (11 -14V)
416 R/B Brake switch 2
Ignition switch ON
0V
Brake pedal depressed
0 - Approximately 4.2V
Engine is running.
Vehicle speed sensor or
417 OR/W ABS actuator and elec- Lift up the vehicle.
tric unit (control unit) In 2nd gear position
Vehicle speed is 40 km/h (25 mph)
SEF552S
420 BR/W Engine is running. Approximately 4 - 9V

Data link connector for
CONSULT-II Idle speed (CONSULT-II is connected and
415 G/R turned on) Approximately 0V
Accelerator position sen- Engine is running.

425 BR Approximately 0V
sor ground Idle speed
Accelerator position sen-
433 LG/W Ignition switch ON Approximately 5V
sor power supply
Ignition switch ON
0.4 - 0.6V
Accelerator position sen- Accelerator pedal released
434 W/PU
sor Ignition switch ON
Approximately 4.0V
Accelerator pedal fully depressed
EC-57
TER- DATA
WIRE
COLOR
NO. Pulse Signal)
Ignition switch ON
Approximately 0V
Accelerator position Accelerator pedal released
435 GY/R
switch (Idle) Ignition switch ON
Approximately 2.7V
Accelerator pedal depressed
Ignition switch ON Approximately 0V

442 B/Y Start signal
BATTERY VOLTAGE
Ignition switch START
(11 - 14V)
Idle speed
SEF550S
439 L/OR Tachometer
Engine is running.
SEF551S
Ignition switch LOCK 0V

507 BR/Y Ignition switch
BATTERY VOLTAGE
Ignition switch ON
(11 - 14V)
EC-58
TROUBLE DIAGNOSIS FOR POWER SUPPLY CD20T
Main Power Supply and Ground Circuit
YEC100A
EC-59
(Contd)
INSPECTION START
H
No
Start engine. CHECK POWER SUPPLY-I.
E
Is engine running? 1. Disconnect ECM harness
connector.
Yes 2. Turn ignition switch to
ON position.
3. Check voltage between
NEF863 ECM connector terminal
507 and ground
Voltage: Battery voltage
H If NG, check the following:
1. Stop engine. 10A fuse
2. Disconnect ECM harness connector. Harness connectors
3. Turn ignition switch to ON position. M52 , F103
Harness for open or
short-circuit between
ECM and ignition switch.
If NG, replace 10A fuse or
repair harness or connec-
tors.
ECM relay
YEC327 OK
F
H
OK
CHECK POWER SUPPLY-II. Go to CHECK
E
1. Short between ECM connector terminal GROUND CIRCUIT on
325 and engine ground with a jump page EC-CD-61.
wire.
2. Check voltage between ECM terminals
107 , 108 , 109 and ground.
NG
H
NG
NEF186A CHECK HARNESS CONTINUITY Check the following:
E
BETWEEN ENGINE CONTROL MODULE Harness connectors
RELAY AND ECM M89 , F96
Check harness continuity between ECM Harness for open or
connector terminals 107 , 108 , 109 and short-circuit between
ECM relay connector terminal p 5 . ECM relay and ECM.
Continuity should exist. If NG, repair harness or
If OK, check harness for short. connectors.
H OK
p
A
NEF187A
ECM relay
connector
NEF188A
EC-60
(Contd)
p
A
ECM relay
connector
H
NG
CHECK VOLTAGE BETWEEN ENGINE Check the following:
E
CONTROL MODULE RELAY AND 15A fuse
GROUND. Harness for open or
Check voltage between ECM relay connec- short-circuit between
tor terminals p
2 , p
3 and ground with ECM relay and battery.
CONSULT-II or tester. If NG, replace fuse or repair
Voltage: Battery voltage harness or connectors.
YEC352
OK
H
NG
CHECK OUTPUT SIGNAL CIRCUIT. Check harness connec-
E
ECM relay Check harness continuity between ECM tors E43 , F2
connector connector terminal 325 and ECM relay Repair harness or connec-
connector terminal p
1 . tors.
Continuity should exist.
If OK, check harness for short-circuit.
OK
H
NG
CHECK ECM RELAY. Replace ECM relay.
E
NEF189A 1. Apply 12V direct current between ECM
relay connector terminals p1 and p 2 .
2. Check continuity between engine control
module relay connector terminals p3 and
p5 .
12V (p 1 -p 2 ) applied:
Continuity exists.
No voltage applied:
ECM relay No continuity
connector
OK
H
NG
CHECK GROUND CIRCUIT. Repair harness or connec-
E
1. Turn ignition switch to LOCK position. tors.
YEC354 2. Check harness continuity between ECM
connector terminals 104 , 105 , 106
and engine ground.
If resistance is too high, loosen, clean and
retighten engine ground.
OK
H
Check ECM pin terminals for damage and
check the connection of ECM harness con-
nector.
NEF190A H
INSPECTION END
Engine ground
NEF399
EC-61
TROUBLE DIAGNOSIS 1 CD20T
Mass Air Flow Sensor (MAFS)

The mass air flow sensor measures the amount of intake air by
analysing a part of the entire flow. When intake air flows into the
intake manifold, heat is withdrawn from the hot film. By regulat-
ing the electrical current that flows through the hot film, the ECM
maintains the hot film temperature on a constant level. The
amount of electric current that is needed to keep the hot film on
a constant temperature level is proportional to the mass of air
that flows into the engine.
NEF663
Check Items
Malfunction is detected when . . .
(Possible Cause)
An excessively high or low voltage from the sensor is Harness or connectors
entered to ECM. (The sensor circuit is open or shorted.)
DIAGNOSTIC TROUBLE CONFIRMATION

PROCEDURE
1) Turn ignition switch to ON position.
2) Select DATA MONITOR mode with CONSULT-II.
3) Start engine and wait for at least 20 seconds.
EC-62
Mass Air Flow Sensor (MAFS) (Contd)
BATTERY
: Detectable line for DTC

Refer to EL-POWER.
: Non-detectable line for DTC
ENGINE MASS AIR

CONTROL FLOW SEN-
MODULE SOR
RELAY
ECM
YEC799
EC-63
Mass air flow sensor harness connector DIAGNOSTIC PROCEDURE
INSPECTION START
H
NG
CHECK POWER SUPPLY. Repair harness or connec-
E
2. Disconnect mass air flow sensor harness
connector.
3. Turn ignition switch to ON position.
4. Check voltage between mass air flow
NEF788
sensor connector terminal p 2 and
ground.
Voltage: Battery positive voltage
OK
Mass air flow H

sensor connector NG
CHECK GROUND CIRCUIT. Repair harness or connec-
E
2. Disconnect ECM harness connector.
3. Check harness continuity between mass
air flow sensor connector terminal p3
and ECM connector terminal 218 .
NEF789 If OK, check harness for short-circuit.
OK
H
NG
CHECK INPUT SIGNAL CIRCUIT. Repair harness or connec-
E
Check harness continuity between mass air tors.
flow sensor connector terminal p4 and
ECM connector terminal 223 , mass air
Mass air flow sensor connector terminal p5 and
flow sensor ECM connector terminal 224 .
connector
If OK, check harness for short.
OK
NEF191A
H
NG
CHECK COMPONENT Replace mass air flow sen-
E
(Mass air flow sensor). sor.
Refer to COMPONENT INSPECTION on
connector next page.
OK
H
Disconnect and reconnect harness connec-
tors in the circuits. Then retest.
Trouble is not fixed.
NEF192A H
Check ECM pin terminals for damage or the
connection of ECM harness connector.
H
INSPECTION END
EC-64
COMPONENT INSPECTION
connector 1. Turn ignition switch to ON position.
2. Start engine and warm it up sufficiently.
3. Check voltage between mass air flow sensor connector ter-
minal p5 and ground.
Conditions Voltage V
Ignition switch ON position (Engine stopped.) Approximately 1.0
NEF792 Idle (Engine is warmed-up sufficiently.) 1.9 - 2.3
4. If NG, remove mass air flow sensor from air duct. Check hot
film for damage or dust.
NEF669
EC-65
Engine Coolant Temperature (ECT) Sensor

The engine coolant temperature sensor is used to detect the
engine coolant temperature. The sensor modifies a voltage sig-
nal from the ECM. The modified signal returns to the ECM as the
engine coolant temperature input. The sensor uses a thermistor
which is sensitive to the change in temperature. The electrical
resistance of the thermistor decreases as temperature
increases.
SEF594K
<Reference data>
Engine coolant
Voltage Resistance
temperature
(V) (k)
C (F)
10 (14) 4.4 7.0 - 11.4
20 (68) 3.5 2.1 - 2.9
50 (122) 2.3 0.68 - 1.00
90 (194) 1.0 0.236 - 0.260
SEF012P
Check Items
(Possible Cause)
entered to ECM. (The sensor circuit is open or shorted.)

PROCEDURE
3) Wait at least 5 seconds.
EC-66
(Contd)
ENGINE COOLANT
TEMPERATURE
SENSOR

ECM
YEC800
EC-67
(Contd)
.
RH strut tower DIAGNOSTIC PROCEDURE
INSPECTION START
H
.
CHECK POWER SUPPLY. NG Repair harness or con-
Engine coolant temperature E
sensor harness connector 1. Turn ignition switch to LOCK posi- nectors.
tion.
2. Disconnect engine coolant tempera-
NEF401
ture sensor harness connector.
4. Check voltage between engine cool-
ant temperature sensor connector
Engine coolant temperature terminal p 2 and ground with CON-
sensor connector SULT-II or tester.
Voltage:
Approximately 4.9V
OK
H
CHECK GROUND CIRCUIT. NG Repair harness or con-
E
NEF193A 1. Turn ignition switch to LOCK posi- nectors.
tion.
2. Check harness continuity between
engine coolant temperature sensor
connector terminal p 1 and engine
Engine coolant temperature ground.
sensor connector
If OK, check harness for short-cir-
cuit.
OK
H
CHECK COMPONENT NG Replace engine coolant
SEF542P E
(Engine coolant temperature sensor). temperature sensor.
Refer to COMPONENT INSPECTION
on next page.
OK
H
Disconnect and reconnect harness
connectors in the circuit. Then retest.

