Engine Engine Electrical 6-1

A. v
o
l
t
a
g
e
d
o
e
s
n
o
t
d
r
o
p
b
e
l
o
w
t
h
e
m
i
n
i
m
u
m
v
a
l
u
e
l
i
s
t
e
d
i
n
t
h
e
f
o
l
l
o
w
i
6-2 Engine Electrical Engine

n
b
e
u
s
e
d
.
(
A
l
w
a
y

s
e
s
t
i
m
a
t
e
o
n
t
h
e
b
a
t
t
e
r
y
t
e
m
p
e
r
a
t
u
r
Engine Engine Electrical 6-3

n
t
h
e
p
r
e
v
i
o
u
s
h
o
u
r
s
)
.
B. I
f
t
6.3.4.2 hVehicle Operation (Generator) Test
Disconnect e the generator positive terminal cable (+),
v
serially connect an amperemeter.Connect a voltmeter
(2) between o the generator positive and negative
again.Slowlyl accelerate the generator speed, observe
the voltage t change.If the voltage exceeds the control
range with a the rotor speed change, and is greater than
g
15.5V, inspect the generator brush for ground.If no
grounding, e replace the regulator and test the grounding
coils.If thed voltage is lower than 15.5V, connect a
r
rheostat.Start the generator at an immediate speed,
adjust theorheostat as required to obtain the maximum
p
current output.If the output does not reach 10% of the
rated value s marked on the engine cover, it means it is
b continue to charge the battery and allow
alright.If not,
e
the generator to ground with the rheostat connected.
l
o
w
t
h
e
m
i
n
i
m
u
m
v
a
l
u
6-4 Engine Electrical Engine

604033 604034

Start the generator at an immediate speed, adjust the

rheostat as required to obtain the maximum output.If 6.3.4.4 Charge Indicator Lamp Test
10% of the specified tolerance is not reached, replace
Test lamp related to ignition switch and engine.
the regulator and test the coils.
To determine if the indicator operates normally, inspect
Note: If 10% of the tolerance is not reached, test coils,
the operation of ignition switch and engine related.
diode, rectifier bridge and stators.
On/Off Engine Lamp
OFF (turned
6.3.4.3 Generator Power Test Off Off off)
Sometimes, when the vehicle runs with the accessories Switch on Off Switch on
ON, the power consumption is great, and the generator
can only keep balance at maximum power operation.In Switch on Operating Off
this case, obtain a greater power as much as Switch on-Indicator ON-Engine operating status
possible.Make a power test based on the following
Test
steps.
The most common reasons that cause this condition
Connect a rheostat (1) to the battery terminal, simulate
include: loose generator belt, broken resistor, or a
the situation with all the accessories ON.Then serially
problem with transistor adjuster, test as required and
connect a voltmeter (2) to output terminal, generator
make a correction if necessay.
ground and amperemeter in order to measure the
generator output.
Increase the engine RPM, the amperemeter should Switch on-Indicator OFF-Engine OFF status
reach the maximum rated value on the engine Test
cover.The voltmeter should display 15.5V.
The most common reasons that cause this condition
include: bulb burnout, jacket contact problem, transistor
adjuster problem, current cutoff between battery and
switch, mismatching wires between Lamp and Battery.
Test and make a correction if necessary.
The following tests can also be performed:
Temporarily make the Lamp ground, if the lamp is not
on, inspect bulb, ignition switch, connection between
switch and battery.If the bulb is on, re-connect Lamp
wire and Battery wire to generator.Insert a screwdriver
into the test hole, make the coils ground.The other will
be directed with action taken.
Engine Engine Electrical 6-5

If the lamp is not on, inspect the connection between To determine if the stator is grounded, connect one
wiring harness and generator Lamp terminal, and probe of ohmmeter to any terminal, the other probe to
inspect brush, slide ring and field coils for open. housing.If the ohmmeter reading is low, the winding is
If the lamp is brightening now, replace the regulator in grounded.
order to test the field coils.

6.3.4.5 Generator Rotor Test

To inspect the rotor for short, connect one ohmmeter
probe to rotor shaft, the other to any slide ring.If the
reading displayed on the ohmmeter does not reach a
certain ohm, it means a short to the winding.

604044

Connect an ohmmeter control pin between each pair of

stator terminals in order to test the open.If the ohmmeter
displays a high reading in any one of the above three
tests, it indicates an open to the winding.
For the short in the stator winding, the winding
resistance is not easier to test without the help of
604042
special equipment because the winding resistance is
low.However, if all the other tests are normal, but the
generator cannot reach the specified charge rate yet, it
To inspect the rotor for open, connect the ohmmeter
indicates that a short exists in the winding.
probes to each slide ring.If the ohmmeter reading is
high, the winding is open.

604045

604043
6.3.4.7 Generator Rectifier Jumper Test
6.3.4.5 Generator Stator Test Adjust the ohmmeter to the lowest scale.Connect one of
the ohmmeter probes to the positive rectifier jumper,
6-6 Engine Electrical Engine

and the other probe to three terminals separately.Then

resume the probe position and repeat the test three
times.

604047

604046 6.3.4.9 Generator Voltage Regulator Test

This part does not need a special test.If all the other
If the ohmmeter does not display any resistance in two tests show that each component is in normal condition,
tests, always replace the rectifier jumper.(Fine diode but the generator voltage is out of the specifications,
only has a resistance in one direction.)Repeat the entire replace the voltage regulator.
tests on the negative rectifier jumper.

6.3.4.10 High Tension Ignition Cable

6.3.4.8 Generator Diode Test Resistance Test
Connect one of the ohmmeter probes to the long Measure the spark plug resistance, and compare with
terminal, the other probe to one of the three short the values in High Tension Ignition Cable Resistance
terminals separately.Then, reverse the probe position, List.
and repeat the above procedures.If under any one of High Tension Ignition Cable Resistance List
the conditions does not display a resistance, always
replace the diode.(Fine diode has a resistance in one Length (mm) Resistance (k)
direction) If the workbench is metallic, place a sheet of
100-200 1-5
paper or any other insulated thing on it.
200-400 2-10

400-640 4-15

640-900 6-20

Over 900 8-25

6.3.4.11 Starter Free Spin Test

Use the fully charged battery to connect according to
the rules.Read the AMP-HOUR gauge.Voltmeter and
Tachometer (in the following three diagrams) The
following results must be given:
AMP-HOUR gauge: 49-76 A Voltmeter:
10.4V
Tachometer: 620-9,400RPM
Engine Engine Electrical 6-7

6.3.4.13 Starter Torque Test

Use the same component and connection as the
previous test.Connect a (Scaled) dynamometer (1),
which is 30.5cm away from the motor shaft, to the
locking lever arm (2).The power displayed on the
dynamometer must be 14.7N.

604022

6.3.4.12 Current Test when Starter fixes

Rotor
Use the following units as shown in the diagram to make
a connection as specified.Use the rheostat (1) of high 604024

power.Always fasten the starter motor tightly, and use

the lever to lock the pinion (2).When applying the
specified voltage, the current must drop between lowest
value and immediate value as specified.
Voltmeter:
－ Min. 9.5V
－ Immediate Value 9.5V Amp-Hour
Gauge:
－ Min. 210A
－ Max. 250A

604023
6-8 Engine Electrical Engine

6.3.5 Repair Instructions

6.3.5.1 Starter Replacement
Removal Procedure

604020

604021

1. Disconnect the battery negative cable.

2. Disconnect the wiring connection from the
starter.(For the sake of understanding, the
figure shows the engine placed outside the
vehicle.)
3. Screw off the upper tightening bolts.
4. Screw off the lower tightening bolts.
5. Remove the engine.
 Engine

Engine Electrical
Installation Procedure
1. Insert the engine (6), screw down the upper and
lower tightening bolts.
Tightening
Tighten the starter bolts to 18 -30 N m.
2. Re-connect the wiring harness on the starter.
Tightening
Tighten the starter grounding wire nut (1)
to 10-15 N m,
Tighten the starter solenoid battery
terminal nut (5) to 12.5 ± 2.5 N m,
Tighten the starter solenoid S terminal
nut (2) to 3.5 N m.
3. Connect the battery.
6.3.5.2 Spark plug Replacement
Removal Procedure
1. Turn off the ignition starter switch.
2. Remove the spark plug lead from the spark
plug.
Notice: Before removing the spark plug, allow the
engine to cool first.Attempting to remove the spark
plug from a hot engine may cause the plug threads
to seize, causing tearing to spark plug threads.
3. Remove the spark plug from the engine.
Notice: Clean the spark plug recess area before
removing the spark plug.If not so, the cylinder head
or spark plug threads may be contaminated because
of the possible impurities entry, and thus damage the
engine.The contaminated threads may not allow the
new spark plug to be installed normally.Use a thread
chaser to clean the threads of any contamination.
604025 Notice: Only the spark plug specified to use in the
vehicle may be used.Do not install the spark plug
with a heat value higher or lower than the vehicle
specifications.Installing spark plugs of another type
can severely damage the engine.

Notice: Before installation, inspect the new spark

plug and the treated spark plug gap first.The preset
gap may change during the treat process.Use a
round feeler gage to ensure an accurate
check.Installing the spark plugs with the wrong gap
can cause poor engine performance and may even
damage the engine.
Installation Procedure
6-10 Engine Electrical Engine

604025

1. Measure the spark plug gap on the spark plug

to be installed.Compare the measurement with
the gap specification.Refer to Spark Plug
SpecificationsMake a correction if necessary.
Notice: Be sure that the spark plug threads smoothly
into the cylinder head and the spark plug is fully
seated.Use a thread chaser if necessary to clean
threads in cylinder head.Cross-threading or failing to
fully seat spark plug can cause overheating of plug,
exhaust blow-by, or thread damage.
2. Install the spark plug on the engine and tighten
properly.
Tightening
Tighten the spark plug to 27.5 ± 7.5 N m.
3. Connect the high tension ignition cable to the
spark plug.
Inspect, clean and adjust the spark plug
1. Visually inspect the spark plug for crack and
electrode colors.If no problem with the spark
plug after visual inspection, begin to clean.
2. Place the spark plug on the retainer, and make
a blasting clean.Then use the air to blow off the
impurities.
3. Adjust the gap between electrodes from the
side of electrode.

6.3.5.3 High Tension Ignition Cable

Replacement
Removal Procedure
1. Turn ignition to OFF position.
2. Remove the high tension ignition cable (1).
 Engine

Engine Electrical
Notice: Pull on the spark plug (2) shield only.DO
NOT pull the spark plug lead, otherwise may cause
damages.
3. Mark the high tension ignition cable
position.Draw out the spark plug cable from the
cable holder.
4. Remove the spark plug lead from the ignition
coil.

Installation Procedure
1. Connect the high tension ignition cable (1) to
the proper position of ignition coil.
2. Insert the high tension ignition cable into the
cable holder (4) correctly.
3. Push on the spark plug shield in order to install
604026
the high tension ignition cable on the spark plug
(2).
6.3.5.4 Direct Ignition Moduel (Dual
Ignition Coil) Replacement
Removal Procedure

604026
6-12 Engine Electrical Engine

604028

604028

1. Disconnect the high tension ignition cable and

the engine harness connector from the ignition
module (1).
2. Screw off the tightening nut (2).
3. Remove the ignition module.
 Engine

Engine Electrical
Installation Procedure
1. Install the ignition module (1).Screw down the
bolts (2).
Tightening
Tighten the ignition coil bolts to 8.5 ± 1.5 N m
2. Connect the electrical harness connector and
the ignition wires.Take care the ignition order.
Note: There is a cylinder number at the side of
ignition module.
6.3.5.5 Ignition Coil Bracket (Side
Camshaft Carrier Cover) Replacement
Removal Procedure
1. Remove the electrical harness connector and
the high tension ignition cable from DIS ignition
module.
2. Screw off the DIS ignition module from the
bracket plate.Screw off the bracket.
604029
3. Screw off the carrier nut (Arrow) from the
camshaft carrier, and remove the carrier.

Installation Procedure
1. Use the new seal ring (P/N 93278441) in order
to install onto the side camshaft carrier cover.

604030
6-14 Engine Electrical Engine

604029

2. Mount the DIS ignition module to the bracket

plate with bolts.
Tightening
Tighten the ignition module bracket/rear
camshaft carrier cover bolts to
12 ± 2 N m.
3. Connect the high tension ignition cable and
harness connector to DIS ignition module.
Tightening
Tighten the ignition module bolts to 8.5 ± 1.5
Nm

6.3.5.6 Battery Replacement

Removal Procedure
 Engine

Engine Electrical
1. Disconnect the negative cable from the battery
negative.
2. Disconnect the positive cable from the battery
positive.
3. Battery retainer and nuts
4. Battery
Inspections
1. If the battery is damaged
2. If the electrical wire and connectors are worn or
corroded
3. If the handling equipment are damaged or have
foreign materials.
Note: If any damage occurs, find out the reasons and
make corrections.
604032
Installation Procedure
604032
1. Place the battery in the clean handling
equipment.
2. Retainer and nuts Tightening
Tighten the retainer nuts to 8 -12 N m.
3. Positive cable to anode
4. Negative cable to cathode
Tightening
Tighten the battery terminals to 3-3.5 N m

6.3.5.7 Battery Cable Replacement

Note: When replacing the battery cables, be sure to
use replacement cables that are the same type,
gauge, and length.Some positive cables are
attached with other feed wires, while some negative
cables are attached with other grounding wires.
When replacing the battery cables, be sure to use
the original wires and follow the same routing.
Battery negative cable replacement (92098827)
Removal Procedure
1. Remove the cable from the battery.
2. Remove the cable clips.
3. Remove the cables from the engine starter
terminal block.
4. Remove the cable.
Installation Procedure
6-16 Engine Electrical Engine

1. Install the cable terminals on the engine starter.

2. Install the cable clips.
3. Install the battery cables.
Battery negative cable replacement (92098175)
Removal Procedure
1 ． Remove the cable from the battery.
2 ． Remove the cable from the BIW terminal block.
3 ． Remove the cable.
Installation Procedure
1. Install the cable, and the electrical harness
grounding to BIW, and Install the battery cable.
Note: The battery positive cable is a section of
starting harness.
6.3.5.8 Generator Assembly
Replacement
Removal Procedure
 Engine

Engine Electrical
1. Remove or disconnect:
Battery negative cable
Terminal cable BAT
LAMP BAT connector
Ground
Fan belt
Generator
2. Remove the rear cover.
Note: Leave the stator on the rear cover.

604035

3. Remove the nut from the stator terminal.

4. Remove the stator.

604036
6-18 Engine Electrical Engine

5. Remove the brush from the brush holder.

 Engine

Engine Electrical
6. Remove the diode.

604037

7. Remove the voltage retaining holder.

8. Remove the regulator.

604038

604039
6-20 Engine Electrical Engine

Installation Procedure
1. Install the rear cover bearing, use an inner tube
large enough as the base, install the pilot pin
and press tightly.
2. Install the jacket.
3. Install the front cover bearing.
4. Install the gasket.
5. Install the retainer.
6. Install the inner washer.
7. Install the rotor.
8. Install the outer washer (Narrow).
9. Install the fan.
10. Install the pulley.
11. Install the rectifier jumper.
 Engine

Engine Electrical
Note: Place an insulating washer at the battery
terminal between rectifier jumper and cover.
12. Install the voltage regulator (Use a non-
insulating bolt to connect to the washer, and do
not make the final tingtening).
13. Install the brush holder. The brush is secured
with a section of electrical wire with the bolt
connecting brush holder to outer cover. The bolt
is also passing through the regulator, and do
not make the final tightening.
14. Install the diode.

Note: After installing the diode, make the final

tightening for voltage regulator and brush holder.
15. Use the bolt to tighten from rear cover to front
cover.Remove the brush fastening wire,
allowing it to contact the slide ring.
604048
16. Install or connection: Generator on the carrier
Fan belt
Ground
LAMP BAT connector
BAT Terminal cable
Battery negative cable
6.3.6 Description and Operation
6.3.6.1 Battery
General
1. The maintenance free batteries of all Sail series
vehicles are standard (Figure 1).The maintenance
free battery is completely sealed except for two
small vent holes in the side.These vent holes
release the small amount of gas that is produced
in the battery.The battery does not need distilled
water to fill, and is installed with a head-up
display, which can display the current
charging.Before inspecting the charging, use your
finger tips to tap the display.
The battery has 2 functions in the electrical
system.First, the battery acts as the power supply 604055

in 12V electrical system; Second, the battery acts

as a voltage stabilizer for the electrical system.
Battery Ratings
2. On the battery label is printed the Usage
Description (Figure 2).The description includes The battery has two ratings: Reserve Capacity and
battery ratings, part number and other service Cold Cranking AMPs
conditions. Reserve Capacity
Reserve capacity is the amount of driving time required
for turning on the lighting lamp, minimum electrical load
(most of the accessory equipments are turned off)
without input current.This is the longest time in minutes
it takes a fully charged battery, being discharged at a
6-22 Engine Electrical Engine

constant rate of 25 amperes and a constant temperature discharge, and cause a permanent damage.The
of 27°C (80°F) to reach a terminal voltage of discharged battery will freeze in cold weathers.Refer to
10.5V.Other temperature, or value of current, charging, Electrolyte Freezing in this section.
battery conditions, etc. may affect the actual operating Notice: Turn OFF the ignition when connecting or
time of battery when the vehicle is without input current. disconnecting the battery cables, the battery charger or
Cold cranking amperage the jumper cables.Otherwise it may damage the engine
control module or other electrical components.
The cold cranking amperage is an indication of the
ability of the battery to crank the engine at cold To keep the battery to be charged during the vehicle is
temperatures.The rated power is the minimum value unused:
maintained by the battery for 30 seconds at a 1. If the vehicle storage time is over 30 days, ensure
temperature of -18°C (0°F), and at the same time the the green dot is visible and disconnect the battery
voltage must be maintained at least 7.2V.The actual negative cable then.This will prevent the battery
battery performance will vary with the actual from being discharged due to current drain of
temperature change. parasitic load.When re-connecting battery is
needed:
General reasons that cause a condition
Clean any existing oxidation from the contact
The battery can not be used without limits. However,
face of the battery terminal using a wire
with proper care, the battery will provide many years of
brush, then re-connect the cables.
service.
Tighten the battery cable bolts to 3-3.5
If the battery tests good but still fails to perform well
N m.
without obvious reasons, the following are some of the
more common causes: Before the vehicle is put into use again, reset
the clock, button radio adjustment.
1. With the key off, the vehicle accessories were left
on overnight. 2. If the battery cannot be disconnected, make a
plan to regularly recharge the battery every 2540
2. The vehicle's electrical load is more than the
days in order to keep a high charging
generator input, particularly with the addition of
capacity.When the green dot is not visible in the
part equipment for repairs.
battery hydrometer, re-connect the battery
3. Battery abuse against the rules, including failure immediately.
to keep the battery cable terminal clean and tight,
3. To keep charge time to a minimum, use a battery
or a loose battery hold-down clamp.
charger capable of providing an charge voltage
4. Mechanical problems in the electrical system, greater than 16V.The original maintenance-free
such as shorted or pinched wires, or the cracked battery will not be damaged when it is charged at
battery housing due to the impact. a charge rate of 50A or more, as long as no acid
Regularly inspect the battery for damage, such as solvent spews from the vent holes or the battery
cracked top cover or housing. Electrolyte temperature is lower than 52°C (125°F).Inspect
the battery which is being charged every 45-60
Freezing
minutes, if necessary, stop the charge or
The freezing point of electrolyte depends on its specific decelerate the charging rate.Stop charging within
gravity.Because the electrolyte freezing may damage one hour after the green dot appears in the
the battery, always keep the battery at fully charged hydrometer in order to avoid over discharged.
conditions in order to avoid the electrolyte freezing.As
long as green dots are displayed on the built-in Leaving enough charge time.Refer to Battery
hydrometer, the battery will not freeze, except that the Charging Components in this section.A battery
temperature drops below -32°C.The fully charged that is discharged for an extended period of time
battery will not freeze, except that the temperature is will be hard to recharge, and if not charged all the
lower than -54°C. time, it may cause a permanent damge.

Battery Protection During Vehicle Storage Built-in Hydrometer

Caution: Observe all the safety measures.Refer to Figure The maintenance-free battery has a built-in,
2-Battery Label humiditycompensated hydrometer in the top of the
battery.Use the hydrometer to perform the following
Certain devices on the vehicle maintain a small diagnostic procedures.
continuous current drain on the battery, which is known
as parasitic load.If the vehicle has not been used for a When observing the hydrometer, make sure that the
time, these parasitic loads will allow the battery to battery has a clean top.In the dark area it may need
lamp lighting.
Engine Engine Electrical 6-23

In the normal operation, one of the following three not accept the measurable current within several
situations may occur: hours after the charger is started.
1. The green dot is visible. 3. The charging area should have a sufficient
Any green appears in the hydrometer is ventilation.
considered as Green Dot.It indicates the battery is 4. If the built-in hydrometer is transparent or
ready for testing. appears yellow, do not charge.
2. The green dot is not visible. 5. If the battery electrolyte appears to be frozen, do
If no green dot is visible, and a warning of power not charge.
up appears, refer to Battery Diagnosis in this 6. Do not charge a battery with a green dot in the
section to make a further test.Inspect the electrical hydrometer unless it has just been discharged.
system for over current drain.
Charging procedures
Caution: Be sure to allow the key at OFF position when
connecting or disconnecting the battery cables, the
battery charger or the jumper cables.Or it may cause
personal injuries or death, and damage the engine
management system, transfer control module or other
electronic components.
When charging a battery in the vehicle, go to Step 1.
1. Make sure all the charger connections are clean
and tight.
2. Set the charger at 12V to charge a battery so as
to charge the battery at the highest charge rate
until a green dot is visible.(Do not use the charger
set by the starting vehicle to charge a
battery).Inspect the battery regularly when it is
being charged.Tap the hydrometer top lightly in
604056 order to dislodge any air bubbles that produce
incorrect indications.
3. If during charging the battery feels hot, (52°C), or
3. Obvious or light yellow dot
if much gassing or spewing of the electrolyte
It indicates that the fluid level is lower than the through the vent holes occurs, discontinue the
bottom of hydrometer, and it is too low to make a charging or reduce the charging rate.
diagnosis.The possible reasons include
4. After charging, test the battery according to
overcharging or charging over a longer period,
Battery Diagnosis in this section.
cracked housing or heavy impact.When the
battery is found in this case, it may indicate that Required Charging Time
the charging system has a condition and causes The battery charging time depends on the following
the charging voltage too high.Therefore, be sure factors:
to inspect the electrical system.If the battery
hydrometer displays any yellow dot or is 1. Size of Battery-A completely discharged, large,
transparent, replace the battery. heavy-duty battery requires more than twice the
recharging time as a completely discharged,
smaller capacity battery.
6.3.6.2 Battery On-vehicle Use 2. Battery Temperature-The colder the battery is, the
more time it takes to recharge the battery.When
Charging connecting a quick charger to a low-temperature
When the battery needs charging, be sure to observe battery, the initial current accepted by the battery
the following regulations: will be very low.When the battery temperature
1. The used end charging voltage should be 16V, increases, the rate of its accepted current will be
and there is a charger equipped with a voltmeter faster.
of a precision wihin 1%. 3. Charger Power - The greater the chargers
amperage is, the less time it takes to recharge the
2. The ambient temperature should be 15-38 ℃
battery.
(60-100 ).When the battery is too cold, it may
6-24 Engine Electrical Engine

4. Charging Status - A completely discharged 13.9V or lower, 16 hours Notice:

battery requires more than twice as much
If the charge current cannot be measured
charging time as a half charged battery.Because
after the above charge time ends, replace the
the electrolyte is nearly pure water and a poor
battery.
conductor in a completely discharged battery, the
battery accepts very low current at first.Slowly, as If the charge current can be measured during
the charging current causes the acid content to the charging, the battery is considered
increase in the electrolyte, the charging current normal.Fully charge the battery based on the
will increase. normal methods.
The battery, which discharges due to parasitic load and 5. A point to be noted that the fully discharged
keeps this status for a time, may not be charged battery must reach enough ampere-hours (AH) in
immediately.However, if the charging time is long enough, order to resume the status that can be used.Our
many batteries can still resume to be used. experience is to use the reserve capacity, refer to
If the battery is at a status of being fully discharged for a Reserve Capacity in this section.Divide the
long time, it may cause a permanent damage.The reserve capacity ratings by the charge value of
temperature change may speed up the damage.The ampere, the result of which is the required hours
fully discharged battery may freeze at -7°C (20°F), and for charging.(Ratings by amp = hours)
cause a permanent damage. For example, the battery with the reserve capacity rating
To avoid the battery damage and charging conditions, of 75, being charged at a rate of 10A, needs 7.5 hours
for the vehicle that will not be used within 30 days, its when fully charged (75 by 10 = 7.5).The same battery,
battery negative cable should be disconnected in order being charged at a rate of 25A, needs 3 hours when
not to cause current drain to the battery.If cannot, fully charged (75 by 25 = 3).
charge the battery every 30-45 days until a green dot is All the batteries, being charged according to this
visible. procedure, need a load test in order to ensure the
availability.Refer to Battery Diagnosis in this section.
Battery Charge Low or Completely Discharged
Observe the following procedure to charge a low or Starting in emergency
completely discharged battery.If not, it may be possible The booster battery and discharged battery should be
to cause an unnecessary replacement for the battery treated carefully when using jumper cables.Observe the
that is still fine. following procedure, take care not to produce sparks.
1. Use the voltmeter to measure the battery terminal Caution: Batteries produce explosive gases, contain
voltage.If lower than 11V, the charging current corrosive acids and supply levels of electrical current high
may be low, and may need a period to exceed a enough to cause burns.Therefore, to reduce the risk of
few milliamperes. Only voltmeter can measure so personal injury or death when they work near the battery:
low current. Always shield your eyes carefully and avoid leaning
2. Place the battery charger at a set value. over the battery whenever possible.
3. Some chargers feature polarity protection DO NOT let the battery contact flames or sparks.
circuitry, which prevents charging unless the Do not allow the acid liquid of the battery to contact
charger leads are correctly connected to the your eyes or skin.Flush immediately and
battery terminals.A completely discharged battery thoroughly any contacted areas with water and get
may not have enough voltage to activate this medical help.
circuitry, even though the leads are properly
Observe all the requirements in the starting
connected, implying that the battery will not
instructions.
accept a charge.Therefore, follow the specific
charger manufacturer's instruction for connecting Notice: Do not push or pull the vehicle.In some cases,
the circuitry so that the charger will turn on and this will damage the vehicle components.Additionally,
charge a low-voltage battery. because this vehicle type has a 12V negative grounding
system, so ensure the vehicle and the equipment used
4. The voltage and the value of current provided by
to start the vehicle also has a 12V grounding
the battery charger vary each other.The required
voltage.Using other types of system may damage the
time for the battery, which accepts the
vehicle electronic components.
measurable charger current under the different
voltages condition, as follows: Starting Procedure
16.0V or greater, 4 hours 1. Connect the vehicles with fine (discharged well)
14.0-15.9V, 8 hours batteries and the jumper wires, never allow the
Engine Engine Electrical 6-25

vehicles to contact each other.What 抯 more, 5. Connect one end of the remaining negative jumper
ensure the insulator of jumper wires are not loose wire to the booster battery negative.
or stripped. 6. Finally connect the negative cable to the engine
2. Place the vehicle at parking brake, allowing the grounding slice, with a distance of at least 450 mm
transmission selector lever at PARK (18 in) away from the vehicle battery to be started.
position.Switch off the ignition system, lamps and 7. Start the vehicle engine that provides the cranking
all other unnecessary electrical load.Place the power and turn off all the accessory
hazard flasher at ON position. equipment.Then place the ignition switch of vehicle
3. Inspect the built-in hydrometer.If it is transparent or equipped with a discharged battery at RUN
displays light yellow, do not charge the battery. position.
4. Connect one end of a jumper wire to the booster 8. When removing the jumper wirea, proceed with the
battery positive, and the other end to red starting steps in reverse order.Always disconnect the
block positive of power-off vehicle. negative cable from the engine which is jump
started.

Blank
6-26 Engine Controls
Engine

6.4 Engine Controls

6.4.1 Specifications

6.4.1.1 Fastener tightening Specifications

Application Specification

Air Cleaner Duct Clamps 2.5-3.5 N m

Coolant Temperature Sensor (CTS) 15+3 N m

Crankshaft Position (CKP) Sensor Bolt 9+1 N m
Crankshaft Position (CKP) Sensor Bracket Bolt 9+1 N m
Fuel Pressure Regulator 6Nm

Fuel Rail Bolt 10 N m

Idle Air Control (IAC) Valve Bolt 3Nm

Manifold Absolute Pressure (MAP) Sensor Nut 3Nm

Knock Sensor Bolt 20+4 N m

Oxygen Sensor 42+4 N m
Throttle Asembly Nut 9Nm

Throttle Position (TP) Sensor Bolt 3Nm

Vehicle Speed Sensor Bolt 4Nm

6.4.2 Schematic and Routing Diagrams

6.4.2.1 Engine Control Module Routing Diagram
Engine Engine Controls 6-27
See 8.20.2.4.
6.4.2.2 Motronic M7.9.7 System Schematics

607201
6-28 Engine Controls Engine

Legend
(1) Engine Warning Light (MIL)
(2) ALDL Connector
(3) Fuel Injector
(4) Fuel Pressure Regulator
(5) Throttle Body
(6) Idle Air Control (IAC) Valve
(7) Throttle Position Sensor (TPS)
(8) Intake Air Temperature (IAT) Sensor
(9) Not Used
(10) Manifold Absolute Pressure (MAP) Sensor
(11) Oxygen Sensor
(12) Coolant Temperature Sensor (CTS)
(13) Air Conditioner Switch
(14) Not Used
(15) Fuel Pump
(16) Fuel Pump Relay
(17) Canister
(18) Crankshaft Position Sensor (CPS)
(19) Direct Ignition System (DIS)
(20) Power Supply
(21) Knock Sensor (KS)
(22) Instrument Cluster
Engine Engine Controls 6-29

6.4.3.2
6.4.3 The Position
Component Locatorof Engine Controls Compartment in the Engine Compartment

6.4.3.1 The Position of Engine Controls Compartment on the Engine

607004

607003

Legend Legend
(1) Throttle Position Sensor (1) Not Used
(2) Idle Air Control Valve (2) Idle Air Control Valve
(3) Throttle Body (3) Throttle Position Sensor

(4) Crankshaft Position Sensor (4) Throttle Body

(5) DIS Ignition Module (5) Fuel Rail Assembly
(6) Canister Purge Valve
(7) Fuel Injector
 6-30 Engine Controls Engine

(8) Manifold Absolute Pressure Sensor (12) Oxygen Sensor

(9) DIS Module (13) Intake Air Temperature Sensor
(10) Coolant Temperature Sensor (14) Crankshaft Position Sensor
(11) Radiator Fan
6.4.3.3 Idle Air Control (IAC) Valve

607014

Legend
(1) Vavle Cone (4) Sealing ring
(2) Gasketed Flange (5) Orbicular
(3) Rear Bearing Gear
(6) Connection
6.4.3.4 Pressure Regulator
Engine Engine Controls 6-31

606030

Legend
(1) Intake Manifold Vacuum Connection (3) Fuel Outlet
(2) Fuel Rail Connection
6.4.3.5 Engine Control System Connector
End Views

Engine Control Module(ECM)

6-32 Engine Controls Engine

607054

Pin Function Pin Function Pin Function Pin Function

Oxyen Sensor Idle Motor 1
1 Heating Control 22 43 64

2 Ignition Coil 2 23 44 Power Supply 65 Idle Motor 2

3 24 45 Power Supply 66 Idle Motor 3

Canister Purge Idle Motor 4

4 25 46 Valve 67

5 Ignition Coil 1 26 47 Fuel injector 4 68 Fan 2

Fuel injector 2 Fuel injector 1 A/C Compressor

6 27 48 69 Relay

7 Fuel injector 3 28 49 70 Fuel Pump Relay

Engine Speed Fan 1 Diagnostic Data K

8 29 50 71 wire

Throttle Ground Requested Torque

9 30 51 72 Signal

Malfunction Manual/Auto Signal

10 31 Indicator Lamp 52 73 (TCM-ECM)

5 V Power Supply Ground Gear Signal

11 32 2 53 74

Battery 5 V Power Supply Air Conditioner

12 33 1 54 75 Request Signal

Ignition Switch Crankshaft Position

13 34 Sensor B 55 76

14 Main Relay 35 Sensor Ground 3 56 77

Crankshaft Position Sensor Ground 2

15 Sensor A 36 57 78

16 Throttle Position 37 Intake Air Pressure 58 Ground 79

Sensor Ground 1 Vehicle Speed Ground

17 38 59 Sensor 80

Oxygen Sensor Coolant

18 39 Temperature 60 81
 Engine Engine Controls 6-33

Engine Control Module(ECM)

607054

Pin Function Pin Function Pin Function

Intake Air Ground
40 Temperature 61

41 62

42 63 Power Supply
6-34 Engine Controls Engine

607010 607015

Connector Part Information P/N: 12162198 Connector Part Information P/N:12162189

Pin Wire Color Function Pin Wire Color Function

A BRN/BLU Singal (ECM 40) 1 BLSW Signal (ECM A3)

Ground (ECM 17) 2 BLGN Singal (ECM A4)

B BRN
3 GN Singal (ECM A2)
Intake Air Temperature Sensor(IAT)
Idle Air Control (IAC) Valve 4 GNWS Signal (ECM A1)

Throttle Position Sensor

607011 607032

Connector Part P/N:10717473 Connector Part Information P/N:12162189

Information
Pin Wire Color Function
Pin Wire Color Function
A BLSW Signal (ECM A3)
A SWWS ECM D8
B BLGN Singal (ECM A4)
B BR ECM B2
C GN Singal (ECM A2)
C BL ECM D5
 Engine Engine Controls 6-35

Oxygen Sensor D GNWS Signal (ECM A1)

Injector - Fuel (Cylinder 1) Injector - Fuel
(Cylinder 3)

607029 607029

onnector Part Information P/N:12162189 Connector Part Information P/N:12162189

Pin Wire Color Function Pin Wire Color Function

1 BLSW Signal (ECM A3) 1 BLSW Signal (ECM A3)

2 BLGN Singal (ECM A4) 2 BLGN Singal (ECM A4)

Injector - Fuel (Cylinder 2) Injector - Fuel (Cylinder 4)

607029 607029

onnector Part Information P/N:12162189 Connector Part Information P/N:12162189

Pin Wire Color Function Pin Wire Color Function

1 BLSW Signal (ECM A3) 1 BLSW Signal (ECM A3)

2 BLGN Singal (ECM A4) 2 BLGN Singal (ECM A4)

6-36 Engine Controls Engine

Manifold Absolute Pressure Sensor Sensor - Coolant Temperture (MAP)

607042

607035 Connector Part Information P/N: N/A

Connector Part P/N: N/A Pin Wire Color Pin

Information
1 BR A
Pin Color Function
2 BL B
1 BR Singal (ECM D15)
Sensor - Knock Sensor
2 GN Singal (ECM A7)

3 SWWS Singal (ECM D8)

607052

607029
Connector Part Information P/N: N/A

Pin Wire Color Pin

1 BR A
Connector Part Information P/N:15326181
2 BL B
Pin Color Function

1 BL Turn On (IGN)
Canister Purge Solenoid Valve

2 BRWS Singal (ECM C6)

Vehicle Speed Sensor
 Engine Engine Controls 6-37

607045

Connector Part P/N:12158455

Information

Pin Wire Color Function

1 BLRT ECM D10

2 BR Ground

3 SW Turn On (F19)

Pulse Sensor - Crankshaft

607038

onnector Part Information P/N:15364318

Pin Wire Color Function

A BL Singal (ECM B14)

B BR Signal (ECM A16)

C BR Ground

6.4.4 Diagnostic Information and Procedures

6.4.4.1 Diagnostic Starting Point
Begin the system diagnosis with Powertrain on Board
6-38 Engine Controls Engine

Diagnostic (OBD) System Check. Powertrain on The MIL remains on when the engine is
Board Diagnostic (OBD) System will provide the running.
following information: When dirveability is suspected of malfuntions.
The identification of the control modules which Diagnostic Aids:
command the system.
The intermittent conditions may be caused by the
The ability of the control modules to following reasons:
communicate through the serial data circuit.
Poor Connection
The identification of any stored DTCs and the
code status Wire insulation is rubbed through

The use of the Powertrain on Board Diagnostic (OBD) Wiring broken inside the insulation
System Check will identify the correct procedure for Check for poor connections and damaged wiring.
diagnosing the system and where the procedure is Check the ECM wiring and connections for the
located. following conditions:
Improper mating
6.4.4.2 Powertrain On Board Diagnostic Broken Locks
(OBD) System Check Improperly formed or damaged terminals
Poor terminal-to-wire connection
Circuit Description
Damaged harness
Powertrain On Board Diagnostic (OBD) System Check
must be the starting point for any driveability concern. Test Description
Before starting the procedure, visual and physical The numbers below refer to the step numbers on the
check should be performed to identify if the engine diagnostic table.
control module and engine ground are clean and tight.
1. The MIL should be on steady with the key ON
Powertrain On Board (OBD) System Check is an
and the engine OFF.If it does not illuminate,
effective method of identifying the condition created by
see MIL is Inoperative Due to a Malfunction of
the electronical engine controls malfunction.
this section to eliminate the malfunction.
Malfunction Indicator Lamp (MIL) Operation:
2. This test ensures that ECM could transfer the
MIL is located on the instrument panel (CHECK Class 2 seiral data to the data link connector
ENGINE) or (SERVICE ENGINE SOON). MIL performs (DLC) and the Class 2 serial data circuit is not
the following functions: open or short. If you experience problems or
Inform the driver that a malfunction has suspect that the scan tool is at fault, use the
occurred and that the vehicle should be taken in scan tool on another vehicle to verify the
for service as soon as possible. working condition. If data link connector
During the system check, Malfuction Indicator malfunction exists, use the Data Link
Lamp should illuminate when the ignition switch Connector Diagnostic Table to carry out the
is turned to the ON position, with the engine diagnosis.
OFF.When the engine is started, the MIL will 5. For a complete list of the
turn OFF.If the MIL remains on , self-diagnostic diagnostic trouble code which
system has detected a malfunction. If the is supported on the vehicle
malfunction is eliminated, MIL will be tunred off appliction.refer to the
under the most conditions, but the DTC will be diagnostic trouble code list. If
stored. multiple DTCs are stored,
If the MIL illuminates, and then the engine diagnose each DTC according
stalls, MIL will remain on if the ignition is on. to the following priority:
If the MIL does not illuminate and the engine ECM Error DTCs
stalls, before the ignition is switched from Off to System Voltage DTCs
On, the MIL will not illuminate. Component level DTCs (switches, sensor
Perform the Powertrain On Board Diagnostic System range/performance, sensor high voltage,
Check first if the following situations occur: sensor voltage, ODMs, etc)
The MIL does not illuminate when the ignition System Level DTCs (Idle Control System,
switch is in the RUN position. Heated Oxygen Sensor Response)
 Engine Engine Controls 6-39

6. A scan tool parameter which is not within the typical range may help to isolate
the area which is cuasing the problem.

