ENGINE CONTROL SYSTEM SECTIONEC CONTENTS

Transcription

1 EINE CONTROL SYSTEM SECTIONEC EC CONTENTS PRECAUTIONS AND PREPARATION3 Speial Servie Tools 3 Engine Fuel & Emission Control System 4 Preautions 5 EINE AND EMISSION CONTROL OVERALL SYSTEM7 Engine Control Module Component Parts Loation7 Ciruit Diagram 9 System Diagram 10 Vauum Hose Drawing 11 System Chart 12 EINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION13 Glow Control System 13 Fuel Injetion System 13 Fuel Injetion Timing System 16 Air Conditioning Cut Control 18 Cooling Fan Control18 CRANKCASE VENTILATION SYSTEM 19 Desription 19 Blow-by Control Valve 19 Ventilation Hose19 INJECTION NOZZLE20 Removal and Installation 20 Test and Adjustment20 ELECTRONIC FUEL INJECTION PUMP22 Removal 22 Installation 23 Disassembly and Assembly24 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION25 DTC and MI Detetion Logi 25 Diagnosti Trouble Code (DTC) 25 Malfuntion Indiator (MI) 26 CONSULT-II30 TROUBLE DIAGNOSIS Introdution36 Introdution 36 Diagnosti Worksheet 37 TROUBLE DIAGNOSIS Work Flow 38 Work Flow 38 Desription for Work Flow 39 TROUBLE DIAGNOSIS Basi Inspetion40 Basi Inspetion40 TROUBLE DIAGNOSIS General Desription 42 Diagnosti Trouble Code (DTC) Chart 42 Symptom Matrix Chart 50 CONSULT-II Referene Value in Data Monitor Mode 53 Major Sensor Referene Graph in Data Monitor Mode 54 ECM Terminals and Referene Value55 TROUBLE DIAGNOSIS FOR POWER SUPPLY 62 Main Power Supply and Ground Ciruit 62 TROUBLE DIAGNOSIS FOR DTC Mass Air Flow Sensor (MAFS) 65 TROUBLE DIAGNOSIS FOR DTC Engine Coolant Temperature (ECT) Sensor 69 TROUBLE DIAGNOSIS FOR DTC Vehile Speed Sensor (VSS) 73 TROUBLE DIAGNOSIS FOR DTC Control Sleeve Position Sensor (CSPS) 76

2 TROUBLE DIAGNOSIS FOR DTC Eletri Governor 80 TROUBLE DIAGNOSIS FOR DTC Injetion Timing Control Valve85 TROUBLE DIAGNOSIS FOR DTC 31, 82, 84, 91, Engine Control Module (ECM)90 TROUBLE DIAGNOSIS FOR DTC Cooling Fan (Overheat) 91 TROUBLE DIAGNOSIS FOR DTC Needle Lift Sensor (NLS)101 TROUBLE DIAGNOSIS FOR DTC Fuel Cut Solenoid Valve 104 TROUBLE DIAGNOSIS FOR DTC Fuel Temperature Sensor (FTS) 108 TROUBLE DIAGNOSIS FOR DTC Aelerator Position Sensor & Swith 112 TROUBLE DIAGNOSIS FOR DTC Crankshaft Position Sensor (TDC) 119 TROUBLE DIAGNOSES FOR DTC 83, Glow Control System 123 TROUBLE DIAGNOSES FOR DTC Air Conditioner Cut Control131 TROUBLE DIAGNOSES FOR DTC EGRC-Solenoid Valve 134 TROUBLE DIAGNOSES FOR DTC Brake Swith 141 TROUBLE DIAGNOSES FOR DTC ECCS-D Relay 145 TROUBLE DIAGNOSES FOR DTC MI & Data Link Connetors 146 TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS149 Start Signal 149 SERVICE DATA AND SPECIFICATIONS (SDS) 151 General Speifiations 151 Injetion Nozzle151 Inspetion and Adjustment 151 When you read wiring diagrams: Read GI setion, HOW TO READ WIRI DIAGRAMS See EL setion, POWER SUPPLY ROUTI for power distribution iruit See EL setion for NATS information and wiring diagram When you perform trouble diagnoses, read GI setion, HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES and HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT For larifiation of system omponent abbreviations and terminology read GI setion SAE J1930 TERMINOLOGY LIST EC-CD-2

3 PRECAUTIONS AND PREPARATION Speial Servie Tools Tool number Tool name KV Nozzle leaning kit V 1 KV Box V 2 KV Brush V 3 KV Nozzle oil sump sraper V 4 KV Nozzle needle tip leaner V 5 KV Nozzle seat sraper V 6 KV Nozzle holder V 7 KV Nozzle hole leaning needle KV Nozzle entering devie Desription NT296 X: Appliable : Not appliable X X KV No 2-4 injetion nozzle holder soket NT293 X KV119E0030 No 1 injetion nozzle holder soket NT563 X NT648 EC-CD-3

4 PRECAUTIONS AND PREPARATION Engine Fuel & Emission Control System BATTERY Always use a 12 volt battery as power soure Do not attempt to disonnet battery ables while engine is running ECM (ECCS-D ontrol module) Do not disassemble ECM If a battery terminal is disonneted, the memory will return to the ECM value The ECM will now start to self-ontrol at its initial value Engine operation an vary slightly when the terminal is disonneted However, this is not an indiation of a problem Do not replae parts beause of a slight variation When ECM is removed for inspetion, make sure to ground the ECM mainframe WIRELESS EQUIPMENT When installing CB ham radio or a mobile phone, be sure to observe the following as it may adversely affet eletroni ontrol systems depending on its installation loation 1) Keep the antenna as far as possible away from the ECM 2) Keep the antenna feeder line more than 20 m (79 in) away from the harness of eletroni ontrols Do not let them run parallel for a long distane 3) Adjust the antenna and feeder line so that the standing-wave ratio an be kept small 4) Be sure to ground the radio to vehile body ELECTRONIC FUEL INJECTOR PUMP Do not disonnet pump harness onnetors with engine running Do not disassemble or adjust eletroni fuel injetion pump, exept for the following parts Camshaft position sensor (pump) Injetion timing ontrol valve Fuel ut solenoid valve ECM mainframe ECM PARTS HANDLI Handle mass air flow sensor arefully to avoid damage Do not disassemble mass air flow sensor Do not lean mass air flow sensor with any type of detergent Do not disassemble No 1 injetion nozzle (builtin needle lift sensor) Even a slight leak in the air intake system an ause serious problems Do not shok or jar the amshaft position sensor (TDC) WHEN STARTI Do not depress aelerator pedal when starting Immediately after starting, do not rev up engine unneessarily Do not rev up engine just prior to shutdown ECM HARNESS HANDLI Connet ECM harness onnetors seurely A poor onnetion an ause an extremely high (surge) voltage to develop in oil and ondenser, thus resulting in damage to ICs Keep ECM harness at least 10 m (39 in) away from adjaent harnesses, to prevent an ECM system malfuntion due to reeiving external noise, degraded operation of ICs, et Keep ECM parts and harnesses dry Before removing parts, turn off ignition swith and then disonnet battery ground able NEF390 EC-CD-4