H
Check ECM pin terminals for damage
and check the connection of ECM har-
ness connector. Reconnect ECM har-
ness connector and retest.
H
INSPECTION END
EC-68
(Contd)
Check resistance as shown in the figure.
Temperature C (F) Resistance k

20 (68) 2.1 - 2.9
50 (122) 0.68 - 1.0
SEF152P 90 (194) 0.236 - 0.260
If NG, replace engine coolant temperature sensor.
SEF012P
EC-69
Vehicle Speed Sensor (VSS)

Models with vehicle speed sensor
The vehicle speed sensor is installed in the transaxle. It contains
Vehicle speed a pulse generator which provides a vehicle speed signal to the
sensor
speedometer. The speedometer then sends a signal to the ECM.
Models without vehicle speed sensor

The ABS actuator and electric unit (control unit) provides a
vehicle speed signal to the speedometer. The speedometer than
sends a signal to the ECM.
AEC110
Check Items
Malfunction is detected when ....
(Possible Cause)
The almost 0 km/h (0 mph) signal from vehicle speed sen- Models with vehicle speed sensor
sor or ABS actuator and electric unit (control unit) is sent Harness or connector
to ECM even when vehicle is being driven. (The vehicle speed sensor circuit is open or shorted.)
Vehicle speed sensor
Models without vehicle speed sensor
Harness or connector
(The ABS actuator and electric unit (control unit) is open or
shorted.)
ABS actuator and electric unit (control unit)
OVERALL FUNCTION CHECK

Use this procedure to check the overall function of the vehicle
speed sensor circuit. During this check, a DTC might not be
confirmed.
1) Jack up drive wheels.
2) Start engine.
3) Read vehicle speed sensor signal in DATA MONI-
TOR mode with CONSULT-II.
The vehicle speed on CONSULT-II should be able to
exceed 10 km/h (6 mph) when rotating wheels with
PEF651U suitable gear position.
------------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------------
1) Jack up drive wheels.
2) Start engine.
3) Rotate drive wheel by hand.
4) Check voltage between ECM connector terminal
417 and ground with voltage tester.
Voltage should vary between approx. 0 - 0.6V.
NEF194A
EC-70
Vehicle Speed Sensor (VSS) (Contd)
MODELS BEFORE VIN - P11U0583350
IGNITION SWITCH
BATTERY ON or START
FUSE
BLOCK Refer to EL-POWER.
(J/B)
: Dectable line for DTC

COMBINATION
METER
(SPEEDOMETER)
VEHICLE
SPEED
SENSOR
ECM
REFER TO THE FOLLOWING

FUSE BLOCK - Junction Box (J/B)
YEC801
EC-71
MODELS AFTER VIN - P11U0583350
YEC101A
EC-72
DIAGNOSTIC PROCEDURE
INSPECTION START
H
CHECK INPUT SIGNAL CIRCUIT. NG Check the following:
E
1. Turn ignition switch to LOCK posi- Harness connectors
tion. M50 , F104
2. Disconnect ECM harness connector Harness for open or
and combination meter harness con- short-circuit between
nector. ECM and combination
3. Check harness continuity between meter.
ECM connector terminal 417 and If NG, repair harness or
combination meter connector termi- connectors.
nal p 9 or p4 .
cuit.
OK
H
YEC124A NG
CHECK SPEEDOMETER FUNCTION. Check the following:
E
Make sure that speedometer functions Harness connectors
correctly. M50 , F104
Harness for open or
OK
short-circuit between
combination meter and
vehicle speed sensor
or ABS actuator and
electric unit (control
unit).
If NG, repair harness or
connectors.
Check vehicle speed
sensor or ABS actuator
and electric unit (control
unit) and its circuit.
Refer to EL section.
H

H
H
INSPECTION END
EC-73
Control Sleeve Position Sensor (CSPS)

The control sleeve position sensor is installed on the electric
Shaft governor. It senses the position of control sleeve (rotor angle)
while the control sleeve is being driven by the electric governor,
and feeds it back to the ECM.
Sensor coil
SEF641S
Check Items
(Possible cause)
detected by ECM. (The control sleeve position sensor circuit is open or
............................................................................................... shorted.)
An incorrect voltage signal from the sensor is detected by Control sleeve position sensor
ECM during engine running.
.
Electronic injection pump DIAGNOSTIC TROUBLE CONFIRMATION
harness connector (control
sleeve position sensor)
PROCEDURE
1) Turn ignition switch to ON position and select DATA
MONITOR mode with CONSULT-II.
2) Start engine and run it for at least 2 seconds at idle
speed.
NEF796
EC-74
(Contd)
INJECTION PUMP (CON-
TROL SLEEVE POSITION
SENSOR)

ECM
YEC802
EC-75
(Contd)
Control sleeve position INSPECTION START
sensor connector
H
NG
CHECK POWER SUPPLY CIRCUIT. Repair harness or connec-
E
2. Disconnect ECM harness connector and
electronic injection pump harness connec-
NEF196A tor.
3. Check harness continuity between control
sleeve position sensor connector terminal
p 3 and ECM connector terminal 320 .
Control sleeve position If OK, check harness for short-circuit.
sensor connector
OK
H
NG
CHECK INPUT SIGNAL CIRCUIT. Repair harness or connec-
E
Check harness continuity between control tors.
p 2 and ECM terminal 321 .
NEF197A
OK
H
NG
Control sleeve position CHECK REFERENCE SIGNAL CIRCUIT. Repair harness or connec-
E
sensor connector Check harness continuity between control tors.
p 1 and ECM connector terminal 322 .
OK
H
NG
CHECK COMPONENT Have the injection pump
NEF198A E
(Control sleeve position sensor). assembly serviced by an
Refer to COMPONENT INSPECTION on authorised service represen-
next page. tative.
OK
H
tors in the circuit. Then retest.
H
nector. Reconnect ECM harness connector
and retest.
H
INSPECTION END
EC-76
(Contd)
Control sleeve posi-
tion sensor, electric Control sleeve position sensor
governor & fuel
temperature sensor 1. Disconnect electronic injection pump harness connector.
connector 2. Check continuity between terminals p 1 and p3 , p
2 and
p3 .
Resistance: Approximately 6.0 [at 25C (77F)]
If NG, take proper action.
NEF680
EC-77
Electric Governor
Return spring
The electric governor is built into the fuel injection pump. It
moves the control sleeve to increase or decrease the amount of
Coil
fuel injected.
Rotor When current flows through the coil, a magnetic force is
produced, rotating the rotor. The rotor shaft is installed to the
control sleeve via a ball pin which is eccentrically situated in
relation to the rotor shaft. With this arrangement, the control
sleeve can be moved in relation to rotor rotation.
Core The rotors rotating angle is determined by a balanced condition
Shaft
of magnetic force (generated by current flow regulated by means
of the ECM) and tension of return spring (installed to rotor). The
Ball pin larger the current flow through the coil, the greater the rotors
rotating angle. This means that the control sleeve moves to the
right, increasing the amount of fuel injected.
The ECM regulates the current flow through the coil by chang-
ing the duty cycle ratio which controls the ON-OFF operation of
the electric governor grounding circuit.
Decrease Increase
Control sleeve
SEF632S
Magnet Core
Rotor
Coil
SEF633S
Check Items
(Possible cause)
Fuel injection feedback system does not operate properly. Main power supply circuit (ECM connector terminals 107 ,
[This system consists essentially of ECM, electric governor 108 , 109 ) and fuse
and control sleeve position sensor.] Harness or connectors
(Electric governor and control sleeve position sensor cir-
cuit)
Electric governor
ECM

PROCEDURE
2) Start engine above 1,200 rpm.
3) Run it for 2 seconds above 1,200 rpm. Return engine
speed to idle.
NOTE:
If malfunction occurs intermittently, conduct suitable driv-
ing pattern for 10 minutes. This makes it possible to deter-
mine the diagnostic trouble.
EC-78
Electric Governor (Contd)
BATTERY

Refer to EL-POWER.
INJECTION PUMP
(ELECTRIC GOVER-
NOR)
ENGINE
CONTROL
MODULE
RELAY
ECM
YEC803
EC-79
INSPECTION START
H
CHECK MAIN POWER SUPPLY.
Refer to EC-CD-59.
.
Electronic injection pump harness
connector (Electric governor)
H
NEF800 NG
CHECK POWER SUPPLY CIRCUIT. Repair harness or con-
E
1. Turn ignition switch to LOCK posi- nectors.
tion.
2. Disconnect ECM harness connector
Injection pump and electronic injection pump har-
connector
ness connector.
injection pump connector terminal
p 7 and ECM connector terminals
107 , 108 , 109 .
NEF199A If OK, check harness for short-circuit.
OK
H
Injection pump E
connector Check harness continuity between nectors.
injection pump connector terminal p 4
and ECM connector terminals 101 ,
102 , 103 .
NEF200A OK
H
CHECK COMPONENT NG Have the injection pump
E
(Electric governor). assembly serviced by an
Refer to COMPONENT INSPECTION authorised service repre-
on next page. sentative.
OK
H
Disconnect and reconnect harness con-
nectors in the circuit. Then retest.

H
H
INSPECTION END
EC-80
Electric governor
Electronic injection pump
harness connector 1. Disconnect electronic injection pump harness connector.
2. Check continuity between injection pump connector termi-
nals p4 and p 7 .
Resistance: Approximately 1.0 [at 25C (77F)]
If NG, replace.
YEC361
EC-81
Timer piston Injection Timing Control Valve

The injection timing control valve is built into the fuel injection
High Low pump. It controls the timer piston to change the fuel injection
pres- pressure
sure timing.
The timing control valve is a solenoid valve located in the line
between high-pressure chamber and low-pressure chamber. It
changes fuel pressure in the high-pressure chamber.
When current flows through the solenoid (the solenoid turns ON),
Fuel injection timing
the timing control valve opens, advancing fuel injection timing.
control valve When current does not flow through it, the timing control valve
SEF638S
closes, retarding injection timing.
The ECM emits an ON-OFF duty cycle signal. The longer the
OFF-duration, the greater the advance angle. The longer the
ON-duration, the greater the retard angle. This means that
changing the ON-OFF duty cycle ratio makes it possible to
achieve an optimal advance angle and accurately control fuel
injection timing.
Check Items
(Possible cause)
Injection timing feedback system does not operate prop- Harness or connectors
erly. (This system consists essentially of ECM, injection [Injection timing control valve, needle lift sensor, crankshaft
timing control valve and needle lift sensor.) position sensor (TDC) circuits]
Needle lift sensor
Air in fuel line
Injection timing control valve circuit it open or shorted. Harness or connectors
(The Injection timing control valve is open or shorted.)