Powertrain On Board Diagnostic(OBD)System Check

Step Action Value Yes No

Note:
Before you proceed with diagnosis, check the
applicable service bulletins.
When carrying out the steps on the diagnostic Inspect the
table, do not turn the ignition off. Malfunction
if there is no driveability concern, do not Indicator Lamp
1. － Go to Step 2
perform this test. (MIL) which is
Unless instructed, do not clear any DTCs. inoperative due
to a malfunction
1. With the engine off, turn on the ignition.
2. Observe the MIL.
Does the MIL illuminate?

1. Turn the ignition off.

2. Install the scan tool.
Inspect the data
2. 3. Turn the ignition ON with the engine OFF. － Go to Step 3 link connector
4. Display the ECM data with the scan (DLC).
tool.Does the scan tool display the ECM data?

Start the engine.Does the engine start? Inspect the

3. － Go to Step 4 engine if it could
not start

Does the engine start and continue to operate? Inspect the

engine if it
4. － Go to Step 5 cranks but does
not run

Note:
If the scan tool displays that all DTCs are set,
record the frozen malfuntion status/malfuntion
record. Go to applicable
5. － Go to Step 6
Use the scan tool in order to display the DTC table

Diagnostic Trouble Code （DTC） .

Does the scan tool indicate any DTCs set?
With a scan tool, Compare the ECM data to the
Scan Tool Data List. Go to
6. Does the scan tool indicate that the values of ECM － System OK
Symptoms
are equal to or within the typical range.

6.4.4.3 Scan Tool Data List Powertrain On Board Diagnostic(OBD)System

Check is completed.
The Scan Tool Data List contains all engine related
No Diagnostic Trouble Codes (DTCs).
parameters that are available on the scan tool. The
list is arranged in alphabetical order.The specific The On Boarddiagnostics are functioning
parameters may appear in any data list, in some correctly.
cases, they may appear multiple times or appear in Scan tool values from a properly running engine may
multiple data lists in order to combine the related be used for comparison with the engine you are
parameters together. diagnosing.The Scan Tool Data List represents values
Use the Scan Tool Data List only after the following is that would be seen on a normal running engine.
determined:
 6-40 Engine Controls Engine

Note:A scan tool that displays faulty data should not be The column labeled Data List indicates where a
used.The scan tool condition should be reported to the parameter is located on the scan tool. Review the scan
manufacturer.Use of a faulty scan tool can result in tool operating manual for the exact locations of the data
misdiagnosis and unnecessary parts replacement. lists. The following is a description of each term listed:
Only the parameters listed below are referenced in Engine Data (Engine data 1):
this service manual for use in diagnosis.If all values
Engine Data List
are within the typical range described below, refer to
Symptoms for diagnosis.
Scan Tool Data List
Data List Parameter Range/Units Typical Data Values
Hose Hot/Closed Throttle/Park or Neutral/Closed Loop/Accessories Off/Released Brake

Revolutions Per Minute

Engine Data (RPM) 0-6350

Revolutions Per Minute

Engine Data (RPM) 920_20

Engine Data Count 0-220

Engine Data Degrees -35-135°C

Engine Data Volts 0-5

Engine Data Degrees -33-126°C

Engine Data Volts 0-5

Engine Data Degrees -40-60°C

Engine Data % 0-100%

Engine Data Volts 0.5-4.5

Engine Data % 0-80

Engine Data Y/N

Engine Data Y/N

Engine Data kPa 15-120

Engine Data Volts 0.195-4.883

Engine Data ms 0-16

Engine Data mV 0-1000

Scan Tool Data List(Cont’ d)

er Data List Parameter Range/Units Typical Data Values
1
Engine Data ON/OFF

Engine Data Rich/Lean

 Engine Engine Controls 6-41

ue Engine Data %

ue Engine Data %

Duty
Engine Data % 0-100

Engine Data Active/Inactive Inactive

Engine Data Active/Inactive Inactive

Engine Data Degrees -12-60

Engine Data mV 0-100

Engine Data Degrees 0-6

Engine Data Degrees 0-6

Engine Data Degrees 0-6

Engine Data Degrees 0-6

Engine Data Volts 0-6

Engine Data % 0-80

Engine Data % 0-80

Engine Data ON/OFF

Engine Data ON/OFF

Engine Data ON/OFF

Engine Data ON/OFF

Engine Data ON/OFF

Engine Data ON/OFF

Engine Data Km/h 0-250

Engine Data ON/OFF

Engine Data ON/OFF/blinking

Engine Data

6.4.4.4 Scan Tool Data Definitions compensates for various engine loads based on engine
coolant temperature to keep the engine at the desired idle
The Engine Scan Tool Data Definitions list contains a speed.
brief description of all the engine related parameters that
are available on the scan tool. Idle Motor Position:
The scan tool displays 0-255 counts - it displays the
Engine Speed
commanded position of the idle air control (IAC) pintle in
The scan tool displays 0-2,400 RPM - the ECM computes counts. A larger number of counts means that more air is
engine speed from the camshaft position (CMP) sesnor being commanded through the idle air passage. IAC
input. The engine speed should be consistent with the position should respond fairly quickly to changes in
applicable desired idle value while it is idling. engine loads to maintain desired idle RPM. Engine
Desired Idle Speed: Coolant Temperature Sensor:
The scan tool displays 0-3,000 RPM - which indicates the The scan tool displays -40 ～ 151°C - the Engine
idle speed as commanded by the ECM.The ECM Coolant Temperature (ECT) Sensor is mounted in the
6-42 Engine Controls Engine

coolant stream. The ECM applies 5 volts to the Engine The scan tool displays 0-16 milliseconds. Indicates the
Coolant Temperature (ECT) sensor circuit.The sensor is amount of time the ECM is commanding each injector
a thermistor, which changes internal resistance as ON during each engine cycle. A longer injector pulse
temperature changes.When the sensor is cold (internal width will cause more fuel to be delivered.Injector pulse
resistance high), the ECM monitors a high signal voltage width (IPW) should increase with increased engine load.
and interprets it as a cold engine. As the sensor warms
(internal resistance decreases), the voltage signal will
Heated Oxygen Sensor 1 Voltage:
decrease and the ECM will interpret the lower voltage as The scan tool displays 0-1000 millivolts - it represents
a warm engine. the fuel control exhaust oxygen sensor output voltage.
This voltage will fluctuate constantly between 0 mv (lean
Intake Air Temperature (IAT) Sensor: exhaust) and 1000 mv (rich exhaust) when the system is
The scan tool displays -40 ～ 151°C - the ECM operating in a Closed Loop.
converts the resistance of the Intake Air Temperature Heated Oxygen Sensor 1 Heater Status:
(IAT) sensor to degrees. The ECM use IAT sensor to
adjust fuel delivery and spark timing according to The scan tool displays On/Off - it represents the status of
incoming air density. The IAT is also compared to the the heated oxygen sensor/heater. Rich/Lean Status:
ECT at startup to identify cold starts for the Heated The scan tool displays the rich/lean status of the mixed
Oxygen Sensor and the EVAP diagnostics. Ambient air.
Temperature: Short Term Fuel Trim Value:
The scan tool displays-40 ～ 151°C - it indicates the The scan tool displays -15 - 15% - Short term fuel trim
intake air temperature (IAT) at the time that the vehicle represents a short term correction to fuel delivery by the
was started. With heated oxygen sensor diagnostic, ECM in response to the amount of time the fuel control
identify if the last start is a cold start. oxygen sensor voltage spends above or below the 450
mv threshold. if the oxygen sensor voltage has mainly
Engine Load: remained less than 450 mv, indicating a lean air/ fuel
The scan tool displays 0 - 100% - engine load is calculated mixture, short term fuel trim will increase into the
by the ECM from the engine speed and MAP sensor positive range above 0 percent and the ECM will add
readings. Engine load should increase with an increase in fuel. If the oxygen sensor voltage stays mainly above
RPM or air flow. the threshold, short term fuel trim will decrease below 0
Throttle Position Sensor: percent into the negative range while the ECM rduces
fuel delivery to compensate for the indicated rich
The scan tool displays 0 -5 volts - voltage is monitored condition. Under certain conditions such as extened idle
by the system control module on the throttle position and high ambient temperatures, canister purge may
singal circuit. cause short term fuel trim to read in the negative range
Throttle Position Angle: during the normal operation. The ECM's maximum
authority to control long term fuel trim allows a range
The scan tool display 0 - 100% - throttle position angle is
between -10(+10) percent. Fuel trim values at or near
calculated by the ECM from the throttle position sensor
maximum authority may indicate an excessively rich or
voltage. For the throttle position angle, it will display 0%
lean system.
at idle speed and 80% at wide open throttle (WOT).
Throttle at Idle Position: Long Term Fuel Trim Value:
The scan tool displays -1-(10)% - Long term (LT) fuel trim
The scan tool displays if the throttle is at idle position.
is derived from the short term (ST) fuel trim value and
Throttle at Wide Open Position: represents a long-term correction of fuel delivery. A value
The scan tool displays if the throttle is at wide open of 0 percent indicates that fuel delivery requires no
position. compensation to maintain the ECM commanded air/ fuel
ratio.A negative value significantly below 0 percent
Manifold Absolute Pressure Sensor: indicates that the fuel system is rich and fuel delivery is
The scan tool displays 15-120 kPa - Manifold Absolute being reduced (decreased injector pulse width). A positive
Pressure (MAP) sensor measures the change in the value significantly more than 0 percent indicates that a
intake manifold pressure which results from engine load lean condition exists and the ECM is compensating by
and speed changes.As the intake manifold pressure adding fuel (increased injector pulse width). Because long
increases, intake vacuum decreases resulting in a higher term fuel trim tends to follow short term fuel trim, a value
MAP sensor voltage and kPa reading. Fuel Injector 1 in the negative range due to canister purge at idle should
not be considered unusual.The ECM's maximum
Pulse Width:
authority to control long term fuel trim allows a range
Engine Engine Controls 6-43

between -10 - (10) percent. Fuel trim values at or near The scan tool displays ON or OFF - indicates the ECM
maximum authority may indicate an excessively rich or commanded state of the fuel pump relay control circuit.
lean system. Canister Purge solenoid Duty Ratio: A/C Request Signal:
The scan tool displays 0-100% - it represents the ECM The scan tool displays YES or NO - indicates the state
commanded PWM duty cycle of the EVAP purge valve. of the A/C request input circuit from the A/C controls.
0 percent displayed indicates no purge, 100 percent The ECM uses the A/C request signal to determine
displayed indcates full purge. whether A/C compressor operation is being requested.

Power Enrichment: A/C Relay Status:

The scan tool displays active or inactive - ACTIVE The scan tool displays ON or OFF - indicates the ECM
displayed indicates that the ECM has detected commanded state of the A/C compressor clutch relay
conditions appropriate to operate in power enrichment driver circuit. A/C compressor clutch should be engaged
mode. When a large increase in throttle position and when Commanded A/C dsiplays ON. Fan 1 Status:
load is detected, the ECM will increase the amount of The scan tool displays ON or OFF - indicates the ECM
fuel delivered by entering Open Loop and increasing the
commanded state of Fan 1. Fan 2 Status:
injector pulse width. This is done to prevent a possible
sag or hesitation from occurring during acceleration. The scan tool displays ON or OFF - indicates the ECM
commanded state of Fan 2. Starter Motor Switch:
Deceleration Fuel Mode:
The scan tool displays the state of the starter motor
The scan tool displays active or inactive - Active is switch.
displayed If the ECM has detected conditions
appropriate to operate in deceleration fuel mode. The Vehicle Speed Sensor:
ECM will command deceleration fuel mode when a The scan tool displays 0-255 km/h (0-155 mph), the
sudden decrease in throttle position has been detected vehicle speed sensor signal is converted into mph and
while the vehicle is traveling over 40 km/h (25 mph). km/h for display.
While in deceleration fuel mode, the ECM will decrease
the amount of fuel delivered by entering Open Loop and TCC Solenoid Status:
decreasing the injectior pulse width. Ignition: The scan tool displays ON or OFF - indicates the on/off
The scan tool displays -12 - 60 degrees - displays the status of the TCC solenoid. MIL Status:
ignition timing commanded by the ECM on the IC circuit. The scan tool displays ON or OFF - indicates that the
A negative value indicates degrees Before Top Dead ECM commands MIL on and off or blink. DTC(S)
Center (BTDC) or spark advance. A positive value Coding:
indicates degrees After Top Dead Center (ATDC) or
Indicates the DTC(S) Coding.
spark retard.
Knock Sensor Voltage: 6.4.4.5 Diagnostic Trouble Code (DTC)
The scan tool displays 0 -100 mv - it represents the Type Definition
knock sensor signal voltage received by the ECM.
Cyliner 1 - 4 Knock Retard: Type 30
The scan tool displays 0 -6 degrees - it indicates the 1. Action Taken When the DTC Sets
ignition retard degrees of ECM in response to the Corresponding DTCs as well as the related
signals from the knock sensor. Battery Voltage: DTC information will be stored in the DTC
memory.
The scan tool displays 8 -16 volts - it represents the
system voltage measured by the ECM at its ignition The failure will be identified by the ECM
feed. during the first drive cycle in which the
diagnostic test has been run and failed, and
Torque Request: the ECM will illuminate the malfunction
The scan tool displays 0 -80 % - it represents the indicator lamp (MIL).
percentage of torque request sent from the automatic 2. Conditions for Clearing the MIL/DTC
transmission to the ECM. Torque Delivered:
The MIL will be turned off after 3 consecutive
The scan tool displays 0 -80 % - it represents the drive cycles that the diagnostic test passes
percentage of torque delivered by the ECM to the and does not fail.
automatic transmission. After 20 consecutive warm-up cycles without
Fuel Pump Relay Status: failure, the DTC will be cleared.
6-44 Engine Controls Engine

Type 31 Corresponding DTCs as well as the related

DTC information will be stored in the DTC
1. Action Taken When the DTC Sets
memory.
Corresponding DTCs as well as the related
2 seconds after the diagnostic test has been
DTC information will be stored in the DTC
run and failed, the failure is identified by the
memory.
ECM and the ECM will illuminate the
The failure is identified by the ECM during the malfunction indicator lamp (MIL).
first drive cycle in which the diagnostic test
2. Conditions for Clearing the MIL/DTC
has been run and failed, and the ECM will not
illuminate the malfunction indicator lamp The MIL will be turned off after 3 consecutive
(MIL). drive cycles that the diagnostic test passes
and does not fail.
2. Conditions for Clearing the MIL/DTC
After 20 consecutive warm-up cycles without
After 20 consecutive warm-up cycles without
failure, the DTC will be cleared.
failure, the DTC will be cleared.
Type 32 Type 37
1. Action Taken When the DTC Sets
1. Action Taken When the DTC Sets
Corresponding DTCs as well as the related
Corresponding DTCs as well as the related
DTC information will be stored in the DTC
DTC information will be stored in the DTC
memory.
memory.
200 milliseconds after the diagnostic test has
The failure is identified by the ECM during the
been run and failed, the failure is identified by
second drive cycle in which the diagnostic
the ECM and the ECM will illuminate the
test has been run and failed, and the ECM
malfunction indicator lamp (MIL).
will illuminate the malfunction indicator lamp
(MIL). 2. Conditions for Clearing the MIL/DTC
2. Conditions for Clearing the MIL/DTC The MIL will be turned off when the diagnostic
test passes without any failure and time
The MIL will be turned off after 3 consecutive
delay.
drive cycles that the diagnostic test passes
and does not fail. The MIL will be turned off when the diagnostic
test passes without any failure and time
After 20 consecutive warm-up cycles without
delay.
failure, the DTC will be cleared.
Type 33 Type 39
1. Action Taken When the DTC Sets
1. Action Taken When the DTC Sets
Corresponding DTCs as well as the related
Corresponding DTCs as well as the related
DTC information will be stored in the DTC
DTC information will be stored in the DTC
memory.
memory.
200 milliseconds after the diagnostic test
The failure is identified by the ECM during the
has been run and failed, the failure is identified by the
second drive cycle in which the diagnostic
ECM and the ECM will allow the malfunction indicator
test has been run and failed, and the ECM
will not illuminate the malfunction indicator lamp (MIL) to flash at the frequency of 2Hz+10%. 2.
lamp (MIL). Conditions for Clearing the MIL/DTC
2. Conditions for Clearing the MIL/DTC The MIL will be turned off when the diagnostic
test passes without any failure and time
After 20 consecutive warm-up cycles without
delay.
failure, the DTC will be cleared.
After 20 consecutive warm-up cycles without
Type 36 failure, the DTC will be cleared.
1. Action Taken When the DTC Sets
Diagnostic Trouble Code (DTC) List/Type
Description Type MIL

DTC P0107 Manifold Absolute Pressure Sensor Circuit Low Voltage 32 on

 Engine Engine Controls
6-45
DTC P0108 Manifold Absolute Pressure Sensor Circuit High Voltage 32 on

DTC P0112 Intake Air Temperature Sensor Indicated Temperature too

High 32 on

DTC P0113 Intake Air Temperature Sensor Indicated Temperature too

Low 32 on

DTC P0116 Engine Coolant Temperature Sensor Signal Irrational Faults 32 on

DTC P0117 Engine Coolant Temperature Sensor Indicated Temperature

too High 32 on

DTC P0118 Engine Coolant Temperature Sensor Indicated Temperature

too Low 32 on

DTC P0120 Throttle Position Sensor Circuit fault 32 on

DTC P0130 HO2S Signal Circuit Low Voltage 32 on

DTC P0132 HO2S Signal Circuit High Voltage 32 on

DTC P0134 HO2S Circuit Insufficient Activity 32 on

DTC P0135 HO2S Heater Circuit Fault 32 on

DTC P0201 Cylinder 1 Fuel injector Circuit fault 30 on

DTC P0202 Cylinder 2 Fuel injector Circuit fault 30 on

DTC P0203 Cylinder 3 Fuel injector Circuit fault 30 on

DTC P0204 Cylinder 4 Fuel injector Circuit fault 30 on

DTC P0230 Fuel Pump Control Circuit fault 36 on

DTC P0325 Knock Sensor Circuit fault 32 on

DTC P0335 Crankshaft Position Sensor Signal Error 36 on

DTC P0443 Canister Purge Valve Drive Level Control Circuit fault 32 on

Diagnostic Trouble Code (DTC) List/Type(Cont’

d)
Description Type MIL

DTC P0443 Canister Purge Valve Drive Level Control Circuit Voltage
too 32 on
Low
DTC P0443 Canister Purge Valve Drive Level Control Circuit Voltage too
High 32 on

DTC P0480 A/C Condenser Cooling Fan Relay Control Circuit fault 32 on

DTC P0500 Vehicle Speed Signal Irrational Faults 32 on

DTC P0506 Idle Speed is Lower Than the Desired Idle Value 32 on

DTC P0507 Idle Speed is Higher than the Desired Value 32 on

DTC P0508 Idle Regulator Control Circuit Voltage too Low 32 on

DTC P0509 Idle Regulator Control Circuit Voltage too High 32 on

DTC P0511 Idle Regulator Control Circuit fault 32 on

DTC P0560 System Voltage Signal Irrational 31 off

DTC P0562 System Voltage too Low 31 off

 6-46 Engine Controls Engine

DTC P0562 System Voltage too High 31 off

DTC P0601 Electronic Control Unit Check Code Error 30 on

DTC P0601 Electronic Control Unit Programming Error 37 on

DTC P0610 Control Module （Model） Type Selection Error 33 off

DTC P0630 Vehicle Identification Number (VIN) Not Programmed or

Matched 37 on

DTC P0645 A/C Compressor Relay Control Circuit fault 31 off

DTC P0646 A/C Compressor Relay Control Circuit Voltage too Low 31 off

DTC P0647 A/C Compressor Relay Control Circuit Voltage too High 31 off

DTC P0650 MIL Control Circuit fault 33 off

DTC P1740 Automatic Transmission Torque Request Signal 33 off

6.4.4.6 Malfunction Indicator Lamp (MIL) Perform the Powertrain On Board Diagnostic System
Check first if the following situations occur:
is Inoperative Due to a Malfunction
The MIL does not illuminate when the ignition
Refer to Engine Controls Schematics: Engine Power, switch is in the RUN position.
Ground, MIL and Data Link.
The MIL remains on when the engine is
Circuit Description running.
The MIL should be on steady with the ignition ON and When dirveability is suspected of malfuntions.
the engine OFF.The ignition supply voltage should be
applied directly on the MIL. The ECM illuminates the
Diagnostic Aids
MIL by grounding the MIL control circuit.With the Intermittent conditions may be induced by poor
ignition ON and the engine OFF, MIL DTC sets and connection, poor wiring insulation or wiring broken
MIL does not illuminate, which indicates that an open inside the insulation. Inspect the following items:
exists in the MIL control circuit. Check the ECM wiring and connections for
the following conditions: Improper mating
Mulfunction Indicator Lamp (MIL) Operation
The MIL is located on the instrument panel (CHECK Broken locks
ENGINE) or (SERVICE ENGINE SOON).The MIL Improperly formed or damaged terminals
performs the following functions: Poor terminal-to-wire connection
Inform the driver that a malfunction has Damaged harness
occurred and that the vehicle should be taken in
If the engine runs OK, check for a
for service as soon as possible.
malfunctioning MIL, an open in the MIL
During the system check, Malfuction Indicator control circuit or an open in the instrument
Lamp should illuminate when the ignition switch cluster ignition feed.
is turned to the ON position, with the engine
If the engine cranks but will not run, check for an
OFF.When the engine is started, the MIL will
open ECM ignition, battery feed, or a poor ECM
turn OFF.If the MIL remains on , self-diagnostic
to engine ground.
system has detected a malfunction. If the
malfunction is eliminated, MIL will be turned off Test Description
under the most conditions, but the DTC will be The numbers below refer to the step numbers on the
stored. diagnostic table.
If the MIL illuminates, and then the engine 2. If the MIL DTC is set ,the MIL Control Circuit
stalls, MIL will remain on if the ignition is on. table will better diagnose the condition.
If the MIL does not illuminate and the engine 6. Connect a test lamp to the battery positive
stalls, before the ignition is switched from Off to voltage, probe each of the ECM ground
On, the MIL will not illuminate. terminals to ensure that a good ground is
present.
 Engine Engine Controls 6-

Malfunction Indicator Lamp (MIL)is inoperative due to a malfunction

Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain On
Diagnostic System Check? Board Diagnostic
1 － Go to Step 2
(OBD) System
Check
Does the scan tool indicate the MIL DTC Go to DTC P0650
set? Malfunction Indicator
2 － Lamp (MIL) Control Go to Step 3
Circuit

3 Inspect the ECM feed fuse. Is the fuse OK? － Go to Step 4 Go to Step 9

Malfunction Indicator Lamp (MIL)is inoperative due to a malfunction(Cont’

d)
Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain On
Diagnostic System Check? Board Diagnostic
1 － Go to Step 2
(OBD) System
Check
1. Turn the ignition off.
2. Disconnect the Engine Control Module.
3. Turn the ignition ON.
4 4. With a test lamp connected to a good － Go to Step 5 Go to Step 8
ground, probe the ECM ignition feed
circuit.
Does the test lamp illuminate?

With a test lamp connected to a good ground,

5 probe the ECM battery feed circuit. Does the － Go to Step 6 Go to Step 8
test lamp illuminate?

Test for faulty ECM grounds or poor ECM

ground connection. Go to Powertrain On
Refer to Testing for Intermittent Conditions Board
6 － Go to Step 7
and Poor Connections in Wiring Systems.Do Diagnostic(OBD)Syst
you find and correct the condition? em Check

Note:The replacement ECM must be Go to Powertrain On

programmed. Replace the ECM. Board
7 － Diagnostic(OBD)Syst －
See ECM Replacement.Do you complete the
replacement? em Check

Locate and repair the opens in the ECM

battery feed circuit or the ECM ignition feed Go to Powertrain On
circuit.Refer to Wiring Repairs in Wiring Board
8 － －
Systems. Diagnostic(OBD)Syst
do you complete the repair? em Check
 6-48 Engine Controls Engine

Locate and repair short to ground in the ECM

ignition feed circuit or the ECM battery feed Go to Powertrain On
circuit.Refer to Wiring Repairs in Wiring Board
9 － －
Systems. Diagnostic(OBD)Syst
do you complete the repair? em Check

6.4.4.7 Data Link Connector Diagnosis are not the cause of the condition. Poor
connection, wiring insulation damage and
Refer to Engine Controls Schematics: Power, Ground, wiring broken inside the insulation may cause
MIL and Data Link Connector. an intermittent condition.
Circuit Description Check for poor connections and damaged
The Class 2 serial data circuit to the Data Link wiring.
Connector (DLC) allows the ECM to communicate Check the ECM wiring and connections for
with the scan tool. If communication between the the following conditions: Improper mating
scan tool and the ECM can not be established, the broken locks
procedure in the DLC diagnosis table should be used Improperly formed or damaged terminals
to diagnose the condition.
Poor terminal-to-wire connection
Diagnostic Aids Damaged harness
Inspect the following items:
Use a corresponding mating terminal to test for
For the ECM to establish communication with proper terminal tension.
the scan tool, the system voltage must be
between 9.0 and 16.0 volts. If the system Test Description
voltage is not within this range, please refer to See the numbers of the procedures in the DLC
Diagnostic System Check-Starting and Diagnosis table for the following numbers:
Charging in Engine Electrical. 11. This vehicle is equipped with an ECM which
Ensure that the correct application (model year, utilizes an electrically erasable programmable
carline, VIN code ) has been selected on the read only memory (EEPROM).When the ECM
scan tool. If communication still can not be is replaced, the new ECM must be
established, tyr the scan tool on another programmed.
vehicle to ensure that the scan tool or cables
Data Link Connector Diagnosis
Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain On
Diagnostic System Check? Board Diagnostic
1 － Go to Step 2
(OBD) System
Check
1. With the engine off, turn on the ignition.
2. Connect a test lamp between the battery
2 feed circuit and the ground circuit of the － Go to Step 4 Go to Step 3
DLC.
Does the test lamp illuminate?

Connect a test lamp between the battery feed

3 circuit of the DLC and chassis ground. － Go to Step 9 Go to Step 10
Does the test lamp illuminate?
 Engine

Engine Controls 6-49

Turn the ignition ON with the engine OFF.
Connect a DMM between the Class 2 serial
4 data circuit of the DLC and a good ground. 0.0 volt Go to Step 5 Go to Step 7
Does the voltage equal to the specified
value?

1. Turn the ignition off.

2. Disconnect the Engine Control Module.
3. Turn the ignition ON with the engine
OFF.
5 4. Connect a DMM between the Class 2 0.0 volt Go to Step 6 Go to Step 8
serial data circuit of the DLC and battery
positive voltage.
Does the voltage measure equal to the
specified value?

Data Link Connector Diagnosis(Cont’

d)
Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain On
Diagnostic System Check? Board Diagnostic
1 － Go to Step 2
(OBD) System
Check
1. Repair the open in the Class 2 serial
data circuit. Go to Powertrain On
2. Refer to Wiring Repairs in Wiring Board
6 － Go to Step 11
Systems. Diagnostic(OBD)Syst
Do you find and correct the condition? em Check

1. Repair the short to voltage in the Class

2 serial data circuit. Go to Powertrain On
2. Refer to Wiring Repairs in Wiring Board
7 － Go to Step 11
Systems. Diagnostic(OBD)Syst
Do you find and correct the condition? em Check

Repair the short to ground in the Class 2 Go to Powertrain On

serial data circuit. Board
8 Refer to Wiring Repairs in Wiring Systems. － Diagnostic(OBD)Syst －
Do you find and correct the condition? em Check
Repair the open in the DLC ground circuits. Go to Powertrain On
Refer to Wiring Repairs in Wiring Systems. Board
9 Do you find and correct the condition? － Diagnostic(OBD)Syst －
em Check
Repair the open or short to ground in the
DLC battery feed circuit. Go to Powertrain On
Replace the fuse as necessary. Refer to Board
10 － －
Wiring Repairs in Wiring Systems. Diagnostic(OBD)Syst
Do you find and correct the condition? em Check

Note:The replacement ECM must be Go to Powertrain On

programmed. Replace the ECM. Board
11 － Diagnostic(OBD)Syst －
See ECM Replacement.
do you complete the repair? em Check

6.4.4.8 DTC P0107 Manifold Absolute Description

Pressure Sensor Circuit Low Voltage
 6-50 Engine Controls Engine

There are three pins connected to the Manifold which the diagnostic test has been run and
Absolute Pressure (MAP) sensor, which is 5 V failed.
reference voltage (Pin 33), ground terminal (Pin 35)
and signal output terminal (Pin 37) separately. Within
Conditions for Clearing the MIL/DTC
the certain measure range, the force applied on the The MIL will be turned off after 3 consecutive
sensor is linear with the measure signal (voltage drive cycles that the diagnostic test passes and
signal), this is the characteristic curve of the pressure does not fail.
sensor.According to this characteristic curve, ECU will After 20 consecutive warm-up cycles without
convert the voltage singal received into intake air failure, the DTC will be cleared.
pressure. When the sensor works properly, the output
The DTC can be cleared with the scan tool.
voltage of Pin 37 should be 0.4V - 4.65V
(corresponding intake pressure is 20 kpa -115 kpa).In
Diagnostic Aids
the diagnostic test, ECU will treat the MAP output Inspect for the following conditions:
voltage signal to the average output voltage of the Poor coonection between the ECU and MAP-
cycle in which crankshft rotates every 180 degrees, inspect the harness connector of the ECU:
as the input of the diagnostic module to identify the － Backed-out terminals
condition. － Improper mating
Conditions for running the DTC － Broken locks
The ignition is ON. － Improperly formed or damaged terminals
Conditions for Setting the DTC － Poor terminal-to-wire connection
Damaged harness -inspect the wiring harness
Average output voltage of the Manifold Absolute
for damage.If the harness appears OK,
Pressure Sensor is <0.195 V
observe the intake air pressure display on the
Action Taken When the DTC Sets scan tool while moving connectors and wiring
Corresponding DTCs as well as the related harnesses related to the sensor. A change in
DTC information will be stored in the DTC the display will indicate the location of the fault.
memory after 2 consecutive drive cycles in If the DTC cannot be duplicated and is determined to
which diagnostic test has been run and failed. be intermittent, reviewing the failure records can be
The MIL on the instrument cluster will be useful in determining when the DTC is last set.
illuminated after 2 consecutive drive cycles in
DTC P0107 Manifold Absolute Pressure Sensor Circuit Low Voltage
Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain
Diagnosis System check? On Board
1 － Go to Step 2 Diagnosis System
Check

1. If the engine idle is unstable, repair the idle

problem before continuing with this table.
see Rough, Unstable, or Incorrect Idle and
Stalling.
2. Install the scan tool, start the engine and Go to Diagnostic
2 allow it to idle. － Go to Step 3
Aid
3. Use the scan tool to monitor the DTC
information.
Does the scan tool indicate DTC P0107 is
current?

With the scan tool, monitor the data display of the

MAP. Go to Diagnostic
3 Is the data display of the sensor less than the 0.195 V Go to Step 4
Aid
specified value?

DTC P0107 Manifold Absolute Pressure Sensor Circuit Low Voltage(Cont’

d)
 Engine Engine Controls 6-5

Step Action Value Yes No

1. Turn off the ignition.
2. Disconnect the MAP sensor plug.
3. Turn on the ignition.
4. Use a DMM to measure the voltage between
4 5.7 V Go to Step 5 Go to Step 6
the MAP harness connector Pin 1 and
ground.
Does the voltage meaure near the specified
value?

Check the MAP signal circuit for a short to ground.

5 Do you find and correct the condition? － Go to Step 10 Go to Step 6

Test the MAP circuit for a short, an open, a high

resistance in the harness, and a poor connection
6 of pins at the ECU end or the sensor end. － Go to Step 10 Go to Step 7
Do you find and correct the condition?

To test the MAP, remove the MAP sensor, and

connect a vacuum gauge at the sensor end, a 5
volts DC power source to the Pin 3 at the MAP
end, Pin 2 to ground, Pin 1 to a DMM. When the
7 pressure indicated on the vacuum gauge drops － Go to Step 9 Go to Step 8
from 100 Kpa to 20 Kpa, does the output voltage
between the Pin 3 and ground also drops from
4.5 volts to 0.4 volts correspondingly?
Replace the MAP sensor.
8 Do you complete the replacement? － Go to Step 10 －

Replace the ECU and have it programmed.

9 Do you complete the replacement? － Go to Step 10 －

1. Clear the DTC.

2. Restart the engine, use the scan tool to
10 monitor the DTC information. － Go to Step 3 System OK
Does the scan tool indicate DTC P0107 is
current?

6.4.4.9 DTC P0108 Manifold Absolute diagnostic module to identify the condition.
Pressure Sensor Circuit High Voltage Conditions for running the DTC
The ignition is ON.
Description
Conditions for Setting the DTC
There are three pins connected to the Manifold
Absolute Pressure (MAP) sensor, which is 5 V Average output voltage of the Manifold Absolute
reference voltage (Pin 33), ground terminal (Pin 35) Pressure Sensor is >4.883 V
and signal output terminal (Pin 37) separately. Within Action Taken When the DTC Sets
the certain measure range, the force applied on the
Corresponding DTCs as well as the related
sensor is linear with the measure signal (voltage
DTC information will be stored in the DTC
signal), this is the characteristic curve of the pressure
memory after 2 consecutive drive cycles in
sensor.According to this characteristic curve, ECU will
which diagnostic test has been run and failed.
convert the voltage singal received into intake air
pressure. When the sensor works properly, the output The MIL will be illuminated after 2 consecutive
voltage should be 0.4V - 4.65V (corresponding intake drive cycles in which the diagnostic test has
pressure is 20 kpa - 115 kpa). In the diagnostic test, been run and failed.
ECU will treat the MAP output voltage signal to the Conditions for Clearing the MIL/DTC
average output voltage of the cycle in which crankshft
rotates every 180 degrees, as the input of the
 6-52 Engine Controls Engine

The MIL will be turned off after 3 consecutive － Broken locks

drive cycles that the diagnostic test passes and － Improperly formed or damaged terminals
does not fail.
－ Poor terminal-to-wire connection
After 20 consecutive warm-up cycles without Damaged harness - inspect the wiring harness
failure, the DTC will be cleared. for damage.If the harness appears OK,
The DTC can be cleared with the scan tool. observe the manifold absolute pressure display
Diagnostic Aids on the scan tool while moving connectors and
Inspect for the following conditions: wiring harnesses related to the sensor. A
change in the display will indicate the location
Poor coonection between the ECU and MAP -
of the fault.
inspect the harness connector of the ECU:
－ Backed-out terminals If the DTC cannot be duplicated and is determined to
be intermittent, reviewing the failure records can be
－ Improper mating
useful in determining when the DTC is last set.
DTC P0108 Manifold Absolute Pressure Sensor Circuit High Voltage
Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain
Diagnostic System Check? On Board
1 － Go to Step 2 Diagnosis System
Check

1. If the engine idle is unstable, repair the idle

problem before continuing with this table.
see Rough, Unstable, or Incorrect Idle and
Stalling.
2. Install the scan tool, start the engine and Go to Diagnostic
2 allow it to idle. － Go to Step 3
Aid
3. Use the scan tool to monitor the DTC
information.
Does the scan tool indicate DTC P0108 is
current?

With the scan tool, monitor the data display of the

MAP. Go to Diagnostic
3 Is the data display of the sensor greater than the 4.88 V Go to Step 4
Aid
specified value?

DTC P0108 Manifold Absolute Pressure Sensor Circuit High Voltage(Cont’

d)
Step Action Value Yes No
1. Turn off the ignition.
2. Disconnect the MAP sensor plug.
3. Turn on the ignition.
4. Use a DMM to measure the voltage between
4 5.7 V Go to Step 5 Go to Step 6
the MAP harness connector Pin 1 and
ground.
Does the voltage meaure near the specified
value?

check for MAP block or intake manifold vacuum

5 leak. － Go to Step 11 Go to Step 6
Do you find and correct the condition?

Inspect the MAP signal circuit for a short to power

6 or a short to 5 volt reference circuit. － Go to Step 11 Go to Step 7
Do you find and correct the condition?
 Engine Engine Controls 6-5

Test the MAP circuit for a short, an open, a high

resistance in the harness, and a poor connection
7 of pins at the ECU end or the sensor end. － Go to Step 11 Go to Step 8
Do you find and correct the condition?

To test the MAP, remove the MAP sensor, and

connect a vacuum gauge at the sensor end, a 5
volt DC power source to the Pin 3 at the MAP
end, Pin 2 to ground, Pin 1 to a DMM. When the
8 pressure indicated on the vacuum gauge drops － Go to Step 10 Go to Step 9
from 100Kpa to 20Kpa, does the output voltage
between the Pin 3 and ground also drops from
4.5 volts to 0.4 volts correspondingly?
Replace the MAP sensor.Do you complete the
9 replacement? － Go to Step 11 －

Replace the ECU and have it programmed. Do

10 you complete the replacement? － Go to Step 11 －

1. Clear the DTC.

2. Restart the engine, use the scan tool to
11 monitor the DTC information. － Go to Step 3 System OK
Does the scan tool indicate DTC P0108 is
current?