5 PRECAUTIONS AND PREPARATION Preautions Before onneting or disonneting the ECM harness onnetor, turn ignition swith OFF and disonnet negative battery terminal Failure to do so may damage the ECM beause battery voltage is applied to ECM even if ignition swith is turned off SEF289H Loosen ECM When onneting ECM harness onnetor, open the ports on harness onnetor, then meet the ports with the pins on the ECM as shown Push slider on harness until it stops Tighten slider ECM harness onnetor NEF754 ECM Pins When onneting or disonneting pin onnetors into or from ECM, take are not to damage pin terminals (bend or break) Make sure that there are not any bends or breaks on ECM pin terminal, when onneting pin onnetors Ports PULL to open ports Slider Harness onnetor NEF755 Perform ECM input/output signal inspetion before replaement Before replaing ECM, perform Terminals and Referene Value inspetion and make sure ECM funtions properly Refer to EC-CD-55 MEF040D SAT652J If MI illuminates or blinks irregularly during engine running, water may have aumulated in fuel filter Drain water from fuel filter If this does not orret the problem, perform speified trouble diagnosti proedures After performing eah TROUBLE DIAGNOSIS, perform OVERALL FUNCTION CHECK or DTC (Diagnosti Trouble Code) CONFIRMATION PROCEDURE The DTC should not be displayed in the DTC CONFIR- MATION PROCEDURE if the repair is ompleted The OVERALL FUNCTION CHECK should be a good result if the repair is ompleted EC-CD-5

6 Battery voltage PRECAUTIONS AND PREPARATION Preautions (Cont d) When measuring ECM signals with a iruit tester, never allow the two tester probes to ontat Aidental ontat of probes will ause a short iruit and damage the ECM power transistor Short Harness onnetor for solenoid valve ECM Solenoid valve Ciruit tester SEF348N EC-CD-6

7 EINE AND EMISSION CONTROL OVERALL SYSTEM Engine Control Module Component Parts Loation Fuel ut solenoid valve EGRC - solenoid valve Needle lift sensor (built - in No 1 nozzle) Eletri fuel injetion pump Vauum pump Engine oolant temperature sensor Fuel filter Mass air flow sensor Glow relay Cooling fan relay Crankshaft position sensor (TDC) EGR valve Cooling fan motors Glow plugs NEF767 EC-CD-7

8 EINE AND EMISSION CONTROL OVERALL SYSTEM Engine Control Module Component Parts Loation (Cont d) Fuel ut solenoid valve Eletri governor Control sleeve position sensor and fuel temperature sensor (built-in) Ejetion timing ontrol valve Aelerator position sensor Aelerator pedal Crank pulley ECM Crankshaft position sensor (TDC) Aelerator pedal (LHD) NEF768 EC-CD-8

9 EINE AND EMISSION CONTROL OVERALL SYSTEM Ciruit Diagram ECM (ECCS-D CONTROL MODULE) DATA LINK CONNECTOR EINE CONTROL MODULE RELAY GLOW RELAY GLOW PLUG MASS AIR FLOW SENSOR EINE COOLANT TEMPERATURE SENSOR FUEL TEMPERATURE SENSOR (INJECTION PUMP) NATS IMMU TACHOMETER STOP LAMP SWITCH EGRC-SOLENOID VALVE MALFUNCTION INDICATOR LAMP GLOW INDICATOR LAMP NEEDLE LIFT SENSOR ACCELERATOR WORK UNIT ACCELERATOR POSITION SWITCH ACCELERATOR POSITION SENSOR INJECTION PUMP INJECTION TIMI CONTROL VALVE FUEL CUT SOLENOID VALVE ELECTRIC GOVERNOR CONTROL SLEEVE POSITION SENSOR CRANKSHAFT POSITION SENSOR (TDC) SPEED- OMETER VEHICLE SPEED SENSOR THERMO CONTROL AMP THERMISTOR TRIPLE- PRESSURE SWITCH FUSE IGNITION SWITCH ON or START IGNITION SWITCH ON FUSE BATTERY AIR CONDITIONER CONTROL PANEL AIR CONDITIONER RELAY To ompressor COOLI FAN RELAY-1 COOLI FAN MOTOR-2 FUSIBLE LINK FUSE BATTERY IGNITION SWTICH OFF ON ON ST COOLI FAN RELAY-2 COOLI FAN RELAY-3 COOLI FAN MOTOR-1 RDNT BRAKE SWITCH EC-CD-9 YEC080

10 EINE AND EMISSION CONTROL OVERALL SYSTEM System Diagram Fuel tank Fuel pump EVAP anister EVAP anister purge volume ontrol solenoid valve Air leaner Fast idle am Mass air flow sensor (Hot wire type) Fuel pressure regulator IACV-FICD solenoid valve Muffler Three way atalyst Injetor Throttle position sensor IACV-AAC valve PCV valve ECM (Engine ontrol module) Ignition swith Malfuntion indiator Spark plug Heated oxygen sensor Engine oolant temperature sensor Knok sensor Three way atalyst SR20De manifold SR20DE under oilpan Battery Ignition oil, power transistor, amshaft position sensor built into distributor Vehile speed sensor Neutral position/ inhibitor swith Air onditioner swith Power steering oil pressure swith Eletrial load signal EC-CD-10 SEF830S

11 EINE AND EMISSION CONTROL OVERALL SYSTEM Vauum Hose Drawing V 2 EGRC - solenoid valve V 3 Vauum pump Air dut V 1 EGR valve NEF770 V 1 V 2 V 3 EGRC-solenoid valve to EGR valve EGRC-solenoid valve to air dut EGRC-solenoid valve to vauum pump Refer to System Diagram on previous page for vauum ontrol system EC-CD-11

12 EINE AND EMISSION CONTROL OVERALL SYSTEM System Chart Crankshaft position sensor (TDC) Fuel injetion ontrol Eletri governor Control sleeve position sensor Fuel injetion timing ontrol Injetion timing ontrol valve Fuel temperature sensor Mass air flow sensor Fuel ut ontrol Fuel ut solenoid valve Engine oolant temperature sensor Needle lift sensor Glow ontrol system Glow relay & glow lamp Aelerator position sensor ECM On board diagnosti system Malfuntion indiator (On the instrument panel) Aelerator position swith Air onditioner swith EGR valve ontrol EGRC-solenoid valve Ignition swith (ON & ST POS) Battery voltage Cooling fan ontrol Cooling fan relays Vehile speed sensor Air onditioning ut ontrol Air onditioner relay Brake swith Atmospheri pressure sensor Cooling fan motor ontrol Cooling fan relay EC-CD-12