PROCEDURE FOR INJECTION TIMING CONTROL
SYSTEM
2) Start engine. Run engine for 10 seconds at idle.
NOTE:
If malfunction occurs intermittently, conduct suitable driv-
ing pattern for 10 minutes. This makes it possible to deter-
mine the diagnostic trouble.

PROCEDURE FOR INJECTION TIMING CONTROL
VALVE CIRCUIT
EC-82
Injection Timing Control Valve (Contd)
BATTERY
Refer to EL-POWER.

ENGINE
CONTROL INJECTION PUMP (INJEC-
MODULE TION TIMING CONTROL
RELAY VALVE)
ECM
YEC804
EC-83
Priming pump
INSPECTION START
H
CHECK FOR AIR IN FUEL FILTER.
1. Move priming pump up and down to
purge air from fuel filter.
2. Perform DIAGNOSTIC TROUBLE
SEF671S CODE CONFIRMATION PROCE-
DURE.
H
CHECK POWER SUPPLY. NG Check the following:
E
tion. E89 , F96
2. Disconnect injection timing control Electronic injection
valve harness connector. pump harness connec-
Fuel injection timing 3. Turn ignition switch to ON position. tor F49
control valve harness
connector 4. Check voltage between injection tim- 15A fuse
NEF804
ing control valve connector terminal Harness for open or
p 3 and ground with CONSULT-II or short-circuit between

tester. injection timing control
Voltage: Battery voltage valve harness connec-
Injection timing control
valve harness connector tor and ECM relay.
OK
connectors.
H
CHECK OUTPUT SIGNAL CIRCUIT. NG Check the following:
E
1. Turn ignition switch to LOCK posi- Electronic injection
NEF201A tion. pump harness connec-
2. Disconnect ECM harness connector. tor F49
3. Check harness continuity between Harness for open or
injection timing control valve connec- short-circuit between
tor terminal p 2 and ECM terminals injection timing control
Injection timing control 202 . valve and ECM.
valve harness connector
If OK, check harness for short-cir- connectors.
cuit.
OK
H
NEF202A
p
A
EC-84
p
A
H
CHECK COMPONENT NG Replace injection timing
E
(Injection timing control valve). control valve.
below.
OK
H

H
H
INSPECTION END
Injection timing 1. Disconnect injection timing control valve harness connector.
control valve
2. Check resistance between terminals p 2 and p3 .
Resistance: Approximately 15 [at 25C (77F)]
If NG, replace injection timing control valve.
YEC364
EC-85
Engine Control Module (ECM)

The ECM consists of a microcomputer and connectors for signal
input and output and for power supply. The module monitors and
controls the engine operation.
SEC220B
Check Item
(Possible Cause)
ECM calculation function is malfunctioning. ECM *
An excessively high or low voltage from the atmospheric ECM *
pressure sensor is detected by the ECM.
ECM reference voltage (2.5V) is excessively high or low. ECM *
ECM version number or switching function is not plausible. ECM *
Ignition switch ON signal evaluation circuit in ECM is ECM *
malfunctioning.
* Actually inspecting the ECM inside circuit is impossible. Then, ECM may be replaced.

PROCEDURE
EC-86
Cooling Fan (Overheat)

SYSTEM DESCRIPTION
Vehicle speed sensor Vehicle speed
E
Engine coolant temperature ECM Cooling

E fan
relay(s)
Air conditioner switch Air conditioner ON signal
E
The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, air con-
ditioner system pressure and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/
OFF]. This system indirectly relates to diagnostic trouble code 28 (Overheat).
Operation
Air conditioner is OFF Air conditioner is ON
temperature C (F)
temperature C (F)
Engine coolant
Engine coolant
. .
102 (216) 102 (216)
.
.
96 (205) 96 (205)
. . . .
20 80 20 80
(12) (50) (12) (50)
Vehicle speed km/h (mph) Vehicle speed km/h (mph)
Cooling fans do not operate Cooling fans operate at low speed Cooling fans operate at high speed
NEF772
ON-BOARD DIAGNOSIS LOGIC

This diagnosis continuously monitors the engine coolant temperature.
If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
indicated.
Check Items
(Possible Cause)
An excessive high engine coolant temperature sensor sig- Harness or connectors
nal is detected by the ECM. (Overheat) (The cooling fan circuit is open or shorted.)
Cooling fan
Radiator hose
Radiator
Radiator cap
Water pump
Thermostat
Fan belt

For more information, refer to 12 MAIN CAUSES OF
OVERHEATING, EC-CD-95.
CAUTION:
When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA
section (Changing Engine Coolant, ENGINE MAINTENANCE). Also, replace the engine oil.
a. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure
to use coolant with the proper mixture ratio. Refer to MA section (Anti-freeze Coolant Mixture
Ratio, RECOMMENDED FLUIDS AND LUBRICANTS).
b. After refilling coolant, run engine to ensure that no water-flow noise is emitted.
EC-87
Cooling Fan (Overheat) (Contd)
Use this procedure to check the overall function of the cooling
fan. During this check, a DTC might not be confirmed.
WARNING:
Never remove the radiator cap when the engine is hot. Seri-
MAX.
ous burns could be caused by high pressure fluid escaping
OK
from the radiator.
MIN.
Wrap a thick cloth around the cap. Carefully remove the cap
by turning it a quarter turn to allow built-up pressure to
escape. Then turn the cap all the way off.
AEC640 1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is
below the proper range, skip the following steps and go to
DIAGNOSTIC PROCEDURE, EC-CD-90.
2) Confirm whether customer filled the coolant or not. If cus-
tomer filled the coolant, skip the following steps and go to
DIAGNOSTIC PROCEDURE, EC-CD-90.
4) Perform COOLING FAN in ACTIVE TEST mode
with CONSULT-II (LOW speed and HI speed).
------------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------------
SEF111X
3) Start engine.
Be careful not to overheat engine.
4) Set temperature control switch to full cold position.
5) Push Air Conditioner switch to ON position.
6) Turn blower fan switch to ON position.
7) Run engine at idle for a few minutes with Air Con-
ditioner operating.
8) Make sure that both cooling fans operate at low
speed.
9) Turn ignition switch to LOCK position.
SEC163BA 10) Push Air Conditioner switch and blower fan switch
to OFF position.
11) Disconnect engine coolant temperature sensor
Cooling fan
harness connector.
Engine coolant 12) Connect 150 resistor to engine coolant tempera-
temperature sensor
harness connector ture sensor harness connector.
13) Restart engine and make sure that both cooling
fans operate at higher speed than low speed.
150 resistor
MEC475B
EC-88
BATTERY IGNITION SWITCH
ON or START
FUSE
BLOCK
(J/B) Refer to EL-POWER.
COOLING COOLING COOLING

FAN FAN FAN
RELAY-3 RELAY-2 RELAY-1
COOLING
TRIPLE- FAN
COOLING PRESSURE MOTOR-2
FAN HIGH SWITCH
MOTOR-1
LOW
ECM

YEC805
EC-89
INSPECTION START
.
Cooling fan relay 2
H
CHECK COOLING FAN LOW NG Check cooling fan low
E
SPEED OPERATION. speed control circuit.
1. Disconnect cooling fan relay-3. (Go to PROCEDURE A .)
2. Turn ignition switch to ON
Cooling fan relay-3 position.
Cooling fan relay-1 YEC383 3. Perform COOLING FAN
in ACTIVE TEST mode
with CONSULT-II.
------------------------------------------------------------- OR -------------------------------------------------------------
2. Start engine.
3. Set temperature switch at
full cold position.
4. Turn Air Conditioner switch
to ON position.
5. Turn blower fan switch to
ON position.
6. Run engine at idle speed
for a few minutes with Air
SEF111X
Conditioner operating.
7. Make sure that both cool-
ing fans operate at low
speed.
OK
H
Cooling fan
CHECK COOLING FAN HIGH NG Check cooling fan high
E
SPEED OPERATION. speed control circuit.
1. Turn ignition switch to LOCK (Go to PROCEDURE B .)
position.
2. Reconnect cooling fan relay-3.
NEF809 3. Disconnect cooling fan relay-1.
position.
5. Perform COOLING FAN
in ACTIVE TEST mode
with CONSULT-II.
------------------------------------------------------------- OR -------------------------------------------------------------
4. Turn Air Conditioner switch
and blower fan switch to
OFF position.
5. Disconnect engine coolant
temperature sensor har-
ness connector.
SEF111X 6. Connect 150 resistor to
engine coolant temperature
sensor harness connector.
Cooling fan 7. Restart engine and make
Engine coolant sure that both cooling fans
temperature sensor operate at higher speed
harness connector
than low speed.
OK
H
p
B
(Go to EC-CD-94.)
resistor
YEC384
EC-90
PROCEDURE A
Cooling fan relay-1