6.4.4.10 DTC P0112 Intake Air Corresponding DTCs as well as the related
DTC information will be stored in the DTC
Temperature Sensor Indicated memory.
Temperature too High After the second consecutive drive cycle that
Description the diagnostic test has run and failed, the
condtion will be identified by ECU.At this time,
There are two pins connected to the Intake Air ECU illuminates the Malfunction Indicator Lamp
Temperature Sensor (IAT) , which is sensor signal (MIL).
terminal (IAT end pin 1 connected to ECU pin 40) and
signal ground terminal (IAT end pin 2 connected to After the DTC P0112 is set, the ECU will use
ECU pin 17). 20°C as a substitute for the intake air
temperature, and when the fault is corrected,
Measuring element of the IAT is a resistor with negative the IAT input signal value will be reused
temperature coefficient. When the intake air is cold, the automatically.
sensor resistance is high and the IAT signal voltage
input to the ECU is high. When the intake air is warm, The conditions for clearing MIL/DTC.
the sensor resistance is low and the IAT signal voltage The MIL will be turned off after 3 consecutive
input to the ECU is low. When the IAT sensor works drive cycles that the diagnostic test passes and
properly, the intake air temperature utilized by the does not fail.
system equals to that indicated by the IAT singal
After 20 consecutive warm-up cycles without
voltage. If the IAT signal terminal is short to ground, the
failure, the DTC will be cleared.
indicated intake air temperature correspondingly may
be higher, and DTC P0112 will be set. Conditions for The DTC can be cleared with the scan tool.
running the DTC Diagnostic Aids
Inspect for the following conditions:
Start and run the engine for 1 minute.
Poor coonection between the ECU and MAP ñ
Conditions for Setting the DTC inspect for the existance of the ECU harness
Intake air temperature indicated by IAT signal connector:
voltage>126°C － Backed-out terminals
－ Improper mating
Action Taken When the DTC Sets
－ Broken locks
 6-54 Engine Controls Engine

－ Improperly formed or damaged terminals observe the intake air temperature display on
－ Poor terminal-to-wire connection the scan tool while moving connectors and
Is the harness damaged ñ inspect the harness wiring harnesses related to the IAT sensor. A
for damage.If the harness appears OK, change in the IAT display will indicate the
location of the fault.
DTC P0112 Intake Air Temperature Sensor Indicated Temperature too High
Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain
Diagnostic System Check? On Board
1 － Go to Step 2 Diagnosis System
Check
1. Turn on the ignition, with the engine OFF.
2. Observe the intake air temperature
parameter with a scan tool.
2 126°C Go to Step 4 Go to Step 3
Does the scan tool show the intake air
temperature parameter greater than the specified
value?
Operate the vehicle according to the conditions for
running the DTC. Go to Diagnostic
3 Does the scan tool indicate DTC P0112 is － Go to Step 4
Aid
current?

DTC P0112 Intake Air Temperature Sensor Indicated Temperature too High(Cont’ d)
Step Action Value Yes No
1. Turn off the ignition.
2. Disconnect the Intake Air Temperature (IAT)
Sensor.
3. Turn on the ignition, with the engine OFF.
4 4. Observe the intake air temperature -33°C Go to Step 6 Go to Step 5
parameter with a scan tool.
Does the scan tool show the intake air
temperature parameter less than the specified
value?
Check the IAT sensor signal circuit for a short to
5 ground. － Go to Step 9 Go to Step 6
Do you find and correct the condition?
Check the circuit between the IAT and ECU for a
high resistance, a poor connection of the pins at
6 the ECU end or the sensor end. Go to Step 9 Go to Step 7
Do you find and correct the condition?
Replace the Intake Air Temperature (IAT) Sensor.
7 Do you complete the replacement? － Go to Step 9 －

Replace the ECU and have it programmed.

8 Do you complete the replacement? － Go to Step 9 －

1. Use the scan tool to clear the DTC.

2. Operate the vehicle according to the
9 conditions for running the DTC. － Go to Step 2 System OK
Is the DTC reset?
Engine Engine Controls 6-55

6.4.4.11 DTC P0113 Intake Air After the second consecutive drive cycle that
the diagnostic test has run and failed, the
Temperature Sensor Indicated condtion will be identified by ECU.At this time,
Temperature too Low ECU illuminates the Malfunction Indicator Lamp
(MIL).
Description
After the DTC P0113 is set, the ECU will use
There are two pins connected to the Intake Air 20°C as a substitute for the intake air
Temperature Sensor (IAT) , which is sensor signal temperature, and when the fault is corrected,
terminal (IAT end pin A connected to ECU pin 40) and the IAT input signal value will be reused
signal ground terminal (IAT end pin B connected to automatically.
ECU pin 17).
Measuring element of the IAT is a resistor with
The conditions for clearing MIL/DTC.
negative temperature coefficient. When the intake air The MIL will be turned off after 3 consecutive
is cold, the sensor resistance is high and the IAT drive cycles that the diagnostic test passes and
signal voltage input to the ECU is high. When the does not fail.
intake air is warm, the sensor resistance is low and After 20 consecutive warm-up cycles without
the IAT signal voltage input to the ECU is low. When failure, the DTC will be cleared.
the IAT sensor works properly, the intake air
The DTC can be cleared with the scan tool.
temperature utilized by the system equals to that
indicated by the IAT singal voltage. If the IAT signal Diagnostic Aids
terminal is short or open to power, the indicated Inspect for the following conditions:
intake air temperature correspondingly may be lower, Poor coonection between the ECU and MAP ñ
and DTC P0113 will be set. inspect for the existance of the ECU harness
connector:
Conditions for running the DTC
－ Backed-out terminals
Start and run the engine for 1 minute.
－ Improper mating
Conditions for Setting the DTC － Broken locks
With the engine at idle, without fuel cutoff － Improperly formed or damaged terminals
condition, and the intake air temperature
－ Poor terminal-to-wire connection
indicated by the IAT singal voltage is lower than
Is the harness damaged ñ inspect the harness
-33°C.
for damage.If the harness appears OK,
Action Taken When the DTC Sets observe the intake air temperature display on
Corresponding DTCs as well as the related the scan tool while moving connectors and
DTC information will be stored in the DTC wiring harnesses related to the IAT sensor. A
memory. change in the IAT display will indicate the
location of the fault.
DTC P0113 Intake Air Temperature Sensor Indicated Temperature too Low
Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain
Diagnostic System Check? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Turn on the ignition, with the engine OFF.

2. Observe the intake air temperature
parameter with a scan tool.
2 -33°C Go to Step 4 Go to Step 3
Does the scan tool show the intake air
temperature parameter less than the specified
value?

Operate the vehicle according to the conditions for

running the DTC. Go to Diagnostic
3 Does the scan tool indicate DTC P0113 is － Go to Step 4
Aid
current?
6-56 Engine Controls Engine

DTC P0113 Intake Air Temperature Sensor Indicated Temperature too Low(Cont’ d)
Step Action Value Yes No
1. Turn off the ignition.
2. Disconnect the Intake Air Temperature (IAT)
Sensor.
3. Connect a 3-ampere jumper wire between
the ground wire and signal wire of the
4 sensor. 126°C Go to Step 6 Go to Step 5
4. Turn on the ignition, observe the intake air
temperature parameter with a scan tool.
Does the scan tool show the intake air
temperature parameter greater than the
specified value?
1. Connect one end of the jumper wire to the
pins at the singal terminal of the IAT sensor,
and the other end of it to a good ground.
2. Observe the intake air temperature
5 parameter with a scan tool. 126°C Go to Step 8 Go to Step 6
Does the scan tool show the intake air
temperature parameter greater than the specified
value?

Inspect the IAT signal wire for a short or open to

6 the electricity. － Go to Step 10 Go to Step 7
Do you find and correct the condition?

Check the circuit between the IAT and ECU for a

short, an open, a high resistance, a poor
7 connection of the pins at the ECU terminal or the － Go to Step 10 Go to Step 8
sensor terminal.
Do you find and correct the condition?

Replace the Intake Air Temperature (IAT) Sensor.

8 Do you complete the replacement? － Go to Step 10 －

Replace the ECU and have it programmed.

9 Do you complete the replacement? － Go to Step 10 －

1. Use the scan tool to clear the DTC.

2. Operate the vehicle according to the
10 conditions for running the DTC. － Go to Step 2 System OK
Is the DTC reset?

6.4.4.12 DTC P0116 Engine Coolant When the engine coolant is cold, the sensor
resistance is high and the ECT signal voltage input to
Temperature Sensor Signal Irrational the ECU is high. When the engine coolant is warm,
Faults the sensor resistance is low and the ECT signal
voltage input to the ECU is low. When the ECT
Description sensor works properly, the engine coolant
There are two pins connected to the Engine Coolant temperature utilized by the system equals to that
Temperature Sensor (ECT) , which is sensor signal indicated by the ECT singal voltage.
terminal (ECT end pin 1 connected to ECU pin 39) After the engine has been running for a while, if the
and sensor ground terminal (ECT end pin 2 engine coolant temperature indicated by the ECT
connected to ECU pin 35). signal voltage increases quite slowly and much lower
Measuring element of the ECT sensor used by the than the reference temperature calculated from the
system is a resistor with negative temperature system internal value, it will be considered that the
coefficient. ECT signal is irrational, and DTC P0116 will be set.
Conditions for running the DTC
Engine Engine Controls 6-57

The ignition switch is turned on. The DTC can be cleared with the scan tool.
Conditions for Setting the DTC Diagnostic Aids
Inspect for the following conditions:
The engine coolant temperature is lower than
the ECU internal calculated reference value Poor coonection between the ECU and ECT
20°C. sensor - inspect for the existance of the ECU
harness connector:
Action Taken When the DTC Sets － Backed-out terminals
Corresponding DTCs as well as the related － Improper mating
DTC information will be stored in the DTC
－ Broken locks
memory.
－ Improperly formed or damaged terminals
After the second consecutive drive cycle that
the diagnostic test has run and failed, the － Poor terminal-to-wire connection
condtion will be identified by ECU.At this time, Damaged harness - inspect the wiring harness
ECU illuminates the Malfunction Indicator Lamp for damage.If the harness appears OK,
(MIL). observe the engine coolant temperature (ECT)
display on the scan tool while moving
The conditions for clearing MIL/DTC. connectors and wiring harnesses related to the
The MIL will be turned off after 3 consecutive ECT sensor. A change in the ECT display will
drive cycles that the diagnostic test passes and indicate the location of the fault.
does not fail. If the DTC can not be duplicated, the information in
After 20 consecutive warm-up cycles without the failure records can be used to determine the
failure, the DTC will be cleared. milage that has elapsed since the DTC last set. It can
determine how often the condition for setting the DTC
occurs, this may assist in diagnosing the condition.
DTC P0116 Engine Coolant Temperature Sensor Signal Irrational Faults
Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain
Diagnostic System Check? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Install the scan tool.

2. Operate the vehicle according to the
conditions for running the DTC. Go to Diagnostic
2 3. Monitor the DTC information with a scan － Go to Step 3
Aid
tool.Does the scan tool indicate DTC P0116
is current?

DTC P0116 Engine Coolant Temperature Sensor Signal Irrational Faults(Cont’

d)
Step Action Value Yes No
1. Turn off the engine.
2. Remove the ECT sensor when the engine is
cold.
3. Place the sensor in the beaker and have it
3 heated, use a DMM to measure the sensor See Data List. Go to Step 4 Go to Step 5
resistance.
Does the sensor resistance comply with the
parameter in the data list?
6-58 Engine Controls Engine

Check the circuit between the ECT and ECU for a

short, an open, a high resistance, a poor
4 connection of the pins at the ECU terminal or the － Go to Step 7 Go to Step 6
sensor terminal.
Do you find and correct the condition?

Replace the ECT sensor.

5 Do you complete the replacement? － Go to Step 7 －

Replace the ECU and have it programmed.

6 Do you complete the replacement? － Go to Step 7 －

1. Clear the DTC.

2. Operate the vehicle according to the
DTC operating conditions, and use a scan tool
7 to monitor the failure information. Does the scan － Go to Step 3 System OK
tool indicate DTC P0116 is current?
Engine Engine Controls 6-59

6.4.4.13 DTC P0117 Engine Coolant condtion will be identified by ECU.At this time,
ECU illuminates the Malfunction Indicator Lamp
Temperature Sensor Indicated (MIL).
Temperature too High
The conditions for clearing MIL/DTC.
Description The MIL will be turned off after 3 consecutive
There are two pins connected to the Engine Coolant drive cycles that the diagnostic test passes and
Temperature Sensor (ECT) , which is sensor signal does not fail.
terminal (ECT end pin 1 connected to ECU pin 39) After 20 consecutive warm-up cycles without
and sensor ground terminal (ECT end pin 2 failure, the DTC will be cleared.
connected to ECU pin 35).
The DTC can be cleared with the scan tool.
Measuring element of the ECT sensor used by the Diagnostic Aids
system is a resistor with negative temperature
Inspect for the following conditions:
coefficient. As the engine coolant warms, the sensor
resistance will decrease, which results in the singal Poor coonection between the ECU and ECT
value input to the ECU in the form of voltage sensor ñ inspect for the existance of the ECU
becoming less.The range of the voltage signal is harness connector:
between 0-5V, the ECU converts it to engine coolant － Backed-out terminals
temperature by searching for the characteristic curve － Improper mating
of the sensor. The diagnostic module of the ECT － Broken locks
sensor will determine the condition according to this
－ Improperly formed or damaged terminals
temperature.
－ Poor terminal-to-wire connection
Conditions for running the DTC Damaged harness - inspect the wiring harness
The ignition switch is turned on. for damage.If the harness appears OK,
observe the engine coolant temperature (ECT)
Conditions for Setting the DTC
display on the scan tool while moving
Engine coolant temperature indicated by ECT connectors and wiring harnesses related to the
signal voltage>135°C ECT sensor. A change in the ECT display will
Action Taken When the DTC Sets indicate the location of the fault.
Corresponding DTCs as well as the related If the DTC can not be duplicated, the information in
DTC information will be stored in the DTC the failure records can be used to determine the
memory. milage that has elapsed since the DTC last set. It can
determine how often the condition for setting the DTC
After the second consecutive drive cycle that
occurs, this may assist in diagnosing the condition.
the diagnostic test has run and failed, the
DTC P0117 Engine Coolant Temperature Sensor Indicated Temperature too High
Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain
Diagnostic System Check? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Turn on the ignition, with the engine OFF.

2. Observe the engine coolant temperature
parameter with a scan tool.
2 140°C Go to Step 4 Go to Step 3
Does the scan tool show the engine coolant
temperature parameter greater than the specified
value?

Operate the vehicle according to the conditions for

running the DTC. Go to Diagnostic
3 Does the scan tool indicate DTC P0117 is － Go to Step 4
Aid
current?
6-60 Engine Controls Engine

DTC P0117 Engine Coolant Temperature Sensor Indicated Temperature too High(Cont’
d)
Step Action Value Yes No
1. Turn off the ignition.
2. Disconnect the engine coolant temperature
(ECT) sensor.
3. Turn on the ignition, with the engine OFF.
4 4. Observe the engine coolant temperature -40°C Go to Step 6 Go to Step 5
parameter with a scan tool.
Does the scan tool show the engine coolant
temperature parameter less than the specified
value?

Test the ECT sensor signal circuit for a short to

ground or a short to the ECT sensor ground
5 circuit. － Go to Step 8 Go to Step 7
Do you find and correct the condition?

Remove the engine coolant temperature (ECT)

6 sensor. － Go to Step 8 －
Do you complete the replacement?

Replace the ECU and have it programmed. Do

7 you complete the replacement? － Go to Step 8 －

1. Use the scan tool to clear the DTC. System OK

2. Operate the vehicle according to the
8 conditions for running the DTC. － Go to Step 2
Is the DTC reset?
Engine Engine Controls 6-61

6.4.4.14 DTC P0118 Engine Coolant condtion will be identified by ECU.At this time,
ECU illuminates the Malfunction Indicator Lamp
Temperature Sensor Indicated (MIL).
Temperature too Low
The conditions for clearing MIL/DTC.
Description The MIL will be turned off after 3 consecutive
There are two pins connected to the Engine Coolant drive cycles that the diagnostic test passes and
Temperature Sensor (ECT) , which is sensor signal does not fail.
terminal (ECT end pin 1 connected to ECU pin 39) After 20 consecutive warm-up cycles without
and sensor ground terminal (ECT end pin 2 failure, the DTC will be cleared.
connected to ECU pin 35).
The DTC can be cleared with the scan tool.
Measuring element of the ECT is a resistor with Diagnostic Aids
negative temperature coefficient. When the engine
Inspect for the following conditions:
coolant is cold, the sensor resistance is high and the
ECT signal voltage input to the ECU is high. When Poor coonection between the ECU and ECT
the engine coolant is warm, the sensor resistance is sensor - inspect for the existance of the ECU
low and the ECT signal voltage input to the ECU is harness connector:
low. When the ECT sensor works properly, the engine － Backed-out terminals
coolant temperature utilized by the system equals to － Improper mating
that indicated by the ECT singal voltage. － Broken locks
If the ECT signal terminal is short or open to power, the － Improperly formed or damaged terminals
indicated temperature correspondingly may be lower,
－ Poor terminal-to-wire connection
and DTC P0118 will be set.
Damaged harness - inspect the wiring harness
Conditions for running the DTC for damage.If the harness appears OK,
The ignition switch is turned on. observe the engine coolant temperature (ECT)
display on the scan tool while moving
Conditions for Setting the DTC connectors and wiring harnesses related to the
Engine coolant temperature indicated by ECT ECT sensor. A change in the ECT display will
signal voltage<-35°C indicate the location of the fault.
Action Taken When the DTC Sets If the DTC can not be duplicated, the information in
the failure records can be used to determine the
Corresponding DTCs as well as the related
milage that has elapsed since the DTC last set. It can
DTC information will be stored in the DTC
determine how often the condition for setting the DTC
memory.
occurs, this may assist in diagnosing the condition.
After the second consecutive drive cycle that
the diagnostic test has run and failed, the
DTC P0118 Engine Coolant Temperature Sensor Indicated Temperature too Low
Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain
Diagnostic System Check? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Turn on the ignition, with the engine OFF.

2. Observe the engine coolant temperature
parameter with a scan tool.
2 -40°C Go to Step 4 Go to Step 3
Does the scan tool show the engine coolant
temperature parameter less than the specified
value?

Operate the vehicle according to the conditions for

running the DTC. Go to Diagnostic
3 Does the scan tool indicate that DTC P0118 failed － Go to Step 4
Aid
this ignition?
6-62 Engine Controls Engine

DTC P0118 Engine Coolant Temperature Sensor Indicated Temperature too Low(Cont’
d)
Step Action Value Yes No
Test the ECT sensor signal circuit for a short to
4 power. － Go to Step 13 Go to Step 5
Do you find and correct the condition?

1. Turn off the ignition.

2. Disconnect the engine coolant temperature
(ECT) sensor.
3. Connect a 3-ampere fused jumper wire
between the signal circuit and ground circuit
5 of the ECT sensor. 140°C Go to Step 7 Go to Step 6
4. Observe the engine coolant temperature
parameter with a scan tool.
Does the scan tool show the engine coolant
temperature parameter greater than the specified
value?

1. Connect one end of a 3-ampere fused

jumper wire to the ECT sensor signal
terminal, and ensure the other end of it to ga
good ground.
6 2. Observe the engine coolant temperature 140°C Go to Step 8 Go to Step 9
parameter with a scan tool.
Does the scan tool show the engine coolant
temperature parameter greater than the specified
value?

Inspect for a faulty connection at the ECT sensor.

7 Do you find and correct the condition? － Go to Step 13 Go to Step 11

Test the ground circuit of the ECT sensor for an

8 open. － Go to Step 13 Go to Step 10
Do you find and correct the condition?

Test the signal circuit of the ECT sensor for an

9 open. － Go to Step 13 Go to Step 10
Do you find and correct the condition?

Check the signal circuit and the ground circuit of

10 the ECT sensor for the connections on the ECU. － Go to Step 13 Go to Step 12
Do you find and correct the condition?

Remove the engine coolant temperature (ECT)

11 sensor. － Go to Step 13 －
Do you complete the replacement?

Replace the ECU module and have it

12 programmed. Do you complete the replacement? － Go to Step 13 －

1. Use the scan tool to clear the DTC.

2. Operate the vehicle according to the
13 conditions for running the DTC. － Go to Step 2 System OK
Is the DTC reset?

6.4.4.15 DTC P0120 Throttle Position Description

Sensor Circuit Fault There are three pins connected to the Throttle
Position Sensor (TPS), which is 5 V reference voltage
Engine Engine Controls 6-63

(TPS terminal pin A connected to ECU pin 32), After the second consecutive drive cycle that
ground terminal (TPS terminal pin B connected to the diagnostic test has run and failed, the
ECU pin 17) and signal output (TPS terminal pin C condtion will be identified by ECU.At this time,
connected to ECU pin 16) separately. TPS is a ECU illuminates the Malfunction Indicator Lamp
potentiometer type sensor. From closed throttle to (MIL).
wide open throttle, the ECU will get the corresponding
voltage signals from a range which is higher than 0
The conditions for clearing MIL/DTC.
but lower than 1 V to a range which is higher than 4 V The MIL will be turned off after 3 consecutive
but lower than 5 V, the ECU will convert the voltage drive cycles that the diagnostic test passes and
signal to the throttle position absolute angle does not fail.
(displayed in percentage) in the software. After 20 consecutive warm-up cycles without
When the TPS works properly, corresponding to the failure, the DTC will be cleared.
operation condition of closed throttle, since there is The DTC can be cleared with the scan tool.
an angle which could not be fully closed mechanically, Diagnostic Aids
the throttle position absolute angle will not equal to
Inspect for the following conditions:
zero, at this time, the output value of the throttle
position absolute angle reflects this mechanical MAP sensor faults - MAP sensor faults may
angle, generally it is about 10%; corresponding to the cause the ECU to make an incorrect
operation condition of wide open throttle, the throttle determination that the TPS is out of range.
position absolute angle is about 90% generally. The Check for an unusually low or high MAP
diagnostic module monitors the value of the throttle reading. This condition will set DTC P0120.See
position absolute angle to determine the condition. MAP Sensor Fault Diagnosis.
Then the following can be diagnosed: Poor coonection between the ECU and TPS -
－ Maximum fault: a short to power inspect the harness connector:
－ Backed-out terminals
－ Minimum fault: a short to ground
－ Improper mating
The DTC of both fault types is DTC P0120.
－ Broken locks
Conditions for running the DTC － Improperly formed or damaged terminals
Engine Speed>920 rpm and maintains for 0.1 － Poor terminal-to-wire connection
second. Use appropriate matching terminals to test if
Conditions for Setting the DTC the tensile force is proper.
Maximum fault: a short to power Throttle Damaged harness - inspect the wiring harness
Position Absolute Angle>95% and for damage.If the harness appears OK,
sustains for 0.1 second observe the TPS display on the scan tool while
moving connectors and wiring harnesses
Minimum fault: a short to ground Throttle
related to the sensor. A change in the display
Position Absolute Angle<3% and
will indicate the location of the fault.
sustains for 0.1 second
If the DTC P0120 can not be duplicated, the
Action Taken When the DTC Sets information in the failure records can be used to
Corresponding DTCs as well as the related determine the milage that has elapsed since the DTC
DTC information will be stored in the DTC last set. It can determine how often the condition for
memory. setting the DTC occurs, this may assist in diagnosing
the condition.
DTC P0120 Throttle Position Sensor Circuit Fault
Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain
Diagnostic System Check? On Board
1 － Go to Step 2 Diagnosis System
Check

DTC P0120 Throttle Position Sensor Circuit Fault(Cont’

d)
 6-64 Engine Controls Engine

Step Action Value Yes No

1. Operate the vehicle according to the
conditions for running the DTC.
2. Connect the scan tool. Go to Diagnostic
2 3. Monitor the DTC information with a scan － Go to Step 3
Aid
tool.Does the scan tool indicate DTC P0120
is current?

If there are other DTCs, please repair those faults

first.
1. Turn on the ignition.
2. Observe the throttle position angle signal Go to Diagnostic
3 with the scan tool when the throttle moves 0%-100% Go to Step 4
Aid
from closed to wide open position.
Does the signal change evenly within the
specified range?

1. Turn off the ignition.

2. Disconnect the TPS connectors.
3. Turn on the ignition.
4. Use a DMM to measure the voltage between
4 5V Go to Step 5 Go to Step 8
the TPS harness connector Pin A and
ground.
Does the voltage measure equal to the specified
value?

Use a DMM to measure the voltage between

the TPS harness connector Pin C and ground.
5 Does the voltage measure equal to the specified 5V Go to Step 6 Go to Step 8
value?

Use a DMM to measure the resistance

between the Pin A and B of the TPS. (Throttle
Position Angle 0%). 20°C, 6.5 k Ω
6 Go to Step 7 Go to Step 9
Does the resistance measure equal to the around
specified value?

Use a DMM to measure the resistance

between the Pin C and B of the TPS. (Throttle
Position Angle 0%). 20°C, 1.8 k Ω
7 Go to Step 8 Go to Step 9
Is the resistance measure within the specified around
range?

Check the TPS circuit for a short, an open, a high

resistance in the harness, and a poor connection
8 of pins at the ECU end or the sensor end. － Go to Step 11 Go to Step 10
Do you find and correct the condition?

Replace the Throttle Position Sensor.

9 Do you complete the replacement? － Go to Step 11 －

Replace the ECU and have it programmed.

10 Do you complete the replacement? － Go to Step 11 －

1. Clear the DTC.

2. Operate the vehicle according to the
conditions for running the DTC.
11 3. Monitor the DTC information with a scan － Go to Step 3 System OK
tool.Does the scan tool indicate DTC P0120
is current?
Engine Engine Controls 6-65

6.4.4.16 DTC P0130 HO2S Signal Circuit Corresponding DTCs as well as the related
DTC information will be stored in the DTC
Irrational Voltage signal memory.
Description After the second consecutive drive cycle that
There are 4 pins connected to the Oxygen Sensor the diagnostic test has run and failed, the
(HO2S), which is 12 V heater power end (HO2S condtion will be identified by ECU.At this time,
terminal pin D connected to the main relay terminal ECU illuminates the Malfunction Indicator Lamp
pin 87), sensor end (HO2S terminal pin A connected (MIL).
to the ECU pin 36), signal end (HO2S terminal pin B The conditions for clearing MIL/DTC.
connected to the ECU terminal pin 18) and heater
The MIL will be turned off after 3 consecutive
control end (HO2S terminal pin C connected to the
drive cycles that the diagnostic test passes and
ECU terminal pin 1) separately.
does not fail.
The system uses a heated oxygen sensor (Model
After 20 consecutive warm-up cycles without
LSH25), in addition to the oxygen sensor signal
failure, the DTC will be cleared.
circuit, there is a heater circuit. The oxygen sensor
inputs the HO2S signal voltage to the ECU through The DTC can be cleared with the scan tool.
the ECU pin 18. Diagnostic Aids
When the oxygen sensor works properly, the signal Inspect for the following conditions:
voltage value of the HO2S changes between 0 V and HO2S wires - the sensor pigtail may be routed
1 V.The reference voltage is 450±30mV, when the incorrectly and contacting the exhaust system.
HO2S voltage is higher than this value, indicating that
Poor ECU and engine body grounds.
the air mixtures is rich (Î<1); when the value is lower
than this value, indicating that the air mixtures is lean Fuel pressure - if the pressure is low, the system
(Î>1). When the Î closed loop control is activated, the will become lean. The ECU can compensate for
ECU monitors the HO2S signal, and adjusts the some decrease. However, if the fuel pressure is
amount of fuel delivery according to the rich or lean too low, DTC P0130 will be set.
condition of the air mixtures reflected by the signal. If Vacuum leaks - inspect for disconnected or
the signal is always restrained within the range which damaged vacuum hoses and for vacuum leaks
is lower than the reference voltage, DTC P0130 will at the intake manifold, throttle body and
be set. Conditions for running the DTC crankcase ventilation system.
Battery voltage>11 V Exhaust leaks - an exhuast leak may cause
Engine reaches normal operating temperature outside air to be pulled into the exhaust gas
stream past the HO2S, causing the system to
2000 rpm<Engine Speed<3000 rpm appear lean. Check for exhaust leaks that may
Throttle Position Angle 5% - 30% cause a false lean condition to be indicated.
Conditions for Setting the DTC Uneven fuel injection of the fuel injectors, fuel
injectors need to be washed.
Î Closed loop control is activated, and there
is no canister control solenoid fault and Fuel contamination - even in small amounts,
0.06V<HO2S Signal Voltage<0.4 V, and can be delivered to the fuel injectors. The water
sustains for 20 S can cause a lean exhaust to be indicated.
Excessive alcohol in the fuel can also cause this
Action Taken When the DTC Sets condition.
If none of the above conditions are present, replace
the affected H2OS.
DTC P0130 HO2S Signal Circuit Irrational Voltage Signal
Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain
Diagnostic System Check? On Board
1 － Go to Step 2 Diagnosis System
Check
 6-66 Engine Controls Engine

DTC P0130 HO2S Signal Circuit Irrational Voltage Signal (Cont’

d)
Step Action Value Yes No
1. Install the scan tool.
2. Operate the vehicle according to the
conditions for running the DTC. Go to Diagnostic
2 3. Monitor the DTC information with a scan － Go to Step 3
Aid
tool.Does the scan tool indicate DTC P0130
is current?

Inspect and test for the following:

1. Exhaust pipes leak.
3 2. Is the sensor installed correctly? － Go to Step 8 Go to Step 4
3. Damaged harness.
Do you find and correct the condition?

1. Turn off the ignition.

2. Disconnect the HO2S connectors.
3. Turn on the ignition.
4 4. Observe the HO2S voltage parameter with a 400 mv Go to Step 6 Go to Step 5
scan tool.
Does the scan tool indicate the HO2S voltage less
than the specified value?

Inspect the HO2S signal circuit for a short to

5 ground or a short to sensor ground. － Go to Step 7 Go to Step 7
Do you find and correct the condition?

Replace the HO2S.

6 Do you complete the replacement? － Go to Step 8 －

Replace the ECU and have it programmed.

7 Do you complete the replacement? － Go to Step 8 －

1. Clear the DTC.

2. Operate the vehicle according to the
DTC operating conditions, and use a scan tool
8 to monitor the failure information. Does the scan － Go to Step 3 System OK
tool indicate DTC P0130 is current?

6.4.4.17 DTC P0132 HO2S Signal Circuit circuit, there is a heater circuit. The oxygen sensor
inputs the HO2S signal voltage to the ECU through
High Voltage the ECU pin 18.
Description When the oxygen sensor works properly, the signal
There are 4 pins connected to the Oxygen Sensor voltage value of the HO2S changes between 0 V and
(HO2S), which is 12 V heater power end (HO2S 1 V.The reference voltage is 450±30mV, when the
terminal pin D connected to the main relay terminal HO2S voltage is higher than this value, indicating that
pin 87), sensor end (HO2S terminal pin A connected the air mixtures is rich (Î<1); when the value is lower
to the ECU pin 36), signal end (HO2S terminal pin B than this value, indicating that the air mixtures is lean
connected to the ECU terminal pin 18) and heater (Î>1). When the Î closed loop control is activated, the
control end (HO2S terminal pin C connected to the ECU monitors the HO2S signal, and adjusts the
ECU terminal pin 1) separately. amount of fuel delivery according to the rich or lean
condition of the air mixtures reflected by the signal. If
The system uses a heated oxygen sensor (Model the HO2S signal voltage is excessively high and
LSH25), in addition to the oxygen sensor signal
Engine Engine Controls 6-67

maintains for a period of time, DTC P0132 will be set. the displayed HO2S voltage changes from
Conditions for running the DTC over1500 mV to around 450 mV, replace the
HO2S.Silicon contamination of the HO2S can
Battery voltage>11 V
also cause a high HO2S voltage to be
Engine reaches normal operating temperature indicated. This condition can be determined by
2000 rpm<Engine Speed<3000 rpm the powdery white deposit on the exhaust
Throttle Position Angle 5% - 30% portion of the HO2S If contamination is noticed,
replace the affected HO2S.
Conditions for Setting the DTC Open HO2S signal or low circuit or faulty HO2S
HO2S Signal Voltage>1.5 V, and sustains for - A poor connection or open in the HO2S signal
20 or low circuit can cause the DTC to set during
S deceleration fuel mode. An HO2S which is
Action Taken When the DTC Sets faulty and not allowing a full voltage swing
between the rich and lean thresholds can also
Corresponding DTCs as well as the related cause this condition. Operate the vehicle while
DTC information will be stored in the DTC monitoring the HO2S voltage with a scan tool. If
memory. the HO2S voltage is limited within a range
After the second consecutive drive cycle that the between 300 mV to 600 mV, check the HO2S
diagnostic test has run and failed, the condtion signal and low circuit wiring and associated
will be identified by ECU.At this time, ECU terminal connections. If the wiring and
illuminates the Malfunction Indicator Lamp connections are OK, replace the HO2S.
(MIL).
The conditions for clearing MIL/DTC.
The MIL will be turned off after 3 consecutive
drive cycles that the diagnostic test passes and
does not fail.
After 20 consecutive warm-up cycles without
failure, the DTC will be cleared.
The DTC can be cleared with the scan tool.
Diagnostic Aids
Inspect the following items:
Fuel pressure - if the pressure is high, the
system will become rich. The ECU can
compensate for some increase.However, if the
fuel pressure is too high, DTC P0132 will be
set.
Inspect the EVAP canister for fuel saturation. If
the EVAP canister is full of fuel, inspect the
canister control and hoses.
Inspect for a leaking fuel pressure regulator
diaphragm by checking the vacuum line to
regulator for the presence of fuel.
An intermittent TP sensor output will cause the
system to go rich due to a false indication of the
engine accelerating.
The fuel injectors are leaking, which should be
replaced.
Shorted HO2S - If the HO2S is internally
shorted, the HO2S voltage displayed on the
scan tool will be over 1.5 volt. Disconnect the
affected HO2S and jumper the HO2S low
circuit to ground with the key ON, engine OFF.If
 6-68 Engine Controls Engine

DTC P0132 HO2S Signal Circuit High

Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain
Diagnostic System Check? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Install the scan tool.

2. Operate the vehicle according to the
conditions for running the DTC. Go to Diagnostic
2 3. Monitor the DTC information with a scan － Go to Step 3
Aid
tool.Does the scan tool indicate DTC P0132
is current?

With the scan tool, monitor the data display of the

HO2S. Go to Diagnostic
3 Is the data display of the HO2S greater than the 1500 mV Go to Step 4
Aid
specified value?

Test-drive the vehicle, accelerating it to the speed

of above 40 km/h and then releasing the
acceleration pedal, with the throttle position angle
less than 3 percent and the engine in deceleration Go to Diagnostic
4 110 mV Go to Step 5
fuel mode, observe the HO2S voltage value. Aid
Does the HO2S voltage measure near the
specified value?

1. Turn off the ignition.

2. Disconnect the HO2S connectors.
5 3. Turn on the ignition. 480 mV Go to Step 6 Go to Step 7
Does the scan tool indicate the HO2S voltage
greater than the specified value?

Inspect the HO2S signal circuit for a short to

6 voltage. － Go to Step 9 Go to Step 8
Do you find and correct the condition?

Replace the HO2S.

7 Do you complete the replacement? － Go to Step 9 －

Replace the ECU and have it programmed.

8 Do you complete the replacement? － Go to Step 9 －

1. Clear the DTC.

2. Operate the vehicle according to the
DTC operating conditions, and use a scan tool
9 to monitor the failure information. Does the scan － Go to Step 3 System OK
tool indicate DTC P0132 is current?

Voltage
Engine Engine Controls 6-69

6.4.4.18 DTC P0134 HO2S Circuit After the second consecutive drive cycle that
the diagnostic test has run and failed, the
Insufficient Activity condtion will be identified by ECU.At this time,
Description ECU illuminates the Malfunction Indicator Lamp
(MIL).
There are 4 pins connected to the Oxygen Sensor
(HO2S), which is 12 V heater power end (HO2S The conditions for clearing MIL/DTC.
terminal pin D connected to the main relay terminal The MIL will be turned off after 3 consecutive
pin 87), sensor end (HO2S terminal pin A connected drive cycles that the diagnostic test passes and
to the ECU pin 36), signal end (HO2S terminal pin B does not fail.
connected to the ECU terminal pin 18) and heater
After 20 consecutive warm-up cycles without
control end (HO2S terminal pin C connected to the
failure, the DTC will be cleared.
ECU terminal pin 1) separately.
The DTC can be cleared with the scan tool.
The system uses a heated oxygen sensor (Model
LSH25), in addition to the oxygen sensor signal Diagnostic Aids
circuit, there is a heater circuit. The oxygen sensor Inspect for the following conditions:
inputs the HO2S signal voltage to the ECU through A poor connection or a damaged harness ñ
the ECU pin 18. inspect the harness connector:
When the oxygen sensor works properly, the signal － Backed-out terminals
voltage value of the HO2S changes between 0 V and － Improper mating
1 V.The reference voltage is 450±30mV, when the － Broken locks
HO2S voltage is higher than this value, indicating that
－ Improperly formed or damaged terminals
the air mixtures is rich (Î<1); when the value is lower
than this value, indicating that the air mixtures is lean － Poor terminal-to-wire connection
(Î>1). When the Î closed loop control is activated, the － Damaged harness
ECU monitors the HO2S signal, and adjusts the Faulty HO2S heater or heater circuit - with the
amount of fuel delivery according to the rich or lean ignition ON, engine OFF, the HO2S voltage
condition of the air mixtures reflected by the signal. If displayed on a scan tool should gradually drop
the HO2S signal voltage remains at or near the to below 250 mV or rise to above 600 mV.If not,
reference voltage of 450 mV for an extended period disconnect the HO2S and connect a test lamp
of time, DTC P0134 will be set. between the HO2S feed and heater control
Conditions for running the DTC circuits. If the test lamp does not illuminate,
repair the open in the feed circuit or sensor
Battery voltage>11 V control circuit.If the test lamp lights and the
Engine reaches normal operating temperature HO2S signal and low circuit are OK, replace
2000 rpm<Engine Speed<3000 rpm the HO2S.
Throttle Position Angle 5% - 30% Test for Intermittent conditions - with the
ignition ON, monitor the HO2S singal voltage
Conditions for Setting the DTC while moving the wiring harness and related
Open HO2S signal circuit connectors. If the fault is induced, the HO2S
0.4V<HO2S Signal Voltage<0.6 V, and sustains signal voltage will change. This may help to
for 20 S isolate the location of the problem.
View the vehicle driving mileage since the last
Action Taken When the DTC Sets diagnostic test failed in the trouble record, and
Corresponding DTCs as well as the related determine the frequency of occurrence in setting the
DTC information will be stored in the DTC DTC. It is helpful to the diagnosis of the conditions.
memory.
DTC P0134 HO2S Circuit Insufficient Activity
Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain
Diagnostic System Check? On Board
1 － Go to Step 2 Diagnosis System
Check
 6-70 Engine Controls Engine

DTC P0134 HO2S Circuit Insufficient Activity(Cont’ d)

Step Action Value Yes No

Notice: Before proceeding with this table,

please observe if there are any other DTCs
present first.
1. Engine reaches normal operating
temperature
2 2. Operate the engine above 1200 rpm for 2 400-600 mv Go to Step 3 Go to Step 4
minutes.
3. Observe the HO2S voltage parameter with a
scan tool.
Does the scan tool indicate the HO2S voltage
change within the specified range?