13 EINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Glow Control System SYSTEM DESCRIPTION Crankshaft position sensor (TDC) Engine oolant temperature sensor Engine speed Engine oolant temperature ECM Glow relay Glow lamp Glow plugs When oolant temperature is lower than 75 C (167 F): Ignition swith ON After the ignition swith has been turned to ON, the glow relay turns ON for a period of time depending on the engine oolant temperature, allowing urrent to flow through the glow plugs Starting After starting the engine, urrent will flow through the glow plugs for 300 seonds, or until the oolant temperature exeeds 50 C (122 F) Fuel Injetion System SYSTEM DESCRIPTION Three types of fuel injetion ontrol are provided to aommodate the engine operating onditions; normal ontrol, idle ontrol and start ontrol The ECM determines the appropriate fuel injetion ontrol Under eah ontrol, the amount of fuel injeted is ompensated to improve engine performane The ECM performs duty yle ontrol on the eletri governor (built into the fuel injetion pump) aording to sensor signals to ompensate the amount of fuel injeted to the preset value START CONTROL Input/output signal line Engine oolant temperature sensor Engine oolant temperature Crankshaft position sensor (TDC) Engine speed ECM Eletri governor Control sleeve position sensor Control sleeve position Fuel injetion volume Coolant temperature getting lower When starting, the ECM adapts the fuel injetion system for the start ontrol The amount of fuel injeted at engine starting is a preset program value in the ECM The program is determined by the engine speed and engine oolant temperature For better startability under ool engine onditions, the lower the oolant temperature beomes, the greater the amount of fuel injeted The ECM ends the start ontrol when the engine speed reahes a oolant temperature dependent value Engine rpm SEF648S EC-CD-13

14 EINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injetion System (Cont d) IDLE CONTROL Input/output signal line Engine oolant temperature sensor Engine oolant temperature Crankshaft position sensor (TDC) Engine speed Air onditioner swith Control sleeve position sensor Air onditioner operation Control sleeve position ECM Eletri governor Aelerator position swith Idle position Vehile speed sensor Vehile speed When the ECM determines that the engine speed is at idle, the fuel injetion system is adapted for the idle ontrol The ECM regulates the amount of fuel injeted orresponding to hanges in load applied to the engine to keep engine speed onstant During the first 270s after a old start, the ECM also provides the system with a fast idle ontrol in response to the engine oolant temperature NORMAL CONTROL Input/output signal line Crankshaft position sensor (TDC) Engine speed Control sleeve position sensor Aelerator position sensor Control sleeve position Aelerator position ECM Eletri governor Vehile speed sensor Vehile speed Fuel injetion volume Aelerator opening larger Engine rpm SEF649S The amount of fuel injeted under normal driving onditions is determined aording to sensor signals The rankshaft position sensor (TDC) detets engine speed and the aelerator position sensor detets aelerator position These sensors send signals to the ECM The fuel injetion data, predetermined by orrelation between various engine speeds and aelerator positions, are stored in the ECM memory, forming a map The ECM determines the optimal amount of fuel to be injeted using the sensor signals in omparison with the map EC-CD-14

15 EINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injetion System (Cont d) FUEL TEMPERATURE COMPENSATION Input/output signal line Fuel temperature sensor Fuel temperature Crankshaft position sensor (TDC) Engine speed ECM Eletri governor Control sleeve position sensor Control sleeve position The amount of fuel leaking at or around high-pressure parts inside the fuel injetion pump varies with fuel temperature and engine speed This will result in a differene between the target amount of fuel injeted and the atual amount The ECM ompensates for the atual amount depending on the signal from the fuel temperature sensor, the ontrol sleeve position sensor and the rankshaft position sensor DECELERATION CONTROL Input/output signal line Aelerator sensor Camshaft position sensor (PUMP) Aelerator position Engine speed ECM Eletri governor The ECM uts power supply delivery to the eletri governor during deeleration for better fuel effiieny The ECM determines the time of deeleration aording to signals from the aelerator sensor and amshaft position sensor (PUMP) EC-CD-15

16 EINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injetion Timing System SYSTEM DESCRIPTION The fuel injetion timing system determines the optimal fuel injetion timing, based on engine speed, injetion quantity, engine oolant temperature and atmospheri pressure The timing is formed by a basi value (Basi Control) and two orretion values By performing a duty yle signal on the timing ontrol valve, the ECM allows the valve to provide optimal injetion timing The ECM also performs feedbak ontrol on the timing ontrol valve using the signal from the needle lift sensor whih detets the atual fuel injetion timing BASIC CONTROL Input/output signal line Crankshaft position sensor (TDC) Needle lift sensor Control sleeve position sensor Engine speed Injetion timing Control sleeve position ECM Injetion timing ontrol valve BTDC (degree) Fuel injetion timing Fuel injetion volume Large Small The optimal fuel injetion timing data, predetermined in proportion to engine speeds and amount of fuel injeted, are stored in the ECM memory The ECM uses the data to ontrol the fuel injetion timing Engine rpm SEF650S HIGH ALTITUDE COMPENSATION Crankshaft position sensor Engine speed Control sleeve position sensor Atmospheri pressure sensor Control sleeve position Atmospheri pressure ECM Injetion timing ontrol valve Needle lift sensor Injetion timing Fuel temperature sensor Fuel temperature For better drivability in high altitude areas, the fuel injetion timing is advaned and the fuel quantity is redued aording to the atmospheri pressure Fuel injetion timing ompensation Normal High altitude Engine rpm NEF771 EC-CD-16

17 EINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injetion Timing System (Cont d) EINE COOLANT TEMPERATURE COMPENSATION (During driving) Input/output signal line Engine speed Crankshaft position sensor (TDC) Engine oolant temperature sensor Needle lift sensor Engine oolant temperature Injetion timing ECM Injetion timing ontrol valve Control sleeve position sensor Control sleeve position Fuel injetion timing ompensation Engine oolant temperature Low High Engine rpm For better exhaust effiieny under ool engine onditions, the fuel injetion timing is ontrolled within a ompensation range depending on the engine speed, engine oolant temperature and amount of fuel injeted SEF652S EINE COOLANT TEMPERATURE COMPENSATION (When starting) Input/output signal line Engine speed Crankshaft position sensor (TDC) Engine oolant temperature sensor Needle lift sensor Engine oolant temperature Ignition timing ECM Injetion timing ontrol valve Fuel injetion timing ompensation Low Engine oolant temperature High For better startability under ool engine onditions, the fuel injetion timing is ompensated aording to the engine oolant temperature Engine rpm SEF651S EC-CD-17