connector Cooling fan motor-1 INSPECTION START
connector
H
E
1. Turn ignition switch to LOCK posi- 10A fuse
tion. 40A, 100A, fusible
YEC385
2. Disconnect cooling fan relay-1 and links
fan motor-1 connector. Harness for open or
. 3. Turn ignition switch to ON position. short-circuit between
Under the vehicle A/C compressor
4. Check voltage between cooling fan cooling fan motor-1
motor-1 connector terminal p 1 , fan and battery.
relay-1 connector terminal p
.
Cooling fan motor-1 1 and Harness for open or
harness connector ground. short-circuit between
Voltage: Battery voltage cooling fan relay-1 and
fuse.
OK
If NG, replace fuse or
fusible links or repair har-
ness or connectors.
NEF416 H
. CHECK GROUND CIRCUIT. NG Repair harness or con-
Under the vehicle . E
Radiator 1. Turn ignition switch to LOCK posi- nectors.
lower hose tion.
2. Disconnect cooling fan relay-2 and
.
Cooling fan fan motor-2 harness connector.
motor-2
harness 3. Check harness continuity
connector between cooling fan relay-1 con-
nector terminal p 5 and cooling
fan relay-2 connector terminal
p 4 ; cooling fan motor-1 con-
nector terminal p 2 and cooling
NEF417
fan relay-2 connector terminal
p 3 . Continuity should exist.
If OK, check harness for short-
circuit.
Cooling fan motor-1
connector Cooling fan relay-2
4. Check harness continuity
Cooling fan connector between cooling fan motor-2
relay-1 con- connector terminal p 1 and
nector
cooling fan relay-1 connector
terminal p 3 ; cooling fan
motor-2 connector terminal p 2
and ground. Continuity should
YEC386 exist.
circuit.
OK
Cooling fan Cooling fan motor-2 H
relay-1 connector connector
p
C
YEC387
EC-91
p
C
Cooling fan relay-1

connector H
E
1. Disconnect ECM harness connector. Harness connectors E43 ,
2. Check harness continuity between ECM F2
terminal 219 and cooling fan relay-1 con- Harness for open or short-
nector terminal p
2 . circuit between cooling fan
Continuity should exist. relay-1 and ECM
If OK, check harness for short-circuit. If NG, repair harness or con-
nectors.
NEF207A OK
H
CHECK COMPONENT NG Replace cooling fan relay.
E
(Cooling fan relay-1, 2).
Refer to COMPONENT INSPECTION,
EC-CD-96.
OK
H
CHECK COMPONENT NG Replace cooling fan motors.
E
(Cooling fan motors).
Refer to COMPONENT INSPECTION,
EC-CD-96.
OK
H

H
and retest.
H
INSPECTION END
PROCEDURE B
Cooling fan Cooling fan INSPECTION START

Cooling fan motor-1 relay-2
relay-3 connector connector
connector
H
E
1. Turn ignition switch to LOCK position. 10A-fuse
2. Disconnect cooling fan relay-2, 3 and 40A, 50A, 100A fusible
cooling fan motor-1. links
3. Turn ignition switch to ON position. Harness for open or
NEF203A 4. Check voltage between cooling fan short-circuit between fan
motor-1 connector terminal p 1 ; cooling motor-1, fan relay-3 and
fan relay-2 connector terminal p1 ; cool- fusible link or fan relay-2,
ing fan relay-3 connector terminals p 1 & 3 and fuse.
p3 and ground. If NG, replace fuse or fus-
Voltage: Battery voltage ible link or repair harness or
connectors.
OK
H
p
D
EC-92
p
D
H
CHECK GROUND CIRCUIT. NG Repair harness or connec-
Cooling fan motor-1 Cooling fan relay-2 E
connector connector 1. Turn ignition switch to LOCK position. tors.
2. Disconnect cooling fan motor-2 harness
connector.
cooling fan motor-1 connector termi-
nal p 2 and cooling fan relay-2 con-
nector terminal p 3 ; cooling fan
motor-2 connector terminal p 1 and
cooling fan relay-3 connector termi-
nal p 5 ; cooling fan relay-2 connec-
tor terminal p 5 and ground.
Cooling fan relay-3 cooling fan motor-2 terminal p 2 and
connector
Cooling fan ground.
motor-2
connector OK
H
E
NEF876 2. Check harness continuity between ECM E43 , F2
terminal 220 and cooling fan relay-3 Harness for open or
connector terminal p2 & cooling fan short-circuit between
relay-2 connector terminal p
2 . cooling fan relay-2, 3 and
Continuity should exist. ECM.
If OK, check harness for short-circuit. If NG, repair harness or
Cooling fan motor-2
connectors.
connector E18 OK
H
CHECK COMPONENT NG Replace cooling fan relays.
E
(Cooling fan relay-2, 3).
Refer to COMPONENT INSPECTION, EC-
CD-96.
OK
YEC389 H
CHECK COMPONENTS NG Replace cooling fan motors.
E
(Cooling fan motors).
Refer to COMPONENT INSPECTION, EC-
CD-96.
Cooling fan
relay-3
OK
H
connector
Trouble is not fixed

Cooling fan H
relay-2
connector Check ECM pin terminals for damage and
NEF204A nector. Reconnect ECM harness connector
and retest.
H
INSPECTION END
EC-93
p
B
Hose adapter
H
NG
CHECK COOLING SYSTEM FOR LEAK. E Check the following
Apply pressure to the cooling system with a for leaks:
tester, and check if the pressure drops. Hose
Testing pressure: Radiator
157kPa (1.57 bar, 1.6 kg/cm2, 23 psi) Water pump
Pressure should not drop. Refer to LC section
CAUTION: (Water Pump).
Higher than the specified pressure may
cause radiator damage.
.
SLC754AA
OK
H
NG
CHECK RADIATOR CAP. E Replace radiator
Apply pressure to cap with a tester. cap.
Radiator cap relief pressure:
Standard
78 - 98 kPa (0.78 - 0.98 bar,
0.8 - 1.0 kg/cm2, 11 - 14 psi)
Limit
59 - 88 kPa (0.59 - 0.88 bar,
0.6 - 0.9 kg/cm2, 9 - 13 psi)
OK
H
SLC755AA NG
CHECK THERMOSTAT. E Replace thermostat.
1. Check valve seating condition at normal
room temperatures.
It should seat tightly.
2. Check valve opening temperature and
maximum valve lift.
Valve opening temperature:
76.5C (170F) [standard]
Maximum valve lift:
More than 8 mm/90C
(0.31 in/194F)
3. Check if valve is closed at 5C (9F)
below valve opening temperature.
For details, refer to LC section
SLC343 (Thermostat).
OK
H
NG
Check engine coolant temperature sensor. E Replace engine cool-
Refer to COMPONENT INSPECTION, ant temperature sen-
EC-69. sor.
OK
H
If the cause can not be isolated, go to 12
MAIN CAUSES OF OVERHEATING on
next page.
H
INSPECTION END
Perform FINAL CHECK by the following procedure after

repair is completed.
1. Warm up engine. Run the vehicle for at least 20 minutes. Pay
attention to engine coolant temperature gauge on the instru-
ment panel. If the reading shows an abnormally high
temperature, another part may be malfunctioning.
2. Stop vehicle and let engine idle. Check the intake and
exhaust systems for leaks by listening for noise or visually
inspecting the components.
3. Allow engine to cool and visually check for oil and coolant
leaks. Then, perform OVERALL FUNCTION CHECK.
EC-94
12 MAIN CAUSES OF OVERHEATING
Engine Step Inspection item Equipment Standard Reference page
OFF 1 Blocked radiator Visual No blocking
Blocked condenser
Blocked radiator grille
Blocked bumper
2 Coolant mixture Coolant tester 50 - 50% coolant mix- See RECOMMENDED
ture FLUIDS AND LUBRI-
CANTS in MA section.
3 Coolant level Visual Coolant up to MAX level See Changing Engine
in reservoir tank and Coolant, ENGINE
radiator filler neck MAINTENANCE in MA
section.
4 Radiator cap Pressure tester 78 - 98 kPa See System Check
(0.78 - 0.98 bar, 0.8 - ENGINE COOLING
1.0 kg/cm2, 11 - 14 psi) SYSTEM in LC section.
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 -
1.0 kg/cm2, 9 - 14 psi)
(Limit)
ON*2 5 Coolant leaks Visual No leaks See System Check
ENGINE COOLING
SYSTEM in LC section.
ON*2 6 Thermostat Touch the upper and Both hoses should be See Thermostat and
lower radiator hoses hot Radiator, ENGINE
COOLING SYSTEM in
LC section.
ON*1 7 Cooling fan CONSULT Operating See TROUBLE DIAG-
NOSIS 8.
OFF 8 Combustion gas leak Color checker Negative
chemical tester
4 Gas analyzer
ON*3 9 Coolant temperature Visual Gauge less than 3/4
gauge when driving
Coolant overflow to Visual No overflow during driv- See Changing Engine
reservoir tank ing and idling Coolant, ENGINE
MAINTENANCE in MA
section.
OFF*4 10 Coolant return from Visual Should be initial level in See ENGINE MAINTE-
reservoir tank to reservoir tank NANCE in MA section.
radiator
OFF 11 Cylinder head Straight gauge feeler 0.1 mm (0.004 in) Maxi- See Inspection, CYL-
gauge mum distortion (warping) INDER HEAD in EM
section.
12 Cylinder block and Visual No scuffing on cylinder See Inspection, CYL-
pistons walls or piston INDER BLOCK in EM
section.
*1: Turn the ignition switch ON.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 mph) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
For more information, refer to OVERHEATING CAUSE ANALYSIS in LC section.
EC-95
Cooling fan relay 1 Cooling fan relays-1, -2, -3
Check continuity between terminals p
3 and p
5 .
Conditions Continuity
12V direct current supply between relay
5 Yes
terminals p1 and p 2
1 2
3 No current supply No
If NG, replace cooling fan relay.
Cooling fan relay 3 Cooling fan relay-2

Check continuity between terminals p
3 and p
4 .
No current supply Yes
5
12V direct current supply between relay
2 4 1 No
terminals p1 and p 2
3
Cooling fan relay 2
5
2 4 1
3
YEC391
Cooling fan motors-1 and -2

1. Disconnect cooling fan motor harness connectors.
2. Supply cooling fan motor terminals with battery voltage and
Cooling fan check operation.
motor-1 & -2
Terminals
FUSE (!) (@)
Cooling fan motor-1 and -2 p
1 p
2
Cooling fan motor should operate.