Operate the vehicle according to the conditions for

running the DTC.
Monitor the DTC information with a scan tool. Go to Diagnostic
3 － Go to Step 4
Does the scan tool indicate DTC P0445 as current Aid
trouble code?

Inspect and test for the following:

1. Exhaust leakage.
4 2. The HO2S is installed correctly. － Go to Step 9 Go to Step 5
3. Damaged wires.
Do you find and correct the condition?

1. Turn off the ignition.

2. Disconnect the HO2S connectors.
3. Turn on the ignition.
5 400 mv Go to Step 7 Go to Step 6
4. Observe the HO2S voltage with a scan
tool.Does the voltage meaure near the specified
value?

Check the HO2S circuit for a short, an open, a

high resistance in the harness, and a poor
6 connection of pins at the ECU end or the sensor － Go to Step 9 Go to Step 8
end.
Do you find and correct the condition?

Replace the HO2S.

7 Do you complete the replacement? － Go to Step 9 －

Replace the ECU and have it programmed.

8 Do you complete the replacement? － Go to Step 9 －

1. Clear the DTC.

2. Operate the vehicle according to the
DTC operating conditions, and use a scan tool
9 to monitor the failure information. Does the scan － Go to Step 4 System OK
tool indicate DTC P0134 is current?

6.4.4.19 DTC P0135 HO2S Heater Circuit terminal pin D connected to the main relay terminal
pin 87), sensor end (HO2S terminal pin A connected
Fault to the ECU pin 36), signal end (HO2S terminal pin B
Description connected to the ECU terminal pin 18) and heater
control end (HO2S terminal pin C connected to the
There are 4 pins connected to the Oxygen Sensor ECU terminal pin 1) separately.
(HO2S), which is 12 V heater power end (HO2S
Engine Engine Controls 6-71

The system uses a heated oxygen sensor (Model After the second consecutive drive cycle that
LSH25), in addition to the oxygen sensor signal the diagnostic test has run and failed, the
circuit, there is a heater circuit. The ECU controls the condtion will be identified by ECU.At this time,
heating process by the output switch signal of pin 1, ECU illuminates the Malfunction Indicator Lamp
that is, when the pin 1 is low potential (ground), the (MIL).
heater circuit is closed; when the pin 1 is high
potential (power on), the heater circuit is open, stops
The conditions for clearing MIL/DTC.
heating the HO2S. The MIL will be turned off after 3 consecutive
drive cycles that the diagnostic test passes and
At the same time, the ECU monitors the heater
does not fail.
control circuit voltage. According to the heating
control switch signal of pin 1 and the condition of the After 20 consecutive warm-up cycles without
voltage, the diagnostic module diagnoses the heater failure, the DTC will be cleared.
circuit. The fault types that can be diagnosed are: The DTC can be cleared with the scan tool.
－ Maximum fault: a short to power Diagnostic Aids
－ Minimum fault: a short to ground Inspect for the following conditions:
A poor connection or a damaged harness ñ
－ Singal fault: open or broken
inspect the harness connector:
－ Irrational fault: excessively high HO2S － Backed-out terminals
internal resistance － Improper mating
The DTC for the above 4 fault types is P0135. － Broken locks
Conditions for running the DTC － Improperly formed or damaged terminals
After the engine is started and reaches normal
－ Poor terminal-to-wire connection
operating temperature for 5 minutes, and 10.98
V<Battery Voltage<15.47 V － Damaged harness
Faulty HO2S heater or heater circuit ñ with the
Conditions for Setting the DTC ignition ON, engine OFF, the HO2S voltage
Maximum fault: a short to power Heater displayed on a scan tool should gradually drop
Control Circuit Voltage>3.6 V, and to below 250 mV or rise to above 600 mV.If not,
sustains for 0.05 S with the heater control disconnect the HO2S and connect a test lamp
swtich between the HO2S feed and heater control
ON. circuits. If the test lamp does not illuminate,
Minimum fault: a short to ground Heater Control repair the open in the feed circuit or sensor
Circuit Voltage 2.2 V, and sustains for 0.05 S control circuit.If the test lamp lights and the
with the heater control swtich OFF. HO2S signal and low circuit are OK, replace
the HO2S.
Signal Fault: open
2.2 V<Heater Control Circuit Voltage<3.6 V, and Test for Intermittent conditions ñ with the
sustains for 0.05 S with the heater control ignition ON, monitor the HO2S singal voltage
swtich OFF. while moving the wiring harness and related
connectors. If the fault is induced, the HO2S
Irrational Fault signal voltage will change. This may help to
The HO2S internal resistance are mainly isolate the location of the problem.
subject to the exhaust temperature and heating
power. When a fault is present on the heater View the vehicle driving mileage since the last
circuit, its resistance will be excessively high. If diagnostic test failed in the trouble record, and
the condition in which the HO2S internal determine the frequency of occurrence in setting the
resistance is greater than the HO2S internal DTC. It is helpful to the diagnosis of the conditions.
resistance predetermined thresholds is met
and maintains for 15 S, it should be determined
as an irrational fault.
Action Taken When the DTC Sets
Corresponding DTCs as well as the related
DTC information will be stored in the DTC
memory.
 6-72 Engine Controls Engine

DTC P0135 HO2S Heater Circuit Fault

Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain
Diagnostic System Check? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Operate the vehicle according to the

conditions for running the DTC.
2. Connect the scan tool.
Go to Diagnostic
2 3. Monitor the DTC information with a scan － Go to Step 3
Aid
tool.
Does the scan tool indicate DTC P0445 as current
trouble code?
1. Disconnect the HO2S.
2. Turn on the ignition.
3 3. Connect a test lamp between HO2S heater － Go to Step 4 Go to Step 6
feed circuit and ground.
Does the test light illuminate?

Use a DMM to measure the sensor connector pin

C voltage.
4 Does the voltage measure near the specified About 2.5V Go to Step 5 Go to Step 6
value?

After the HO2S has cooled down for at least 10

minutes, measure the HO2S.
5 Heating wire resistance. 2-5 Ω (20°C) Go to Step 8 Go to Step 7
Does the resistance measure near the specified
value?

Check the HO2S circuit for a short, an open, a

high resistance in the harness, and a poor
6 connection of pins at the ECU end or the sensor － Go to Step 9 Go to Step 6
end.
Do you find and correct the condition?

Replace the HO2S.

7 Do you complete the replacement? － Go to Step 9 －

Replace the ECU and have it programmed.

8 Do you complete the replacement? － Go to Step 9 －

1. Use the scan tool to clear the DTC.

2. Operate the vehicle according to the
9 conditions for running the DTC. － Go to Step 3 System OK
Is the DTC reset?
Engine Engine Controls 6-73

6.4.4.20 DTC P0201 Cylinder 1 Fuel Corresponding DTCs as well as the related
DTC information will be stored in the DTC
injector Circuit Fault memory.
Description The MIL will be turned off after 3 consecutive
There are 2 pins connected to the Cylinder 1 fuel drive cycles that the diagnostic test passes and
injector, which is 12 V feed voltage (cylinder 1 fuel does not fail.
injecotr pin 1 connected to the main relay terminal pin After 20 consecutive warm-up cycles without
87), control terminal input (cylinder 1 fuel injector pin failure, the DTC will be cleared.
2 connected to the ECU pin 27) separately. In the The DTC can be cleared with the scan tool.
system, cylinder 1 fuel injector is driven by the driving
chip, which can realize the self diagnostic function on Diagnostic Aids
drive level and notify the CPU's internal failure The following conditions can cause an intermittent
diagnostic module of the failure information, by malfunction to occur:
comparing the switch signal from CPU to the actual
Important: Prior to repairing the parts, remove all the
potential of drive level output end.The fault types that chips from the connector surface.Prior to diagnosing or
can be diagnosed are: replacing the parts, check the connector gasket.Ensure
－ Maximum fault: a short to power the gasket is mounted correctly.The gasket may
－ Minimum fault: a short to ground prevent the pollutant from entering.
A poor connection at terminal - inspect harness
－ Singal fault: open or broken
connectors for backed-out terminals, improper
The DTC for the three fault types is P0201. mating, broken locks, improperly formed or
damaged terminals, and poor terminal-to-wire
Conditions for running the DTC
connection.Use a corresponding mating
After the engine starts normally terminal to test for proper tension.
Conditions for Setting the DTC Damaged harness - inspect the wiring harness
Max. Failure: for damage.If the harness inspection does not
The driving chip detects that the pin 27 is short reveal a problem, observe the display on the
to power scan tool while moving connectors and wiring
Min. Failure: harnesses related to the sensor. A change in
The driving chip detects that the pin 27 is short the display on the scan tool will indicate the
to ground location of the fault.
Signal Failure: Inspect the ECU and engine grounds for
The driving chip detects that the pin 27 is open secure and clean connections.
or broken If the DTC is determined to be intermittent, reviewing
Action Taken When the DTC Sets the Failure Records can be useful in determining
when the DTC was last set.
DTC P0201 Cylinder 1 Fuel injector Circuit Fault
Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain
Diagnostic System Check? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Operate the vehicle according to the

conditions for running the DTC.
2. Connect the scan tool. Go to Diagnostic
2 3. Monitor the DTC information with a scan － Go to Step 3
Aid
tool.Does the scan tool indicate DTC P0201
is current?

DTC P0201 Cylinder 1 Fuel injector Circuit Fault(Cont’

d)
 6-74 Engine Controls Engine

After
the
first
cons
ecuti
ve
drive
cycle
that
the
diag
nosti
c
test
has
run
and
faile
d,
the
cond
tion
will
be
ident
ified
by
ECU
.At
this
time,
ECU
illumi
nate
s the
Malf
uncti
on
Indic
ator
Lam
p
(MIL)
.
The conditions for clearing MIL/DTC.
Step Action Value Yes No
1. Turn off the ignition.
2. Disconnect the fuel injector 1 connector.
3. Turn on the ignition.
3 4. Use a DMM to measure the voltage between 3.7 volt Go to Step 4 Go to Step 6
the cylinder 1 fuel injector harness connector
Pin 2 and ground.
Is the voltage measure within the specified
range?
 Engine

Engine Controls 6-75

Connect a test lamp between cylinder 1 fuel
injector harness connector Pin 1 and ground.
4 When the battery voltage is OK, does the test － Go to Step 5 Go to Step 6
lamp reach its normal brightness?

Test the fuel injector. See Fuel Injector Coil Test. 20°C,
5 Does the test meet the specified value? 13-16 Ω Go to Step 6 Go to Step 7

Check the cylinder 1 fuel injector circuit for a short,

an open, a high resistance in the harness, or a
6 poor connection of pins at the ECU end or the fuel － Go to Step 9 Go to Step 8
injector end.
Do you find and correct the condition?

Replace the fuel injector.

7 Do you complete the replacement? － Go to Step 9 －

Replace the ECU and have it programmed.

8 Do you complete the replacement? － Go to Step 9 －

1. Clear the DTC.

2. Operate the vehicle according to the DTC
operating conditions, and use a scan tool to
9 monitor the DTC information. － Go to Step 3 System OK
Does the scan tool indicate DTC P0201 is
current?

6.4.4.21 DTC P0202 Cylinder 2 Fuel The driving chip detects that the pin 6 is short
to ground
injector Circuit Fault
Signal Failure:
Description The driving chip detects that the pin 6 is open
There are 2 pins connected to the Cylinder 2 fuel or broken
injector, which is 12 V feed voltage (cylinder 2 fuel Action Taken When the DTC Sets
injecotr pin 1 connected to the main relay terminal pin
Corresponding DTCs as well as the related
87), control terminal input (cylinder 2 fuel injector pin
DTC information will be stored in the DTC
2 connected to the ECU pin 6) separately. In the
memory.
system, cylinder 2 fuel injector is driven by the driving
chip, which can realize the self diagnostic function on The MIL will be turned off after 3 consecutive
drive level and notify the CPU's internal failure drive cycles that the diagnostic test passes and
diagnostic module of the failure information, by does not fail.
comparing the switch signal from CPU to the actual After 20 consecutive warm-up cycles without
potential of drive level output end.The fault types that failure, the DTC will be cleared.
can be diagnosed are: The DTC can be cleared with the scan tool.
－ Maximum fault: a short to power
Diagnostic Aids
－ Minimum fault: a short to ground
The following conditions can cause an intermittent
－ Singal fault: open or broken malfunction to occur:
The DTC for the three fault types is P0202. Important: Prior to repairing the parts, remove all the
chips from the connector surface.Prior to diagnosing or
Conditions for running the DTC replacing the parts, check the connector gasket.Ensure
After the engine starts normally the gasket is mounted correctly.The gasket may
Conditions for Setting the DTC prevent the pollutant from entering.
Max. Failure: A poor connection at terminal - inspect harness
The driving chip detects that the pin 6 is short connectors for backed-out terminals, improper
to power mating, broken locks, improperly formed or
Min. Failure: damaged terminals, and poor terminal-to-wire
 6-76 Engine Controls Engine

After the first consecutive drive cycle that the

diagnostic test has run and failed, the condtion
will be identified by ECU.At this time, ECU
illuminates the Malfunction Indicator Lamp
(MIL).
The conditions for clearing MIL/DTC.
connection.Use a corresponding mating the display on the scan tool will indicate the
terminal to test for proper tension. location of the fault.
Damaged harness - inspect the wiring harness Inspect the ECU and engine grounds for
for damage.If the harness inspection does not secure and clean connections.
reveal a problem, observe the display on the If the DTC is determined to be intermittent, reviewing
scan tool while moving connectors and wiring the Failure Records can be useful in determining
harnesses related to the sensor. A change in when the DTC was last set.
DTC P0202 Cylinder 2 Fuel injector Circuit Fault
Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain
Diagnostic System Check? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Operate the vehicle according to the

conditions for running the DTC.
2. Connect the scan tool. Go to Diagnostic
2 3. Monitor the DTC information with a scan － Go to Step 3
Aid
tool.Does the scan tool indicate DTC P0202
is current?

DTC P0202 Cylinder 2 Fuel injector Circuit Fault(Cont’

d)
Step Action Value Yes No
1. Turn off the ignition.
2. Disconnect the fuel injector connector.
3. Turn on the ignition.
3 4. Use a DMM to measure the voltage between 3.7 volt Go to Step 4 Go to Step 6
the cylinder 2 fuel injector harness connector
Pin 2 and ground.
Is the voltage measure within the specified
range?
Connect a test lamp between cylinder 2 fuel
injector harness connector Pin 1 and ground.
4 When the battery voltage is OK, does the test － Go to Step 5 Go to Step 6
lamp reach its normal brightness?

Test the fuel injector. See Fuel Injector Coil Test.

5 Does the test meet the specified value? 20°C, 13-16 Ω Go to Step 6 Go to Step 7

Check the cylinder 2 fuel injector circuit for a short,

an open, a high resistance in the harness, or a
6 poor connection of pins at the ECU end or the fuel － Go to Step 9 Go to Step 8
injector end.
Do you find and correct the condition?

Replace the fuel injector.

7 Do you complete the replacement? － Go to Step 9 －
 Engine

Engine Controls 6-77

Replace the ECU and have it programmed.
8 Do you complete the replacement? － Go to Step 9 －

1. Clear the DTC.

2. Operate the vehicle according to the DTC
operating conditions, and use a scan tool to
9 monitor the DTC information. － Go to Step 3 System OK
Does the scan tool indicate DTC P0202 is
current?

6.4.4.22 DTC P0203 Cylinder 3 Fuel Corresponding DTCs as well as the related
DTC information will be stored in the DTC
injector Circuit Fault memory.
Description The MIL will be turned off after 3 consecutive
There are 3 pins connected to the Cylinder 3 fuel drive cycles that the diagnostic test passes and
injector, which is 12 V feed voltage (cylinder 3 fuel does not fail.
injecotr pin 1 connected to the main relay terminal pin After 20 consecutive warm-up cycles without
87), control terminal input (cylinder 3 fuel injector pin failure, the DTC will be cleared.
2 connected to the ECU pin 7) separately. In the The DTC can be cleared with the scan tool.
system, cylinder 3 fuel injector is driven by the driving
chip, which can realize the self diagnostic function on Diagnostic Aids
drive level and notify the CPU's internal failure The following conditions can cause an intermittent
diagnostic module of the failure information, by malfunction to occur:
comparing the switch signal from CPU to the actual
Important: Prior to repairing the parts, remove all the
potential of drive level output end.The fault types that chips from the connector surface.Prior to diagnosing or
can be diagnosed are: replacing the parts, check the connector gasket.Ensure
－ Maximum fault: a short to power the gasket is mounted correctly.The gasket may
－ Minimum fault: a short to ground prevent the pollutant from entering.
A poor connection at terminal - inspect harness
－ Singal fault: open or broken
connectors for backed-out terminals, improper
The DTC for the three fault types is P0203. mating, broken locks, improperly formed or
damaged terminals, and poor terminal-to-wire
Conditions for running the DTC
connection.Use a corresponding mating
After the engine starts normally terminal to test for proper tension.
Conditions for Setting the DTC Damaged harness - inspect the wiring harness
Max. Failure: for damage.If the harness inspection does not
The driving chip detects that the pin 7 is short reveal a problem, observe the display on the
to power scan tool while moving connectors and wiring
Min. Failure: harnesses related to the sensor. A change in
The driving chip detects that the pin 7 is short the display on the scan tool will indicate the
to ground location of the fault.
Signal Failure: Inspect the ECU and engine grounds for
The driving chip detects that the pin 7 is open secure and clean connections.
or broken If the DTC is determined to be intermittent, reviewing
Action Taken When the DTC Sets the Failure Records can be useful in determining
when the DTC was last set.
DTC P0203 Cylinder 3 Fuel injector Circuit Fault
Step Action Value Yes No
 6-78 Engine Controls Engine

After
the
first
cons
ecuti
ve
drive
cycle
that
the
diag
nosti
c
test
has
run
and
faile
d,
the
cond
tion
will
be
ident
ified
by
ECU
.At
this
time,
ECU
illumi
nate
s the
Malf
uncti
on
Indic
ator
Lam
p
(MIL)
.
The conditions for clearing MIL/DTC.
Do you perform the Powertrain On Board Go to Powertrain
Diagnostic System Check? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Operate the vehicle according to the

conditions for running the DTC.
2. Connect the scan tool. Go to Diagnostic
2 3. Monitor the DTC information with a scan － Go to Step 3
Aid
tool.Does the scan tool indicate DTC P0203
is current?
 Engine

Engine Controls 6-79

DTC P0203 Cylinder 3 Fuel injector Circuit Fault(Cont’
d)
Step Action Value Yes No
1. Turn off the ignition.
2. Disconnect the fuel injector 3 connector.
3. Turn on the ignition.
3 4. Use a DMM to measure the voltage between 3.7 volt Go to Step 4 Go to Step 6
the cylinder 3 fuel injector harness connector
Pin 2 and ground.
Is the voltage measure within the specified
range?
Connect a test lamp between cylinder 3 fuel
injector harness connector Pin 1 and ground.
4 When the battery voltage is OK, does the test － Go to Step 5 Go to Step 6
lamp reach its normal brightness?

Test the fuel injector. See Fuel Injector Coil Test. 20°C,
5 Does the test meet the specified value? 13-16 Ω Go to Step 6 Go to Step 7

Check the cylinder 3 fuel injector circuit for a short,

an open, a high resistance in the harness, or a
6 poor connection of pins at the ECU end or the fuel － Go to Step 9 Go to Step 8
injector end.
Do you find and correct the condition?

Replace the fuel injector.

7 Do you complete the replacement? － Go to Step 9 －

Replace the ECU and have it programmed.

8 Do you complete the replacement? － Go to Step 9 －

1. Clear the DTC.

2. Operate the vehicle according to the DTC
operating conditions, and use a scan tool to
9 monitor the DTC information. － Go to Step 3 System OK
Does the scan tool indicate DTC P0203 is
current?

6.4.4.23 DTC P0204 Cylinder 4 Fuel － Minimum fault: a short to ground

injector Circuit Fault － Singal fault: open or broken
The DTC for the three fault types is P0204.
Description
There are 2 pins connected to the Cylinder 4 fuel Conditions for running the DTC
injector, which is 12 V feed voltage (cylinder 4 fuel After the engine starts normally
injecotr pin 1 connected to the main relay terminal pin Conditions for Setting the DTC
87), control terminal input (cylinder 4 fuel injector pin
Max. Failure:
2 connected to the ECU pin 47) separately. In the
The driving chip detects that the pin 47 is short
system, cylinder 4 fuel injector is driven by the driving
to power
chip, which can realize the self diagnostic function on
drive level and notify the CPU's internal failure Min. Failure:
diagnostic module of the failure information, by The driving chip detects that the pin 47 is short
comparing the switch signal from CPU to the actual to ground
potential of drive level output end.The fault types that Signal Failure:
can be diagnosed are: The driving chip detects that the pin 47 is open
－ Maximum fault: a short to power or broken
 6-80 Engine Controls Engine

After the first consecutive drive cycle that the

diagnostic test has run and failed, the condtion
will be identified by ECU.At this time, ECU
illuminates the Malfunction Indicator Lamp
(MIL).
The conditions for clearing MIL/DTC.
Action Taken When the DTC Sets A poor connection at terminal - inspect harness
connectors for backed-out terminals, improper
Corresponding DTCs as well as the related
mating, broken locks, improperly formed or
DTC information will be stored in the DTC
damaged terminals, and poor terminal-to-wire
memory.
connection.Use a corresponding mating
The MIL will be turned off after 3 consecutive terminal to test for proper tension.
drive cycles that the diagnostic test passes and
Damaged harness - inspect the wiring harness
does not fail.
for damage.If the harness inspection does not
After 20 consecutive warm-up cycles without reveal a problem, observe the display on the
failure, the DTC will be cleared. scan tool while moving connectors and wiring
The DTC can be cleared with the scan tool. harnesses related to the sensor. A change in
the display on the scan tool will indicate the
Diagnostic Aids location of the fault.
The following conditions can cause an intermittent
Inspect the ECU and engine grounds for
malfunction to occur:
secure and clean connections.
Important: Prior to repairing the parts, remove all the
If the DTC is determined to be intermittent, reviewing
chips from the connector surface.Prior to diagnosing or
the Failure Records can be useful in determining
replacing the parts, check the connector gasket.Ensure
when the DTC was last set.
the gasket is mounted correctly.The gasket may
prevent the pollutant from entering.
DTC P0204 Cylinder 4 Fuel injector Circuit Fault
Step Action Value Yes No
Do you perform the Powertrain On Board Go to Powertrain
Diagnostic System Check? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Operate the vehicle according to the

conditions for running the DTC.
2. Connect the scan tool. Go to Diagnostic
2 3. Monitor the DTC information with a scan － Go to Step 3
Aid
tool.Does the scan tool indicate DTC P0204
is current?

DTC P0204 Cylinder 4 Fuel injector Circuit Fault(Cont’

d)
Step Action Value Yes No
1. Turn off the ignition.
2. Disconnect the fuel injector 4 connector.
3. Turn on the ignition.
4. Use a DMM to measure the voltage between
3 3.7 volt Go to Step 4 Go to Step 6
the cylinder 4 fuel injector harness connector
Pin 2 and ground.
Is the voltage measure within the specified
range?
 Engine

Engine Controls 6-81

Connect a test lamp between cylinder 4 fuel
injector harness connector Pin 1 and ground.
4 When the battery voltage is OK, does the test － Go to Step 5 Go to Step 6
lamp reach its normal brightness?

Test the fuel injector. See Fuel Injector Coil Test.

5 Does the test meet the specified value? 20°C, 13-16 Ω Go to Step 6 Go to Step 7

Check the cylinder 4 fuel injector circuit for a short,

an open, a high resistance in the harness, or a
6 poor connection of pins at the ECU end or the fuel － Go to Step 9 Go to Step 8
injector end.
Do you find and correct the condition?

Replace the fuel injector.

7 Do you complete the replacement? － Go to Step 9 －

Replace the ECU and have it programmed.

8 Do you complete the replacement? － Go to Step 9 －

1. Clear the DTC.

2. Operate the vehicle according to the DTC
operating conditions, and use a scan tool to
9 monitor the DTC information. － Go to Step 3 System OK
Does the scan tool indicate DTC P0204 is
current?
 6-82 Engine Controls Engine

6.4.4.24 DTC P0230 Control Circuit Signal Failure:

An open or broken circuit with Pin 69, drive level
Failure - Oil Pump switch of oil pump relay is turnd off, and an open
Description or broken circuit with the pin.

Four pins connected to oil pump relay. They are 12V Action taken when the DTC sets.
main relay supply power (Relay end pin 30 connected The corresponding DTC, and the relative failure
to main relay end pin 87), control end (Relay end pin information enter the DTC memory.
85 connected to ECU pin 69), ignition switch signal
After 2 seconds when the diagnostic test has
input (Relay end pin 86 connected to ignition switch
run and failed, the trouble is identified by ECU
pin 15), relay voltage output end (Relay end pin 87
immediately.At this time ECU illuminates the
connected to oil pump motor pin A).
Malfunction Indicator Lamp (MIL).
Low potential of oil pump relay control end (ECU Pin
69) is valid.Oil pump relay is driven by the drive chip, Conditions for clearing the MIL/DTC.
which realize the self diagnostic function on drive The MIL will be turned off after the third
level and can notify the Internal CPU failure consecutive drive cycle that the diagnostic test
diagnostic module of the failure information, by passes without a fault.
comparing the switch signal from CPU with the actual After 20 consecutive warm-up cycles without a
potential of drive level output end.The failure types fault, the DTC is cleared off immediately.
that can be diagnosed are:
The DTC can be cleared off with a scan tool.
－ Max. failure: a short circuit of Pin to Power
when the drive level switch is turned on Diagnostic Aids
－ Min. failure: a short circuit of Pin to Ground Intermittent conditions may occur due to a poor
connection, wire insulating layer worn out or wire
when the drive level switch is turned off
damaged inside the insulating layer.
－ Signal failure: an open or short circuit of Pin
Check the following:
when the drive level switch is turned off The DTC of the
A poor connection with ECU or fuel pump relay
three failure types is P0230. Conditions for
- inspect the harness connector:
Running the DTC － Backed-out terminals
Max. Failure: － Improper mating
Engine is operative.
－ Broken locks
Min. Failure, Signal Failure:
The ignition switch is turned on. － Improperly formed or damaged terminals
Conditions for Setting the DTC － Poor terminal-to-wire connection
Harness damaged - inspect the harness
Max. Failure:
Drive level switch of oil pump relay is turned damage
on, and an short circuit with Pin to Power View the vehicle driving mileage since the last
Supply. diagnostic test failed in the trouble record, and
determine the frequency of occurrence in setting the
Min. Failure:
Drive level switch of oil pump relay is turned DTC. It is helpful to the diagnosis of the conditions.
off, and an short circuit with Pin to Ground.
DTC P0230 Control Circuit Failure - Oil Pump
Step Action Value Yes No
Has the powertrain On Board Diagnosis system Go to Powertrain
check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Turn on the ignition.

2. With a scan tool instruct the fuel pump relay
to switch on and off. Go to Diagnostic
2 － Go to Step 3
Aids
Does the relay execute each Switch On and
Switch Off order?
 Engine

Engine Controls 6-83

DTC P0230 Control Circuit Failure - Oil Pump(Cont’
d)
Step Action Value Yes No
1. Turn off the ignition.
2. Disconnect the relay, turn on the ignition
switch, and do not start the engine.
3 3. Use the test lamp with a good connection, － Go to Step 4 Go to Step 5
and connect to the power supply end Pin 2
of oil pump relay.
4. Does the test lamp illuminate?

1. Connect a test lamp between the relay

control circuit and the power supply end of
relay.
4 2. With a scan tool instruct the relay to switch － Go to Step 6 Go to Step 5
on and off.
Does each order allow the test lamp to turn on
and off?

Check the relay circuit if a short, an open circuit, a

great resistance in the harness, or a poor
5 connection with ECU end or relay end pin. － Go to Step 8 Go to Step 7
Is any failure found and repaired?

Replace the relay.

6 Is the replacement operation completed? － Go to Step 8 －

Replace the ECU and perform the programming.

7 Is the replacement operation completed? － Go to Step 8 －

1. Clear off the DTC.

2. Operate the vehicle according to the DTC
operating conditions, and use a scan tool to
8 monitor the failure information. － Go to Step 3 System OK
Does the scan tool indicate DTC P0230 as current
DTC?

6.4.4.25 DTC P0325 Circuit Failure - happen, and the ECU may retard the ignition timing
based on it.
Knock Sensor
Diagnostic module may monitor the standardized
Description knock reference value (Unit: V).When the engine
The two pins connected to the knock sensor (KS) are operates normally, and the knock sensor is operative
separately signal output (KS end pin 1 connected to regularly, the voltage signal of knock sensor may
ECU end pin 19), and signal output (KS end pin 2 fluctuate in the upper and lower limits corresponding
connected to ECU Pin 20). to the RPM. Once the signal voltage exceeds the
valve value, the knock sensor with trouble may be
The knock sensor is mounted on the engine block, considered.Then the following can be diagnosed:
and vibrates at different vibration frequencies under
the different engine operating conditions, and － Max. Failure: The background noise may
produces the voltage signal containing different kinds rise abruptly due to the engine damage.
of frequency.This signal is magnified, filtered, rectified － Min. Failure: The background noise may be
and integrated in ECU, and in the end this integral extremely low due to a short or open circuit
value of knocking signal is compared with the knock to the ground.
reference value. And if the specific value exceeds a
The failure code of the two faults are both P0325.
certain valve value, a knock may be considered to
Conditions for Running the DTC
 6-84 Engine Controls Engine

The ignition switch is turned on. Engine Conditions for clearing the MIL/DTC.
Cooling Water Temperature>40°C The MIL will be turned off after the third
Engine Speed>2000 rev/min. consecutive drive cycle that the diagnostic test
passes without a fault.
Conditions for Setting the DTC
After 20 consecutive warm-up cycles without a
If any of the following two conditions happens, the fault, the DTC is cleared off immediately.
knock sensor may be considered as fault.
The DTC can be cleared off with a scan tool.
Min. Failure: a short or open circuit to the
ground Diagnostic Aids
－ The standardized knock reference Check the following:
value<the lower limit (the limit value is A poor connection with ECU - inspect the knock
relative to the speed) sensor and the ECU connector.
－ And the engine speed>2200 rev/min. － Backed-out terminals
Max. Failure: The background noise rises － Broken locks
abruptly due to the engine damage. The
－ Improperly formed or damaged terminals
standardized knock reference value>the upper
limit (the limit value is relative to the speed). Harness laying error - inspect the knock sensor
harness to ensure the harness is not too near to
Action taken when the DTC sets. the high voltage wire.
The corresponding DTC, and the relative failure View the vehicle driving mileage since the last
information enter the DTC memory. diagnostic test failed in the trouble record, and
After the second consecutive drive cycle that determine the frequency of occurrence in setting the
the diagnostic test has run and failed, the DTC. It is helpful to the diagnosis of the conditions.
trouble may be identified by ECU
immediately.At this time ECU illuminates the
Malfunction Indicator Lamp (MIL).

DTC P0325 Circuit Failure ñ Knock Sensor

Step Action Value Yes No
Has the powertrain On Board Diagnosis system Go to Powertrain
check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

DTC P0325 Circuit Failure ñ Knock Sensor(Cont’

d)
Step Action Value Yes No

Notice: If the engine knock can be heard,

repair the engine mechanical failure prior to
performing this diagnosis.
1. Operate the vehicle according to the
operating conditions of DTC. Go to Diagnostic
2 － Go to Step 3
2. For DTC P 0325, use a scan tool to monitor Aids
the given information of diagnostic DTC until
the test runs.
Does the scan tool indicate the DTC failed this
ignition?

1. Disconnect the engine control module and

the knock sensor.
3 2. Test the knock sensor circuit if an open or － Go to Step 7 Go to Step 4
short circuit to the ground.
Is any failure found and repaired?
 Engine

Engine Controls 6-85

Check the circuit terminal of knock sensor if a
4 poor connection occurs. － Go to Step 7 Go to Step 5
Is any failure found and repaired?

Replace the knock sensor.

5 Is the replacement operation completed? － Go to Step 7 －

Replace the ECU and perform the programming.

6 Is the replacement operation completed? － Go to Step 7 －

1. Clear off the DTC.

2. Operate the vehicle according to the DTC
operating conditions, and use a scan tool to
7 monitor the failure information. － Go to Step 2 System OK
Does the scan tool indicate DTC P0325 as current
DTC?

6.4.4.26 DTC P0335 Signal Error - － Vehicle speed>25 km/h; or when DTC
P0500 is set, Vehicle speed<1 km/h; or the
Crankshaft Position Sensor
engine speed >850 rev/min.
Description Signal Failure
Crankshaft position sensor has two pins, Pin 1 － RPM signal is consecutive.
connected to ECU Pin 15, and Pin 2 connected to ECU
Pin 34. Conditions of setting the DTC
The signal wheel of crankshaft position sensor is 60-2 Max. Failure: ECU senses that each loop is
Tooth, mounted on the belt disk, among which the more than 58 tooth spaces.
width of 57 tooth spaces is 3_, and the 58th tooth Min. Failure: ECU senses that each loop is less
width is 15_, the 2nd tooth falling edge after the wide than 58 tooth spaces.
tooth space (15_) as the ECU reference position.
Signal Failure: The crankshaft rotates one
ECU calculates the engine speed and senses the
circle, and ECU doesn't receive reference
crankshaft position according to 58 X signal of
points.
crankshaft position sensor and the signal of reference
point.If the following occurs, DTC P0335 may be set Unreasonable Failure: The reference point
up. signal loses frequently.

－ Max. Failure: Too more frequent correction Action taken when the DTC sets.
to one more tooth space The corresponding DTC, and the relative failure
－ Min. Failure: Too more frequent correction information enter the DTC memory.
to one less tooth space After 2 seconds when the diagnostic test has
－ Signal Failure: The crankshaft rotates one run and failed, the trouble is identified by ECU
immediately.At this time ECU illuminates the
circle, and ECU doesn't find reference
Malfunction Indicator Lamp (MIL).
points.
－ Unreasonable Failure: The reference point Conditions for clearing the MIL/DTC
signal loses frequently. The MIL will be turned off after the third
consecutive drive cycle that the diagnostic test
Conditions for Running the DTC passes without a fault.
Max., Min. Failure
After 20 consecutive warm-up cycles without a
－ Vehicle speed>25 km/h; or when DTC fault, the DTC is cleared off immediately.
P0500 is set, Vehicle speed<1 km/h; or the The DTC can be cleared off with a scan tool.
engine speed >850 rev/min.
Unreasonable failure
Diagnostic Aids
 6-86 Engine Controls Engine

DTC P0335 may be caused due to the reason that A poor connection with terminals - inspect the
the secondary parts leak high voltage to the ignition harness connector if a failure of Backed-out
module.Check the following: terminals, mismatching, damaged locking,
The harness laying is incorrect, and near to the improper or damaged shape, and a connection
secondary ignition parts. failure with the wires.Use appropriate matching
terminals to test if the tensile force is proper.
Electric arc is emitted from between the ignition
coils and the harness or ignition control module Harness damaged - inspect if the harness
(Inspect the ignition for cracks, carbon tracking, damagedIf there is no harness failure, move
or other damages). the connector and wires relative to the sensor,
while observing the indication shown on the
Electric arch is emitted from the secondary scan tool.Change the indication failure position
ignition coils and the wiring harness. on the scan tool.
Important: Prior to repairing the parts, remove all the If ECU and the engine grounding connection is
chips from the connector surface.Prior to diagnosing or reliable and clean.
replacing the parts, check the connector gasket.Ensure
the gasket is mounted correctly.The gasket may If the DTC is determined as intermittent failure, look
prevent the pollutant from entering. up the failure record, and it can be determined how
the DTC is set last time.
DTC P0335 Signal Failure ñ Reference Point of Crankshaft Position Sensor
Step Action Value Yes No
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

Does the engine crank? Go to 揈 ngine

crank with
difficulties,
2 － Go to Step 3 Poor Idling and
Engine Stall
Inspection
Proceduresî

1. Disconnect the crankshaft position sensor.

2. Use a DMM to measure the sensor 20°C,
3 resistance. Go to Step 4 Go to Step 7
770-950 Ω
Is it near to the specified value?

Inspect the CKP sensor harness if a short circuit

to ground, a short or open circuit or great
4 resistance to power supply, and inspect a poor － Go to Step 9 Go to Step 5
connection with CKP and ECU end pins.
Is any problem found and repaired?

Inspect if the CKP sensor signal wheel is

5 damaged, or installed improperly. Is any problem － Go to Step 6 Go to Step 7
found or repaired?

Replace CKP sensor signal wheel or re-install it.

6 Is the repair completed? － Go to Step 9 －

Replace the CKP sensor.

7 Is the replacement operation completed? － Go to Step 9 －

Replace the ECU and perform the programming.