18 EINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION INPUT/OUTPUT SIGNAL LINE Air Conditioning Cut Control Air onditioner swith Air onditioner ON signal Aelerator position sensor Vehile speed sensor Aelerator valve opening angle Vehile speed ECM Air onditioner relay Engine oolant temperature sensor Engine oolant temperature SYSTEM DESCRIPTION This system improves aeleration when the air onditioner is used When the aelerator pedal is fully depressed, the air onditioner is turned off for a few seonds When engine oolant temperature beomes exessively high, the air onditioner is turned off This ontinues until the oolant temperature returns to normal INPUT/OUTPUT SIGNAL LINE Vehile speed sensor Cooling Fan Control Vehile speed Engine oolant temperature sensor Engine oolant temperature ECM Cooling fan relay(s) Air onditioner swith Air onditioner ON signal The ECM ontrols the ooling fan orresponding to the vehile speed, engine oolant temperature, and air onditioner ON signal The ontrol system has 3-step ontrol [OFF/LOW/HIGH] Operation Air onditioner is OFF Air onditioner is ON Engine oolant temperature C ( F) 102 (216) 96 (205) Engine oolant temperature C ( F) 102 (216) 96 (205) (12) (50) Vehile speed km/h (mph) Cooling fans do not operate Cooling fans operate at low speed 20 (12) Vehile speed km/h (mph) Cooling fans operate at high speed 80 (50) NEF772 EC-CD-18

19 CRANKCASE VENTILATION SYSTEM Blow-by ontrol valve Desription In this system blow-by gas is suked into the air inlet pipe through the ontrol valve after oil separation by the oil separator in the roker over Baffle plate FRESH AIR BLOW BY GAS SEF851S Blow-by ontrol valve Blow-by Control Valve Chek ontrol valve for logging and abnormalities Intake manifold Roker over SEC586B Ventilation Hose 1 Chek hoses and hose onnetions for leaks 2 Disonnet all hoses and lean with ompressed air If any hose annot be freed of obstrutions, replae SEC692 EC-CD-19

20 INJECTION NOZZLE CAUTION: Do not disassemble injetion nozzle assembly Entrust disassembly or adjustment to BOSCH servie shop Plug flare nut with a ap or rag so that no dust enters the nozzle No 1 injetion nozzle Nozzle side Combustion hamber side NEF396 Removal and Installation 1 Remove fuel injetion tube and spill tube 2 Remove injetion nozzle assembly Also remove gasket from nozzle end 3 Install injetion nozzle in the reverse order of removal Injetion nozzle to engine: : N m (60-70 kg-m, ft-lb) Injetion nozzle to tube: : N m (22-25 kg-m, ft-lb) Spill tube: : N m (40-50 kg-m, ft-lb) a Always lean the nozzle holes b Always use new injetion nozzle gasket Note that small washer should be installed in speified diretion d Bleed air from fuel system NEF774 Test and Adjustment WARNI: When using nozzle tester, be areful not to allow diesel fuel sprayed from nozzle to ontat your hands or body, and make sure your eyes are properly proteted with goggles INJECTION PRESSURE TEST 1 Install nozzle to injetion nozzle tester and bleed air from flare nut EF791A EC-CD-20

21 SEF672A INJECTION NOZZLE Test and Adjustment (Cont d) 2 Pump the tester handle slowly (one time per seond) and wath the pressure gauge 3 Read the pressure gauge when the injetion pressure just starts dropping Initial injetion pressure: Used 14,423-15,651 kpa ( bar, kg/m 2, 2,091-2,269 psi) New 15,000-16,000 kpa ( bar, kg/m 2, 2,175-2,320 psi) Always hek initial injetion pressure using a new nozzle If the pressure is not orret, replae nozzle assembly LEAKAGE TEST 1 Maintain the pressure at about 981 to 1,961 kpa (98 to 196 bar, 10 to 20 kg/m 2, 142 to 284 psi) below initial injetion pressure 2 Chek that there is no dripping from the nozzle tip or around the body 3 If there is leakage, replae nozzle Good GOOD Faulty More than 30 WRO SEF674A SEF079S SPRAY PATTERN TEST 1 Chek spray pattern by pumping tester handle one full stroke per seond a If main spray angle is within 30 degrees as shown, injetion 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 orreted, replae nozzle EC-CD-21

22 ELECTRONIC FUEL INJECTION PUMP ( , ) (16-21, 12-15) (13-18, 9-13) Front of engine (32-38, 23-27) (60-70, 43-51) : N m (kg-m, in-lb) : N m (kg-m, ft-lb) (16-21, 12-15) (24-28, 17-20) ( , ) (24-28, 17-20) (50-60, 36-43) NEF777 V 1 V 2 Rear bak over V 4 Water onnetor Injetion pump sproket V 5 Braket V 3 Injetion pump braket V 7 Eletroni fuel injetion pump V 8 Key V 6 Braket Removal 1 Remove battery Disonnet eletroni injetion pump harness onnetors Injetion timing mark (Yellow painted mark) 2 Set No 1 piston at TDC on its ompression stroke TDC: Crankshaft pulley noth without painted mark 3 Remove fuel hoses (supply, return and spill) and injetion tubes 4 Remove air dut and injetion pump timing belt over 5 Remove injetion pump timing belt Refer to EM setion ( Injetion Pump Timing Belt ) TDC (Without painted mark) SEF655S EC-CD-22

23 ELECTRONIC FUEL INJECTION PUMP Removal (Cont d) 6 Remove injetion pump sproket with Tool Remove key from injetion pump shaft and store safely SEF656S 7 Remove injetion pump assembly Injetion pump sproket Key SEF657S Alignment mark Installation 1 Install key on injetion pump shaft, then install injetion pump sproket 2 Install injetion pump timing belt Refer to EM setion ( Injetion Pump Timing Belt ) 3 Adjust injetion timing Refer to Basi Inspetion, EC-CD-40 4 Install all parts removed NEF866 EC-CD-23

24 ELECTRONIC FUEL INJECTION PUMP Installation (Cont d) Fuel ut solenoid valve (20-25, 14-18) O-ring Washer : Do not reuse : N m (kg-m, in-lb) : N m (kg-m, ft-lb) 7-10 (07-10, 61-87) (20-25, 14-18) NEF778 Disassembly and Assembly CAUTION: Do not disassemble the parts not shown in the illustration above Before installing injetion timing ontrol valve, apply a oat of diesel fuel to O-ring and its mating area Insert injetion timing ontrol valve straight into bore in fuel pump body After properly positioning injetion timing ontrol valve, visually hek for fuel leaks After assembling the parts, erase Diagnosti Trouble Code (DTC), and perform DTC CONFIRMATION PROCE- DURE (or OVERALL FUNCTION CHECK) EC-CD-24