AEC781 If NG, replace cooling fan motor.
EC-96
Needle Lift Sensor (NLS)

Nozzle holder
The needle lift sensor is built into the No. 1 nozzle. Its inductive
Inductive
pick-up coli pick-up element senses the lifting of the injection nozzle needle
and thus the start of injection. The signal is evaluated by the
ECM and compared with the target timing. Deviations in timing,
for example caused by changes in fuel temperature, are sensed
by the ECM and corrected.
Nozzle
NEF689
Check Items
(Possible Cause)
An improper signal from the sensor is sent to ECM. Harness or connectors
Needle lift sensor
Air in fuel line
Clogging No. 1 injection nozzle

PROCEDURE
NOTE:
Before diagnostic trouble confirmation, be sure to check
battery voltage is above 9V.
1) Turn ignition switch to ON position and select
DATA MONITOR mode with CONSULT-II.
2) Start engine and run it for 2 seconds above 1,200
rpm.
EC-97
Needle Lift Sensor (NLS) (Contd)
NEEDLE
LIFT SEN-
SOR

ECM
YEC806
EC-98
Needle Lift Sensor (NLS) (Contd)
Priming pump INSPECTION START
H
CHECK FOR AIR IN FUEL FILTER.
1. Move priming pump up and down to
purge air from fuel filter.
2. Perform DIAGNOSTIC TROUBLE
CODE CONFIRMATION PROCE-
SEF671S DURE.
Needle lift sensor

harness connector H
CHECK INPUT SIGNAL CIRCUIT. NG Repair harness or con-
E
tion.
2. Disconnect ECM harness connector
and needle lift sensor harness con-
nector.
needle lift sensor connector terminal
SEF606S
p 1 and ECM connector terminal
345 .
cuit.
Needle lift sensor
connector OK
H
E
Check resistance between needle lift nectors.
sensor connector terminal p2 and
ECM connector terminal 333 .
NEF206A If OK, check harness for short-circuit.
OK
H
CHECK NO. 1 INJECTION NOZZLE
Needle lift sensor FOR CLOGGING.
connector Refer to spray pattern test of INJEC-
TION NOZZLE.
If NG, replace No. 1 injection nozzle.
H
NEF205A
H
H
INSPECTION END
EC-99
Fuel Cut Solenoid Valve

Fuel cut solenoid valve When the ignition switch is OFF, the ECM turns the fuel cut
solenoid valve OFF (under this condition, no current flows
through the fuel cut solenoid valve), shutting off fuel supply.
Ignition
switch
When the engine is not operating due to trouble, the fuel cut
ECM solenoid valve may be OFF even when the ignition switch is ON.
SEF667S
Check Items
(Possible Cause)
Fuel cut solenoid valve circuit is malfunctioning. Harness or connectors
(The solenoid valve circuit is open or shorted.)

PROCEDURE
3) Start engine. (If no start, circuit is open).
4) Warm engine up sufficiently.
5) Turn ignition switch to LOCK position and wait at
least 5 seconds.
6) Start engine and rev it up above 1,300 rpm.
Release pedal and wait at least 3 seconds.
EC-100
Fuel Cut Solenoid Valve (Contd)
BATTERY
Refer to EL-POWER.

INJECTION PUMP
(FUEL CUT SOLE-
NOID VALVE)
ENGINE
CONTROL
MODULE
RELAY
ECM
YEC807
EC-101
. DIAGNOSTIC PROCEDURE
Electronic injection
pump harness connector
(Fuel cut solenoid valve) INSPECTION START
H
Check power supply. Refer to
EC-CD-59.
H
NEF815
CHECK OUTPUT SIGNAL CIRCUIT. NG Repair harness or con-
E
1. Turn ignition switch to ON nectors.
position.
2. Select FUEL CUT SOL/V in
ACTIVE TEST mode with
CONSULT-II.
3. Touch ON and OFF alter-
nately.
4. Check that operating sound is
emitted.
----------------------------------------------------------------- OR -----------------------------------------------------------------
C2FCS01 1. Turn ignition switch to LOCK
position.
2. Disconnect ECM harness con-
nector and electronic injection
Electronic injection pump harness connector.
pump harness con-
nection 3. Check harness continuity
between fuel cut solenoid valve
connector terminal p 1 and
ECM connector terminal 349 .
If OK, check harness for short.
NEF226A OK
H
CHECK COMPONENT NG Replace fuel cut solenoid
E
(Fuel cut solenoid valve). valve.
on next page.
OK
H

H
H
INSPECTION END
EC-102
FUSE
1. Remove fuel cut solenoid valve.
2. Check for lifting shaft when applying 12V direct current to
terminals.
If NG, replace fuel cut solenoid valve.
Shaft SEF859S
EC-103
Fuel Temperature Sensor (FTS)

The fuel temperature sensor is used to detect the fuel tempera-
ture in the injection pump. The sensor modifies a voltage signal
from the ECM. The modified signal returns to the ECM as the fuel
temperature input. The sensor uses a thermistor which is sensi-
tive to the change in temperature. The electrical resistance of the
thermistor decreases as temperature increases.
The sensor is built into the inside electrical circuit of the injection
pump.
Check Items
(Possible Cause)
detected by ECM. (The sensor circuit is open or shorted.)

PROCEDURE
EC-104
Fuel Temperature Sensor (FTS) (Contd)
INJECTION PUMP
(FUEL TEMPERATURE
SENSOR)

ECM
YEC808
EC-105
. DIAGNOSTIC PROCEDURE
Electronic injection
pump harness connector
(Fuel temperature sensor) INSPECTION START
H
CHECK POWER SUPPLY. NG Repair harness or con-
E
tion.
2. Disconnect fuel temperature sensor
harness connector.
NEF818
4. Check voltage between injection
pump connector terminal p 6 and
ground with CONSULT-II or voltage
Injection pump tester.
connector
Voltage:
Approximately 5V
OK
H
E
NEF819 1. Turn ignition switch to LOCK posi- nectors.
tion.
injection pump connector terminal
Injection pump p 5 and ECM connector terminals
connector 335 , 436 .
F50
cuit.
OK
H
NEF208A CHECK COMPONENT NG Have the injection pump
E
(Fuel temperature sensor). assembly serviced by an
Refer to COMPONENT INSPECTION authorised service repre-
on next page. sentative.
OK
H
connectors in the circuits. Then retest.
H
H
INSPECTION END
EC-106
Wait until fuel temperature sensor reaches room temperature.
Check resistance between terminals p 5 and p 6 .
Fuel temperature C (F) Resistance k

25 (77) Approximately 1.9
If NG, have the injection pump assembly serviced by an autho-

YEC366 rised service representative.
EC-107
Accelerator Position Sensor & Switch

The accelerator position sensor is installed on the upper end of
the accelerator pedal assembly. The sensor detects the accel-
erator position and sends a signal to the ECM. The ECM uses
the signal to determine the amount of fuel to be injected.
Output voltage between terminal No. 4 and 5 (V)
Throttle valve opening angle (deg)
NEF822
Check Items
(Possible Cause)
An excessively low or high voltage from the sensor is Harness or connectors
detected by the ECM. (The sensor or switch circuit is open or shorted.)
Accelerator position switch

PROCEDURE
3) Depress accelerator pedal fully and keep it for at least
1 second. Then release it and wait at least 5 seconds.

PROCEDURE (For accelerator stiching)
3) Start engine and rev it up above 1,300 rpm.
4) Depress brake pedal immediately after releasing
accelerator pedal and keep it at least 5 seconds.
EC-108
(Contd)
ACCELERATOR
POSITION SEN-
SOR

ECM
YEC809
EC-109
(Contd)
ECM

ACCELERATOR
DEPRESSED WORK UNIT
RELEASED
YEC810
EC-110
(Contd)
Accelerator
pedal INSPECTION START
sensor harness con-
nector (Accelerator position sensor)
H
NG
CHECK POWER SUPPLY. Check the following:
E
1. Turn ignition switch to LOCK position. Harness connectors
2. Disconnect accelerator position sensor M50 , F104
NEF823
harness connector. Harness for open or
3. Turn ignition switch to ON position. short-circuit between
4. Check voltage between accelerator posi- ECM and accelerator
tion sensor connector terminal p 5 and position sensor.
ground with CONSULT-II or voltage If NG, repair harness or
tester. connectors.
Accelerator position Voltage: Approximately 5V
sensor connector
OK
H
CHECK GROUND CIRCUIT. NG Check the following:
E
1. Turn ignition switch to LOCK position. Harness connectors
2. Check harness continuity between accel- M50 , F104
NEF824 erator position sensor connector terminal Harness for open or
p 4 and engine ground. short-circuit between
Continuity should exist. ECM and accelerator
If OK, check harness for short-circuit. position sensor.
OK connectors.
sensor connector
H
CHECK INPUT SIGNAL CIRCUIT. NG Check the following
E
2. Check harness continuity between ECM M50 , F104
terminal 434 and accelerator position Harness for open or
sensor connector terminal p2 . short-circuit between
NEF825 Continuity should exist. ECM and accelerator
If OK, check harness for short-circuit. position sensor
OK connectors.
Accelerator position H
sensor connector CHECK COMPONENT NG
Replace accelerator pedal
E
(Accelerator position sensor). assembly.
EC-CD-113.
OK
H
NEF209A tors in the circuit. Then retest.