8 Is the replacement operation completed? － Go to Step 9 －

1. Use a scan tool to clear the DTCs.

9 2. Operate the vehicle according to the DTC － Go to Step 3 System OK
operating conditions, and is the DTC re-set?
Engine Engine Controls 6-87

6.4.4.27 DTC P0443 Control Circuit trouble may be identified by ECU

immediately.At this time ECU illuminates the
Failure - Drive Level of Canister Control Malfunction Indicator Lamp (MIL).
Valve The DTC can be cleared off with a scan tool.
Description Diagnostic Aids
There are two pins connected to the canister purge Check the following:
control valve (EVAP for short). They are separately
A poor connection with ECU - Inspect if the
12V main relay supply power (EVAP Pin 1 connected
harness connector exists:
to Main Relay 87), and control end (EVAP end Pin 2
－ Backed-out terminals
connected to ECU Pin 46).
－ Improper mating
Drive level of canister purge control valve is driven by
the drive chip, which realizes the self diagnostic － Broken locks
function on drive level and can notify the CPU internal － Improperly formed or damaged terminals
failure diagnostic module of the failure information, by － Poor terminal-to-wire connection
comparing the switch signal from CPU with the actual Harness Laying Error - Inspect if the harness is
potential of drive level output end. damaged.If the harness appears normal,
Conditions for Running the DTC disconnect ECU and EVAP, turn on the ignition
switch and observe the voltmeter connected
After the engine starts normally
between the EVAP end and the ECU end of
Conditions for Setting the DTC canister solenoid control circuit, at the same
The control end is open, and the drive level is time move the connector and the harness
disconnected. relative to the canister solenoid. If the voltage
changes, it indicates that a failure exists at this
Action taken when the DTC sets. location.
The corresponding DTC, and the relative View the vehicle driving mileage since the last
failure information enter the DTC memory. diagnostic test failed in the trouble record, and
After the second consecutive drive cycle that determine the frequency of occurrence in setting the
the diagnostic test has run and failed, the DTC. It is helpful to the diagnosis of the conditions.
DTC P0443 Control Circuit Failure - Drive Level of Canister Purge Control Valve
Step Action Value Yes No
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Operate the vehicle according to the

operating conditions of DTC.
2. Connect the scan tool.
3. Use the scan tool to monitor the DTC Go to Diagnostic
2 － Go to Step 3
information. Aids
Does the scan tool indicate DTC P0443 as current
DTC?

With the scan tool, instruct the purge solenoid

valve to actuate, does the purge solenoid react to Go to Diagnostic
3 － Go to Step 4
each order? Aids

DTC P0443 Control Circuit Failure - Drive Level of Canister Purge Control Valve(Cont’
d)
Step Action Value Yes No
6-88 Engine Controls Engine

Conditions for clearing the MIL/DTC

The MIL will be turned off after the third
consecutive drive cycle that the diagnostic
test passes without a fault.
After 20 consecutive warm-up cycles without
a fault, the DTC is cleared off immediately.
1.Turn off the ignition.
2.Disconnect the canister solenoid.
3.Turn on the ignition.
4 4.Connect a test lamp between EVAP wire － Go to Step 5 Go to Step 6
plug Pin 1 and the ground.
When the battery is normal, does the test lamp
reach its normal brightness?

1. The ignition switch is turned on.

2. Use a DMM to test the voltage between the
5 ECU control circuit of canister solenoid About 3.7V Go to Step 7 Go to Step 6
harness plug Pin 2 and the ground.
Test if the voltage meets the specified value?

Test if the EVAP control circuit is open.

6 Is any failure found and repaired? － Go to Step 10 Go to Step 7

Inspect the EVAP harness if a short circuit to

ground, a short or open circuit or great resistance
7 to power supply, and inspect a poor connection － Go to Step 10 Go to Step 8
with EVAP and ECU end pins.
Is any problem found and repaired?

Replace the purge solenoid.

8 Is the replacement operation completed? － Go to Step 10 －

Replace the ECU and perform the programming.

9 Is the replacement operation completed? － Go to Step 10 －

1. Use the scan tool to clear the DTC.

2. Use the scan tool to monitor the DTC
10 information. － Go to Step 3 System OK
Is the DTC re-set?

6.4.4.28 DTC P0444 Too Low Voltage for comparing the switch signal from CPU with the actual
potential of drive level output end.
Control Circuit - Drive Level of Canister
Purge Control Valve Conditions for Running the DTC
After the engine starts normally
Description
Conditions for Setting the DTC
There are two pins connected to the canister purge
control valve (EVAP for short). They are separately The control end is short to the ground, and the
12V main relay supply power (EVAP Pin 1 connected drive level is disconnected.
to Main Relay 87), and control end (EVAP end Pin 2 Action taken when the DTC sets.
connected to ECU Pin 46).
The corresponding DTC, and the relative
Drive level of canister purge control valve is driven by failure information enter the DTC memory.
the drive chip, which realizes the self diagnostic
After the second consecutive drive cycle that
function on drive level and can notify the CPU internal
the diagnostic test has run and failed, the
failure diagnostic module of the failure information, by
trouble may be identified by ECU
Engine Engine Controls 6-89

immediately.At this time, ECU illuminates the Harness Laying Error - Inspect if the harness is
Malfunction Indicator Lamp (MIL). damaged.If the harness appears normal,
The DTC can be cleared off with a scan tool. disconnect ECU and EVAP, turn on the ignition
switch and observe the voltmeter connected
Diagnostic Aids between the EVAP end and the ECU end of
Check the following: canister solenoid control circuit, at the same
A poor connection with ECU - Inspect if the time move the connector and the harness
relative to the canister solenoid. If the voltage
harness connector exists:
changes, it indicates that a failure exists at this
－ Backed-out terminals
location.
－ Improper mating
View the vehicle driving mileage since the last
－ Broken locks
diagnostic test failed in the trouble record, and
－ Improperly formed or damaged terminals determine the frequency of occurrence in setting the
－ Poor terminal-to-wire connection DTC. It is helpful to the diagnosis of the conditions.
DTC P0444 Too Low Voltage for Control Circuit - Drive Level of Canister Purge Control
Valve
Step Action Value Yes No
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Operate the vehicle according to the

operating conditions of DTC.
2. Connect the scan tool.
3. Use the scan tool to monitor the DTC Go to Diagnostic
2 － Go to Step 3
information. Aids
Does the scan tool indicate DTC P0444 as current
DTC?

With the scan tool, instruct the purge solenoid

valve to actuate, does the purge solenoid react to Go to Diagnostic
3 － Go to Step 4
each order? Aids

DTC P0444 Too Low Voltage for Control Circuit - Drive Level of Canister Purge Control
Valve(Cont’ d)
Step Action Value Yes No
1.Turn off the ignition.
2.Disconnect the canister solenoid.
3.Turn on the ignition.
4 4.Connect a test lamp between EVAP wire － Go to Step 5 Go to Step 6
plug Pin 1 and the ground.
When the battery is normal, does the test lamp
reach its normal brightness?

1. The ignition switch is turned on.

2. Use a DMM to test the voltage between the
5 ECU control circuit of canister solenoid About 3.7V Go to Step 7 Go to Step 6
harness plug Pin 2 and the ground.
Test if the voltage meets the specified value?

Test if the EVAP control circuit is short to the

6 ground. － Go to Step 10 Go to Step 7
Is any failure found and repaired?
6-90 Engine Controls Engine

Conditions for clearing the MIL/DTC

The MIL will be turned off after the third
consecutive drive cycle that the diagnostic test
passes without a fault.
After 20 consecutive warm-up cycles without a
fault, the DTC is cleared off immediately.
Inspect the EVAP harness if a short circuit to
ground, a short or open circuit or great resistance
7 to power supply, and inspect a poor connection － Go to Step 10 Go to Step 8
with EVAP and ECU end pins.
Is any problem found and repaired?

Replace the purge solenoid.

8 Is the replacement operation completed? － Go to Step 10 －

Replace the ECU and perform the programming.

9 Is the replacement operation completed? － Go to Step 10 －

1. Use the scan tool to clear the DTC.

2. Use the scan tool to monitor the DTC
10 information. － Go to Step 3 System OK
Is the DTC re-set?

6.4.4.29 DTC P0445 Too High Voltage for trouble may be identified by ECU
immediately.At this time, ECU illuminates the
Control Circuit - Drive Level of Canister Malfunction Indicator Lamp (MIL).
Purge Control Valve The DTC can be cleared off with a scan tool.
Description Diagnostic Aids
There are two pins connected to the canister purge Check the following:
control valve (EVAP for short). They are separately
A poor connection with ECU - Inspect if the
12V main relay supply power (EVAP Pin 1 connected
harness connector exists:
to Main Relay 87), and control end (EVAP end Pin 2
－ Backed-out terminals
connected to ECU Pin 46).
－ Improper mating
Drive level of canister purge control valve is driven by
the drive chip, which realizes the self diagnostic － Broken locks
function on drive level and can notify the CPU internal － Improperly formed or damaged terminals
failure diagnostic module of the failure information, by － Poor terminal-to-wire connection
comparing the switch signal from CPU with the actual Harness Laying Error - Inspect if the harness is
potential of drive level output end. damaged.If the harness appears normal,
Conditions for Running the DTC disconnect ECU and EVAP, turn on the ignition
switch and observe the voltmeter connected
After the engine starts normally
between the EVAP end and the ECU end of
Conditions for Setting the DTC canister solenoid control circuit, at the same
The control end is short to the power supply, time move the connector and the harness
relative to the canister solenoid. If the voltage
and the drive level is connected. Action taken
changes, it indicates that a failure exists at this
when the DTC sets. location.
The corresponding DTC, and the relative View the vehicle driving mileage since the last
failure information enter the DTC memory. diagnostic test failed in the trouble record, and
After the second consecutive drive cycle that determine the frequency of occurrence in setting the
the diagnostic test has run and failed, the DTC. It is helpful to the diagnosis of the conditions.
DTC P0445 Too High Voltage for Control Circuit - Drive Level of Canister Purge Control
Engine Engine Controls 6-91

Valve
Step Action Value Yes No
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Operate the vehicle according to the

operating conditions of DTC.
2. Connect the scan tool.
3. Use the scan tool to monitor the DTC Go to Diagnostic
2 － Go to Step 3
information. Aids
Does the scan tool indicate DTC P0445 as current
DTC?

With the scan tool, instruct the purge solenoid

valve to actuate, does the purge solenoid react to Go to Diagnostic
3 － Go to Step 4
each order? Aids

DTC P0445 Too High Voltage for Control Circuit - Drive Level of Canister Purge Control
Valve(Cont’ d)
Step Action Value Yes No
1. Turn off the ignition.
2. Disconnect the canister solenoid.
3. Turn on the ignition.
4 4. Connect a test lamp between EVAP wire － Go to Step 5 Go to Step 6
plug Pin 1 and the ground.
When the battery is normal, does the test lamp
reach its normal brightness?

1. The ignition switch is turned on.

2. Use a DMM to test the voltage between the
5 ECU control circuit of canister solenoid About 3.7V Go to Step 7 Go to Step 6
harness plug Pin 2 and the ground.
Test if the voltage meets the specified value?

Test if the EVAP control circuit is short to the

6 electricity － Go to Step 10 Go to Step 7
Is any failure found and repaired?

Inspect the EVAP harness if a short circuit to

ground, a short or open circuit or great resistance
7 to power supply, and inspect a poor connection － Go to Step 10 Go to Step 8
with EVAP and ECU end pins.
Is any problem found and repaired?

Replace the purge solenoid.

8 Is the replacement operation completed? － Go to Step 10 －

Replace the ECU and perform the programming.

9 Is the replacement operation completed? － Go to Step 10 －

1. Use the scan tool to clear the DTC.

2. Use the scan tool to monitor the DTC
10 information. － Go to Step 3 System OK
Is the DTC re-set?
 6-92 Engine Controls Engine

6.4.4.30 DTC P0480 Control Circuit Action taken when the DTC sets.
Failure - Cooling Fan Relay of A/C The corresponding DTC, and the relative failure
information enter the DTC memory.
Condenser
After the second consecutive drive cycle that the
Description diagnostic test has run and failed, the trouble
There are three pins connected to the A/C cooling fan may be identified by ECU immediately.At this
relay. They are 12V power supply end (Relay end pin time, ECU illuminates the Malfunction Indicator
30 connected to Fuse F20), main relay power supply Lamp (MIL).
(Relay end pin 85 connected to main relay 87), control Conditions for clearing the MIL/DTC
end (Relay end pin 86 connected to ECU Pin 50).
The MIL will be turned off after the third
For the control signal end ECU Pin 50 of A/C cooling consecutive drive cycle that the diagnostic test
fan relay, the low potential is valid.For the A/C cooling passes without a fault.
fan relay, CJ920 acts as the drive chip.Drive chips
After 20 consecutive warm-up cycles without a
realize the self diagnostic function on drive level and
can notify the Internal CPU failure diagnostic module fault, the DTC is cleared off immediately.
of the failure information, by comparing the switch The DTC can be cleared off with a scan tool.
signal from CPU with the actual potential of drive level
Diagnostic Aids
output end.The failure types that can be diagnosed
are: Check the following:

－ Max. failure: a short circuit of Pin to Power A poor connection with ECU - Inspect the
following for the harness connector:
when the drive level is switched on.
－ Backed-out terminals
－ Min. failure: a short circuit of Pin to Ground
－ Improper mating
when the drive level is disconnected.
－ Broken locks
－ Signal failure: an open or broken circuit of
－ Improperly formed or damaged terminals
Pin when the drive level is disconnected.
－ Poor terminal-to-wire connection
The DTC of the above three troubles is P0480.
Harness Laying Error - Inspect if the harness is
Conditions for Running the DTC damaged.If the harness appears normal,
After the engine starts normally disconnect ECU, turn on the ignition switch,
and observe the ECU harness voltmeter
Conditions for Setting the DTC
connected between the drive circuit of fan relay
Max. Failure: and the ground, at the same time move the fan
The control end pin is short to the power relay connector and the wiring harness.The
supply, and the drive level is connected. changed voltage indicates the place where
Min. Failure: failure occurs.
The control end is short to the ground, and the View the mileage in the frozen malfunction status/
drive level is disconnected. malfunction record which failed in the last diagnosis.It
Signal Failure: is helpful to determine the frequency formed by the
The control end is open, and the drive level is setting conditions of DTC.
disconnected.
DTC P0480 Control Circuit Failure - Cooling Fan Relay of A/C Condenser
Step Action Value Yes No
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Close the engine, turn on the ignition.

2. With the scan tool, instruct the electric fan
relay to switch on and off. Go to Diagnostic
2 － Go to Step 3
Does the relay execute each Switch On and Aids
Switch Off order?
 Engine Engine Controls 6-93

DTC P0480 Control Circuit Failure - Cooling Fan Relay of A/C Condenser(Cont’
d)
Step Action Value Yes No
1. Turn off the ignition.
2. Disconnect the relay, turn on the ignition,
and do not start the engine.
3 3. Use the test light with good grounding to test － Go to Step 4 Go to Step 5
the power supply end of the relay.
Does the test light illuminate?

1. Connect a test lamp between the relay

control circuit and the power supply end of
relay.
4 2. With the scan tool, instruct the relay to － Go to Step 6 Go to Step 5
switch on and off.
Does each order allow the test lamp to turn on
and off?

Check the relay circuit if a short, an open circuit, a

great resistance in the harness, or a poor
5 connection with ECU end or relay end pin. － Go to Step 8 Go to Step 7
Is any failure found and repaired?

Replace the relay.

6 Is the replacement operation completed? － Go to Step 8 －

Replace the ECU and perform the programming.

7 Is the replacement operation completed? － Go to Step 8 －

1. Clear off the DTC.

2. Operate the vehicle according to the DTC
operating conditions, and use a scan tool to
8 monitor the failure information. － Go to Step 3 System OK
Does the scan tool indicate DTC P0480 as current
DTC?

6.4.4.31 DTC P0500 Unreasonable － The vehicle gear is applied (AT: D Gear or R
Gear) and the engine is at operating conditions,
Failure - Speed Signal
namely the cylinder charging efficiency>50%
Description and the engine RPM>4000 rev/min. The vehicle
speed<5 km/h
The speed sensor is Hall sensor, with ECU Pin 59 as
speed sensor signal end. ECU converts the frequency Action taken when the DTC sets.
signal produced by the speed sensor to speed The corresponding DTC, and the relative failure
signal.If the engine is at a certain load and some information enter the DTC memory.
rotation speed, and the vehicle speed is too low, DTC
P0500 will be set. After the second consecutive drive cycle that
the diagnostic test has run and failed, the
Conditions for Running the DTC trouble may be identified by ECU
Engine Coolant Temperature>65°C immediately.At this time, ECU illuminates the
Malfunction Indicator Lamp (MIL).
Conditions for Setting the DTC
If any of the following two conditions happens, the
Conditions for clearing the MIL/DTC
speed sensor may be determined as fault. The MIL will be turned off after the third
consecutive drive cycle that the diagnostic test
－ The vehicle is skidding at oil break, namely 2000
passes without a fault.
rev/min.<Engine RPM<4000 rev/min, and the
vehicle speed<20 km/h After 20 consecutive warm-up cycles without a
fault, the DTC is cleared off immediately.
 6-94 Engine Controls Engine

The DTC can be cleared off with a scan tool.

DTC P0500 Signal Error - Vehicle Speed Sensor
Step Action Value Yes No
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Operate the vehicle according to the

operating conditions of DTC.
2. Connect the scan tool.
3. Use the scan tool to monitor the DTC Go to Diagnostic
2 － Go to Step 3
information. Aids
Does the scan tool indicate DTC P0500 as current
DTC?

1. Turn off the ignition.

2. Disconnect VSS.
3. Switch on the ignition, and do not start the
3 engine. － Go to Step 4 Go to Step 5
4. Use the test light to check the VSS supply
circuit.
Does the test lamp illuminate?

Use the test lamp to inspect the VSS grounding

4 circuit, does the test lamp illuminate? － Go to Step 6 Go to Step 5

Inspect the VSS harness if a short or open circuit,

or a great resistance to the power supply.
5 Inspect a poor connection with the VSS terminal － Go to Step 11 Go to Step 6
and ECU terminal pins, is the trouble found and
repaired?

DTC P0500 Signal Error - Vehicle Speed Sensor(Cont’

d)
Step Action Value Yes No
1. Remove the VSS, and connect to the
harness connector.
2. Use a DMM to test the voltage of the VSS
harness connector Pin 1 to the ground.
6 When the VSS is near to the iron, its － Go to Step 7 Go to Step 9
voltage should be 0V.
When the VSS is far away from the iron,
its voltage should be 0V.
Measure if the voltage meets the above voltage?

Inspect if the signal wheel of vehicle speed sensor

7 is damaged, or installed improperly. Is any － Go to Step 8 Go to Step 9
problem found or repaired?

Replace or re-install the signal wheel.

8 Is the replacement operation completed? － Go to Step 11 －

Replace the VSS.

9 Is the replacement operation completed? － Go to Step 11 －

Replace the ECU, and perform the programming.

10 Is the replacement operation completed? － Go to Step 11 －
 Engine

Engine Controls 6-95

1. Use a scan tool to clear the DTCs.
2. Operate the vehicle according to the
11 operating conditions of DTC. － Go to Step 3 System OK
Is the DTC re-set?
 6-96 Engine Controls Engine

6.4.4.32 DTC P0506 Idle Speed Lower Action taken when the DTC sets.
Than Desired Idle Value The corresponding DTC, and the relative failure
information enter the DTC memory.
Description After the second consecutive drive cycle that
The main task of idle control is: Frequently correct the the diagnostic test has run and failed, the
output torque transferred by the engine to the clutch trouble may be identified by ECU
to get the steady idling.When the accelerator is at idle immediately.At this time, ECU illuminates the
position and the idle control is set up, always make Malfunction Indicator Lamp (MIL).
corrections. The correction indicates the increased or
reduced torque adjustment at some time to ensure Conditions for clearing the MIL/DTC
the idle speed is consistent with the desired idle The MIL will be turned off after the third
value.And this part of torque adjustment is realized by consecutive drive cycle that the diagnostic test
adjusting the position of idle actuator (Step Motor) passes without a fault.
motor pivot, and accordingly adjusting the air amount After 20 consecutive warm-up cycles without a
bypassed by the step motor. fault, the DTC is cleared off immediately.
Suppose the correction has reached the limit value, The DTC can be cleared off with a scan tool.
but the idle speed is quite different from the desired
idle value. At this time a failure may likely occur to the Diagnostic Aids
idle actuator (step motor), and thus influence the idle Check the following:
control results.Therefore, the diagnostic module takes A poor connection with ECU or idle air control
the correction of idle control and the engine speed as valve - inspect the harness connector:
the main monitoring object, and make judgements on
－ Backed-out terminals
the failures.Then the following can be diagnosed:
－ Improper mating
－ Min. Failure: The idle speed is greatly lower
－ Broken locks
than the desired idle value, and meanwhile
the correction has reached the highest limit － Improperly formed or damaged terminals
value. － Poor terminal-to-wire connection
If the harness is damaged - inspect if the
Conditions for Running the DTC harness is damaged
The vehicle is below the altitude of 4000m.
Is the air intake system blocked up - inspect if
The engine runs and is at idle operation. the air inlet pipe is dented, the air filter element
Engine Coolant Temperature>80°C is choked up or the foreign material clogs up the
air intake system.
Intake Air Temperature>20°C
Throttle Body - inspect if the idle air control
No failure with the canister purge control valve
channel or the throttle is blocked up, if the idle
and its drive level, No failure record on
air control channel, the throttle or the valve flap
revolution sensor, vehicle speed sensor, intake
is over deposited.
temperature sensor, water temperature sensor,
and idle control. A great deal of vacuum leakage - inspect the
causes why a great deal of vacuum leakage
Conditions for Setting the DTC occurs, such as improper installation of or a
The desired idle value is 150 rev/min greater failure with the positive crankcase ventilation
than the idle speed. valve, or disconnection with the brake booster
And the correction reaches the limit value. hose.
The cylinder charging efficiency<70%, If the DTC cannot be recreated and determined as
namely remove the failure caused by the intermittent symptom, viewing the failure record is
increasing of resistance torque due to helpful to determine the time when the DTC is set
personal factors. No failure with intake air finally.Also see Testing for Intermittent Conditions and
pressure sensor Poor Connections in the Wiring System.

DTC P0506 Idle Speed Lower Than Desired Idle Value

ep Action Value Yes No
 Engine Engine Controls 6-
97
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Connect the scan tool.

2. Use the scan tool to monitor the DTC Go to Other DTC
2 information. － Go to Step 4
Diagnostic Table.
Does any other DTC exist?

1. Start the engine.

2. Close all of the accessories.
3. With the scan tool, instruct the revolution to
rise to 1500rpm, fall down to 650rpm, then
Go to Diagnostic
3 rise to 1500rpm again, while monitoring the ± 50 rpm Go to Step 4
Aids
engine speed on the scan tool. And under
each instructed revolution, does the engine
speed maintain the desired idle value as
specified?

1. Disconnect the idle motor.

2. Install J370327-A idle motor analyzer onto
the control harness connector of idle motor.
3. Start the engine, instruct the revolution to
4 rise to 1500rpm, fall down to 650rpm, and － Go to Step 6 Go to Step 5
rise to 1500rpm again with the scan tool,
while observing the node lamps. Do all the
node lamps switch over circularly between
red and green (never go out)?

1. Test the following circuits if an open circuit, if

a short to the power supply or the ground.
Low voltage circuit of Idle Regulator Coil
1.
High voltage circuit of Idle Regulator Coil
1.
Low voltage circuit of Idle Regulator Coil
5 2. － Go to Step 11 Go to Step 9
High voltage circuit of Idle Regulator Coil
2.
2. A poor connection with the harness
connector of idle motor and with the ECU
harness connector.
When any failure is found, repair it if needed. Is
the failure removed?

Inspect the idle regulator connector for loose or a

6 poor connection. － Go to Step 11 Go to Step 7
Is any failure found and removed?

DTC P0506 Idle Speed Lower Than Desired Idle Value(Cont’ d)

Step Action Value Yes No
 6-98 Engine Controls Engine

Inspect the following with your eyes/apparently.

Throttle Body Movement - twisting with
the check screw of the throttle retaining
bar Air intake system is blocked up -
inspect if the air inlet pipe is dented, the
air filter element is dirt or the foreign
7 － Go to Step 11 Go to Step 8
material clogs up the air intake system.
Remove the idle motor.
Inspect if the idle motor is too dirt, and the
throttle is too dirt.
Do the above conditions need repairing?

Replace the idle motor.

8 Are the replacement procedures completed? － Go to Step 11 －

Inspect the ECU connector for loose or a poor

9 connection. － Go to Step 11 Go to Step 10
Is any failure found and removed?

Replace the ECU and perform the programming.

10 Is the replacement operation completed? － Go to Step 11 －

1. When necessary, re-install and connect the

parts.
2. Start the engine.
3. Close all of the accessories.
4. With the scan tool, instruct the revolution to
11 rise to 1500rpm, fall down to 650rpm, rise to ± 50 rpm Go to Step 11 Go to Step 3
1500rpm again, while monitoring the engine
revolution on the scan tool.
Under each revolution order, does the engine
RPM maintain within the desired idle value range
as specified?

1. Use the scan tool to clear the DTC.

2. Use the scan tool to monitor the code
12 information. － Go to Step 3 System OK
Is the diagnostic code re-set?

6.4.4.33 DTC P0507 Idle Speed Greater control results.Therefore, the diagnostic module takes
the correction of idle control and the engine speed as
Than Desired Idle Value the main monitoring object, and make judgements on
Description the failures.Then the following can be diagnosed:

The main task of idle control is: Frequently correct the － Max. Failure: The actual RPM is greatly
output torque transferred by the engine to the clutch higher than the desired RPM, and
to get the steady idling.When the accelerator is at idle meanwhile the correction has reached the
position and the idle control is set up, always make lowest limit value.
corrections. The correction indicates the increased or Conditions for Running the DTC
reduced torque adjustment at some time to ensure
the actual RPM is consistent with the desired The vehicle is below the altitude of 4000m.
RPM.And this part of torque adjustment is realized by The engine runs and is at idle operation.
adjusting the position of idle actuator (Step Motor) Engine Coolant Temperature>80°C
motor pivot, and accordingly adjusting the air amount
Intake Air Temperature>20°C
bypassed by the step motor.
No failure with the canister purge control valve
Suppose the correction has reached the limit value,
and its drive level, No failure record on
but the actual RPM is quite different from the desired
revolution sensor, vehicle speed sensor, intake
RPM. At this time a failure may likely occur to the idle
actuator (step motor), and thus influence the idle
 Engine Engine Controls 6-99

temperature sensor, water temperature sensor, Check the following:

and idle control. A poor connection with ECU or idle air control
Conditions for Setting the DTC valve - inspect the harness connector:
－ Backed-out terminals
The desired idle is less than the actual
revolution - 150 rev/min.. － Improper mating

And the correction reaches the minimum limit － Broken locks

value. － Improperly formed or damaged terminals
Non-engine braking conditions － Poor terminal-to-wire connection
Is the harness damaged - inspect if the harness
is damaged
Is the air intake system blocked up - inspect if
Action taken when the DTC sets. the air inlet pipe is dented, the air filter element
The corresponding DTC, and the relative failure is choked up or the foreign material clogs up the
information enter the DTC memory. air intake system.
After the second consecutive drive cycle that Throttle body - inspect if the idle air control
the diagnostic test has run and failed, the channel or the throttle is blocked up, the idle air
trouble may be identified by ECU control channel and the idle air control pivot is
immediately.At this time, ECU illuminates the severely deposited, the throttle hole or the
Malfunction Indicator Lamp (MIL). throttle valve flap is severely deposited.

Conditions for clearing the MIL/DTC A great deal of vacuum leakage - inspect the
conditions that causes a great deal of vacuum
The MIL will be turned off after the third leakage, such as improper installation of or a
consecutive drive cycle that the diagnostic test failure with the positive crankcase ventilation
passes without a fault. valve, or disconnection with the brake booster
After 20 consecutive warm-up cycles without a hose.
fault, the DTC is cleared off immediately. If the DTC cannot be recreated and determined as
The DTC can be cleared off with a scan tool. intermittent symptom, viewing the failure record is
helpful to determine the time when the DTC is set
Diagnostic Aids
finally.
DTC P0507 Idle Speed Higher Than Desired Idle Value
ep Action Value Yes No
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Connect the scan tool.

2. Use the scan tool to monitor the DTC Go to Other DTC
2 information. － Go to Step 4
Diagnostic Table.
Does any other DTC exist?

1. Start the engine.

2. Close all of the accessories.
3. With the scan tool, instruct the revolution to
rise to 1500rpm, fall down to 650rpm, then
Go to Diagnostic
3 rise to 1500rpm again, while monitoring the ± 50 rpm Go to Step 4
Aids
engine speed on the scan tool. And under
each instructed revolution, does the engine
speed maintain the desired idle value as
specified?
 6-100 Engine Controls Engine

1. Disconnect the idle motor.

2. Install J370327-A idle motor analyzer onto
the control harness connector of idle motor.
3. Start the engine, instruct the revolution to
4 rise to 1500rpm, fall down to 650rpm, and － Go to Step 6 Go to Step 5
rise to 1500rpm again with the scan tool.At
the same time, observe the node lamps. Do
all the node lamps switch over circularly
between red and green (never go out)?

1. Test the following circuits if an open circuit, if

a short to the power supply or the ground.
Low voltage circuit of Idle Regulator Coil
1.
High voltage circuit of Idle Regulator Coil
1.
Low voltage circuit of Idle Regulator Coil
5 2. － Go to Step 11 Go to Step 9
High voltage circuit of Idle Regulator Coil
2.
2. A poor connection with the harness
connector of idle motor and with the ECU
harness connector.
When any failure is found, repair it if needed. Is
the failure removed?

Inspect the idle regulator connector for loose or a

6 poor connection. Go to Step 11 Go to Step 7
Is any failure found and removed?

DTC P0507 Idle Speed Higher Than Desired Idle Value(Cont’ d)

Step Action Value Yes No
Inspect the following with your eyes/apparently.
Throttle Body Movement - twisting with
the check screw of the throttle retaining
bar Air intake system is blocked up -
inspect if the air inlet pipe is dented, the
air filter element is dirt or the foreign
7 － Go to Step 11 Go to Step 8
material clogs up the air intake system.
Remove the idle motor.
Inspect if the idle motor is too dirt, and the
throttle is too dirt.
Do the above conditions need repairing?

Replace the idle motor.

8 Are the replacement procedures completed? － Go to Step 11 －

Inspect the ECU connector for loose or a poor

9 connection. － Go to Step 11 Go to Step 10
Is any failure found and removed?

Replace the ECU and perform the programming.

10 Is the replacement operation completed? － Go to Step 11 －
 Engine Engine Controls 6-
101
1. When necessary, re-install and connect the
parts.
2. Start the engine.
3. Close all of the accessories.
4. With the scan tool, instruct the revolution to
11 rise to 1500rpm, fall down to 650rpm, rise to ± 50 rpm Go to Step 11 Go to Step 3
1500rpm again, while monitoring the engine
revolution on the scan tool.
Under each revolution order, does the engine
RPM maintain within the desired idle value range
as specified?

1. Use the scan tool to clear the DTC.

2. Use the scan tool to monitor the code
12 information. － Go to Step 3 System OK
Is the diagnostic code re-set?

6.4.4.34 DTC P0508 Too Low Voltage immediately.At this time,ECU illuminates the
Malfunction Indicator Lamp (MIL).
with Control Circuit - Idle Regulator
Conditions for clearing the MIL/DTC
Description The MIL will be turned off after the third
There are four pins connected to the idle regulator (IAC consecutive drive cycle that the diagnostic test
for short). They are control signal end of Coil 1 (IAC passes without a fault.
end Pin 1 connected to ECU Pin 64), control signal end
After 20 consecutive warm-up cycles without a
of Coil 1 (IAC end Pin 2 connected to ECU Pin 65),
fault, the DTC is cleared off immediately.
control signal end of Coil 2 (IAC end Pin 3 connected
to ECU Pin 66), control signal end of Coil 2 (IAC end The DTC can be cleared off with a scan tool.
Pin 4 connected to ECU Pin 67). Diagnostic Aids
The driver of two-phase step motor controls the Check the following:
angular displacement of step motor rotors by changing
the polarity of two coils.If the diagnostic module A poor connection with ECU or idle motorñ
detects a short with some pin of step motor to the Inspect if the harness connector exists:
ground, DTC P0508 will be set. － Backed-out terminals
－ Improper mating
Conditions for Running the DTC
－ Broken locks
ECU is not within the time from the turning off
－ Improperly formed or damaged terminals
of ignition switch to the ending of ECU internal
treatment. － Poor terminal-to-wire connection
And 10 V<Battery Voltage<16 V Harness damaged - inspect if the harness
damaged
And the DTC of step motor drive level is not
set yet. While moving the connector and the harness
relative to the idle motor, observe the step
Conditions for Setting the DTC indication of idle motor on the scan tool.If it
A short with one pin of step motor to the shows a change, it means a failure to the
ground Action taken when the DTC sets. location.
The corresponding DTC, and the relative If the DTC cannot be recreated and determined as
failure information enter the DTC memory. intermittent symptom, viewing the failure record is
helpful to determine the time when the DTC is set
After the second consecutive drive cycle that
finally.
the diagnostic test has run and failed, the
trouble may be identified by ECU
DTC P0508 Too Low Voltage with Control Circuit - Idle Regulator
Step Action Value Yes No
 6-102 Engine Controls Engine

Has the powertrain On Board Diagnosis (OBD) Go to Powertrain

system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Operate the vehicle according to the

operating conditions of DTC.
2. Connect the scan tool.
3. Use the scan tool to monitor the DTC Go to Diagnostic
2 － Go to Step 3
information. Aids
Does the scan tool indicate DTC P0508 as current
DTC?

DTC P0508 Too Low Voltage with Control Circuit - Idle Regulator(Cont’
d)
Step Action Value Yes No
1. Start the engine.
2. Close all of the accessories.
3. With the scan tool, instruct the revolution to
rise to 1500rpm, fall down to 650rpm, then
rise to 1500rpm again, while monitoring the Go to Diagnostic
3 ± 50 rpm Go to Step 4
engine revolution on the scan tool. Aids
Under each revolution order, does the engine
RPM maintain within the desired idle value range
as specified?

1. Disconnect the idle motor.

2. Install J370327-A idle motor analyzer onto
the control harness connector of idle motor.
3. Start the engine, instruct the revolution to
4 rise to 1500rpm, fall down to 650rpm, and － Go to Step 9 Go to Step 5
rise to 1500rpm again with the scan tool.
At the same time, observe the node lamps. Do all
the node lamps switch over circularly between red
and green (never go out)?

A poor connection with the idle control harness

connector and with the ECU harness connector.If
5 any failure occurs, it needs repairing. － Go to Step 9 Go to Step 6
Is the failure removed?
 Engine Engine Controls
6-103
1. Inspect the following circuit for a short to the
ground
Low voltage circuit of Idle Regulator Coil
1
High voltage circuit of Idle Regulator Coil
1
6 Low voltage circuit of Idle Regulator Coil － Go to Step 9 Go to Step 7
2
High voltage circuit of Idle Regulator Coil
2
2. When any failure occurs, make a repair if
needed.
Is the failure removed?

7 Replace the idle regulator, is the failure removed? － Go to Step 9 Go to Step 8

Replace the ECU and perform the programming.

8 Is the replacement operation completed? － Go to Step 9 －

1. Use the scan tool to clear the DTC.

2. Use the scan tool to monitor the DTC
9 information. － Go to Step 3 System OK
Is the DTC re-set?

6.4.4.35 DTC P0509 Too High Voltage A short with one pin of step motor to the power
supply
with Control Circuit - Idle Regulator
Action taken when the DTC sets.
Description The corresponding DTC, and the relative
There are four pins connected to the idle regulator (IAC failure information enter the DTC memory.
for short). They are control signal end of Coil 1 (IAC
After the second consecutive drive cycle that
end Pin 1 connected to ECU Pin 64), control signal end
the diagnostic test has run and failed, the
of Coil 1 (IAC end Pin 2 connected to ECU Pin 65),
trouble may be identified by ECU
control signal end of Coil 2 (IAC end Pin 3 connected
immediately.At this time,ECU illuminates the
to ECU Pin 66), control signal end of Coil 2 (IAC end
Malfunction Indicator Lamp (MIL).
Pin 4 connected to ECU Pin 67).
The driver of two-phase step motor controls the Conditions for clearing the MIL/DTC
angular displacement of step motor rotors by changing The MIL will be turned off after the third
the polarity of two coils.If the diagnostic module consecutive drive cycle that the diagnostic test
detects a short with some pin of step motor to the passes without a fault.
power supply, DTC P0509 will be set. After 20 consecutive warm-up cycles without a
Conditions for Running the DTC fault, the DTC is cleared off immediately.
ECU is not within the time from the turning off The DTC can be cleared off with a scan tool.
of ignition switch to the ending of ECU internal Diagnostic Aids
treatment.
Check the following:
And 10 V<Battery Voltage<16 V
A poor connection with ECU or idle motor -
And the DTC of step motor drive level is not Inspect if the harness connector exists:
set yet.
－ Backed-out terminals
Conditions for Setting the DTC － Improper mating
 6-104 Engine Controls Engine

－ Broken locks indication of idle motor on the scan tool.If it

－ Improperly formed or damaged terminals shows a change, it means a failure to the
location.
－ Poor terminal-to-wire connection
Harness damaged - inspect if the harness If the DTC cannot be recreated and determined as
damaged intermittent symptom, viewing the failure record is
helpful to determine the time when the DTC is set
While moving the connector and the harness finally.
relative to the idle motor, observe the step
DTC P0509 Too High Voltage with Control Circuit - Idle Regulator
Step Action Value Yes No
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Operate the vehicle according to the

operating conditions of DTC.
2. Connect the scan tool.
3. Use the scan tool to monitor the DTC Go to Diagnostic
2 － Go to Step 3
information. Aids
Does the scan tool indicate DTC P0509 as current
DTC?

DTC P0509 Too High Voltage with Control Circuit - Idle Regulator(Cont’
d)
Step Action Value Yes No
1. Start the engine.
2. Close all of the accessories.
3. With the scan tool, instruct the revolution to
rise to 1500rpm, fall down to 650rpm, then
Go to Diagnostic
3 rise to 1500rpm again, while monitoring the ± 50 rpm Go to Step 4
Aids
engine speed on the scan tool. And under
each instructed revolution, does the engine
speed maintain the desired idle value as
specified?