25 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION DTC and MI Detetion Logi When a malfuntion is deteted for the first time, the malfuntion (DTC) is stored in the ECM memory The MI will light up eah time the ECM detets a malfuntion However, if the same malfuntion is experiened in two onseutive driving patterns and the engine is still running, the MI will stay lit up For diagnosti items ausing the MI to light up, refer to Diagnosti Trouble Code (DTC) Chart, EC-CD-42 Diagnosti Trouble Code (DTC) HOW TO READ DTC The diagnosti trouble ode an be read by the following methods 1 The number of flashes of the malfuntion indiator in the Diagnosti Test Mode II (Self-Diagnosti Results) Examples: 11, 13, 14, et These DTCs are ontrolled by NISSAN 2 CONSULT-II Examples: CRANK POS SEN (TDC), et Output of the trouble ode warns that the indiated iruit has a malfuntion However, when using MI in Mode II there is no indiation to determine whether the malfuntion is still ourring or has ourred in the past and row returned to normal CONSULT-II an identify the timing of a malfuntions and so use of CONSULT-II (if available) is reommended DTCs are stored up to a maximum of 7 items that have highest priority in eah grouped DTC ourred at that time A new entry of DTC an overwrite an existing entry with a lower priority if the DTC memory is full If 7 DTCs are read, other remained DTCs an be read after the existing DTC item has been orreted and the DTC is erased HOW TO ERASE DTC The diagnosti trouble ode an be erased by the following methods Seleting ERASE in the SELF-DIAG RESULTS mode with CONSULT-II Changing the diagnosti test mode from Diagnosti Test Mode II to Mode I twie (Refer to HOW TO SWITCH DIAGNOSTIC TEST MODES ) If the battery terminal is disonneted, the diagnosti trouble ode will be lost within 24 hours When you erase the DTC, using CONSULT-II is easier and quiker than swithing the diagnosti test modes Erasing DTC is possible only when the ECM has reognised the DTC item is orreted If erasing is not possible, turn the ignition swith to the LOCK position one Wait for at least 5 seonds and then turn it ON (engine stopped) again HOW TO ERASE DTC (With CONSULT-II) 1 If the ignition swith stays ON after repair work, be sure to turn ignition swith to the LOCK position one Wait for at least 5 seonds and then turn it ON (Engine stopped) again 2 Turn CONSULT-II ON and touh EINE 3 Touh SELF-DIAG RESULTS 4 Touh ERASE (The DTC in the ECM will be erased) 1 Touh Engine 2 Touh SELF-DIAG RESULTS 3 Touh ERASE (The DTC in the ECM will be erased) C2SSE03 EC-CD-25

26 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Diagnosti Trouble Code (DTC) (Cont d) HOW TO ERASE DTC (No Tools) 1 If the ignition swith stays ON after repair work, be sure to turn ignition swith to LOCK position one Wait at least 5 seonds and then turn it ON again 2 Change the diagnosti test mode from Mode II to Mode I twie When hanging modes, wait at least 2 seonds (Refer to EC-CD-27) ON BOARD DIAGNOSTIC SYSTEM FUNCTION The ON BOARD DIAGNOSTIC SYSTEM FUNCTION The on board diagnosti system has the following three funtions: Malfuntion Indiator (MI) 1 The malfuntion indiator will light up when the ignition swith is turned ON without the engine running This is a bulb hek If the malfuntion indiator does not light up, refer to EL setion ( WARNI LAMPS AND CHIME ) or see EC-CD-27 2 When the engine is started, the malfuntion indiator should go off If the lamp remains on, the on board diagnosti system has deteted an engine system malfuntion If MI illuminates or flashes irregularly after starting engine, water may have aumulated in fuel filter Drain water from fuel filter 1 BULB CHECK : This funtion heks the MI bulb for damage (blown, open iruit, et) 2 MALFUNCTION : This is a usual driving ondition When a malfuntion is deteted, the WARNI MI will light up to inform the driver that a malfuntion has been 3 SELF-DIAGNOSTIC RESULTS SAT652J deteted : This funtion allows diagnosti trouble odes to be read Refer to HOW TO SWITCH DIAGNOSTIC TEST MODES on next page Ignition swith in ON position Condition Engine stopped Engine running Diagnosti Test Mode I BULB CHECK Diagnosti Test Mode II SELF-DIAGNOSTIC RESULTS MALFUNCTION WARNI EC-CD-26

27 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfuntion Indiator (MI) (Cont d) HOW TO SWITCH DIAGNOSTIC TEST MODES Turn ignition swith to ON position (Do not start engine) Diagnosti Test Mode I BULB CHECK G Start engine Diagnosti Test Mode I MALFUNCTION WARNI Data link onnetor for CONSULT-II (Connet CHK and IGN terminals with a suitable harness) DIAGNOSTIC TEST MODE II SELF-DIAGNOSTIC RESULTS Data link onnetor for CONSULT-II (Connet CHK and IGN terminals with a suitable harness) Swithing the diagnosti test mode is not possible when the engine is running EC-CD-27

28 DIAGNOSTIC TEST MODE I BULB CHECK In this mode, the MALFUNCTION INDICATOR on the instrument panel should stay ON If it remains OFF, hek the bulb Refer to EL setion ( WARNI LAMPS AND CHIME ) or see EC-CD-27 DIAGNOSTIC TEST MODE I MALFUNCTION WARNI MALFUNCTION INDICATOR Condition When the malfuntion is deteted or the ECM s CPU is malfuntioning (The MI Illumination of the ON DTC Chart ) Refer to EC-CD-43 OFF No malfuntion These Diagnosti Trouble Code Numbers are larified in Diagnosti Test Mode II (SELF-DIAGNOSTIC RESULTS) DIAGNOSTIC TEST MODE II SELF-DIAGNOSTIC RESULTS In this mode, a diagnosti trouble ode is indiated by the number of flashes of the MALFUNCTION INDI- CATOR as shown below Example: Diagnosti trouble ode No 12 and ode No ON ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfuntion Indiator (MI) (Cont d) OFF Code No 12 Code No 43 Unit: seond SEF212NA Long (06 seond) flashes indiate the number of ten digits, and short (03 seond) flashes indiate the number of single digits For example, the malfuntion indiator flashes 4 times for 06 se and then it flashes three times for about 03 se This indiates the DTC 43 and refers to the malfuntion of the aelerator position sensor In this way, all the deteted malfuntions are lassified by their diagnosti trouble ode numbers The DTC 55 refers to no malfuntion (See DIAGNOSTIC TROUBLE CODE CHART, EC-CD-44) HOW TO ERASE DIAGNOSTIC TEST MODE II (Self-diagnosti results) The diagnosti trouble ode an be erased from the bakup memory in the ECM when the diagnosti test mode is hanged twie from Diagnosti Test Mode II to Diagnosti Test Mode I (Refer to HOW TO SWITCH DIAGNOSTIC TEST MODES on previous page) If the battery terminal is disonneted, the diagnosti trouble ode will be lost from the bakup memory within 24 hours Be areful not to erase the stored memory before starting trouble diagnoses If the MI blinks or NATS MALFUNCTION is displayed on SELF-DIAG RESULTS sreen, perform self-diagnosti results mode with CONSULT-II using NATS program ard (NATS-E940) Refer to EL setion Confirm no self-diagnosti results of NATS is displayed before touhing ERASE in SELF-DIAG RESULTS mode with CONSULT-II When replaing ECM, initialisation of NATS system and registration of all NATS ignition key IDs must be arried out with CONSULT-II using NATS program ard (NATS- C2SDR02 E940) Therefore, be sure to reeive all keys from vehile owner Regarding the proedures of NATS initialisation and NATS ignition key ID registration, refer to CON- SULT-II operation manual, NATS EC-CD-28