H
and retest.
H
INSPECTION END
EC-111
(Contd)
INSPECTION START
(Accelerator position switch)
H
OK
CHECK OVERALL FUNCTION. E
INSPECTION END
position.
2. Check OFF ACCEL POS in
PEF123W DATA MONITOR mode with
CONSULT-II.
Accelerator pedal released:
ON
Accelerator pedal depressed:
OFF
---------------------------------------------------------------- OR ----------------------------------------------------------------
1. Turn ignition switch to LOCK
position.
2. Check continuity between ECM
connector terminal 435 and
ground.
Continuity:
Accelerator pedal released:
No
NEF210A Accelerator pedal depressed:
Yes
NG
H
Accelerator
NG
CHECK GROUND CIRCUIT. E
Check the following:
switch con- 1. Disconnect accelerator switch harness Harness connectors
nector connector. M52 , F103
2. Check harness continuity between Harness for open circuit
accelerator switch connector terminal between accelerator switch
p1 and ECM connector terminal 426 . and ECM connector termi-
Continuity should exist. nal 426 .
If NG, repair harness or con-
OK nectors.
NEF212A H
NG
CHECK INPUT SIGNAL CIRCUIT. E
Check the following:
Check harness continuity between ECM Harness connectors
connector terminal 435 and accelerator F103 , M52
switch connector terminal p
3 . Harness for open or short-
Continuity should exist. circuit between accelerator
Accelerator
switch connector
switch and ECM
OK
H
NG
CHECK COMPONENT E
Replace accelerator switch.
(Accelerator switch).
on next page.
OK
H
NEF211A Disconnect and reconnect harness connec-
H
and retest.
H
INSPECTION END
EC-112
(Contd)
sensor connector
M68
1 2 3 4 5 M68
1. Disconnect accelerator position sensor harness connector.
2 4 2. Make sure that resistance between accelerator position sen-
sor terminals p2 and p 4 changes when opening throttle
valve manually.
Throttle valve conditions Resistance [at 25C (77F)]
YEC368
Completely closed Approximately 1.2 k
Partially open 1.2 - 1.9 k
Completely open Approximately 1.9 k
If NG, replace accelerator pedal assembly.
CAUTION:
Do not disassemble accelerator pedal assembly.
Accelerator position COMPONENT INSPECTION

sensor connector
Accelerator switch
M68
1. Disconnect accelerator switch harness connector.
1 2 3 4 5 M68 2. Check continuity between accelerator switch connector ter-
1 3 minals p
1 and p 3 .
Accelerator pedal released No
Accelerator pedal depressed Yes
YEC369
If NG, replace accelerator pedal assembly.
CAUTION:
Do not disassemble accelerator pedal assembly.
EC-113
TROUBLE DIAGNOSIS 13 CD20E
Core Crankshaft Position Sensor (TDC)

The crankshaft position sensor (TDC) monitors engine speed by
means of signals from the sensing plate (with two protrusions)
installed to the crankshaft pulley. The datum signal output is
detected at ATDC 70 and sent to the ECM. The sensor signal
is used for fuel injection control and fuel injection timing control.
Magnet
Coil
SEF615S
Crank pulley
Crankshaft position
sensor (TDC)
SEF616S
Check Items
(Possible Cause)
An incorrect signal from the sensor is detected by ECM Harness or connectors
during engine running and cranking. (The sensor circuit is open.)

PROCEDURE
Before performing the following procedure, confirm
that battery voltage is more than 9V.
1) Turn ignition switch to ON position and select
2) Start engine and run it for at least 3 seconds above
1,200 rpm.
EC-114
Crankshaft Position Sensor (TDC) (Contd)
CRANKSHAFT POSI-
TION SENSOR (TDC)

ECM
YEC811
EC-115
INSPECTION START
H
CHECK INPUT SIGNAL CIRCUIT. NG Repair harness or con-
E
tion.
Crankshaft position
sensor (TDC) 2. Disconnect crankshaft position sen-
harness connector sor (TDC) and ECM harness con-
SEF617S
nectors.
3. Check continuity between ECM ter-
minal 344 and crankshaft position
sensor (TDC) connector terminal
Crankshaft position p 3 .
harness connector Continuity should exist.
cuit.
OK
H
Loosen and retighten engine ground
NEF213A
screws.
OK
H
Crankshaft position E
sensor connector Check harness continuity between nectors.
crankshaft position sensor (TDC) con-
nector terminal p2 and ECM connec-
tor terminal 331 .
NEF214A
OK
H
CHECK COMPONENT NG Replace crankshaft posi-
E
[Crankshaft position sensor (TDC)]. tion sensor (TDC).
on next page.
OK
H
H
H
INSPECTION END
EC-116
1. Disconnect crankshaft position sensor (TDC) harness con-
nector.
2. Loosen the fixing bolt of the sensor.
3. Remove the sensor.
4. Visually check the sensor for chipping.
5. Check resistance between crankshaft position sensor (TDC)
terminals p2 and p 3 .
SEF620S Resistance: Approximately 1.2 - 1.5k

[at 25C (77F)]
If NG, replace crankshaft position sensor (TDC).
Crankshaft position
sensor (TDC) con-
nector
NEF440
EC-117
TROUBLE DIAGNOSES 14 CD20T
.
Glow Control System
Glow lamp indicator When coolant temperature is lower than 75C (167F):
Ignition switch ON
After ignition switch has been turned to ON, the glow relay
turns ON for a period of time depending on engine coolant
Time , [S]
temperature, allowing current to flow through the glow plugs.

Starting
.
After starting the engine, current will flow through the glow
1.5
plugs for 300 seconds, or until the coolant temperature
.
exceeds 50C (122F).
(-40) (-4) (32) (68) (104) (140)
Engine coolant temperature , C (F)
Pre-glow
Time , [S]
.
(-40) (-4) (32) (68) (104) (140)
.
.
Post glow
Time , [S]
.
.
(-40) (-4) (32) (68). (104)
.
(140)
NEF834
COMPONENT DESCRIPTION
Glow plug
Ceramic heater
Resistor The glow plug is provided with a ceramic heating element to
obtain a high-temperature resistance. It glows in response to a
signal sent from the ECM, allowing current to flow through the
glow plug via the glow relay.
SEF857S
Check Items
(Possible cause)
Glow relay signal circuit is open or shorted. Harness or connectors
(The glow relay signal circuit is open or shorted)
Glow relay
Glow indicator lamp circuit is open or shorted. Harness or connectors
(The glow indicator lamp circuit is open or shorted.)
Glow lamp
EC-118
Glow Control System (Contd)
PROCEDURE
EC-119
YEC102A
EC-120
Glow relay
INSPECTION START
(Glow relay signal circuit)
H
Check power supply to ECCS-D relay.
Refer to TROUBLE DIAGNOSIS FOR
Glow relay
harness connector POWER SUPPLY (EC-CD-59).
NEF835
H
E
1. Turn ignition switch to the LOCK 15A fuse
position. 80A fusible link
Glow relay con-
nector
2. Disconnect glow relay. Harness continuity
3. Turn ignition switch to the ON posi- between glow relay
tion. and fuse.
4. Check voltage between glow relay If NG, replace fuse or
connector terminals p 1 , p
5 and fusible link or repair har-
ground with tester. ness or connectors.
YEC370
OK
H
CHECK OUTPUT SIGNAL CIRCUIT. NG Check harness connec-
E
1. Turn ignition switch to the LOCK tors F96 , E89
Glow relay
connector position. Repair harness or con-
2. Disconnect ECM harness connector. nectors.
ECM connector terminal 214 and
glow relay connector terminal p 2 .
cuit.
NEF215A
OK
H
CHECK GLOW PLUG AND GLOW NG Replace glow plug or
E
RELAY. glow relay.
(EC-CD-124, 125).
OK
H
H
H
INSPECTION END
EC-121
INSPECTION START
(Glow indicator lamp circuit)
H
CHECK POWER SUPPLY CIRCUIT. NG Check the following:
E
1. Turn ignition switch to LOCK posi- Harness for open or
tion. short-circuit between
2. Disconnect combination meter har- combination meter and
ness connector. battery.
3. Turn ignition switch to ON position. 10A fuse
4. Check voltage between combination If NG, replace fuse or
meter harness connector terminal repair harness or con-
p 5 or p1 and body ground. nectors.
OK
H
E
tion. M50 , F104
2. Disconnect ECM harness connector. Harness for open or
YEC119A
3. Check harness continuity between short-circuit between
ECM connector terminal 221 and ECM and combination
combination meter connector termi- meter.
nal p 7 or p17 . If NG, repair harness or
Continuity should exist. connectors.
cuit.
OK
H
CHECK GLOW INDICATOR LAMP. NG Replace glow indicator
E
Make sure that glow indicator lamp is lamp.
not burnt out.
OK
H
H
H
YEC120A INSPECTION END
EC-122
INSPECTION START
(Glow plug circuit)
Glow relay connector
H
CHECK POWER SUPPLY-I. NG Check the following:
E
1. Turn ignition switch to LOCK posi- Harness for open or
tion. short-circuit between
2. Disconnect glow relay harness con- glow relay and battery.
nector. 80A fusible link
NEF873 3. Check voltage between glow relay If NG, replace fusible link
harness connector terminal p 5 and and repair harness con-
engine ground. nectors.
Glow relay Glow plug OK
connector connector
H
CHECK POWER SUPPLY-II. NG Check the following:
E
1. Disconnect glow plug harness con- Harness connectors
nector. E2 , F46
2. Check harness continuity between Harness for open or
glow plug harness connector and short-circuit between
YEC374
glow relay harness connector termi- glow plug and glow
nal p 3 . relay.
If OK, check harness for short-cir- connector.
cuit.
OK
H
CHECK GLOW PLUG AND GLOW NG Replace glow plug or
E
RELAY. glow relay.
(EC-CD-124, 125).
OK
H
H
INSPECTION END
EC-123
SYSTEM OPERATION CHECK
Set voltmeter between glow plug and engine body.
Glow plug plate
SEC554B
1. Pre-glow control system

a. Turn ignition switch to ON position.
b. Read voltage.
Voltage:
Pre-glow time
Battery voltage for an engine coolant temperature

dependent time.
* Repeatedly turning the ignition switch to ON
position and to LOCK position may change
the pre-glow time.
.
(-4) (32) (68) (104)
Engine coolant temperature NEF838
2. After-glow system
Start engine and read voltage.
Voltage:
After glow time (sec.)
Battery voltage for 5* minutes

* Engine coolant temperature is lower than 50C
(122F).
.
(-4) (32) (68) (104)
NEF839
Glow relay Glow relay
1. Check relay for coil continuity between glow relay terminals
p3 p
2 p 1 and p 2 .
2. Check relay for proper operation by applying 12V dc voltage
between glow relay terminals p 1 and p 2 and checking con-
p5 p1 tinuity between terminals p3 and p 5 .
Coil voltage Continuity p

3 and p
5 Contact point
0V No OFF
Contact point
12V Yes ON
12V dc
Ohmmeter
SEC564B
EC-124
Glow plug
1. Remove glow plug connecting plate.
2. Check each glow plug for continuity.
Continuity should exist:
Approximately 0.5 [at 25C (77F)]
Ohmmeter
If NG, replace glow plug.
SEF630K
Glow nut 3. Install glow plug connecting plate securely.