1. Disconnect the idle motor.

2. Install J370327-A idle motor analyzer onto
the control harness connector of idle motor.
3. Start the engine, instruct the revolution to
4 rise to 1500rpm, fall down to 650rpm, and － Go to Step 9 Go to Step 5
rise to 1500rpm again with the scan tool,
while observing the node lamps. Do all the
node lamps switch over circularly from red to
green (never go out)?

A poor connection with the idle control harness

connector and with the ECU harness connector.If
5 any failure occurs, it needs repairing. － Go to Step 9 Go to Step 6
Is the failure removed?
 Engine Engine Controls
6-105
1. Inspect the following circuit for a short to the
power supply
Low voltage circuit of Idle Regulator Coil
1
High voltage circuit of Idle Regulator Coil
1
6 Low voltage circuit of Idle Regulator Coil － Go to Step 9 Go to Step 7
2
High voltage circuit of Idle Regulator Coil
2
2. When any failure is found, repair it if needed.
Is the failure removed?

7 Replace the idle regulator, is the failure removed? － Go to Step 9 Go to Step 8

Replace the ECU and perform the programming.

8 Is the replacement operation completed? － Go to Step 9 －

1. Use the scan tool to clear the DTC.

2. Use the scan tool to monitor the DTC
9 information. － Go to Step 3 System OK
Is the DTC re-set?

6.4.4.36 DTC P0511 Control Circuit Signal Failure: An open to one pin of step
motor
Failure - Idle Regulator
Or Unreasonable Failure: More than one
Description failure type may exist at a time, such as a
There are four pins connected to the idle regulator (IAC short with one pin, and an open to the other
for short). They are control signal end of Coil 1 (IAC pin.
end Pin 1 connected to ECU Pin 64), control signal end Action taken when the DTC sets.
of Coil 1 (IAC end Pin 2 connected to ECU Pin 65),
The corresponding DTC, and the relative failure
control signal end of Coil 2 (IAC end Pin 3 connected
information enter the DTC memory.
to ECU Pin 66), control signal end of Coil 2 (IAC end
Pin 4 connected to ECU Pin 67). Conditions for clearing the MIL/DTC
The driver of two-phase step motor controls the The MIL will be turned off after the third
angular displacement of step motor rotors by consecutive drive cycle that the diagnostic test
changing the polarity of two coils.If the diagnostic passes without a fault.
module detects an open circuit to some pin of step After 20 consecutive warm-up cycles without a
motor, or no less than one failure type exists, or if a fault, the DTC is cleared off immediately.
short with some pin to the power supply, and a open
to the other pin, DTC P0511 will be set. The DTC can be cleared off with a scan tool.

Conditions for Running the DTC Diagnostic Aids

ECU is not within the time from the turning off Check the following:
of ignition switch to the ending of ECU internal A poor connection with ECU or idle motor -
treatment. Inspect if the harness connector exists:
And 10 V<Battery Voltage<16 V － Backed-out terminals
－ Improper mating
And the DTC of step motor drive level is not
set yet. － Broken locks
－ Improperly formed or damaged terminals
Conditions for Setting the DTC
 6-106 Engine Controls Engine

－ Poor terminal-to-wire connection shows a change, it means a failure to the

Harness damaged - inspect if the harness location.
damaged If the DTC cannot be recreated and determined as
While moving the connector and the harness intermittent symptom, viewing the failure record is
relative to the idle motor, observe the step helpful to determine the time when the DTC is set
indication of idle motor on the scan tool.If it finally.
DTC P0511 Control Circuit Failure - Idle Regulator
Step Action Value Yes No
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Operate the vehicle according to the

operating conditions of DTC.
2. Connect the scan tool.
3. Use the scan tool to monitor the DTC Go to Diagnostic
2 － Go to Step 3
information. Aids
Does the scan tool indicate DTC P0511 as current
DTC?

DTC P0511 Control Circuit Failure - Idle Regulator(Cont’

d)
Step Action Value Yes No
1. Start the engine.
2. Close all of the accessories.
3. With the scan tool, instruct the revolution to
rise to 1500rpm, fall down to 650rpm, then
Go to Diagnostic
3 rise to 1500rpm again, while monitoring the ± 50 rpm Go to Step 4
Aids
engine speed on the scan tool. And under
each instructed revolution, does the engine
speed maintain the desired idle value as
specified?

1. Disconnect the idle motor.

2. Install J370327-A idle motor analyzer onto
the control harness connector of idle motor.
3. Start the engine, instruct the revolution to
4 rise to 1500rpm, fall down to 650rpm, and － Go to Step 9 Go to Step 5
rise to 1500rpm again with the scan tool,
while observing the node lamps. Do all the
node lamps switch over circularly from red to
green (never go out)?

1. A poor connection with the idle control

harness connector and with the ECU
5 harness connector. － Go to Step 9 Go to Step 6
2. If any failure occurs, it needs repairing. Is the
failure removed?
 Engine

Engine Controls 6-107

1. Inspect the following circuit for a short or an
open to the power supply.
Low voltage circuit of Idle Regulator Coil
1
High voltage circuit of Idle Regulator Coil
1
6 Low voltage circuit of Idle Regulator Coil － Go to Step 9 Go to Step 7
2
High voltage circuit of Idle Regulator Coil
2
2. When any failure is found, repair it if needed.
Is the failure removed?

7 Replace the idle regulator, is the failure removed? － Go to Step 9 Go to Step 8

Replace the ECU and perform the programming.

8 Is the replacement operation completed? － Go to Step 9 －

1. Use the scan tool to clear the DTC.

9 2. Use the scan tool to monitor the DTC － Go to Step 3 System OK
information. Is the DTC re-set?
 6-108 Engine Controls Engine

ECU doesn't illuminate the Malfunction Indicator

Lamp (MIL).
Conditions for clearing the MIL/DTC
After 20 consecutive warm-up cycles without a
fault, the DTC is cleared off immediately.
The DTC can be cleared off with a scan tool.
6.4.4.37 DTC P0560 System Voltage Sampling Value of System Voltage<2.5 V
Signal is Unreasonable Action taken when the DTC sets.
The corresponding DTC, and the relative failure
Description information enter the DTC memory.
The nominal value of system voltage is 12V, but under Diagnostic Aids
the normal conditions, the actual voltage value may
Check the following:
change between 9-16V.ECU makes a sampling to the
system voltage (ECU Pin 63, 44, 45) after the voltage A poor connection with or a damage to the harness -
passes through the main relay, and do the monitoring inspect if the harness is damaged. If the harness
and the diagnosing based on the sampling results.If the appears normal, observe the system voltage shown
sampling value is lower than an impossible value on the scan tool, at the same time move the
(lower than 2.5V), it can be considered that the connectors and the harness relative to ECU,
sampling circuit of system voltage has a failure, and Instrument Harness and Engine Harness.If it shows a
thus causes ECU to get an unreasonable system change, it means a failure to the location.
voltage signal, then DTC P0560 will be set. If the DTC cannot be recreated, view the vehicle driving
Conditions for Running the DTC mileage since the last diagnostic test failed in the
trouble record, and determine the frequency of
The engine runs
occurrence in setting the DTC. It is helpful to the
Conditions for Setting the DTC diagnosis of the conditions.
DTC P0560 System Voltage Signal is Unreasonable
Step Action Value Yes No
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Operate the vehicle according to the

operating conditions of DTC.
2. Connect the scan tool.
3. Use the scan tool to monitor the DTC Go to Diagnostic
2 － Go to Step 3
information. Aids
Does the scan tool indicate DTC P0560 as current
DTC?

1. Start the engine, allowing the revolution

greater than 1000RPM.
Go to DTC P0562
3 2. Use a DMM to test the charging voltage of 9-16 V Go to Step 4 Diagnostic
the engine. Procedures
Is the voltage within the specified value range?
 Engine

Engine Controls 6-109

1. Close the engine, and disconnect the
negative of the battery.
2. Disconnect ECU connectors.
3. Connect the battery negative cable.
4 4. Turn on the ignition. － Go to Step 7 Go to Step 5
5. Connect the test light between the harness
terminal Pin 44, Pin 63 and Pin 45 of ECU
and the ground.
Does the test light reach the normal brightness?

DTC P0560 System Voltage Signal is Unreasonable(Cont’

d)
Step Action Value Yes No
Inspect an open or a short to the circuit between
the battery and the harness terminal Pin 44, Pin
5 63 and Pin 45 of ECU, and check the harness － Go to Step 7 Go to Step 6
resistance, a poor connection with ECU end pin.
Is any failure found and repaired?

Replace the ECU and perform the programming.

6 Is the replacement operation completed? － Go to Step 7 －

1. Use the scan tool to clear the DTC.

2. Start and run the engine.
7 3. Use the scan tool to monitor the DTC － Go to Step 3 System OK
information.
Is the DTC re-set?
 6-110 Engine Controls Engine

ECU doesn't illuminate the Malfunction Indicator

Lamp (MIL).
Conditions for clearing the MIL/DTC
After 20 consecutive warm-up cycles without a
fault, the DTC is cleared off immediately.
The DTC can be cleared off with a scan tool.
6.4.4.38 DTC P0562 System Voltage is The corresponding DTC, and the relative failure
information enter the DTC memory.
Too Low
Diagnostic Aids
Description Check the following:
The nominal value of system voltage is 12V, but
A poor connection with or a damage to the harness ñ
under the normal conditions, the actual voltage value inspect if the harness is damaged. If the harness
may change between 9-16V.ECU makes a sampling appears normal, observe the system voltage shown
to the system voltage (ECU Pin 63, 44, 45) after the
on the scan tool, at the same time move the
voltage passes through the main relay, and do the connectors and the harness relative to ECU,
monitoring and the diagnosing based on the sampling
Instrument Harness and Engine Harness.If it shows a
results.If the system voltage is lower than one valve
change, it means a failure to the location.
value (10 V), DTC P0562 will be set.
If the DTC cannot be recreated, view the vehicle driving
Conditions for Running the DTC mileage since the last diagnostic test failed in the
The engine runs trouble record, and determine the frequency of
occurrence in setting the DTC. It is helpful to the
Conditions for Setting the DTC diagnosis of the conditions.
2.5 V<Sampling Value of System Voltage<10 V
Action taken when the DTC sets.
DTC P0562 System Voltage is Too Low
Step Action Value Yes No
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Operate the vehicle according to the

operating conditions of DTC.
2. Connect the scan tool.
3. Use the scan tool to monitor the DTC Go to Diagnostic
2 － Go to Step 3
information. Aids
Does the scan tool indicate DTC P0562 as current
DTC?

1. Start the engine, allowing the revolution

greater than 1000RPM.
3 2. Use a DMM to test the charging voltage of 9-16 V Go to Step 9 Go to Step 4
the engine.
Is the voltage within the specified value range?

At different RPM of the engine, are all the

4 charging voltages within the specified values? 9-16 V Go to Step 6 Go to Step 5

Inspect an open or a short to the charging harness

from Generator to Battery, too high internal
5 resistance within the harness, a poor connection － Go to Step 9 Go to Step 7
with the generator harness connector pins. Is any
failure found and repaired?
 Engine

Engine Controls 6-111

Inspect an open or a short to the circuit between
the battery and the harness terminal Pin 44, Pin
63 and Pin 45 of ECU, and check too high
6 internal resistance within the harness, a poor － Go to Step 9 Go to Step 7
connection with ECU end pin. Is any failure found
and repaired?

7 Replace the generator. Is any failure removed? － Go to Step 9 Go to Step 8

DTC P0562 System Voltage is Too Low(Cont’

d)
Step Action Value Yes No
Replace the ECU and perform the programming.
8 Is the replacement operation completed? － Go to Step 9 －

1. Use the scan tool to clear the DTC.

2. Start and run the engine.
9 3. Use the scan tool to monitor the DTC － Go to Step 3 System OK
information.
Is the DTC re-set?
 6-112 Engine Controls Engine

ECU doesn't illuminate the Malfunction Indicator

Lamp (MIL).
Conditions for clearing the MIL/DTC
After 20 consecutive warm-up cycles without a
fault, the DTC is cleared off immediately.
The DTC can be cleared off with a scan tool.
6.4.4.39 DTC P0563 System Voltage is No failure with the vehicle speed sensor.
Too High Action taken when the DTC sets.
The corresponding DTC, and the relative failure
Description information enter the DTC memory.
The nominal value of system voltage is 12V, but Diagnostic Aids
under the normal conditions, the actual voltage value
Check the following:
may change between 9-16V.ECU makes a sampling
to the system voltage (ECU Pin 63, 44, 45) after the A poor connection with or a damage to the harness -
voltage passes through the main relay, and do the inspect if the harness is damaged. If the harness
monitoring and the diagnosing based on the sampling appears normal, observe the system voltage shown
results.If the system voltage is higher than one valve on the scan tool, at the same time move the
value (16V), DTC P0563 will be set. connectors and the harness relative to ECU,
Instrument Harness and Engine Harness.If it shows a
Conditions for Running the DTC change, it means a failure to the location.
The engine runs If the DTC cannot be recreated, view the vehicle driving
Conditions for Setting the DTC mileage since the last diagnostic test failed in the
trouble record, and determine the frequency of
Sampling Value of System Voltage>16 V
occurrence in setting the DTC. It is helpful to the
And the vehicle speed>25 km/h diagnosis of the conditions.
DTC P0563 System Voltage is Too High
Step Action Value Yes No
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Operate the vehicle according to the

conditions under which the failure occurs.
2. Connect the scan tool.
3. Use the scan tool to monitor the DTC Go to Diagnostic
2 － Go to Step 3
information. Aids
Does the scan tool indicate DTC P0563 as a
current DTC?

1. Start the engine, allowing the RPM greater

than 1000RPM.
3 2. Observe the system voltage on the scan 9-16 V Go to Step 8 Go to Step 4
tool. Is the system voltage within the
specified values?

Use a DMM to test the engine charging voltage.

4 At different RPMs of the engine, is the charging 9-16 V Go to Step 8 Go to Step 5
voltage within the specified values?

Inspect an open or a short to the circuit between

the battery and the harness terminal Pin 44, Pin
63 and Pin 45 of ECU, and check too high
5 internal resistance within the harness, a poor － Go to Step 8 Go to Step 6
connection with ECU end pin. Is any failure found
and repaired?
 Engine

Engine Controls 6-113

Replace the generator.
6 Is the failure removed? － Go to Step 8 Go to Step 7

DTC P0563 System Voltage is Too High(Cont’

d)
Step Action Value Yes No
Replace the ECU and perform the programming.
7 Is the replacement operation completed? － Go to Step 8 －

1. Use the scan tool to clear the DTC.

2. Operate the vehicle according to the
conditions under which the failure occurs.
8 3. Use the scan tool to monitor the DTC － Go to Step 3 System OK
information.
Is the DTC re-set?
6-114 Engine Controls Engine

6.4.4.40 DTC P0601 Check Code Error - The MIL will be turned off after the third
consecutive drive cycle that the diagnostic test
Electronic Control Unit passes without a fault.
Description After 20 consecutive warm-up cycles without a
There is some necessary information inside the ECU. fault, the DTC is cleared off immediately.
Originally there are some default values, but they must be The DTC can be cleared off with a scan tool.
finally re-programmed by the Assembly Facilities or ECU
Diagnostic Aids
DTC P0601 Check Code Error - Electronic Control Unit
Step Action Value Yes No
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Operate the vehicle according to the

operating conditions of DTC.
2. Connect the scan tool.
3. Use the scan tool to monitor the DTC Go to Diagnostic
2 － Go to Step 3
information. Aids
Does the scan tool indicate DTC P0601 as urrent
DTC?

1. Use the scan tool to clear the DTC.

2. Use the scan tool to monitor the DTC
3 information. － Go to Step 4 Go to Step 2
Is the DTC re-set?

Replace the ECU and perform the programming.

4 Is the replacement operation completed? － Go to Step 5 －

1. The ignition switch is turned on.

2. Use the scan tool to monitor the DTC
5 information. － Go to Step 3 System OK
Is the DTC re-set?

supplier, otherwise self-test of ECU will be considered as DTC P0601 indicates some necessary information
a failure.The diagnostic module is diagnosing on the ECU inside the ECU. Originally there are default values, but
check code programming (The information is re- they are not re-programmed by the Assembly Factory or
programmed by the ECU supplier). Conditions for ECU supplier. The only repair method is to replace
Running the DTC ECU. Correct software and nominal files must always be
used to program the replaced ECU.
The ignition switch is turned on.
Conditions for Setting the DTC
ECU check code has not been programmed Action
taken when the DTC sets.
The corresponding DTC, and the relative failure
information enter the DTC memory.
After the first driving cycle in the diagnosis test
failure reporting, the trouble may be identified by ECU
immediately.At this time, ECU illuminates the Malfunction
Indicator Lamp (MIL). Conditions for clearing the
MIL/DTC
Engine Engine Controls 6-115

6.4.4.41 DTC P0602 Check Code Error - immediately. At a time ECU illuminates the
Malfunction Indicator Lamp (MIL).
Electronic Control Unit
Conditions for clearing the MIL/DTC:

DTC P0602 Programming Error - Electronic Control Unit

Step Action Value Yes No
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Programme on the engine control

module with a correct software.
2 2. Re-test DTC P0602. Is DTC － Go to Step 3 System OK
P0602 set?

Replace the engine control module (Replacing the Go to Powertrain

engine control module needs programming). On Board
3 Is the operation completed? － Diagnosis System －
Check

Description When the diagnostic test passes without failure or

time delay, the MIL will be turned off immediately.
There is some necessary information inside the ECU.
Originally there are some default values, but they must When the diagnostic test passes without failure or
be finally re-programmed by the Assembly Facilities or time delay, the DTC will be cleared off
ECU supplier, otherwise self-test of ECU will be immediately.
considered as a failure.
Diagnose on the programming of type selection
coding (This information is re-programmed by the
Assembly Facilities).
Diagnose on the programming of diagnostic data
identification code (The information is
reprogrammed by the ECU supplier).
Diagnose on the programming of lock-up code for
locking ECU function (This information is
reprogrammed by the Assembly Facilities).
Conditions for Running the DTC:
The ignition is switched on.
Conditions for Setting the DTC:
The type selection coding has not been
programmed.
The diagnostic data identification code has not
been programmed.
The lock-up code for locking the ECU function
doesn 抰 work.
Action taken when the DTC sets.
The corresponding DTC, and the relative failure
information enter the DTC memory.
After 200 milliseconds when the diagnostic test
has run and failed, the trouble is identified by ECU
 6-116 Engine Controls Engine

6.4.4.42 DTC P0610 Control Module considered that the vehicle gear has been applied. At
this time ECU automatically considers it as Auto Gear or
(Vehicle Model) Manual Gear. When the recognized value is not
Type Selection Error consistent with the reserved internal value, DTC P0610
is set.
Conditions for Setting the DTC
Manual Gear Manual Gear
When the vehicle is running (D gear or R gear), the marking When the vehicle is running (D gear or R gear), the marking
position of driving status indicates as Auto gear, and ECU position of driving status indicates as Manual gear, and ECU
recognizes that the high potential of Pin 73 (that is Pin 73 is recognizes that the low potential of Pin 73 (that is Pin 73 is
suspended in the air) lasts 7 seconds. suspended in the air) lasts 7 seconds.

Description Conditions for Running the DTC

ECU Pin.73 is used to judge Manual Gear/Auto Gear. If A/C switch is turned off.
the pin is connected to the ground, it means ECU is And Engine Coolant Temperature>75°C
considered as Auto Gear.Otherwise, if Pin 73 is
suspended in the air, it means ECU considers it as And 6,200rev/min.>Engine Speed>2,000rev/ min.
Manual Gear.When the engine speed and its load are And Engine Relative Load>50.3%
always higher than a certain value at a time, it can be
Action taken when the DTC sets. The DTC can be cleared off with a scan tool.
The corresponding DTC, and the relative failure Diagnostic Aids
information enter the DTC memory. DTC P0610 indicates a type selection error to the
ECU doesn't illuminate the Malfunction control module ECU, and the only repair method is to
Indicator Lamp (MIL). replace the ECU which matches with the
vehicle.Always use the correct software and the
Conditions for clearing the MIL/DTC
vehicle nominal value, make a programming on the
After 20 consecutive warm-up cycles without a replaced ECU.
fault, the DTC is cleared off immediately.
DTC P0610 Type Selection Error of Control Module (Vehicle Model)
Step Action Value Yes No
Has the powertrain On Board Diagnosis system Go to Powertrain
check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Install the scan tool.

2. Operate the vehicle according to the
operating conditions of DTC.
3. Use the scan tool to monitor the DTC Go to Diagnostic
2 － Go to Step 3
information. Aids
Does the scan tool indicate DTC P0610 failed this
ignition?

Is the vehicle equipped with automatic

3 transmission? － Go to Step 4 Go to Step 5

1. Close the engine, and disconnect the battery.

2. Disconnect the ECU connectors, use a DMM
4 to test the resistance between ECU harness － Go to Step 7 Go to Step 6
Pin 73 and the ground.
Is ECU harness Pin 73 grounding well?

Test if the ECU harness Pin 73 is suspended and

5 corrected? － Go to Step 9 Go to Step 7
 Engine Engine Controls
6-117
DTC P0610 Type Selection Error of Control Module (Vehicle Model)(Cont’
d)
Step Action Value Yes No
Test an open to ECU harness Pin 73, a great
resistance in the harness, a short to the power
6 supply or a poor connection with the connectors. － Go to Step 9 Go to Step 8
Is any failure found and repaired?

Re-program the ECU.

7 Is the operation completed? － Go to Step 9 －

Replace the ECU and perform the programming.

8 Is the replacement operation completed? － Go to Step 9 －

1. Use the scan tool to clear the DTC.

2. Operate the vehicle according to the DTC
operating conditions, and use a scan tool to
9 monitor the failure information. － Go to Step 3 System OK
Does the scan tool indicate DTC P0610 as current
DTC?
6-118 Engine Controls Engine

6.4.4.43 DTC P0630 Vehicle Conditions for Setting the DTC

Indentification Number （VIN） Not VIN has not been re-programmed.

Programmed, or Mismatched - Electronic Action taken when the DTC sets.

Control Unit The corresponding DTC, and the relative failure
information enter the DTC memory.
Description After 200 milliseconds when the diagnostic test
There is some necessary information inside the ECU. has run and failed, the trouble is identified by
Originally there are some default values, but they ECU immediately. At a time ECU illuminates the
must be finally re-programmed by the Assembly Malfunction Indicator Lamp (MIL).
Facilities or ECU supplier, otherwise self-test of ECU
will be considered as a failure. This module
Conditions for clearing the MIL/DTC:
diagnoses on the programming of VIN (The When the diagnostic test passes without failure
information is programmed by the Assembly or time delay, the MIL will be turned off
Facilities). immediately.
When the diagnostic test passes without failure
Conditions for Running the DTC
or time delay, the DTC will be cleared off
The ignition is switched on. immediately.
DTC P0630 Vehicle Identification （VIN） Not Programmed, Mismatched -
Electronic
Control Unit
Step Action Value Yes No
Has the Powertrain On Board Diagnosis (OBD) Go to Powertrain
System Check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check.

Do you programme the VIN on ECU?

2 Re-test DTC P0630. － Go to Step 3 System OK
Is DTC P0630 set?

Replace the engine control module (Replacing the Go to Powertrain

engine control module needs programming). On Board
3 Is the operation completed? － Diagnosis System －
Check
 Engine Engine Controls 6-119

ECU doesn't illuminate the Malfunction Indicator

Lamp (MIL).
Conditions for clearing the MIL/DTC
After 20 consecutive warm-up cycles without a
fault, the DTC is cleared off immediately.
The DTC can be cleared off with a scan tool.
6.4.4.44 DTC P0645 Control Circuit Drive chip detects an open or broken circuit with Pin
70, and the internal ECU drive level is disconnected.
Failure - A/C Compressor Relay
Action taken when the DTC sets.
Description The corresponding DTC, and the relative failure
There are four pins connected to the A/C compressor information enter the DTC memory.
relay. They are separately 12 V common power Diagnostic Aids
supply end (Relay end Pin 30 connected to Battery),
Intermittent conditions may occur due to a poor
12 V main relay power supply (Relay end Pin 85
connection, wire insulating layer worn out or wire
connected to Main Relay 87), control signal end
damaged inside the insulating layer.
(Relay end Pin 86 connected to ECU Pin 70), power
supply end of A/C compressor electromagnetic clutch Check the following:
(Relay end Pin 87 connected to Electromagnetic A poor connection with ECU or A/C compressor
Clutch Pin A). relay - inspect the harness connector:
For the control signal end of the A/C compressor relay, － Backed-out terminals
the low potential is valid.A/C compressor relay is driven － Improper mating
by the drive chip, which realizes the self diagnostic － Broken locks
function on the internal circuit and can notify the
－ Improperly formed or damaged terminals
Internal CPU failure diagnostic module of the failure
information, by comparing the switch signal from CPU － Poor terminal-to-wire connection
with the actual potential of ECU-level output end. Harness damaged - inspect the harness
Conditions for Running the DTC damage

After the engine starts normally View the vehicle driving mileage since the last
diagnostic test failed in the trouble record, and
Conditions for Setting the DTC determine the frequency of occurrence in setting the
DTC. It is helpful to the diagnosis of the conditions.
DTC P0645 Control Circuit Failure - A/C Compressor Relay
Step Action Value Yes No
Has the powertrain On Board Diagnosis system Go to Powertrain
check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Install the scan tool.

2. Operate the vehicle according to the
operating conditions of DTC.
3. Use the scan tool to monitor the DTC Go to Diagnostic
2 － Go to Step 3
information. Aids
Does the scan tool indicate DTC P0645 failed this
ignition?

1. Turn off the ignition.

2. Disconnect the relay.
3. Turn on the ignition switch, and do not start
3 the engine. － Go to Step 4 Go to Step 6
4. Use the test lamp with good grounding to
test the relay power supply end.
Does the test lamp illuminate?
 6-120 Engine Controls Engine

DTC P0645 Control Circuit Failure - A/C Compressor Relay(Cont’

d)
Step Action Value Yes No
1. Connect a test lamp between the relay
control circuit and the power supply end of
relay.
4 2. With the scan tool, instruct the relay to － Go to Step 7 Go to Step 5
switch on and off.
Does each order allow the test lamp to turn on
and off?

Inspect an open to the relay control circuit.

5 Is any failure found and repaired? － Go to Step 9 Go to Step 6

Check the relay circuit if a short, an open circuit to

the ground, a great resistance in the harness, or a
6 poor connection with ECU end or relay end pin. － Go to Step 9 Go to Step 8
Is any failure found and repaired?

Replace the relay.

7 Is the replacement operation completed? － Go to Step 9 －

Replace the ECU and perform the programming.

8 Is the replacement operation completed? － Go to Step 9 －

1. Clear off the DTC.

2. Operate the vehicle according to the DTC
operating conditions, and use a scan tool to
9 monitor the failure information. － Go to Step 3 System OK
Does the scan tool indicate DTC P0645 as current
DTC?
 Engine Engine Controls 6-121

ECU doesn't illuminate the Malfunction Indicator

Lamp (MIL).
Conditions for clearing the MIL/DTC
After 20 consecutive warm-up cycles without a
fault, the DTC is cleared off immediately.
The DTC can be cleared off with a scan tool.
6.4.4.45 DTC P0646 Too Low Voltage for The control signal end is short to the ground, and the
drive level of ECU control end is disconnected.
Control Circuit - A/C Compressor Relay
Action taken when the DTC sets.
Description The corresponding DTC, and the relative failure
There are four pins connected to the A/C compressor information enter the DTC memory.
relay. They are separately 12 V common power Diagnostic Aids
supply end (Relay end Pin 30 connected to Battery),
Intermittent conditions may occur due to a poor
12 V main relay power supply (Relay end Pin 85
connection, wire insulating layer worn out or wire
connected to Main Relay 87), control signal end
damaged inside the insulating layer.
(Relay end Pin 86 connected to ECU Pin 70), power
supply end of A/C compressor electromagnetic clutch Check the following:
(Relay end Pin 87 connected to Electromagnetic A poor connection with ECU or A/C compressor
Clutch Pin A). relay ñ inspect the harness connector:
For the control signal end of the A/C compressor relay, － Backed-out terminals
the low potential is valid.A/C compressor relay is driven － Improper mating
by the drive chip, which realizes the self diagnostic － Broken locks
function on the internal circuit and can notify the
－ Improperly formed or damaged terminals
Internal CPU failure diagnostic module of the failure
information, by comparing the switch signal from CPU － Poor terminal-to-wire connection
with the actual potential of ECU-level output end. Harness damaged ñ inspect the harness
Conditions for Running the DTC damage

After the engine starts normally View the vehicle driving mileage since the last
diagnostic test failed in the trouble record, and
Conditions for Setting the DTC determine the frequency of occurrence in setting the
DTC. It is helpful to the diagnosis of the conditions.
DTC P0646 Too Low Voltage for Control Circuit - A/C Compressor Relay
Step Action Value Yes No
Has the powertrain On Board Diagnosis system Go to Powertrain
check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check
1. Install the scan tool.
2. Operate the vehicle according to the
operating conditions of DTC.
Go to Diagnostic
2 3. Use the scan tool to monitor the DTC － Go to Step 3
Aids
information.
Does the scan tool indicate DTC P0646 failed this
ignition?
1. Turn off the ignition.
2. Disconnect the relay, turn on the ignition, and
do not start the engine.
3 － Go to Step 4 Go to Step 6
3. Use the test lamp with good grounding to test
the relay power supply end.
Does the test lamp illuminate?
6-122 Engine Controls Engine

1. Connect a test lamp between the relay

control circuit and the power supply end of
relay.
4 2. With the scan tool, instruct the relay to － Go to Step 7 Go to Step 5
switch on and off.
Does each order allow the test lamp to turn on
and off?

DTC P0646 Too Low Voltage for Control Circuit - A/C Compressor Relay(Cont’
d)
Step Action Value Yes No
Inspect if the relay control circuit is short to the
5 ground. － Go to Step 9 Go to Step 6
Is any failure found and repaired?
Check the relay circuit if a short circuit to the
ground, a great resistance in the harness, or a
6 poor connection with ECU end or relay end pin. － Go to Step 9 Go to Step 8
Is any failure found and repaired?
Replace the relay.
7 Is the replacement operation completed? － Go to Step 9 －

Replace the ECU and perform the programming.

8 Is the replacement operation completed? － Go to Step 9 －

1. Clear off the DTC.

2. Operate the vehicle according to the DTC
operating conditions, and use a scan tool to
9 monitor the failure information. － Go to Step 3 System OK
Does the scan tool indicate DTC P0646 as current
DTC?
 Engine Engine Controls 6-123

ECU doesn't illuminate the Malfunction Indicator

Lamp (MIL).
Conditions for clearing the MIL/DTC
After 20 consecutive warm-up cycles without a
fault, the DTC is cleared off immediately.
The DTC can be cleared off with a scan tool.
6.4.4.46 DTC P0647 Too High Voltage for The control signal end is short to the power supply, and
the drive level of ECU control end is connected.
Control Circuit - A/C Compressor Relay
Action taken when the DTC sets.
Description The corresponding DTC, and the relative failure
There are three pins connected to the A/C information enter the DTC memory.
compressor relay. They are separately 12V common Diagnostic Aids
power supply end (Relay end Pin 30 connected to
Intermittent conditions may occur due to a poor
Battery k1.30), 12 V main relay power supply (Relay
connection, wire insulating layer worn out or wire
end Pin 85 connected to Main Relay k1.87), control
damaged inside the insulating layer.
end (Relay end Pin 86 connected to ECU Pin
70).Power supply end of A/C compressor Check the following:
electromagnetic clutch (Relay end Pin 87 connected A poor connection with ECU or A/C compressor
to Electromagnetic Pin A). relay - inspect the harness connector:
For the control signal end of the A/C compressor relay, － Backed-out terminals
the low potential is valid.A/C compressor relay is driven － Improper mating
by the drive chip, which realizes the self diagnostic － Broken locks
function on the internal circuit and can notify the
－ Improperly formed or damaged terminals
Internal CPU failure diagnostic module of the failure
information, by comparing the switch signal from CPU － Poor terminal-to-wire connection
with the actual potential of ECU output end. Harness damaged - inspect the harness
Conditions for Running the DTC damage

After the engine starts normally View the vehicle driving mileage since the last
diagnostic test failed in the trouble record, and
Conditions for Setting the DTC determine the frequency of occurrence in setting the
DTC. It is helpful to the diagnosis of the conditions.
DTC P0647 Too High Voltage for Control Circuit - A/C Compressor Relay
Step Action Value Yes No
Has the powertrain On Board Diagnosis system Go to Powertrain
check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check
1. Install the scan tool.
2. Operate the vehicle according to the
operating conditions of DTC.
Go to Diagnostic
2 3. Use the scan tool to monitor the DTC － Go to Step 3
Aids
information.
Does the scan tool indicate DTC P0647 failed this
ignition?
1. Turn off the ignition.
2. Disconnect the relay, turn on the ignition, and
do not start the engine.
3 － Go to Step 4 Go to Step 6
3. Use the test lamp with good grounding to test
the relay power supply end.
Does the test lamp illuminate?
6-124 Engine Controls Engine

1. Connect a test lamp between the relay

control circuit and the power supply end of
relay.
4 2. With the scan tool, instruct the relay to － Go to Step 7 Go to Step 5
switch on and off.
Does each order allow the test lamp to turn on
and off?

DTC P0647 Too High Voltage for Control Circuit - A/C Compressor Relay(Cont’
d)
Step Action Value Yes No
Inspect if the relay control circuit is short to the
5 power supply. － Go to Step 9 Go to Step 6
Is any failure found and repaired?
Check the relay circuit if an open circuit, a great
resistance in the harness, or a poor connection
6 with ECU end or relay end pin. － Go to Step 9 Go to Step 8
Is any failure found and repaired?
Replace the relay.
7 Is the replacement operation completed? － Go to Step 9 －

Replace the ECU and perform the programming.

8 Is the replacement operation completed? － Go to Step 9 －

1. Clear off the DTC.

2. Operate the vehicle according to the DTC
operating conditions, and use a scan tool to
9 monitor the failure information. － Go to Step 3 System OK
Does the scan tool indicate DTC P0647 as current
DTC?
 Engine Engine Controls 6-125

6.4.4.47 DTC P0650 Control Circuit Action taken when the DTC sets.
Failure - MIL The corresponding DTC, and the relative failure
information enter the DTC memory.
Description ECU doesn't illuminate the Malfunction
There are two pins connected to MIL: Ignition Switch Indicator Lamp (MIL).
Signal Input (MIL end Pin 4 connected Main Relay
15), Control Signal End (The other MIL pin connected Conditions for clearing the MIL/DTC
to ECU Pin 31). After 20 consecutive warm-up cycles without a
MIL is driven by the drive chip, which realizes the self fault, the DTC is cleared off immediately.
diagnostic function on the internal circuit and can The DTC can be cleared off with a scan tool.
notify the Internal CPU failure diagnostic module of
Diagnostic Aids
the failure information, by comparing the switch signal
from CPU with the actual potential of ECU output Check the following:
end.The failure types that can be diagnosed are: A poor connection with ECU - Inspect if the
Max. failure: a short circuit of Pin to Power harness connector exists:
when the drive level of internal control is － Backed-out terminals
switched on. － Improper mating
Min. failure: a short circuit of Pin to Ground － Broken locks
when the drive level of internal control is － Improperly formed or damaged terminals
disconnected.
－ Poor terminal-to-wire connection
Signal failure: an open or broken circuit of Pin Use the matching terminals to test the correct
when the drive level of internal control is tensile force of the terminals.
disconnected.
Is the harness damaged - inspect if the harness
The DTC of the above three troubles is P0650. is damaged. If the instrument is normal,
Conditions for Running the DTC disconnect the ECU, turn on the ignition switch,
After the engine starts normally and while moving the connectors and the
harness relative to the MIL, observe the
Conditions for Setting the DTC voltage changes on the DMM which is
Max. Failure: connected between the MIL control circuit of
The control end pin is short to the power supply, ECU harness connector and the ground. If the
and the drive level of internal control is voltage changes, it indicates a failure at this
connected. location.
Min. Failure: View the vehicle driving mileage since the last
The control end is short to the ground, and the diagnostic test failed in the trouble record, and
drive level of internal control is disconnected. determine the frequency of occurrence in setting the
Signal Failure: DTC. It is helpful to the diagnosis of the conditions.
The control end circuit is open, and the drive
level of internal control is disconnected.
DTC P0650 Control Circuit Failure - MIL
Step Action Value Yes No
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

Does any other DTC exist? Go to Diagnostic

2 － Go to Step 3 Aids

Turn on the ignition switch, and observe the

3 gauge. － Go to Step 4 Go to Step 5
Does the MIL lamp illuminate?
 6-126 Engine Controls Engine

Start the engine. Go to Diagnostic

4 Does the MIL lamp go out? － Aids Go to Step 6

DTC P0650 Control Circuit Failure - MIL(Cont’

d)
Step Action Value Yes No
1. Turn off the ignition switch.
2. Remove the instrument panel.
5 3. Inspect the MIL lamp. － Go to Step 11 Go to Step 6
Is the MIL lamp damaged and replaced?

1. Use the uncharged test lamp to connect in

series between the MIL control circuit and
the battery.
6 2. Turn on the ignition. － Go to Step 7 Go to Step 8
3. Use the scan tool to operate the MIL lamp.
Does the test lamp go out according to the order?

Inspect a poor connection with the instrument

7 plug. － Go to Step 11 Go to Step 9
Is any failure found and repaired?

Inspect the MIL circuit if a short to the power

supply, a short or an open to the ground, a poor
8 connection with ECU end or MIL end pin, a great － Go to Step 11 Go to Step 10
resistance in the harness. Is any failure found and
repaired?

Replace the instrument panel.

9 Is the replacement operation completed? － Go to Step 11 －

Replace the ECU and perform the programming.

10 Is the replacement operation completed? － Go to Step 11 －

1. Clear off the DTC.

2. Operate the vehicle according to the
DTC operating conditions, and use a scan tool
11 to monitor the failure information. Does the scan － Go to Step 3 System OK
tool indicate DTC P0650 is current?