29 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfuntion Indiator (MI) (Cont d) RELATIONSHIP BETWEEN MI, DTC, CONSULT-II AND DRIVI PATTERNS This driving pattern does not satisfy self-diagnosti ondition This driving pattern satisfies self-diagnosti ondition SELF-DIAGNOSTIC TIME FINISH START Engine (IGN) RUN (ON) STOP (OFF) 1* MI ON OFF ECM Diagnosti Trouble Code (DTC) DISPLAY NO DISPLAY 2* 3* DEFECT EXIST STOP CONSULT-II SELF- DIAGNOSTIC RESULTS SCREEN & DATA MONITOR (AUTO TRIG) SCREEN SELF- DIAGNOSTIC RESULTS SCREEN DTC exist DTC does not exist COUNTER 4* NEF764 *1: When a malfuntion is deteted, MI will light up *2: When a malfuntion is deteted for the first time, the DTC will be stored in ECM *3: The DTC will not be displayed any longer after vehile is driven 40 times without the same malfuntion (The DTC still remains in ECM) *4: Other sreens exept SELF-DIAGNOSTIC RESULTS & DATA MONITOR (AUTO TRIG) annot display the malfuntion DATA MONITOR (AUTO TRIG) an display the malfuntion at the moment it is deteted EC-CD-29

30 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Fuse box CONSULT-II CONSULT-II INSPECTION PROCEDURE 1 Turn off ignition swith 2 Connet CONSULT-II to data link onnetor for CON- SULT-II (Data link onnetor for CONSULT-II is loated behind the fuse box over) Data link onnetor for CONSULT-II SEF900P 3 Turn on ignition swith 4 Touh START 5 Touh EINE 6 Perform eah diagnosti test mode aording to eah servie proedure For further information, see the CONSULT-II Operation Manual PEF895K PEF216U EC-CD-30

31 EINE CONTROL MODULE COMPONENT PARTS/CONTROL SYSTEMS APPLICATION EINE CONTROL MODULE COMPONENT PARTS INPUT ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont d) Item SELF-DIAG- NOSTIC RESULTS DIAGNOSTIC TEST MODE DATA MONITOR ACTIVE TEST Camshaft position sensor (PUMP) *1 X *2 X Mass air flow sensor X X Engine oolant temperature sensor X X Control sleeve position sensor X X X Fuel temperature sensor X X Vehile speed sensor X X Aelerator position sensor X X Aelerator position swith X Brake lamp swith X *2 X Crankshaft position sensor (TDC) X X Needle lift sensor X X Ignition swith (start signal) X Ignition swith (ON signal) X Air onditioner swith X Brake swith X Battery voltage X Injetion timing ontrol valve X X X Fuel ut solenoid valve X X X OUTPUT Air onditioner relay X Glow relay X X EGRC-solenoid valve X X Cooling fan relay X X X: Appliable *1: Imaginary sensor, whih produes seondary engine revolution signal using needle lift sensor pulse *2: CONSULT-II may not display, but self-diagnosti results are available with MI EC-CD-31

32 SELF-DIAGNOSTIC MODE Regarding items deteted in SELF-DIAG RESULTS mode, refer to Diagnosti Trouble Code (DTC) hart (See EC-CD-28) DATA MONITOR MODE Monitored item [Unit] ECM input signals Main signals CKPSvRPM (TDC) [rpm] j j CMPSvRPM - PUMP [rpm] j j COOLAN TEMP/S [ C] or [ F] j j VHCL SPEED SE [km/h] or [mph] j j FUEL TEMP SEN [ C] or [ F] j j ACCEL POS SEN [V] j j OFF ACCEL POS [ON/OFF] j j C/SLEEV POS/S [V] j j BATTERY VOLT [V] j j START SIGNAL [ON/OFF] j j AIR COND SIG [ON/OFF] j j j j [ON/OFF] j j MAS AIR/FL SE [V] j j BRAKE SW [ON/OFF] BRAKE SW2 [ON/OFF] IGN SW ACT INJ TIMG [ ] TARGET F/INJ [mm 3 /STRE] ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont d) j j Desription The engine speed omputed from the rankshaft position sensor (TDC) signal is displayed The engine speed omputed from the amshaft position sensor (PUMP) signal is displayed The engine oolant temperature (determined by the signal voltage of the engine oolant temperature sensor) is displayed The vehile speed omputed from the vehile speed sensor signal is displayed The fuel temperature (determined by the signal voltage of the fuel temperature sensor) is displayed The aelerator position sensor signal voltage is displayed Indiates [ON/OFF] ondition from the aelerator position swith signal The ontrol sleeve position sensor signal voltage is displayed The power supply voltage of ECM is displayed Indiates [ON/OFF] ondition from the starter signal Indiates [ON/OFF] ondition of the air onditioner swith as determined by the air onditioner signal Indiates [ON/OFF] ondition of the stio lamp swith Indiates [ON/OFF] ondition of the stio lamp swith 2 Indiates [ON/OFF] ondition from ignition swith The signal voltage of the mass air flow sensor is displayed The atual injetion timing angle determined by the ECM (an approximate average angle between injetion start and end from TDC) is displayed The target fuel injetion quantity (determined by the ECM aording to the input signal) is indiated Remarks When the engine oolant temperature sensor is open or short-iruited, ECM enters fail-safe mode The engine oolant temperature determined by the ECM is displayed After starting the engine, [OFF] is displayed regardless of the starter signal When the engine is stopped, a ertain value is indiated NOTE: Any monitored item that does not math the vehile being diagnosed is deleted from the display automatially EC-CD-32