Do not bump glow plug heating element. If it is bumped,
replace glow plug with new one. (If glow plug is dropped
Glow harness
Connecting
from a height of 0.1 m (3.94 in) or greater, replace with
plate new one.)
If glow plug installation hole is contaminated with
Washer carbon, remove using a reamer or suitable tool.
Spring washer Hand-tighten glow plug by turning it 2 to 3 times, then
tighten using a tool to specified torque.
Glow plug
: 15 - 20 Nm (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
SEC565B
EC-125
Air Conditioner Cut Control

The Air Conditioner relay is controlled by the ECM. During the
following conditions, the ECM will cut the power supply towards
the air conditioner relay:
Starting engine
Quick acceleration from low speed
Undershooting of idle speed
High engine coolant temperature [above 107C (225F)].
Malfunctioning of engine speed sensor, accelerator position
sensor or vehicle speed sensor when engine speed is below
2,100 rpm.
Check Items
(Possible cause)
Air conditioner relay signal circuit is shorted. Harness or connectors
(The air conditioner relay signal circuit is shorted).

PROCEDURE
1) Turn ignition switch and air conditioner switch to the
ON position.
EC-126
Air Conditioner Cut Control (Contd)
IGNITION SWITCH
ON or START
FUSE
BLOCK
(J/B) Refer to EL-POWER.

AIR CONDITIONER
RELAY
To compressor
(Refer to HA-A/C.)
A/C
CONTROL
PANEL
THERMO
TRIPLE- CONTROL
LOW HIGH PRESSURE AMP.
SWITCH
NORMAL
THERMISTOR
ECM

YEC813
EC-127
Air Conditioner Cut Control (Contd)
INSPECTION START
(Air conditioner relay signal circuit)
harness connector
H
E
1. Turn ignition switch to LOCK posi- Harness and connec-
tion. tors for open or short-
2. Disconnect air conditioner relay har- circuit between ignition
ness connector. switch and air condi-
YEC375 3. Turn ignition switch to ON position. tioner relay.
4. Check voltage between air condi- 10A fuse
tioner relay connector terminals p 2 , If NG, replace or repair
p 5 and engine ground. the parts affected.
Air conditioner relay Voltage: Battery voltage
harness connector
OK
H
E
tion. E43 , F2
2. Disconnect ECM harness connector. Harness for open or
NEF218A
3. Check harness continuity between short-circuit between
ECM harness connector terminal ECM and air condi-
204 and air conditioner relay har- tioner relay.
ness connector terminal p 1 . If NG, repair harness or
Continuity should exist. connectors.
cuit.
OK
H
CHECK AIR CONDITIONER RELAY. NG Replace air conditioner
E
Refer to HA section for inspection. relay.
OK
H
H
H
INSPECTION END
EC-128
EGRC-Solenoid Valve
SYSTEM DESCRIPTION
Engine speed
Camshaft position sensor (TDC)
E
Air conditioner ON signal

Air conditioner switch EGRC-solenoid valve
E E
Engine coolant temperature ECM

E
Atmospheric pressure
Atmospheric pressure sensor
E
Mass air flow

E
The ECM receives signals sent from the engine coolant tempera-
ture sensor, crankshaft position sensor (TDC), atmospheric pres-
sure sensor, mass air flow sensor and air conditioner switch to
determine engine speed and operating conditions. Based on
these signals, the ECM controls the EGR control solenoid valve
operation.
No EGR operation will take place when the engine coolant tem-
perature is below 70C (158F), when idling, at starting and dur-
ing a period of time after starting the engine (70 - 200 seconds,
depending on engine coolant temperature).
Engine coolant Load EGRC-solenoid valve EGR valve Amount of EGR gas
temperature C (F)
Below 70 (158) Any OFF Fully closed

(Closed)
ON
Low load (Open) Fully open Large
Above 70 (158)
High load OFF Fully closed
(Closed)
COMPONENT DESCRIPTION
To control valve
The EGR control solenoid valves control vacuum pressure act-
To intake
air flow ing on the EGR valve. The EGR control valve will then be fully
opened or fully closed, as required.
Thus, intake air passages are opened or closed in relation to
Vacuum
signal
exhaust gas and intake air. Utilizing the relationship between
exhaust gas pressure and intake air pressure control, the amount
of EGR (exhaust gas recirculated) is regulated in large or small
volumes.
SEF240PH
Check Items
(Possible cause)
EGRC-solenoid valve A circuit is shorted. Harness or connectors
(EGRC-solenoid valve A circuit is open or shorted).
EGRC solenoid valve A
EC-129
EGRC-Solenoid Valve (Contd)
PROCEDURE
1) Turn ignition switch to the ON position.
EC-130
BATTERY
Refer to EL-POWER. : Detectable line for DTC

ENGINE
CONTROL
MODULE
RELAY
EGRC- EGRC-
SOLENOID SOLENOID
VALVE A VALVE B
ECM
YEC814
EC-131
INSPECTION START
EGRC solenoid valve A (Circuit for EGRC-solenoid valve A)
harness connector
H
Refer to Trouble Diagnosis for main
power supply (EC-CD-59)
NEF219A
H
E
1. Turn ignition switch to the LOCK Harness continuity
position. between ECM relay
2. Disconnect EGRC-solenoid valve A and EGRC-solenoid
EGRC solenoid
valve A harness harness connector. valve A connector.
connector 3. Turn ignition switch to the ON posi- If NG, repair harness or
tion. connectors.
4. Check voltage between connector
terminal p 2 and engine ground.
OK
NEF220A
H
E
1. Turn ignition switch to the LOCK Harness for open or
position. short-circuit between
2. Disconnect ECM harness connector. ECM and solenoid
3. Check harness continuity between valve.
ECM harness connector terminal If NG, repair harness or
208 and EGRC solenoid valve A connectors.
connector terminal p 1 .
cuit.
OK
H
CHECK COMPONENTS NG Replace malfunctioning
E
(EGRC-solenoid valve). component(s).
EC-CD-135.
OK
H
H
or the connection of ECM harness con-
nector. Reconnect ECM harness con-
nector and retest.
H
INSPECTION END
EC-132
INSPECTION START
EGR EGR CONTROL OPERATION
valve
H
CHECK OVERALL FUNCTION. OK INSPECTION END
E
1. Start engine and warm it up suffi-
ciently. (Air conditioner is OFF).
2. Perform diagnostic test mode II
NEF433
(Self-diagnostic results).
Make sure that diagnostic trouble
code No. 55 is displayed.
3. Make sure that EGR diaphragm
moves up and down (Use your finger
EGR or a suitable tool) under the following
valve conditions:
At idle:
Spring does not move.
Racing engine from idle to 2800
rpm:
NEF434 Spring moves up and down.
NG
H
CHECK VACUUM SOURCES TO EGR OK CHECK COMPONENTS
E
VALVE. (EGR valve).
1. Disconnect vacuum hoses to EGR (See page EC-CD-135.)
valve.
NG
2. Make sure that vacuum exists under
the following conditions:
At idle:
H
Vacuum should not exist.
Replace malfunctioning
Racing engine from idle to 2800
component(s).
rpm:
Vacuum should exist.
NG
H
p
A
EC-133
p
A
H
CHECK CONTROL FUNCTION. OK CHECK VACUUM
E
1. Turn ignition switch to ON HOSE.
position. Check vacuum hose
2. Turn EGRC-solenoid valve A for clogging, cracks or
ON and OFF in ACTIVE improper connection.
TEST mode with CONSULT-II
C2ESA01 and check operating sound.
-------------------------------------------------------------------- OR --------------------------------------------------------------------
1. Check voltage between EGRC
solenoid valve A connector ter-
minal p 1 , and ground with
tester under the following condi-
tions:
Voltage:
At idle
Battery voltage
Approximately 0.4V
NEF435
NG
H
Perform electrical circuit inspection.
Crack
Refer to EC-CD-132.
OK
H
Clogging p
B
Improper connection
NEF846
.
EGRC-solenoid valve
harness connector
NEF436
EC-134
EGR valve
EGR valve
Apply vacuum to EGR vacuum port with a hand vacuum pump.
EGR valve spring should lift.
If NG, replace EGR valve.
MEF137D
EGRC-solenoid valve
FUSE
Check air passage continuity.
Air passage Air passage
Condition continuity continuity
between pA and p
B between pA and p
C
12V direct current sup-

ply between terminals Yes No
p1 and p 2
BATTERY
No supply No Yes
MEC488B
If NG, replace solenoid valve.
EC-135
Brake Switch
The ECM receives signals from two brake switches. One is a
conventional brake lamp switch, the other is referred to as a
redundant (RDNT) brake switch.
In case the accelerator pedal does not return to the idle position
(pedal sticks), the driver will react by depressing the brake. In
this (emergency) situation, the ECM will disregard the accelera-
tor pedal signal and bring back the engine speed to 1200 rpm.
Check Items
(Possible Cause)
Brake switch circuits are open or shorted. Harness or connectors
(Brake switch circuits are open or shorted.)
Stop lamp switch
RDNT brake switch

PROCEDURE
2) Depress brake pedal for at least 1 minute.
EC-136
Brake Switch (Contd)
YEC103A
EC-137
INSPECTION START
(RDNT brake switch)
RDNT brake switch

harness connector
H
E
tion. F104 , M50
2. Disconnect RDNT brake switch har- (RHD models)
ness connector. Harness connectors
YEC377
3. Turn ignition switch to ON position. F2 , E43
4. Check voltage between RDNT brake (LHD models)
switch harness connector terminal Harness for open or
p 1 and body ground. short-circuit between