6.4.4.48 DTC P1740 Torque Request improve the softness of gearshift. And the torque
request signal will transfer the torque adjusting
Signal - Automatic Transmission request, and finally makes it by means of ECU
Description changing to the ignition advance angle, at a certain
range of duty ratio (9-91%, according to the supplier's
The control module TCU of automatic transmission Technical Specifications). Generally, the gearshift time
transfers a torque request signal to ECU by means of will not be long, so the above torque adjusting request
the ECU (Pin 72).The torque request signal is a PWM from TCU will also be short. The torque request signal
(Pulse-Width Modulation) input with a frequency of will go back to 12V soon, and the duty ratio returns to
100HZ, and a voltage amplitude of 12V. The request 100% again. The failure types that have been
signal is converted to a certain duty ratio after the diagnosed are:
ECU received it.Under the normal conditions, the
torque request signal is stable at 12V most of the Max. Failure: The duty ratio of torque request
time, namely the duty ratio is 100% most of the signal is always at a higher status.
time.Only under some conditions, such as sudden Min. Failure: The duty ratio of torque request
vehicle acceleration or deceleration, TCU requests signal is always at a lower status.
ECU to control the engine torque output so as to
 Engine Engine Controls 6-127

Unreasonable Failure: The duty ratio of torque The corresponding DTC, and the relative failure
request signal is within the torque adjusting information enter the DTC memory.
request range, but the torque adjusting request ECU doesn't illuminate the Malfunction
will last too long. Indicator Lamp (MIL).
If any one of the above three troubles occurs, DTC
P1740 will be set.
Conditions for clearing the MIL/DTC
After 20 consecutive warm-up cycles without a
Conditions for Running the DTC fault, the DTC is cleared off immediately.
ECU has recognized the The DTC can be cleared off with a scan tool.
automatic transmission. Starting
Conditions ended. Diagnostic Aids
Conditions for Setting the DTC Check the following:
Min. Failure: A poor connection with or a harness damage to ECU
The time delay with the adjusting signal of zero end and TCU end plug - inspect the harness
exceeds 2 S. connector:
－ Backed-out terminals
Unreasonable Failure:
－ Improper mating
Within the same drive cycle, the torque request
signal has not been found, and the torque － Broken locks
adjusting request from TCU has exceeded 2.5S. － Improperly formed or damaged terminals
And this condition exceeds 3 times.
－ Poor terminal-to-wire connection
Action taken when the DTC sets. － Damaged harness

DTC P1740 Torque Request Signal - Automatic Transmission

Step Action Value Yes No
Has the powertrain On Board Diagnosis (OBD) Go to Powertrain
system check been performed? On Board
1 － Go to Step 2 Diagnosis System
Check

1. Start and run the engine.

2. Connect the scan tool.
3. Use the scan tool to monitor the DTC Go to Diagnostic
2 information. － Go to Step 3
Aids
Does the scan tool indicate DTC P1740 as current
DTC?

Use the DMM to test an open, a short circuit

between ECU Pin 72 and TCU, a great resistance
3 in the harness, a poor connection with ECU end － Go to Step 7 Go to Step 4
or TCM end pin. Is any failure found and repaired?

DTC P1740 Torque Request Signal - Automatic Transmission(Cont’ d)

Step Action Value Yes No
1. Operate the vehicle according to the
conditions under which TCU requests ECU
to control the engine torque change.
4 2. Use the oscilloscope to test the duty ratio of － Go to Step 6 Go to Step 5
torque request signal for the automatic
transmission, and see if any change occurs
to the signal duty ratio.

Replace the TCU.

5 Is the failure removed? － Go to Step 7 Go to Step 6
 6-128 Engine Controls Engine

Replace the ECU and perform the programming.

6 Is the replacement operation completed? － Go to Step 7 －

1. Use the scan tool to clear the DTC.

2. Use the scan tool to monitor the DTC
7 information. － Go to Step 3 System OK
Is the DTC re-set?
 Engine Engine Controls 6-129

6.4.4.49 Symptoms Check the vacuum hose for cracking, twisting

and proper connection according to the vehicle
Important Preliminary Inspections Before emission control information shown on the
Starting label.Perform a thorough check for any forms
of leakage or block-up.
Before using the symptom table:
Check the air intake pipe for any dent or
Perform Powertrain On Board Diagnosis (OBD)
damage.
System Check and verify all of the following
conditions: Check the installation location of the throttle
body for air leakage.
－ The engine control module and the
malfunction indicator lamp (MIL) are Check the harness for improper connection,
operating correctly. sticking, scratch or other damages.

－ There are no DTCs stored. Check the sensor/components for loss,

damage or looseness.
－ The scan tool data is within the normal
Use the following tables to diagnose the symptom
operating range.See Scan Tool Data List.
complaints:
Verify the customer's concern.
Hard Start
Perform a visual check.
Surges/Chuggles
Find the proper symptom position in the list at the end
Lack of Power, Sluggishness, or Sponginess
of this chapter.Operate according to procedures in the
appropriate diagnosis table.If the failure cannot be Detonation/Spark Knock
recreated, see Intermittent Conditions. Hesitation, Sag, Stumble
Visual Check Cuts out, Misses
If only perform a careful check on some symptom Poor Fuel Economy
procedures.The failure can be found out, and thus Rough, Unstable, or Incorrect Idle and Stalling
you can save valuable time.Visual checks include the
Dieseling, Run-on
following items:
Backfire
Check the engine control module (ECU)
grounda for being clean, tight and in the correct Blocked Engine Exhaust System Check
locations.
6.4.4.50 Intermittent Conditions
nspections Action
The condition is not currently present but is indicated in DTC history. OR There is a customer conern, but
cannot currently be duplicated, if the condition is not DTC related).

Before starting, refer to Important Premilinary Inspections in Symptoms.

The fault must be present to locate a condition using the DTC table.If a condition
is intermittent, the use of DTC tables may result in the replacement of good
parts.
ector Inspection Many intermittent conditions (Open or short circuit) occur with harness/connector
movement caused by vibration, engine torque, impact/rough pavement of the circuits.
Apply the appropriate procedures in the following to check this condition:
Move the related connector and harness, meanwhile monitor the appropriate
scan tool data.
Move the related connector and harness, and with the scan tool, instruct
the components to open (or close).Observe the component operation.
When the engine is operating, move the related connector and harness,
meanwhile monitor the engine operation.
If the movement of harness or connector can affect the indicating data, the component/
system operation or the engine operation, make necessary inspection on and repair to
the harness/connector.Refer to Electrical Connection or Wires in this table.

6.4.4.50 Intermittent Conditions(Cont’ d)

 6-130 Engine Controls Engine

Inspections Action
can Tool Check Use the scan tool to quick check the parameters.Quick check function can be used to
record the realtime data at a time.The recorded data can be played back and
analyzed.The scan tool can also be used to draw signle parameter diagrams and
combined parameter diagrams for comparing.Quick check not only can be manually
triggered when the symptom is noted, but also can be set to an advance trigger when
the DTC sets.
Record the abnormal values captured in the data, the system or components may be
instructed to perform a further inspection.

al Connection and Wires Intermittent conditions may be caused by the improper electrical connection/lack of
terminal tensile force or many failures with the wires.Carefully inspect the suspected
circuit for the following conditions:
Inspect the plug for improper mating, or if the terminal is not inserted into the
connector case completely (backed out).
Inspect the improperly formed or damaged terminals.Tetst if the terminals lack of
tensile force.
Inspect the wires and terminals for a poor connection, including the terminal
wound on the insulator.The test requests the terminal to be removed from the
connector case.
Inspect if any corrosion/water feeding occurs.
The wire is tight, cut out or scratched.
The routing is incorrect, too near to the high voltage/high current devices, such
as secondary ignition parts, motor, generator.These parts may cause electric
noise to happen in the circuit, and interfere with the normal operation for the
circuit.
The incorrect installation of non-factory or aftermarket add-on accessories.
ent Malfunction Indicator The following conditions may cause an intermittent MIL and no DTCs:
MIL) with NO DTCs Electromagnetic interference caused by a malfunctioning relay, ECU drived
solenoid, or switch.They may cause strong electric fluctuations.Generally, such
condition may occur when the fault parts are operating.
The incorrect installation of non-factory or aftermarket add-on accessories, such
as lights, radio equipment, and motors.
The Malfunction Indicator Lamp (MIL) is intermittently shorted to ground.
The ECU grounds are loose.
If the scan tool can be used to instruct the MIL to open and close, and the above
conditions do not occur and the DTC doesn't set, then use the latest calibration
software to re-programme the ECU and re-inspect the MIL operation.
ed DTCs are lost. Take a test and detect if the DTC memory is lost as follows:
1. Disconnect the engine coolant temperature (ECT) sensor.
2. Start the engine.
3. Use the scan tool to monitor the DTC status, and observe if the DTC occurs.
4. Allow the engine to idle, until the DTC occurs.
5. Turn off the ignition key switch and wait at least 30 seconds.
6. Turn on the ignition.
7. Monitor the scan tool if the DTC occurs.
Even if the ignition is turned off and lasts at least 30 seconds, the ECU should also
store the information and keep it in the memory (As long as the ECU battery input and
the ground circuit are not interfered, the information should be stored randomly).If the
DTC information is not stored, the ECU battery and its ground is normal, then the
ECU may have a failure.
al Inspections Test for an open diode across the A/C compressor clutch and for other open diodes.
The incorrect installation of non-factory or aftermarket add-on accessories, such as
lights, radio equipment, and motors.
Test the generator for a faulty rectifier bridge that may allow AC noise into the electrical
system.

6.4.4.51 Hard Start

 Engine
En
gine Controls 6-131
ns Action
anks OK, but does not start for a long time.Does eventually run, or may start but immediately dies.

Refer to Powertrain On Board Diagnostic(OBD)System Check.

Before starting, first refer to Intermittent Conditions.
Search for technical bulletins.

Inspect the engine coolant temperature (ECT) sensor for being skewed in
value.Connect the scan tool and compare the ECT value to the intake air
temperature (IAT) value on a cold engine.The temperature difference between
ECT value and IAT value should be within ±3°C (5°F).If the temperature
difference between ECT sensor and IAT sensor is out of range, test the
resistance.If the resistance of ECT sensor is not within the specification, refer to
Low Voltage Circuit for Engine Coolant Temperature (ECT) Sensor or High
Voltage Circuit for Intake Air Temperature (IAT) Sensor.
Inspect the crankshaft position (CKP) sensor on the scan tool.If there is no
responding, inspect the sensor input circuit.
Inspect the MAP sensor for correct installation and connection.
Use the scan tool to inspect the Idle Air Control (IAC) operation.Refer to Control
Circuit Failure - Idle Regulator.

Inspect the fuel pump relay circuit for operating correctly.Refer to Control Circuit
Failure - Oil Pump.
Inspect if the fuel pressure is too low.Refer to Fuel System Pressure Test.
Inspect the fuel injector for a fault.Refer to ECT within 10-35 ℃ (50-95°F) or Fuel
Injector Coil Test - ECT Exceeds 10-35 ℃ (50-95°F).
Inspect the fuel for a contaminated condition.Refer to Alcohol/Contaminants - in -
Fuel Diagnosis.
 6-132 Engine Controls Engine

6.4.4.51 Hard Start(Cont’ d)

ections Action
Inspect if the ignition voltage output is correct according to the following
procedures:
－ Attach J26792 Spark Tester to the engine ground.
－ Connect one end of the spark plug wire to the J26792 Spark Tester.Connect
the other end of spark plug wire to the coil to be tested.
－ Connect one end of the second spark plug wire to the other coil
brace.Connect the other end of the second spark plug wire to the ground.
－ Start the engine, meanwhile observe the J26792 Spark Tester.The spark can
be seen.
－ For each ignition coil, repeat the above procedures.
If the spark does not occur on the spark plug, inspect the following conditions:
－ Inspect the coil for cracks, carbon tracking/spark over or a resistance value
outside the specified range.
Coil Resistance
11-15 k Ω
－ Inspect the spark plug wire for spark over/crossed discharging, cracks,
carbon tracking, spark plug boot damage, pinched, improper routing or a
resistance value outside the specified range.
Resistance of Spark Plug Wire
1968 Ω /m (600 Ω /ft)
Note:Spray a little water fog to the secondary ignition coils, and help to
determine the intermittent conditions.If the secondary ignition parts fail, the
spark will occur with the ignition parts to the ground.
－ Damaged Module
－ Ignition system wire - a damage to the ignition module input, loose
grounding or system wire.
Remove the spark plug and inspect for the following conditions:
－ Heavy deposits
－ Cracks
－ Wear
－ Improper gap
－ Burned or damaged electrodes
－ Incorrect type
If the spark plugs are gas or oil fouled, determine the cause before replacing the
spark plugs.
al Excessive oil in combustion chamber - leaking valve seals
Low cylinder compression - refer to Engine Compression Test in Engine
Mechanical.
Inspect the following components for incorrect basic engine parts:
－ Cylinder heads
－ Camshafts and valve assembly
－ Pistons, etc.

Inspections Action
DEFINITION: Engine power variation under steady throttle or cruise.Feels like the vehicle speeds up and slows down without a
change in the accelerator pedal position.

6.4.4.52 Surges/Chuggles
 Engine
En
gine Controls 6-133
6.4.4.52 Surges/Chuggles(Cont’ d)
Inspections Action
Refer to Powertrain On Board Diagnostic (OBD) System Check.
Refer to Intermittent Conditions.
Search for technical bulletins.
Ensure that the driver understands the operation of the transmission torque
converter clutch (TCC) and A/C compressor operation as explained in the
owner's manual. Inform the customer how the TCC and the A/C clutch operates.
tem Inspect the heated oxygen sensor (HO2S).The heated oxygen sensor should
respond quickly to different throttle positions.If not, inspect the HO2S for silicon
or other contaminants from fuel or use of improper sealant.The sensors may
have a white powdery coating..Silicon contamination causes a high but false
HO2S signal voltage (rich exhaust indication).Refer to Silicon Contamination of
Heated Oxygen Sensors Notice.The engine control module may reduce the
engine oil feeding, and cause a severe deterioration of drive performance.
Inspect the related MAP wires.

m Inspect the fuel pressure.Refer to Fuel System Pressure Test.

Inspect the fuel for a contaminated condition.Refer to Alcohol/Contaminants - in -
Fuel Diagnosis.
Ensure each injector wire is connected to the proper injector/cylinder correctly.
 6-134 Engine Controls Engine

6.4.4.52 Surges/Chuggles(Cont’ d)
Inspections Action
tem Inspect if the ignition voltage output is correct according to the following
procedures:
－ Attach J26792 Spark Tester to the engine ground.
－ Connect one end of the spark plug wire to the J26792 Spark Tester.Connect
the other end of spark plug wire to the coil to be tested.
－ Connect one end of the second spark plug wire to the other coil
brace.Connect the other end of the second spark plug wire to the ground.
－ Rotate the engine, meanwhile observe the J26792 Spark Tester.The spark
can be seen.
－ For each ignition coil, repeat the above procedures.
If no spark appears on the spark plug, inspect for the following conditions:
－ Inspect the coil for cracks, carbon tracking/spark over or a resistance value
outside the specified range.
Coil Resistance
11-15 k Ω
－ Inspect the spark plug wire for spark over/crossed discharging, cracks,
carbon tracking, hole plug boot damage, pinched, improper routing or a
resistance value outside the specified range.
Resistance of Spark Plug Wire
1968 Ω /m (600 Ω /ft)
Important: Spray a little water fog to the secondary ignition coils, and help to
determine the intermittent conditions.If the secondary ignition parts fail, the
spark will occur with the ignition parts to the ground.
－ Damaged Ignition Module
－ Ignition system wire - a damage to the ignition module input, loose
grounding or system wire.
Remove the spark plug and inspect the following:
－ Heavy deposits
－ Cracks
－ Wear
－ Improper gap
－ Burned or damaged electrodes
－ Incorrect type
If the spark plugs are gas or oil fouled, determine the cause before replacing the
spark plugs.
nspections Inspect the TCC operation.
Inspect the exhaust system for blocking up.
Inspect the exhaust system pipeline for a damage or dent.
Inspect the silencer for thermal fatigue or possible internal failure.
Inspect the 3-way catalyst for blocking up by measuring the rear pressure of the
exhaust system.Refer to Blocked Engine Exhaust System Check.

6.4.4.53 Lack of Power, Sluggishness, or Sponginess

Inspections Action
DEFINITION: The engine delivers less than expected power. Little increase in speed, or a total lack of acceleration when the
accelerator pedal is pushed down.
 Engine
En
gine Controls 6-135
Ignition System Inspect if the ignition voltage output is correct according to the following
procedures:
－ Attach J26792 Spark Tester to the engine ground.
－ Connect one end of the spark plug wire to the J26792 Spark Tester.Connect
the other end of spark plug wire to the coil to be tested.
－ Connect one end of the second spark plug wire to the other coil
brace.Connect the other end of the second spark plug wire to the ground.
－ Rotate the engine, meanwhile observe the J26792 Spark Tester.The spark
can be seen.
－ For each ignition coil, repeat the above procedures.
If no spark appears on the spark plug, inspect for the following conditions:
－ Inspect the coil for cracks, carbon tracking/spark over or a resistance value
outside the specified range.
Coil Resistance
11-15 k Ω
－ Inspect the spark plug wire for spark over/crossed discharging, cracks,
carbon tracking, hole plug boot damage, pinched, improper routing or a
resistance value outside the specified range.
Resistance of Spark Plug Wire
1968 Ω /m (600 Ω /ft)
Important: Spray a little water fog to the secondary ignition coils, and help to
determine the intermittent conditions.If the secondary ignition parts fail, the
spark will occur with the ignition parts to the ground.
－ Damaged Ignition Module
Ignition system wire - a damage to the ignition module input, loose grounding or
system wire.
－ Remove the spark plug and inspect the following:
－ Heavy deposits
－ Cracks
－ Wear
－ Improper gap
－ Burned or damaged electrodes
－ Incorrect type
If the spark plugs are gas or oil fouled, determine the cause before replacing the
spark plugs.
Engine Mechanical Excessive oil in combustion chamber - leaking valve seals
Low cylinder compression
Inspect the following components for incorrect basic engine parts:
－ Camshafts
－ Cylinder heads －
Pistons, etc.
Additional Inspections Inspect the exhaust system for blocking up.Check the following:
Inspect the exhaust system pipeline for a damage or dent.
Inspect the silencer for thermal fatigue or possible internal failure.
Inspect the 3-way catalyst for possible blocking up.Refer to Blocked Engine
Exhaust System Check.
Inspect the correct TCC operation.

6.4.4.54 Detonation/Spark Knock

Inspections Action
 6-136 Engine Controls Engine

: A mild to severe ping which usually occurs worse while under acceleration. The engine makes sharp metallic
change with throttle opening.
Refer to Powertrain On Board Diagnostic (OBD) System Check.
Before starting, first refer to Intermittent Conditions.
Search for technical bulletins.

Inspect if the fuel pressure is too low.Refer to Fuel System Pressure Test.
Inspect the fuel for a contaminated condition.Refer to Alcohol/Contaminants - in -
Fuel Diagnosis.

em Inspect the correct heat type of spark plug. Refer to Spark Plug Usage in Engine
Electrical.

ng System Test for obvious overheating conditions.

Low engine coolant level
Restricted air flow to the radiator or restricted water flow through the radiator
Electric cooling fan circuit has a failure and does not work.
The correct coolant mixture ratio is 50/50.Refer to Coolant Description in Engine
Cooling.
hanical Excessive oil in combustion chamber - leaking valve seals
Low cylinder compression - refer to Engine Compression Test in Engine
Mechanical.
Excessive carbon buildup in the combustion chamber.Clean the chambers using
top engine cleaner.Follow the instructions on the can.
Inspect the following components for incorrect basic engine parts:
－ Camshafts
－ Cylinder heads
－ Pistons, etc.
spections Drive the vehicle and apply the shift lever to Drive gear or Overdrive gear, and
inspect the gear switch input for the transmission.
Inspect the TCC operation.Applying the TCC too soon can cause the engine to
spark knock.
If the scan tool readings are normal, and there are no engine mechanical faults,
fill the fuel tank with a know quality gasoline that has a minimum octane reading
of 87 and re-evaluate vehicle performance.

6.4.4.55 Hesitation, Sag, Stumble

Inspections Action
:Momentary lack of response as the accelerator is pushed down.This condition can occur at any vehicle
ondition is usually more pronounced when first trying to make the vehicle move, as from a stop sign.This condition
he engine to stall if severe enough.
Refer to Powertrain On Board Diagnostic (OBD) System Check.
Refer to Intermittent Conditions.
Search for technical bulletins.

6.4.4.55 Hesitation, Sag, Stumble(Cont’ d)

Inspections Action
 Engine
En
gine Controls 6-137
r/System Inspect the heated oxygen sensor (HO2S).The heated oxygen sensor (HO2S)
should respond quickly to a change in throttle position.If the HO2S does not
respond to different throttle positions, inspect for contamination from fuel, silicon
or other contaminants, or incorrect use of sealant.The sensors may have a white
powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication).Refer to Silicon Contamination of Heated
Oxygen Sensors Notice.The engine control module may reduce the engine oil
feeding, and cause a severe deterioration of drive performance.
Inspect the crankshaft position (CKP) sensor on the scan tool. If there is no
responding, inspect the sensor input circuit.
Inspect the throttle position adjuster and related wires.
Inspect the MAP sensor and related wires.

ystem Inspect the fuel pressure.Refer to Fuel System Pressure Test.

Inspect the fuel for a contaminated condition.Refer to Alcohol/Contaminants - in -
Fuel Diagnosis.
Inspect the fuel injectors.
Inspect the items that cause an engine to run rich.
Inspect the items that cause an engine to run lean.

n System Inspect if the ignition voltage output is correct according to the following
procedures:
－ Attach J26792 Spark Tester to the engine ground.
－ Connect one end of the spark plug wire to the J26792 Spark Tester.Connect
the other end of spark plug wire to the coil to be tested.
－ Connect one end of the second spark plug wire to the other coil
brace.Connect the other end of the second spark plug wire to the ground.
－ Rotate the engine, meanwhile observe the J26792 Spark Tester.The spark
can be seen.
－ For each ignition coil, repeat the above procedures.
If no spark appears on the spark plug, inspect for the following conditions:
－ Inspect the coil for cracks, carbon tracking/spark over or a resistance value
outside the specified range.
Coil Resistance
11-15 k Ω
－ Inspect the spark plug wire for spark over/crossed discharging, cracks,
carbon tracking, hole plug boot damage, pinched, improper routing or a
resistance value outside the specified range.
Resistance of Spark Plug Wire
1968 Ω /m (600 Ω /ft)
Important: Spray a little water fog to the secondary ignition coils, and help to
determine the intermittent conditions.If the secondary ignition parts fail, the
spark will occur with the ignition parts to the ground.
－ Damaged Module
－ Ignition system wire - a damage to the ignition module input, loose
grounding or system wire.
Remove the spark plug and inspect the following:
－ Heavy deposits
－ Cracks
－ Wear
－ Improper gap
－ Burned or damaged electrodes
－ Incorrect type
 6-138 Engine Controls Engine

If the spark plugs are gas or oil fouled, determine the cause before replacing the
spark plugs.

6.4.4.56 Cuts out, Misses

ctions Action
ady pulsation or jerking that follows engine speed, which is usually more pronounced as the engine load

Refer to Powertrain On Board Diagnostic(OBD)System Check.

Refer to Intermittent Conditions.
Search for technical bulletins.

Inspect the system fuel pressure.Refer to Fuel System Pressure Test.

Inspect the fuel injector.
Inspect the fuel for a contaminated condition.Refer to Alcohol/Contaminants - in -
Fuel Diagnosis.
Inspect for the fuel in the vacuum hose of fuel pressure regulator.
 Engine
En
gine Controls 6-139
1. Inspect the conditions that cause a incorrect idle.
The throttle body is restricted, of heavy deposits or
damaged. Restricted intake air system; Large vacuum leaks.
2. Inspect the throttle position sensor and related circuit wires.Refer to Throttle
Position Sensor Circuit Failure.
3. Inspect the correct operating of positive crankcase ventilation.
4. Drive the vehicle and apply the shift lever to Drive gear or Overdrive gear, and
inspect the input signal of gear selector switch for the transmission.
5. Inspect the following parts for the damage: Damaged crankshaft absorber.
Damaged crankshaft position sensor
 6-140 Engine Controls Engine

6.4.4.56 Cuts out, Misses(Cont’ d)

Inspections Action
em Inspect if the ignition voltage output is correct according to the following
procedures:
－ Attach J26792 Spark Tester to the engine ground.
－ Connect one end of the spark plug wire to the J26792 Spark Tester.Connect
the other end of spark plug wire to the coil to be tested.
－ Connect one end of the second spark plug wire to the other coil
brace.Connect the other end of the second spark plug wire to the ground.
－ Rotate the engine, meanwhile observe the J26792 Spark Tester.The spark
can be seen.
－ For each ignition coil, repeat the above procedures.
If no spark appears on the spark plug, inspect for the following conditions:
－ Inspect the coil for cracks, carbon tracking/spark over or a resistance value
outside the specified range.
Coil Resistance
11-15 k Ω
－ Inspect the spark plug wire for spark over/crossed discharging, cracks,
carbon tracking, hole plug boot damage, pinched, improper routing or a
resistance value outside the specified range.
Resistance of Spark Plug Wire
1968 Ω /m (600 Ω /ft)
Important: Spray a little water fog to the secondary ignition coils, and help to
determine the intermittent conditions.If the secondary ignition parts fail, the
spark will occur with the ignition parts to the ground.
－ Damaged Ignition Module
－ Ignition system wire - a damage to the ignition module input, loose
grounding or system wire.
Remove the spark plug and inspect the following:
－ Heavy deposits
－ Cracks
－ Wear
－ Improper gap
－ Burned or damaged electrodes
－ Incorrect type
－ If the spark plugs are gas or oil fouled, determine the cause before replacing
the spark plugs.
－ Inspect the following intermittent ignition system for the conditions:
－ Intermittent signal of crankshaft position sensor.
Intermittent from the ignition supply circuit or the sensor ground circuit to the
crankshaft position sensor.
6.4.4.56 Cuts out, Misses(Cont’ d)
Inspections Action
 Engine
En
gine Controls 6-141
hanical Inspect the engine for the following conditions:
－ Inspect the compression.
－ Sticking or leaking valves
－ Worn camshaft lobes
－ Valve timing
－ Worn rocker arm
－ Broken valve spring
－ Excessive oil in combustion chamber - leaking valve seals
－ Low cylinder compression
－ Inspect the following components for incorrect basic engine parts:
－ Camshafts
－ Cylinder heads
－ Pistons, etc.
spections Inspect the exhaust system for blocking up.
－ Inspect the exhaust system pipeline for a damage or dent.
－ Inspect the silencer for thermal fatigue or possible internal failure.
－ Inspect the 3-way catalyst for possible blocking up.
Electromagnetic interference (EMI) can cause an engine misfire condition.You
can usually detect EMI with a scan tool by monitoring the engine speed
parameter.A sudden increase in the engine speed parameter, with little change in
actual engine speed indicates that EMI is present.Inspect the secondary ignition
coil routing for high voltage components (near the ignition control circuits) if a
condition exists.
Inspect the intake and the exhaust manifold passages for casting flash.
Inspect the motor base for a condition.
6.4.4.57 Poor Fuel Economy
Inspections Action
N:Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, the fuel economy is
wer than it was on this vehicle at one time, as previously shown by an actual road test.

Refer to Powertrain On Board Diagnostic(OBD)System Check.

Refer to Intermittent Conditions.
Search for technical bulletins.
Verify the owner's driving habits, by asking the following questions:
－ Is the A/C ON very frequently?
－ Are the tires at the correct pressure?
－ Are the tires sticking?
－ Is there excessively heavy loads being carried?
－ Is the acceleration rate too much, too often?
Inspect the fuel pressure.Refer to Fuel System Pressure Test.
Inspect the fuel injector.
Inspect the fuel for a contaminated condition.Refer to Alcohol/Contaminants - in
Fuel Diagnosis.
Ensure each injector wire is connected to the proper injector/cylinder correctly.
Inspect for the fuel in the vacuum hose of fuel pressure regulator.

6.4.4.57 Poor Fuel Economy(Cont’ d)

Inspections Action
 6-142 Engine Controls Engine

ystem Inspect the crankshaft position (CKP) sensor on the scan tool.If there is no
responding to both, inspect the sensor input circuit.
Inspect the air intake system and the crankcase for air leaks.
Test for correct calibration of the speedometer.Connect the J33431-B Signal
Generator to the electrical connector of speed sensor. Turn on the ignition
(Switch), open the visual inspector, and monitor the speedometer.
ystem Inspect if the ignition voltage output is correct according to the following
procedures:
－ Attach J26792 Spark Tester to the engine ground.
－ Connect one end of the spark plug wire to the J26792 Spark Tester.Connect
the other end of spark plug wire to the coil to be tested.
－ Connect one end of the second spark plug wire to the other coil
brace.Connect the other end of the second spark plug wire to the ground.
－ Rotate the engine, meanwhile observe the J26792 Spark Tester.The spark
can be seen.
－ For each ignition coil, repeat the above procedures.
If no spark appears on the spark plug, inspect for the following conditions:
－ Inspect the coil for cracks, carbon tracking/spark over or a resistance value
outside the specified range.
Coil Resistance
11-15 k Ω
－ Inspect the spark plug wire for spark over/crossed discharging, cracks,
carbon tracking, hole plug boot damage, pinched, improper routing or a
resistance value outside the specified range.
Resistance of Spark Plug Wire
1968 Ω /m (600 Ω /ft)
Important: Spray a little water fog to the secondary ignition coils, and help to
determine the intermittent conditions.If the secondary ignition parts fail, the
spark will occur with the ignition parts to the ground.
－ Damaged Ignition Module
－ Ignition system wire - a damage to the ignition module input, loose
grounding or system wire.
Remove the spark plug and inspect the following:
－ Heavy deposits
－ Cracks
－ Wear
－ Improper gap
－ Burned or damaged electrodes
－ Incorrect type
If the spark plugs are gas or oil fouled, determine the cause before replacing the
spark plugs.
ooling System Inspect for the engine coolant level.
Test if the engine thermostat is incorrect or has a failure.For the thermostat, the
initial open temperature is 94 ℃ , and the full open temperature is 107 ℃ .
Transmission System Inspect if the high speed gear TCC cannot be engaged.
Inspect if the clutch disk is skidding.

6.4.4.57 Poor Fuel Economy(Cont’ d)

Inspections Action
 Engine
En
gine Controls 6-143
Engine Mechanical Inspect the engine for the following conditions:
－ Inspect the compression.
－ Sticking or leaking valves
－ Worn camshaft lobes
－ Valve timing
－ Worn rocker arm
－ Broken valve spring
－ Excessive oil in combustion chamber - leaking valve seals
Inspect the following components for incorrect basic engine parts:
－ Camshafts
－ Cylinder heads
－ Pistons, etc.
Additional Inspections Inspect the exhaust system for blocking up.
－ Inspect the exhaust system pipeline for a damage or dent.
－ Inspect the silencer for thermal fatigue or possible internal failure.
－ Inspect the 3-way catalyst for possible blocking up.
6.4.4.58 Rough, Unstable, or Incorrect Idle and Stalling
Inspections Action
DEFINITION:The engine runs unevenly at idle. If severe, the engine or the vehicle may shake.Engine idle may vary in
speed.Either conditions may be severe enough to stall the engine.
Preliminary Refer to Powertrain On Board Diagnostic(OBD)System Check.
Refer to Intermittent Conditions.
Search for technical bulletins.

Fuel System Inspect the fuel pressure.Refer to Fuel System Pressure Test.
Inspect the fuel injectors.
Inspect the fuel for a contaminated condition.
Inspect for the fuel in the vacuum hose of fuel pressure regulator.
Ensure each injector wire is connected to the proper injector/cylinder correctly.

Sensor/System Inspect the conditions that cause a incorrect idle.

－ The throttle body is restricted, of heavy deposits or damaged.
－ Restricted intake air system.
－ Large vacuum leaks.
Inspect the correct operating of the crankcase ventilation.
Inspect the throttle position sensor and related wires.
Inspect if the sensor circuit voltage is correct.
Drive the vehicle and apply the shift lever to Drive gear or Overdrive gear, and
inspect the input signal of gear selector switch for the transmission.
6.4.4.58 Rough, Unstable, or Incorrect Idle and Stalling(Cont’ d)
Inspections Action
 6-144 Engine Controls Engine

Ignition System Inspect if the ignition voltage output is correct according to the following
procedures:
－ Attach J26792 Spark Tester to the engine ground.
－ Connect one end of the spark plug wire to the J26792 Spark Tester.Connect
the other end of spark plug wire to the coil to be tested.
－ Connect one end of the second spark plug wire to the other coil
brace.Connect the other end of the second spark plug wire to the ground.
－ Rotate the engine, meanwhile observe the J26792 Spark Tester.The bright
blue spark should be seen.
－ For each ignition coil, repeat the above procedures.
If no spark appears on the spark plug, inspect for the following conditions:
－ Inspect the coil for cracks, carbon tracking/spark over or a resistance value
outside the specified range.
Coil Resistance
11-15 k Ω
－ Inspect the spark plug wire for spark over/crossed discharging, cracks,
carbon tracking, hole plug boot damage, pinched, improper routing or a
resistance value outside the specified range.
Resistance of Spark Plug Wire
1968 Ω /m (600 Ω /ft)
Important: Spray a little water fog to the secondary ignition coils, and help to
determine the intermittent conditions.If the secondary ignition parts fail, the
spark will occur with the ignition parts to the ground.
－ Damaged Ignition Module
－ Ignition system wire - a damage to the ignition module input, loose
grounding or system wire.
Remove the spark plug and inspect the following:
－ Heavy deposits
－ Cracks
－ Wear
－ Improper gap
－ Burned or damaged electrodes
－ Incorrect type
If the spark plugs are gas or oil fouled, determine the cause before replacing the
spark plugs.
Engine Mechanical Inspect the engine for the following conditions:
－ Inspect the compression.
－ Sticking or leaking valves
Worn camshaft lobes
－ Valve timing
－ Worn rocker arm
－ Broken valve spring
－ Excessive oil in combustion chamber - leaking valve seals
Inspect the following components for incorrect basic engine parts:
－ Camshafts
－ Cylinder heads －
Pistons, etc.
6.4.4.58 Rough, Unstable, or Incorrect Idle and Stalling(Cont’ d)
Inspections Action
 Engine
En
gine Controls 6-145
Additional Inspections Inspect the exhaust system for blocking up.
－ Inspect the exhaust system pipeline for a damage or dent.
－ Inspect the silencer for thermal fatigue or possible internal failure.
－ Inspect the 3-way catalyst for possible blocking up.
Inspect the motor base for a condition.
Electromagnetic interference (EMI) on the reference circuit can cause an engine
misfire condition.You can usually detect EMI with a scan tool by monitoring the
engine speed parameter.A sudden increase in the engine speed parameter, with
little change in actual engine speed indicates that EMI is present.Inspect the
secondary ignition coil routing for high voltage components (near the ignition
control circuits) if a condition exists.
Inspect the motor base for a condition.
Inspect the intake and the exhaust manifold passages for casting flash.
6.4.4.59 Dieseling, Run-on
Inspections Action
DEFINITION:The engine continues to run after the key is turned OFF, but runs very rough.If the engine runs smooth, inspect the
ignition switch and the ignition switch adjustment.
Preliminary Refer to Powertrain On Board Diagnostic(OBD)System Check.
Refer to Intermittent Conditions.
Search for technical bulletins.

Fuel System Inspect the fuel injector.

Additional Inspections Inspect if the batter positive voltage is short to any ignition supply circuit.

6.4.4.60 Backfire
s Action
s in the intake manifold or in the exhaust system, making a loud popping noise.

Refer to Powertrain On Board Diagnostic (OBD) System Check.

Refer to Intermittent Conditions.
Search for technical bulletins.

Inspect the following intermittent ignition system for the conditions:

－ Intermittent signal of crankshaft position
－ Intermittent from the ignition supply circuit or the sensor ground circuit to the
crankshaft position sensor.
Inspect the MAP sensor.
Inspect if the fuel pressure is too low.Refer to Fuel System Pressure Test.
Inspect the fuel for a contaminated condition.Refer to Alcohol/Contaminants - in -
Fuel Diagnosis.
Ensure each injector wire is connected to the proper injector/cylinder correctly.
 6-146 Engine Controls Engine

Inspect if the ignition voltage output is correct according to the following

procedures:
－ Attach J26792 Spark Tester to the engine ground.
－ Connect one end of the spark plug wire to the J26792 Spark Tester.Connect
the other end of spark plug wire to the coil to be tested.
－ Connect one end of the second spark plug wire to the other coil
brace.Connect the other end of the second spark plug wire to the ground.
－ Rotate the engine, meanwhile observe the J26792 Spark Tester.The spark
can be seen.
－ For each ignition coil, repeat the above procedures.
If the spark does not occur on the spark plug, inspect the following conditions:
－ Coil - cracks, carbon tracking/spark over or a resistance value outside the
specified range.
Coil Resistance
11-15 k Ω
－ Spark plug wire - spark over/crossed discharging, cracks, carbon tracking,
hole plug boot damage, pinched, improper routing or a resistance value
outside the specified range.
Resistance of Spark Plug Wire
1968 Ω /m (600 Ω /ft)
Important: Spray a little water fog to the secondary ignition coils, and help to
determine the intermittent conditions.If the secondary ignition parts fail, the
spark will occur with the ignition parts to the ground.
－ Damaged Ignition Module
－ Ignition system wire - a damage to the ignition module input, loose
grounding or system wire.
Remove the spark plug and inspect the following:
－ Heavy deposits
－ Cracks
－ Wear
－ Improper gap
－ Burned or damaged electrodes
－ Incorrect type
If the spark plugs are gas or oil fouled, first determine the cause before replacing
the spark plugs.
6.4.4.60 Backfire(Cont’ d)
ctions Action
l Inspect the engine for the following conditions:
Inspect the compression.
Sticking or leaking valves
Worn camshaft lobes
Valve timing
Bending pushrod
Worn rocker arm
Broken valve spring
Excessive oil in combustion chamber - leaking valve seals
Low cylinder compression
Inspect the following components for incorrect basic engine parts:
－ Camshafts
－ Cylinder heads
－ Pistons, etc.
 Engine
En
gine Controls 6-147
ons Inspect the intake and the exhaust manifold for casting flash.
Inspect the TCC operation.
Inspect the exhaust system for blocking up.
－ Inspect the exhaust system for a damage or the passages for a dent.
－ Inspect the silencer for thermal fatigue or possible internal failure.
－ Inspect the 3-way catalyst for possible blocking up.Refer to Exhaust Leaks in
Engine Exhaust System.
 6-148 Engine Controls Engine

6.4.4.61 Blocked Engine Exhaust System Check

Step Action Value Yes No
Has the Powertrain On Board Diagnosis (OBD) Go to Powertrain
System Check been performed? On Board
1 － Go to Step 2 Diagnosis (OBD)
System Check.