33 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont d) Monitored item [Unit] FUEL CUT S/V [ON/OFF] ECM input signals Main signals AIR COND RLY [ON/OFF] j GLOW RLY [ON/OFF] j COOLI FAN [LOW/HI/OFF] EGRC SOL/V A [ON/OFF] j Desription The ontrol ondition of the fuel ut solenoid valve (determined by ECM aording to the input signal) is indiated OFF Fuel ut solenoid valve is not operating ON Fuel ut solenoid valve is operating The air onditioner relay ontrol ondition (determined by ECM aording to the input signal) is indiated The glow relay ontrol ondition (determined by ECM aording to the input signal) is displayed Indiates the ontrol ondition of the ooling fans (determined by ECM aording to the input signal) LOW Operates at low speed HI Operates at high speed OFF Stopped The ontrol ondition of the EGRCsolenoid valve (determined by ECM aording to the input signal) is indiated OFF EGRC-solenoid valve is not operating ON EGRC-solenoid valve is operating Remarks When the fuel ut solenoid valve is not operating, fuel supply is shut off EC-CD-33

34 ACTIVE TEST MODE ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont d) TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY) TARGET F/INJ COOLI FAN FUEL CUT SOL/V EGRC SOL/V A GLOW RLY INJ TIMI Engine: Return to the original trouble ondition Fix the target injetion quantity using CONSULT-II Ignition swith: ON Operate the ooling fan at LOW, HI speed and turn OFF using CONSULT-II Ignition swith: ON Turn solenoid valve ON and OFF with the CONSULT-II and listen to operating sound Ignition swith: ON Turn solenoid valve ON and OFF with the CONSULT-II and listen to operating sound Ignition swith: ON (Engine stopped) Turn the glow relay ON and OFF using CONSULT-II and listen to operating sound Engine: Return to the original trouble ondition Retard the injetion timing using CONSULT-II If trouble symptom disappears, see CHECK ITEM Cooling fan moves at LOW, HI speed and stops Solenoid valve makes an operating sound Solenoid valve makes an operating sound Glow relay makes the operating sound If trouble symptom disappears, see CHECK ITEM Control sleeve position sensor Harness and onnetor Cooling fan motor Harness and onnetor Solenoid valve Harness and onnetor Solenoid valve Harness and onnetor Fuel pump relay Adjust initial injetion timing EC-CD-34

35 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont d) REAL TIME DIAGNOSIS IN DATA MONITOR MODE CONSULT-II has two kinds of triggers and they an be seleted by touhing SETTI in DATA MONI- TOR mode 1 AUTO TRIG (Automati trigger): The malfuntion will be identified on the CONSULT-II sreen in real time In other words, DTC and malfuntion item will be displayed at the moment the malfuntion is deteted by ECM DATA MONITOR an be performed ontinuously until a malfuntion is deteted However, DATA MONITOR annot ontinue any longer after the malfuntion detetion 2 MANU TRIG (Manual trigger): DTC and malfuntion item will not be displayed automatially on CONSULT-II sreen even though a malfuntion is deteted by ECM DATA MONITOR an be performed ontinuously even though a malfuntion is deteted Use these triggers as follows: 1 AUTO TRIG While trying to detet the DTC by performing the DTC CONFIRMATION PROCEDURE, be sure to selet to DATA MONITOR (AUTO TRIG) mode You an onfirm the malfuntion at the moment it is deteted While narrowing down the possible auses, CONSULT-II should be set in DATA MONITOR (AUTO TRIG) mode, espeially in ase the inident is intermittent Inspet the iruit by gently shaking (or twisting) suspiious onnetors, omponents and harness in the DTC CONFIRMATION PROCEDURE The moment a malfuntion is found the DTC will be displayed (Refer to GI setion, Inident Simulation Tests in HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT ) 2 MANU TRIG If the malfuntion is displayed as soon as DATA MONITOR is seleted, reset CONSULT-II to MANU TRIG By seleting MANU TRIG you an monitor and store the data The data an be utilized for further diagnosis, suh as a omparison with the value for the normal operating ondition SETTI AUTO TRIG A malfuntion an be displayed on DATA MONITOR sreen automatially if deteted MANU TRIG A malfuntion an not be displayed on DATA MONITOR sreen automatially even if deteted PEF529Q EC-CD-35

36 TROUBLE DIAGNOSIS Introdution Introdution INFO CAUSE SEF858S SEF233G The engine has an ECM to ontrol major systems suh as fuel injetion ontrol, fuel injetion timing ontrol, glow ontrol system, et The ECM aepts input signals from sensors and instantly drive the eletroni fuel injetion pump use the data to based on urrent ambient onditions It is essential that both input and output signals are orret and stable At the same time, it is important that there are no problems suh as vauum leaks, or other problems with the engine It is muh more diffiult to diagnose a problem that ours intermittently rather than atastrophially Most intermittent problems are aused by poor eletri onnetions or faulty wiring In this ase, areful heking of suspeted iruits may help prevent the replaement of good parts A visual hek only may not be suffiiënt to determine the ause of the problems A road test with CONSULT-II or a iruit tester onneted should be performed Follow the Work Flow on the next page Before undertaking atual heks, take a few minutes to talk with a ustomer who approahes with a driveability omplaint The ustomer an supply good information about suh problems, espeially intermittent ones Find out what symptoms are present and under what onditions they our A Diagnosti Worksheet like the example on next page should be used Start your diagnosis by looking for onventional problems first This will help troubleshoot driveability problems on a vehile with an eletronially ontrolled engine SEF234G EC-CD-36

37 TROUBLE DIAGNOSIS Introdution KEY POINTS WHAT Vehile & engine model WHEN Date, Frequenies WHERE Road onditions HOW Operating onditions, Weather onditions, Symptoms Diagnosti Worksheet There are many operating onditions that lead to the malfuntion of engine omponents A good grasp of suh onditions an make troubleshooting faster and more aurate In general, eah ustomer feels differently about a problem It is important to fully understand the symptoms or onditions for a ustomer omplaint Utilize a diagnosti worksheet like the one shown below in order to organize all the information for troubleshooting SEF907L WORKSHEET SAMPLE Customer name MR/MS Model & Year VIN Engine # Trans Mileage Inident Date Manuf Date In Servie Date Symptoms h Startability h Idling h Driveability h Impossible to start h No ombustion h Partial ombustion h Partial ombustion when warming-up engine h Partial ombustion when ooling down engine h Possible but hard to start h Others [ ] h No fast idle h Unstable h High idle h Low idle h Others [ ] h Stumble h Surge h Knok h Lak of power h Others [ ] h Engine stall h At the time of start h While aelerating h Just after stopping h While idling h While deelerating h While loading Inident ourrene h Just after delivery h Reently h In the morning h At night h In the daytime Frequeny h All the time h Under ertain onditions h Sometimes Weather onditions Weather h Not affeted h Fine h Raining h Snowing h Others [ ] Temperature h Hot h Warm h Cool h Cold h Humid F h Cold h During warm-up h After warm-up Engine onditions Engine speed 0 2,000 4,000 6,000 8,000 rpm Road onditions h In town h In suburbs h Highway h Off road (up/down) Driving onditions h Not affeted h At starting h While idling h At raing h While aelerating h While ruising h While deelerating h While turning (RH/LH) Vehile speed mph Malfuntion indiator h Turned on h Not turned on EC-CD-37