RDNT brake switch Voltage: Battery voltage RDNT brake switch
harness connector harness connector ter-
OK
minal p 1 and ECM
connector terminal
416 .
connectors.
YEC378
H
E
tion.
RDNT brake switch harness connec-
tor terminal p2 and body ground.
circuit.
OK
H
CHECK COMPONENT.
(RDNT brake switch)
on next page.
OK
H
H
H
INSPECTION END
EC-138
2
1 Stop lamp switch and RDNT brake switch
1. Turn ignition switch to LOCK position.
1 2
2. Disconnect switch harness connectors.
3. Check continuity between terminals p 1 and p
2 .
Continuity:
Brake pedal Stop lamp switch RDNT brake switch
Released No No
YEC379 Depressed Yes Yes
If NG, replace stop lamp switch or RDNT brake switch.
EC-139
ECM Relay
The ECM Relay shuts off the main power supply to the ECM
within 5 seconds after the ignition switch has turned to the
LOCK position.
Check Items
(Possible cause)
ECM relay shut-off time is too late. Harness or connectors
(The ECM relay circuit is shorted).
ECM relay
ECM

PROCEDURE
1) Turn ignition switch to the ON position and select
2) Turn ignition switch to the LOCK position and wait
at least 5 seconds.
3) Turn ignition switch to the ON position and wait at
least 2 seconds.
Refer to Trouble Diagnosis for Power Supply (EC-CD-59) for
ECM relay circuit inspection.
EC-140
MI & Data Link Connectors

Malfunction indicator (MI) circuit is monitored for open or short-
circuit. If the circuit is malfunctioning, MI can not report it but
CONSULT-II can.
Check Items
(Possible cause)
MI circuit is open or shorted. Harness or connectors
(MI circuit is open or shorted).
MI lamp
ECM

PROCEDURE
2) Start engine and run it for at least 2 seconds at idle
speed.
------------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------------
2) Check that MI lits on.
EC-141
MI & Data Link Connectors (Contd)
YEC104A
EC-142
DIAGNOSTIC PROCEDURE: MODELS BEFORE VIN -
P11U0548750
Combination meter INSPECTION START
harness connector (MI circuit)
H
CHECK MI BULB. NG Replace MI bulb.
E
1. Turn ignition switch to LOCK posi-
YEC380 tion.
2. Disconnect combination meter har-
ness connector.
3. Apply battery voltage between com-
bination meter terminal p 5 and p
13 .
Combination meter 4. Check that MI lits on.

harness connector
OK
H
E
2. Check voltage between combination short-circuit between
YEC381
meter terminal p 5 and body combination meter and
ground. ignition switch.
Voltage: Battery voltage 10A fuse
If NG, repair or replace
OK
harness or fuse.
Combination meter
harness connector
H
E
tion. M50 , F104

2. Disconnect ECM harness connector. If NG, repair harness or
NEF222A 3. Check continuity between combina- connectors.
tion meter connector terminal p13 Harness and connec-
and ECM connector terminal 215 . tors for open or short-

Continuity should exist. circuit between ECM
If OK, check harness for short-cir- and combination meter.
cuit.
OK
H
H
H
INSPECTION END
EC-143
DIAGNOSTIC PROCEDURE: MODELS AFTER VIN -
P11U0548750
INSPECTION START
(MI circuit)
H
CHECK MI DIODE. NG Repair or replace combi-
E
1. Turn ignition switch to LOCK posi- nation meter.
YEC121A tion.
2. Disconnect combination meter har-
ness connector.
3. Apply battery voltage between com-
bination meter terminal p 1 and p8 .
4. Check that MI lits on.
OK
H
E
2. Check voltage between combination short-circuit between
YEC122A
meter terminal p 1 and body combination meter and
ground. ignition switch.
Voltage: Battery voltage 10A fuse
If NG, repair or replace
OK
harness or fuse.
H
E
tion. M50 , F104

2. Disconnect ECM harness connector. If NG, repair harness or
YEC123A 3. Check continuity between combina- connectors.
tion meter connector terminal p8 Harness and connec-
and ECM connector terminal 215 . tors for open or short-

Continuity should exist. circuit between ECM
If OK, check harness for short-cir- and combination meter.
cuit.
OK
H
H
H
INSPECTION END
EC-144
Start Signal
BATTERY
Refer to EL-POWER.

OFF ST IGNITION
SWITCH
ACC ON
FUSE
BLOCK
(J/B)
Refer to EL-POWER.
ECM

YEC817
EC-145
Start Signal (Contd)
INSPECTION START
H
CHECK OVERALL FUNCTION. OK INSPECTION END
E
position.
2. Check START SIGNAL in
DATA MONITOR mode with
C2DMM04 CONSULT-II.
IGN ON OFF
IGN START ON
-------------------------------------------------------------------- OR --------------------------------------------------------------------
1. Turn ignition switch to the
LOCK position.
2. Disconnect ECM harness con-
nector.
3. Turn ignition switch to START
position.
4. Check voltage between ECM
NEF223A
connector terminal 422 and
ground.
Voltage:
Ignition switch START
Battery voltage
Except above
Fuse Approximately 0V
NG
H
Check if 10A fuse is OK. NG Replace 10A fuse.
E
OK
NEF224A H
CHECK INPUT SIGNAL CIRCUIT. NG Check the following:
E
1) Turn ignition switch to LOCK posi- Harness or connec-
tion. tors M50 , F104
2) Disconnect 10A fuse. Harness for open or
3) Check harness continuity between short-circuit between
ECM connector terminal 422 and ECM and fuse block.
fuse block. If NG, repair harness
Continuity should exist. or connectors.
OK
H
H
ness connector. Reconnect ECM harness
connector and retest.
H
INSPECTION END
EC-146
SERVICE DATA AND SPECIFICATIONS (SDS) CD20T
General Specifications
Unit : rpm Pump numbers
Engine CD20T Pump assembly
Engine Part number
Maximum engine speed 5,400 number
A/C ON 825 25 NP-VE4/

CD20T 16700 2J620
Idle speed 10E2200L736
A/C OFF 825 25
Pump data is not yet available.
Refer to CALIBRATION STANDARD published
by BOSCH.)
Injection Nozzle
INSPECTION AND ADJUSTMENT
Injection nozzle assembly
Unit: kPa (bar, kg/cm2, psi)
Initial injection pressure
14,423 - 15,651 (144.2 - 156.5,
New
148 - 159, 2,091 - 2,269)
15,000 - 16,000 (150.0 - 160.0,
Used
153 - 163, 2,175 - 2,320)
Inspection and Adjustment

Plunger lift mm (in) 0.89 0.08
ELECTRIC GOVERNOR
(Injection timing) at plunger lift timing mark Resistance [at 25C (77F)] 1.0
MASS AIR FLOW SENSOR CRANKSHAFT POSITION SENSOR (TDC)

Supply voltage V 5.0V Resistance [at 25C (77F)] Approximately 1,215 - 1,485
Output voltage V 1.9 - 2.3*
*: Engine is warmed up sufficiently and idling under no-load.
GLOW PLUG
Resistance [at 25C (77F)] 0.5
ENGINE COOLANT TEMPERATURE
SENSOR
ACCELERATOR POSITION SENSOR
20 (68) 2.1 - 2.9
Resistance k
50 (122) 0.68 - 1.00 Throttle valve conditions
[at 25C (77F)]
90 (194) 0.236 - 0.260 Completely closed Approximately 1.2
Partially open 1.2 - 1.9
Completely open Approximately 1.9
CONTROL SLEEVE POSITION SENSOR
Resistance [at 25C (77F)] 6.0
FUEL TEMPERATURE SENSOR

INJECTION TIMING CONTROL VALVE
25 (77) Approximately 1.9
Resistance [at 25C (77F)] Approximately 15
EC-147
SERVICE DATA AND SPECIFICATIONS (SDS) CD20T
NOTE
EC-148

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ENGINE CONTROL SYSTEM

When you read wiring diagrams:

Special Service Tools

Engine Fuel & Emission Control System

ECM (ECCS-D control module) WIRELESS EQUIPMENT

ECM PARTS HANDLING

Supplemental Restraint System (SRS) AIR

Precautions for On Board Diagnostic (OBD)

When connecting ECM harness connectors, push in

Before replacing ECM, perform Terminals and Reference

If MI illuminates or blinks irregularly during engine

Engine Control Module Component Parts

Vacuum Hose Drawing

Refer to System Diagram on previous page for vacuum control system.

Crankshaft position sensor E E Fuel injection control E Electric governor

Control sleeve position sensor E

E Fuel injection timing control E Injection timing control

Mass air flow sensor E

Engine coolant temperature E

E Glow control system E Glow relay & glow lamp

Accelerator position sensor E

Air conditioner switch E

Ignition switch (ON & ST POS.) E

E Cooling fan control E Cooling fan relays

Vehicle speed sensor or ABS E

E Cooling fan motor control E Cooling fan relay

Glow Control System

When coolant temperature is lower than 75C (167F):

Fuel Injection System

Engine speed Electric

Air conditioner operation

Control sleeve position

The amount of fuel injected under normal driving conditions is

sensor detects accelerator position. These sensors send signals

Engine speed ECM Electric

Control sleeve position

Fuel Injection Timing System

Injection timing Injection

The optimal fuel injection timing data, predetermined in propor-

HIGH ALTITUDE COMPENSATION

Control sleeve position

Engine coolant temperature

Control sleeve position

For better exhaust efficiency under cool engine conditions, the

ENGINE COOLANT TEMPERATURE COMPENSATION (When starting)

Air Conditioning Cut Control

Accelerator valve opening angle

Engine coolant temperature

Cooling Fan Control

Engine coolant temperature ECM E Cooling fan relay(s)

Air conditioner switch Air conditioner ON signal

Blow-by Control Valve

Nozzle side Removal and Installation

Test and Adjustment

INJECTION PRESSURE TEST

SPRAY PATTERN TEST

6.3 - 8.2 (0.64 - 0.84, 55.6 - 72.9)

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