38 TROUBLE DIAGNOSIS Work Flow Work Flow CHECK IN Listen to ustomer omplaints (Get symptoms) STEP I Chek, print out or write down, and erase Diagnosti Trouble Code (DTC) Symptoms olleted Verify the symptom by driving in the ondition the ustomer desribed No symptoms, exept MI lights up, or Malfuntion Code exists at STEP II STEP II *1 STEP III Normal Code (at STEP II) Malfuntion Code (at STEP II) Verify the DTC by performing the DTC CONFIRMATION PROCEDURE *1 STEP IV Choose the appropriate ation Malfuntion Code (at STEP II or IV) Normal Code (at both STEP II and IV) BASIC INSPECTION *2 STEP V SYMPTOM BASIS (at STEP I or III) Perform inspetions aording to Symptom Matrix Chart TROUBLE DIAGNOSIS FOR SPECIFIC DTC STEP VI REPAIR/REPLACE FINAL CHECK Confirm that the inident is ompletely fixed by performing BASIC INSPECTION and DTC CONFIRMATION PROCEDURE (or OVERALL FUNCTION CHECK) Then, erase the unneessary (already fixed) DTCs in ECM STEP VII CHECK OUT *1: If the inident annot be dupliated, refer to GI setion ( Inident Simulation Tests, HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT ) *2: If the on board diagnosti system annot be performed, hek main power supply and ground iruit Refer to TROUBLE DIAGNOSIS FOR MAIN POWER SUPPLY AND GROUND CIRCUIT, EC-CD-62 EC-CD-38

39 TROUBLE DIAGNOSIS Work Flow Desription for Work Flow STEP STEP I STEP II STEP III STEP IV STEP V STEP VI STEP VII DESCRIPTION Get detailed information about the onditions and the environment when the inident/symptom ourred using the DIAGNOSTIC WORKSHEET as shown on the next page Before onfirming the onern, hek and write down (print out using CONSULT-II) the Diagnosti Trouble Code (DTC), then erase the ode Refer to EC-CD-25) The DTC an be used when dupliating the inident at STEP III & IV Study the relationship between the ause, speified by DTC, and the symptom desribed by the ustomer (The Symptom Matrix Chart will be useful Refer to EC-CD-50) Try to onfirm the symptom and under what onditions the inident ours The DIAGNOSTIC WORK SHEET is useful to verify the inident Connet CONSULT-II to the vehile in DATA MONITOR (AUTO TRIG) mode and hek real time diagnosis results If the inident annot be verified, perform INCIDENT SIMULATION TESTS Refer to GI setion If the malfuntion ode is deteted, skip STEP IV and perform STEP V Try to detet the Diagnosti Trouble Code (DTC) by driving in (or performing) the DTC CONFIRMATION PROCEDURE Chek and read the DTC by using CONSULT-II During the DTC verifiation, be sure to onnet CONSULT-II to the vehile in DATA MONITOR (AUTO TRIG) mode and hek real time diagnosis results If the inident annot be verified, perform INCIDENT SIMULATION TESTS Refer to GI setion In ase the DTC CONFIRMATION PROCEDURE is not available, perform the OVERALL FUNCTION CHECK instead The DTC annot be displayed by this hek, however, this simplified hek is an effetive alternative The result of the OVERALL FUNCTION CHECK is the same as the DTC detetion Take the appropriate ation based on the results of STEP I through IV If the malfuntion ode is indiated, proeed to speifi TROUBLE DIAGNOSIS FOR DTC If the normal ode is indiated, proeed to the BASIC INSPECTION Refer to EC-CD-40 Then perform inspetions aording to the Symptom Matrix Chart Refer to EC-CD-50 Identify where to begin diagnosis based on the relationship study between symptom and possible auses Inspet the system for mehanial binding, loose onnetors or wiring damage using (traing) Harness Layouts Gently shake the related onnetors, omponents or wiring harness with CONSULT-II set in DATA MONI- TOR (AUTO TRIG) mode Chek the voltage of the related ECM terminals or monitor the output data from the related sensors with CONSULT-II Refer to EC-CD-55 The DIAGNOSTIC PROCEDURE in EC setion ontains a desription based on open iruit inspetion A short iruit inspetion is also required for the iruit hek in the DIAGNOSTIC PROCEDURE For details, refer to GI setion ( Ciruit Inspetion, HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRI- CAL INCIDENT ) Repair or replae the malfuntioning parts One you have repaired the iruit or replaed a omponent, you need to run the engine in the same onditions and irumstanes whih resulted in the ustomer s initial omplaint Perform the DTC CONFIRMATION PROCEDURE and onfirm the normal ode (Diagnosti trouble ode No 55) is deteted If the inident is still deteted in the final hek, perform STEP VI by using a different method from the previous one Before returning the vehile to the ustomer, be sure to erase the unneessary (already fixed) DTC in ECM (Refer to EC-CD-25) EC-CD-39

40 TROUBLE DIAGNOSIS Basi Inspetion Basi Inspetion Preaution: Perform Basi Inspetion without eletrial or mehanial loads applied; Headlamp swith is off, Air Conditioner swith is off, Rear defogger swith is off, Steering wheel is in the straight-ahead position, et Priming pump SEF142I SEF671S BEFORE STARTI 1 Chek servie reords for any reent repairs that may indiate a related problem, or the urrent need for sheduled maintenane 2 Open engine hood and hek the following: Harness onnetors for faulty onnetions Vauum hoses for splits, kinks, or faulty onnetions Wiring for faulty onnetions, pinhes, or uts 3 Using priming pump, bleed air from fuel system Refer to Fuel Filter Chek in MA setion Data link onnetor for CONSULT-II CONNECT CONSULT-II TO THE VEHICLE Connet CONSULT-II to the data link onnetor for CONSULT-II and selet EINE from the menu Refer to EC-CD-30 Diesel taho tester Injetion tube SAT703J DOES EINE START? Yes No Turn ignition swith to the LOCK position, wait 5 seonds and then start engine If engine fails to start, hek diagnosti trouble ode (DTC) Run engine for 10 minutes SEF689S CHECK IDLE SPEED Read engine idle speed in DATA MONITOR mode with CONSULT-II 825 rpm ± 25 (in N position) -OR - Chek idle speed using tahometer tester 825 rpm ± 25 (in N position) PEF190P (Go to V A on next page) EC-CD-40