1. Remove the heated oxygen sensor.

2. Install the exhaust back pressure tester
J35314-A/BT-8515/BT-8515A or equivalence
onto HO2S1 position of the heated oxygen
sensor.
2 3. Under the normal operating temperature, 8.6 kpa. Go to Step 4 Go to Step 3
allow the engine to idle.
4. Observe the exhaust system back pressure
reading on the gauge.
Does the reading exceed the specified value?

1. Place the exhaust pressure tester on the

heated oxygen sensor, and increase the
engine speed to 2,000 rev/min.
3 2. Observe the exhaust system back pressure 20.7 kpa. Go to Step 4 System OK
reading on the gauge.
Does the reading exceed the specified value?

Repair the restricted condition for the exhaust

system.The possible conditions may include:
Damaged pipelines
Heat deformation
4 － Go to Step 5 －
Internal conditions of the silencer
Restricted converter
Is the operation completed?

1. Install the exhaust pressure tester onto the

position of the heated oxygen sensor, and
increase the engine speed to 2000 rev/min.
5 2. Observe the exhaust system back pressure 20.7 kpa. Go to Step 2 System OK
reading on the measuring gauge.
Does the reading exceed the specified value?

6.4.4.62 Engine Control Module Diagnosis Engine Control Module Diagnosis

MalfunctionCode.
Engine Diagnosis System Check Fuel System excessive rich or lean.
Important: Correctly understand and use the table to Customer Complaint Dirve Performance
narrow the diagnosis time and prevent unnecessary part Symptom
replacement.
Power System On BoardDiagnostic (OBD) System
After completing the appearance inspection, Power Check is designed as a drive performance and emission
System On Board(OBD) Diagnosis System Check system diagnostic main table. Always take Power
should be performed.On Board Diagnosis System System On BoardDiagnostic （OBD） System
Check will provide instructions for diagnosis of the
Check as the starting point of power system diagonosis.
following conditions:
Power System On BoardSystem Check is a edit method
Engine Control Module will have inoperative or
for identification of malfunction.The opinion of the driver
damaged, non engine control module data or
normally could be devided as one of the following:
immediately repair the engine (Multifunction
Indication Lamp), Multifunction Indication Lamp Immediately repair the engine （multifunction
inoperative. indication light） continuous illumination. Drive
Ability Mulfunction
Engine Engine Controls 6-149

Engine not Star or stall after start what happens in a circuit with an open or a shorted
wire, and you should be able to identify a shorted or
Diagnostic Procedure Application
open circuit using a DMM. Application of DMM
The used diagnostic procedure of this section is
designed for finding and repairing mulfunctions of You should be familiar with DMM.Use DMM to measure
related to the power system.The common practice is to the voltage (v), resistance (ohm), electricity （amp），
employ the following introduced 5 basic steps to find capacity (Faraday), Interruption （Min/Max） and
appropriate malfunction diagnostic plan. frequency. Use of circuit test tools
To learn about customer complaint, it is very Only when the diagnostic procedure is raised, use the test
important to let the technician to be informed lamp.You should know how to use the jumper wire test
about complaint contents. Otherwise it will cause components with fuse and DMM for indication of read
wrong diagnosis or unnecessary out.But not to damage the terminal.You should know how
diagnosis.Among them, the technician must learn to use J35616-A adapter socket to test the adaptor
if that the condition is always happening, only modules, and apply when the diagnostic procedure
appears in a particular situation, or definitely is of needs to probe connectors at front. Engine Control
discontinuity.Thus in helping the technician to
Module Repair Notice
reproduce or diagnosis the problem.The other
reason that the technician must understand the Engine Control Module is able to accept vehicle normal
customer complaint contents is that, the current, but must cautiously operate, avoiding any circuit
technician can decide if the complaint needs overload.When testing open or short circuit, do not be
repair or it is of vehicle normal operation from grounded or apply with voltage on the engine control
this.Attempt to diagnosis a complaint that belongs module, unless special notification to the non diagnostic
to a normal phenomena, but also to cause procedure.These circuit can only use J39200 DMM for
unnecessary maintenance. test.
Is the disgonosis operation normal? Use Only for removal or replacement of engine control
Powertrain On Board （OBD） System module, you must follow the procedural operation
introduced in this section.
Check.This is the starting point of procedure
diagnosis , and be always to begin from here. Static discharge damage
Does this indicates diagnostic malfunction code? Electric components used in the control system is
If the diagnostic malfunction code is identified designed normally for only transmitting very low
through disagnosis, Powertrain On Board voltage.Electric components is easily subject to static
Diagnosis (OBD) System Check will lead you to discharge damage.Static electricity not more than 100v
appropriate table. can cause some electric components being
Is the customer complaint related to special damaged.Some person has several approach to
Powertrain system sub system? If no setting of carrying static electricity.The most common electricity
related diagnostic malfunction code, the short cut carrying way is abrasion and induction.Personal sliding
mode for the next step to determine malfunction on vehicle seats is a example of attritted
position is to narrow it to a particular special electrification.When a shoe of sound insulation is beside
Powertrain sub system.If a particular Powertrain a high voltage object and grounded instantly, it will
subsystem could be defined as malfunction produce faradic electricity.Load with the same polarity
cause, the diagnosis will be more easy. has mutual exclusiton enable people to bring same
popularity load.Static electricity can cause damage.You
Is the malfunction related to the power system?
must carefully deal with and test the electrical
Some customer complaint is observed as it may
components.
be relating to the Powertrain, but in fact it is
caused by the other system of vehicles. After sales (added) electrical and vacuum
Necessary Basic Knowledge equipment
Contents of this section of the manual must be used, to After sale (added) electrical and vacuum equipment is
be familiar with some basic knowledge.These knowledge defined as equipment connected with electrical or
will help you to finish the diagnostic procedure introduced vacuum system that is installed to the vehicle in any
form after the vehicle leaves the original plant.For this
by this section. Basic Circuit Knowledge
kind of equipment, design on the vehicle is not
Basic electric knowledge must be understand, and allowed.For this, you must be specially cautious when
learn the meaning of voltage (v), ampere (am) and adding equipment after the vehicle is selled.
electric resistance （ohm） .You should understand
Underhood appearance inspection
6-150 Engine Controls Engine

Underhood appearance inspection is very introduction of time for setting diagnostic malfunction
important.Appearance inspection normally can exclude code.
malfunction.These quick inspection only spends a few
minutes, but can economize time and help you clear the
Run diagnostic malfunction code condition
problem.For details refer to Appearance Inspection in Running condition (induction condition) is the engine
Symptom. control module test sensor/system front must meet.Only
these conditions are created, reliable sensor/system
All Powertrain malfunction diagnosis have to start from
could be carried, and will not cause false indication. And
appearance inspection.Appearance inspection often
enables you to clear simple malfunction, but not need to it will not produce false indication. Conditions for
use tables. diagnostic malfunction code
Inspect all vacuum hose for clamping, cutting, Setting of conditions is that must be met for setting of
disconnect or inappropriate arrangement. diagnostic malfunction code.Only after the running
Inspect appropriate grounding connection for conditions are met （like the above mentioned） , you
correct, grounding hole eye for connecting to the can only inspect the sensor/system.If induction condition
grounding point, star pattern pad for installation. are met, and engine control module has detected a
abnormal sensor/system condition, appropriate
Inspect the battery positive connection box
malfunction code will be setted.
clamping nut if it is loosened.
Inspect the other guiding wire inside the engine
Actions adopted for setting of diagnostic
chamber for sound connection, burn out, or malfunction code
fragments attainment, wire dead clamp or Action employed refers to adopted steps of engine
harness contact sharp edge or heat exhaustion control module for setting of diagnostic malfunction
manifold. code. Purpose for these action is for one of the following
Inspect the fuse for melt or loss, relay for loss or 3 kinds.
installation position incorrect. Inform the malfunction to the driver
Diagnosis malfunction (DTC) table application Maintain vehicle drive performance
When diagnose the Powertrain system, diagnostic In prevention of any malfunction that causes
procedure in this section or introduced in other section vehicle damage.
on Powertrain will almost all be used.The diagnostic Clearance of malfunction indication lamp/
procedure will be mainly presented in the form of
diagnostic malfunction code conditions.
table.At the beginning of each diagnostic malfunction
code, it is a circuit diagram or a reference circuit A particular condition must be met, can only closing of
diagram, circuit description, and condition or note malfunction indication lamp and/or clearance of
reading support information of the diagnostic diagnostic malfunction code. Diagnostic aid
malfunction code in the table will help you to understand When producing of diagnostic malfunction code or drive
the tested system, related components in the test, performance malfunction conditions, Diagnostic aid
engine control module test system (provocation provides useful information.Some times, relying on
condition) mode, engine control module for how to diagnostic malfunction code setting of data quick
define diagnostic failure (setting of diagnostic retrieve, or driver information, it can recognize the
malfunction code condition), and which table can be failure, at least also to narrow the malfunction to small
executed.The following serves an example of diagnostic list of possible interruption conditions.If like this,
support information and diagnostic malfunction code diagnostic aid can be interpreted as searching for
table. Circuit Diagram contents and the most reasonable path of determining
Circuit diagram on the diagnostic support information interruption conditions. Test Description
page will exhibit the related circuit and components Test description has interpreted the cause of execution of
when setting of diagnostic malfunction code.When a particular test, and what will the test find.Information is
checking the circuit in the table, you may refer to the numbered according to the corresponding steps in the
diagram.If there is only one circuit diagram for diagnostic table.As for why to carry out a particular step,
reference, or needing more detailed circuit information, or such a step should produce what kind of result, refer to
you may refer to Engine Control Module Schematic the next step number needed for execution.Refer to the
Diagram in Wiring System. explanation description with the same number of Test
Circuit description Description Diagnostic Table
The circuit description interprets related sensor and/or Diagnostic Table is a systematic method for diagnostic
circuit for setting of diagnostic malfunction code.Brief malfunctional code.This table consists of 5 columns:
Engine Engine Controls 6-151

step number, operation, numeric value, Yes and No.Step off.Connection can only be disconnected with
number indicates for steps of execution.Operation force.Force needed for interrupt of connection depends
column includes required information for execution of on the inspected terminal dimension. Big terminal, such
test.The final sentence of each operational block always as metric combination series, it can be interrupted with
raises one question.The question can only be answered hand, but not to be shake off.Replace the damaged
by YES or NO. The answer of the question will indicate terminal, but not need to repair.
you the next step to which column Yes or No.The
answer of YES or No for each test will lead to the next
Diagnosis interruptive malfunction
reasonable step in the diagnostic table.A large part of Diagnosis interruptive condition is very hard.Setting
YES and NO frame will lead you to the next reasonable conditions of diagnostic malfunction code will not surely
step in the diagnostic table.However, some frames may appear.This does not mean the failure has been
guide you to receive diagnostic help during other system excluded, and it only indicates malfunction interruptive
diagnosis, or when interruptive condition exists. appearing. Malfunction will appear in the
future.Therefore, try every means to diagnosis the
Beginning from step 1 of table top, unless indicated with
malfunction and inflict for exclusion.The only way for
notice or caution. Do not jump over this step or table,
diagnosis of interruptive condition is to collect
unless YES/NO column especially stipulated.Shuffling
information when diagnosing malfunction code.Practice
through normally cause misdiagnosis.After malfunction
with the 2 kind of method, and observe through quick
is find, perform necessary inspection, then inspect the
retrival data and by the driver.Refer to the latest Techline
maintenance effect.
Procedure
Inspection of maintenance effect
You must explain and ensure diagnostic code operation
and passing through, If you want to know if the test runs 6.4.4.63 Air Conditioning Circuit System
and pass the test, use the malfunction diagnostic Diagnosis Controlled by Engine Control
instrument and select malfunction code status, note the Module
code that needs verification.Now you can observe the
diagnosis test status.For diagnosis repair, you can drive Circuit Diagram Description (refer to air
the vehicle and ensure the symptom to disappear. conditioning system schematic diagram)
Check the terminal contact When selecting of heating, ventilation and air
Before replacing a component, it is required to check the conditioning system controller, send a signal through the
terminal contact for many tables.The reason lies in that, air conditioner switch circuit to the control module.Air
executing of inspection in the table can only be done by conditioning relay is controlled by the engine control
checking the jumper or the continuity of direct module.Control module monitor air conditioning system
connection circuit, but not the jump connection refrigerant pressure. If the air conditioning refrigerant
continuity of components.Check the terminal contact, and engine operation condition is between specified
avoiding replacing perfect components, and repeating of acceptable demarked range, the engine the engine
malfunction due to indirect connection, to allow part of control module will allow the air conditioning relay to
the repair work more easy, for example to replace operate.Meanwhile provide grounding wiring to the air
terminal of components but not components itself.For conditioning system relay in the engine control
this, if it is required to do this operation, it is very module.When the air conditioning relay operates, the
important to check the terminal contact. battery positive voltage is applied on the compressor
Only there is a new terminal in hand, it is very easy to clutch coil.
check the terminal.J38125-B terminal repair tool kit is for Only asking for opening of the air conditioning system
checking the terminal source for sound terminal when the engine runs, the engine control module will
contact.It includes all terminal series used at enable the air conditioner compressor clutch, unless the
present.When inspect of terminal contact, start from following situation appears:
checking the positive terminal.The terminal should Vehicle speed less than 40 KM/h, and throttle
straightly and aligned to other terminals in other terminal opening greater than 50-60%(relating to specific
row.The terminal should not be distorted, bended or rpm)
damaged.As the same, the negative terminal should be
checked for alignment for damage.Finally, use the new Engine water temperature below 15°C or greater
positive terminal of the same series. than 115°C

(for example metric combination 150, Weatherpack etc) Within a particular delay time after the engine
to connect the negative terminal to be checked.It should starts, the specific value depends on the starting
not come away or should not be easily shake water temperature and altitude, in plain area,
6-152 Engine Controls Engine

delay time more than -10°C equals to 10 seconds pad broken, deformation, and wiring connection
，-20°C is 200 seconds，-30°C is 240 seconds. for failure.Use the appropriate match terminal to
test tensile for appropriateness.
Air conditioning closes within 4 seconds.
Wiring harness damage- inspect wiring harness
Air conditioning pressure sensor is over 440p/
for damage.If it fails to find any problem in the
sq.mi(4.6v) or below 35p/sq.mi (0,35v)
wiring harness, move away the harness related
(determined by the air conditioning system
with the sensor, and meanwhile observe the
pressure)
indication of the malfunction diagnosis
Diagnostic aid instrument.If the malfunction diagnosis instrument
Inspect the following items: indicates a change, it shows there is a problem in
this position.
Important: Before repair components, clear any scraps
on the connector surface.Before diagnosis or If engine control module and engine grounding
replacement of components, first to check the connector connection reliable, and clean.
gascket.Ensure the pad to be installed correctly.The pad If it is determined that the diagnostic code belongs to
can stop pollutants to enter. interruptive malfunction, then check the malfunction
Poor terminal contact-inspect wiring harness record which can determine when is the diagnostic code
connector terminal for loosening, mismatch, lock set.
Air conditioning circuit diagnosis of controlled by engine control module
Step Action Numeric value Yes No
Whether having executed Powertrain On Go to Powertrain
Board(OBD) System Check? On Board
1 － Go to Step 2 Diagnosis (OBD)
System
Inspection

Whether stored any engine control module, Diagnosis

heating, ventilation, in air conditioning system appropriate
2 malfunction code? － diagnosis Go to Step 3
malfunction code.

Air conditioning circuit diagnosis of controlled by engine control module (Cont’ d)

Step Action Numeric value Yes No

Note:Before continuing execution of this

step, the following conditions must be
followed:
Ambient temperature must be higher than
5°C (41°F)
Air conditioning pressure must be above
35p/ sq.mi.(0.4v)
3 Coolant temperature must be lower than － Go to Step 13 Go to Step 4
121°C (250°F)
1. Turn the air conditioning shifting switch to
OFF
2. Turn on the ignition switch, and keep the
engine blowing out
3. Test the air conditioning clutch for engament
Air conditioning clutch for engagement?

1. Start and keep the engine to run at the

speed of 1000 - 1500rpm
2. Turn the air conditioning shifting switch to air Refer to Diagnosis
4 conditioning mode. － Go to Step 5
Aid
3. Observe the air conditioning system clutch
Air conditioning clutch for engagement?
 Engine Engine Controls 6-153

1. Hold the air conditioning shift switch on to

the air conditioning mode
2. Observe the air conditioning system request
5 indication on the malfunction diagnostic － Go to Step 8 Go to Step 6
instrument.
Air conditioning request indication is YES.

Observe the air conditioning system pressure Go to Heating,

sensor indication on the malfunction diagnostic Ventilation and Air
instrument. Conditioning
6 Whether pressure indicated by air conditioning 0.4v － 4.6v System Go to Step 7
system pressure sensor indication comply with Air Conditioning
the stipulation？ System Diagnosis

1. Connect J39500-B refrigerant recycle,

recirculation and restaffing (ACR4)
instrument to monitor the refrigerant high end Go to Air
pressure. Conditioning
Go to Air System
2. Use J39500-B refrigerant for recycle, System Diagnosis
35p/sp.mi-440p/ (A/C)Refrigerant
7 recirculation and restaffing (ACR4) in Heating,
sp.mi Pressure Sensor
instrument to monitor the refrigerant high end Ventilation and Air
Circuit
pressure Conditioning
If the high pressure side refrigerant pressure is System
between the stipulated value?

Inspect the air conditioning system clutch fuse Go to Step 10

8 If the conditioning system clutch fuse melted － Go to Step 9

Air conditioning circuit diagnosis of controlled by engine control module (Cont’ d)

Step Action Numeric value Yes No
1. Remove the air conditioning clutch fuse 2. Go to Step 18 Go to Step 15
Remove the air conditioning system relay
3. Test the following circuit status:
If air conditioning system relay
accumulator positive power supply circuit
short circuit to the ground.
9 If accumulator positive power supply to －
air conditioning system clutch grounding
short
Diode tube short circuit
4. If failure is found, perform necessary repair
work.
Whether find and correct the status?

1. Remove the air conditioning system relay Go to Step 12 Go to Step 11

2. Connect the jumper wire of the 10A fuse to
between the air conditioning system clutch
10 coil power supply socket of the accumulator －
positive and air conditioning system relay
connector
If the air conditioning clutch is engaged?
6-154 Engine Controls Engine

Test the following circuit status: Go to Step 18 Go to Step 15

1. The accumulator positive power supply
circuit to the air conditioning relay open
circuit.
2. The accumulator positive power supply
circuit to the air conditioning relay open
11 circuit. －
3. The air conditioning system clutch grounding
circuit open
4. Poor contact of air conditioning clutch coil
connector terminal
Do you find and correct the status?

Test the air conditioning relay terminal in the Go to Step 18 Go to Step 16

under-hood attachment wiring conjunction box for
poor contactIf poor terminal contact is found,
12 replace the under-hood attachment wiring －
conjunction box.
Do you find and correct the status?

1. Close the ignition switch Go to Step 14 Go to Step 16

2. Remove the air conditioner system relay
13 3. Connect the ignition switch －
Is the air conditioning clutch engaged?

Disconnect the air conditioning clutch connector. Go to Step 15 Go to Step 17

14 Is the air conditioning clutch engaged? －

Replace the air conditioning system clutch Go to Step 18

15 Is the replacement operation finished? － －

Replace the air conditioning relay compressor. Go to Step 18

16 Is the replacement operation finished? － －

Determine and repair the malfunction of short Go to Step 18

circuit to voltage between the accumulator
17 positive power supply circuit to the air conditioning － －
system clutch.
Is the repair completed?

Air conditioning circuit diagnosis of controlled by engine control module (Cont’ d)

Step Action Numeric value Yes No
Engine Engine Controls 6-155

Note:Before continuing execution of this Go to Step 3

step, the following conditions must be
followed:
Ambient temperature must be higher than
5°C (41°F)
The air conditioning system pressure must
be higher than 35p/sp.mi
（0.4v）。
Cooling temperature must be lower than
121°C (41°F)
1. Start and keep the engine to run at the
18 － System OK
speed of 1000-1500rpm
2. Turn the air conditioning system selection
switch to ON.
3. The air conditioning clutch engagement
sound is heard.
4. Wait for 5 seconds, then turn the air
conditioning shifting switch to OFF.
5. The air conditioning clutch engagement
sound is heard.
Is the air conditioning system clutch coil engaged
and separated?
6-156 Engine Controls Engine

6.4.4.64 Electric cooling fan diagnosis Poor contact of the engine control module,
cooling fan relay or cooling fan motor-inspect
Circuit description the wiring harness connector for the following
Fan motor is supplied by the wiring conjunction box problem.
for power. When current control fuse 1 and fan 2, 3 － Terminal loosen
from the fan in the wiring conjunction box controls the
－ Fit inappropriated
fuse via the relay coil flowing through the engine
control module to be grounded, the cooling fan relay － Broken locks
is power on.When the fan is at high speed operation, － Improperly formed or damaged terminals －
the low speed control circuit of the fan and high
speed control circuit are all grounded.When the low Poor terminal-to-wire connection
speed fan control circuit is grounded, the low speed Test Description
fan operates.
The step number in the following number malfunction
When the fan is at low speed operation, the engine diagnosis table:
control module provides grounding access for cooling
fan 1 relay.Close fan 1 relay, current reaches the right 1. When setting of particular diagnosis
side cooling fan motor from the underhood malfunction code, the engine control module
attachment wiring conjunction box through the relay will allow the engine cooling fan for
angle end.During the low speed operation, the operation.Before using this table, first refer to
grounding access of the right side cooling fan motor the appropriate diagnosis code table.
is through the cooling fan 2 relay and left side engine 2. Before diagnosis, allow the engine coolant
cooling fan motor. Allow the 2 low speed operating temperature dropping to below 100°C (212°F).
cooling fan to form connection in series. 3. Cooling fan operating condition:
When the fan is at high speed operation, the engine When there is a problem with the water
control module provides grounding access for cooling sensor, no matter for any other condition,
fan 1 relay.The engine control module provides the 2 fans are all running at a high speed.
grounding access for cooling fan 2 relay and cooling
Water temperature exceeds the high
fan 3 relay.Thus close all 3 cooling fan relays.During
threshold value103°C, no matter in any
fan high speed operation, left and right side engine
other condition, both fans are running at
cooling fan all attain current from the wiring conjunction
high speed.
box and each cooling fan has their own grounding
access. Diagnostic aid Idle speed with the air conditioning not
turned on: water temperature exceeds the
If it is a over heat problem for customer complaint, low threshold value 93°C , both fans are
determine the complaint for actual overflow owing to running at low speed;
boiling, and illumination of the warning lamp, or
engine coolant temperature (ECT) meter for Turn on the air conditioner with idle speed:
indication of over heat. Metering gauge precision is to both fans running a low speed.
indicate the engine coolant temperature sensor Air conditioner isn't turned on during
reading and that of the metering gauge reading for driving: when water temperature exceeds
comparison through indication of the malfunction low threshold value 93°C , and vehicle
diagnosis instrument.If the engine indeed is too hot speed is lower than 80 KM/h, both fans are
and the metering instrument indicates too hot, but the running at a low speed.
cooling fan isn't turned on, the engine cooling Drive with air conditioner turned on: when
temperature sensor (ECT) may drift to be out of the vehicle speed is lower than 45 KM/h;
calibration range, needing replacement.If the engine vehicle speed is at 45-80 KM/h and water
too hot and cooling fan is on, the cooling system is temperature exceeds the low threshold
suspected to have problem, needing inspection. value 93°C , both fans are running at low
Inspect the following circumstances: speed.
Electric Cooling Fan Diagnosis
Action Numeric value Yes No
 Engine Engine Controls
6-157
having executed Powertrain On Go to Step 2 Go to Powertrain
BD) System Check? On Board
－ Diagnosis (OBD)
System
Inspection
ction diagnosis code set? Go to Go to Step 3
corresponding
- diagnostic
malfunction code
table

llation of malfunction diagnosis Go to Step 4

ument
n at diagnosis of all fan malfunction,
ne cooling temperature must be lower Go to cooling fan
the stipulated value. 100°C （212°F）
table #1
n the engine and air conditioner is
ed off, turn on the ignition switch.
ling fan turned off?

unction diagnostic instrument to Go to Step 5

the fan running at low speed. Go to cooling fan
－
cooling fans shift to high speed? table #2

t: Wait for 3-5 seconds, to determine Go to Step 6

has been shifted from low speed to
ed. Go to cooling fan
－
malfunction diagnostic instrument to table #3
the fan running at low speed.
cooling fans shift to high speed?

from the output window on the Go to Step 8 Go to Step 7

unction diagnostic instrument.
onditioner is turned off, the engine is －
ing at idle speed.
ling fan turned on?

he air conditioner Go to Step 9

ling fan turned － System OK

oner request indicated on the Go to Air Go to Step 10

on diagnosis instrument is YES? Conditioning
System Diagnosis
－ in Heating,
Ventilation and Air
Conditioning
System

oner request indicated on the Go to Air

on diagnosis instrument is YES? Go to Air Conditioning
conditioning System Diagnosis
circuit diagnosis in Heating,
－
controlled by Ventilation and Air
engine control Conditioning
module. System

place the required programme of the

ontrol module Replace the engine － System OK －
module, is the operation completed?
6-158 Engine Controls Engine

6.4.4.65 Fuel System Pressure Test 8. Test the ability of fuel system to maintain a
particular fuel pressure range.Fuel pump may
System description need circulation for multiple times, then it can
Appropriate fuel pressure is necessary to maintain reach the pressure range.
engine effective operation and emission, and if the 9. When accelerating cruise or steering difficulty,
fuel pressure is not within the specification, the decrease of fuel pressure may cause
vehicle drive performance may be affected or the insufficient oil supply.Insufficient oil supply may
emission level is increased. cause power damage, surge, or engine
The fuel system include the following components: misfiring, the malfunction diagnosis instrument
may be used.If it happens with extreme
Fuel strainer insufficient oil supply, the oxygen sensor may
Fuel pump be lower than 500 millivolt and the fuel injector
Fuel oil filter pulse width will increase.
Fuel feed pipe 13. When the engine is at idle, the manifold
pressure is very low (degree of vacuum very
Fuel oil pressure regulator
high) The low pressure (degree of vacuum very
Fuel oil duct high) acts on the fuel pressure regulator
Oil injector membrane, causing the fuel pressure to further
decrease.Fuel pressure at idle slightly changes
Fuel return hose
with the pressure, but the fuel pressure at idle
Test Description speed can not be lower than that when the
The step number in the following number malfunction engine burning out indicated in Step 2.
diagnosis table: 14. This test is designed to determine if the fuel
2. Test the ability of fuel system to reach a pressure too high is caused by fuel return pipe
particular fuel pressure range.Fuel pump may or fuel pressure regulator detent plug. Too
need circulation for multiple times, then it can densely status will set DTC P0132.Driving
reach the pressure range. condition relating to too densely fuel instance
include walking difficulty (then emitting with
6. If the fuel system pressure decreases to
black smoke) and thick sulphur smell.
above 5p/sq.mi.within 10 minutes, that shows
one or multiple leakage.
Fuel system pressure test
Step Action Numeric value Yes No
Has Powertrain On Board (OBD) System Check Go to Step 2 Go to Powertrain
been executed? On Board
1 － Diagnosis (OBD)
System Check

1. Installation of fuel pressure meter. Go to Step 6 Go to Step 3

2. Turn on the ignition switch, and keep the
engine burning out.
3. Use the malfunction diagnosis instrument to
command the fuel pump to be turned on. Fuel Pressure 335
2
KPa at Idle
4. When the fuel pump is running, monitor the
fuel pressure.
Is the fuel pressure indicated by the fuel pressure
meter within specified range?

Is the fuel pressure indicated by the fuel pressure Go to Step 14 Go to Step 4

3 meter within the specified range? 335 KPa

Visual inspect the fuel system of oil leakage. Go to Step 21 Go to Step 5

4 Do you find and correct the status? －

Is the fuel pressure indicated by the fuel pressure Go to Step 7 Go to Step 16

5 meter within the specified range? 0 KPa
 Engine

Engine Controls 6-159

Fuel system pressure test(Cont’ d)
Step Action Numeric value Yes No

Note:When the fuel pump stalls for operation, Go to Step 7 Go to Step 9

the fuel pressure may slightly change, then is
at stable and keeps unchanged.
6 Observe the fuel pressure on the fuel pressure 34 KPa
meter.
Is fuel pressure decreased to below specified
value within 10 minutes?

1. Release the fuel pressure. Go to Step 19 Go to Step 8

2. Install the fuel pipe cut-out connector to
between oil supply pipe, fuel return pipe and
fuel distribution passage.
3. Open the fuel supply valve, close the return
pipe valve.
4. Turn on the ignition switch, and keep the
7 engine burning out. 335 KPa
5. Discharge air in the fuel system.
6. Use the malfunction diagnosis instrument to
command the fuel pump to be turned on.
7. Wait for creation o fuel pressure.
Does the fuel pressure meter indicate the fuel
pressure stable within specified range?

1. Command the fuel pump to be turned on. Go to Step 17

2. With the fuel pump running, close the fuel
feed valve. Go to Fuel Injector
8 －
Is the fuel pressure indicated by the fuel pressure Balance Test
meter within the specified range?

Is the fuel pressure suspected of dropping-off Go to Step 10 Go to Step 12

9 during acceleration, cruise, or hard cornering? －

Visual inspect of the following components, Go to Step 21 Go to Step 11

whether they have blockage.
Fuel oil filter
10 －
Fuel feed pipe
Do you find and correct any of the conditions?

1. Remove the fuel pumpRefer to Electric Fuel Go to Step 21 Go to Step 17

Pump Replacement
2. Visual Inspection of the Following
Components:
Is the fuel pump strainer blocked, and is
the position and installation on the fuel
11 transmitter assembly correct. －
If there is a leakage with the fuel pump
hose
Inspect the fuel pump, whether they are
suitable to this vehicle.
Do you find and correct any of the conditions?

1. Start the engine. Go to Step 13

2. Allow the engine to run at idle, until the
engine reaches the normal operation
12 temperature. 21-69 kilopascal Go to Symptom
If the fuel pressure decreases to be within the
specified range?
 6-160 Engine Controls Engine

Fuel system pressure test(Cont’ d)

Step Action Numeric value Yes No
1. Disconnect the fuel pressure regulator Go to Step 17
vacuum hose.
2. When the engine runs at idle, allow the 12-
13 14 inch vacuum to act to the fuel pressure 21-69 kilopascal Go to Step 18
regulator.
If the fuel pressure is decreased to be within the
specified range?

1. Release the fuel pressure.

2. Disconnect the fuel return pipe
3. Connect a particular long flexible fuel hose
to the fuel return pipe outlet passage.
4. Place the flexible hose opening end to the
14 gasoline container permitted. 335 KPa Go to Step 20 Go to Step 15
5. Use the malfunction diagnosis instrument to
command the fuel pump to be turned on.
Is the fuel pressure indicated by the fuel pressure
meter within specified range?

Visual inspection of fuel outlet passage, if they

15 are blocked. － Go to Step 21 Go to Step 19
Do you find and correct any of the conditions?

Visual Inspection of the Following Conditions:

Fuel oil filter blockageRefer to Oil Duct and
Fuel Filter Replacement
Fuel oil pipe blockedRefer to Fuel Feed
Hose/Hard Pipe Replacement (filter to the Go to Fuel Pump
16 engine) － Go to Step 21 Circuit
Fuel Pump Strainer blockage Diagnosis”
Fuel Pump Flexible Pipe LeakageRefer to
Electric Fuel Pump Replacement
Do you find and correct any of the conditions?

Change fuel oil pumpRefer to Electric Fuel Pump

17 Replacement － Go to Step 21 －
Is the repair completed?

Determine and repair the fuel pressure regulator

18 vacuum leakage － Go to Step 21 －
Is the repair completed?

Change fuel pressure regulatorRefer

19 Fuel Pressure regulator Replacement Is － Go to Step 21 －
the repair completed?

Determine and exclude blockage in the fuel return

20 pipe. － Go to Step 21 －
Is the repair completed?
 Engine

Engine Controls 6-161

1. Release the fuel pressure.
2. Restore the fuel system to the original
status.
3. Installation of fuel pressure meter.
4. Turn on the ignition switch, and keep the
engine burning out.
21 335 KPa at idle System OK Go to Step 2
5. Use the malfunction diagnosis instrument to
command the fuel pump to be turned on.
6. When the fuel pump is running, monitor the
fuel pressure.
Does the fuel pressure meter indicate the fuel
pressure stable within specified range?

6.4.4.66 Fuel Injector Coil Test-engine The step number in the following number malfunction
diagnosis table:
coolant temperature (ECT) between 10-
2. Engine Coolant temperature (ECT) affects the
35 fuel injector resistance and fuel injector
℃ (50-95 ℃ ) detector detects the malfunction fuel injector
ability.If the engine coolant temperature is
Circuit description within specified value, refer to Fuel Injector Coil
Engine Control Module (ECU) utilizes the driver control Test- Engine coolant temperature (ECT) is
fuel injector control circuit.Fuel injector fuse provides between 10-35°C"
power supply to fuel injector, and controls the module 3. Due to current initial fluctuation, the indication
grounding through the engine.The driver controls the on the DMM in the first 1 second is not surely
fuel injector grounding circuit, and allows for fuel pulse. accurate.Therefore, the lowest voltage
Diagnostic aid indicated by the DMM after the 1rt second
Test the engine fuel injector harness if there exists the should be recorded.Voltage indication on the

Resistance (ohm) Voltage indicator under 10°C-35°C （50°F-95°F）

5.7-6.6

Fuel injector number Voltage reading Pass/Failure

１ 6.3 Pass

2 5.6 Failure

3 6.2 Pass

4 6.1 Pass
following conditions: DMM is between the specified value.Refer to
Poor contact of terminals. examples.Owing to fuel injector winding
preheating and resistance change, the voltage
Inspect the harness connector if there exists the indicated on the DMM may increase during the
following conditions: － Terminal loosen whole test process.Abnormal reading shows
－ Fit inappropriate there is interruption exists in the fuel injector,
and the fuel injector must be changed.Fuel
－ Broken locks
injector exceeding the specified range must be
－ Improperly formed or damaged terminals regarded as having problem, and it must be
－ Poor terminal-to-wire connection changed.

Use the appropriate match terminal to test

tensile for appropriateness.
Wiring harness damage
Inspect the wiring harness for damage.
Test Description
6-162 Engine Controls Engine

Fuel injector coil test-engine coolant temperature(ECT), between 10°C-35°C （

50°F-
95°F）
Step Action Numeric value Yes No
Has Powertrain On Board(OBD) System Check Go to Powertrain
been executed? On Board
1 － Go to Step 2 Diagnosis (OBD)
System Check

1. Use malfunction diagnostic instrument to Go to fuel injector

monitor the engine coolant temperature coil test - engine
parameter cooling
10°C-35°C (50°F- temperature (ECT)
2 2. When the engine is turned OFF, TURN ON Go to Step 6
95°F) exceeds 10°C-
the ignition
If measured value is between the specified value? 35°C
(50°F-95°F)

Note:Fuel system may not be applied with

pressure.Refer to Fuel Pressure Release
Pressure
1. Install J39021 fuel injector coil/equalizer
tester, J39021-210 fuel injector selector
switch box and J39021-410 fuel injector coil
test wiring harness.
2. Select the coil test on the fuel injector tester
0.5AMP position
3. Connect the lead of the DMM to the fuel
injector tester and select DC voltage tenths Go to Fuel Injector
3 5.7-6.6v Go to Step 4
scale. Balance Test
4. Select an fuel injector on the J39021-210
injector selector switch box.
5. Press down Press Start Test button on the
fuel injector coil/equalizer tester。
6. After the first second, record the lowest
reading.
7. For each of the fuel injector, repeat this
test.Is the fuel injector reading abnormal or
exceeds the specified value range?

1. Remove the upper intake manifold.

2. Test the fuel injector wiring harness between
connector and fuel injector for the following
conditions:
4 There exists an open or short circuit to － Go to Step 6 Go to Step 5
the ground in the fuel injector wiring
harness.
Poor terminal contact in the fuel injector.
Do you find and correct any of the conditions?

Replace the malfunction fuel injector.

5 Is the replacement operation finished? － Go to Step 6 －

If there still exists any driving performance Go to

problem? corresponding
6 － diagnostic System OK
malfunction code
table
Engine Engine Controls 6-163

6.4.4.67 Fuel injector coil test -engine Inspect the wiring harness for damage.
Coolant temperature (ECT) exceeds 10- Test Description
The step number in the following number malfunction
35 ℃ diagnosis table:
(50-95degrees Fahrenheit) 2. Engine Cooling Liquid Temperature (ECT)
affects the fuel injector resistance and fuel
Circuit description injector detector detects the malfunction fuel
Engine Control Module (ECU) utilizes the driver injector ability.
control fuel injector control circuit.Fuel injector fuse
3. Due to current initial fluctuation, the indication
provides power supply to the fuel injector, and
on the DMM in the first 1 second is not surely
controls the module grounding through the
accurate.Therefore, the lowest voltage
engine.The driver controls the fuel injector grounding
indicated by the DMM after the 1rt second
circuit, and allows for fuel pulse.
should be recorded.Owing to fuel injector
Diagnostic aid winding preheating and fuel injector winding
Test the engine fuel injector harness if there exists the resistance change, the voltage indicated on the
following conditions: DMM may increase during the whole test
process.Abnormal voltage reading or
Poor contact of terminals. comparatively large unstable voltage pulse
Inspect the harness connector if there exists indicates fuel injector internal poor contact.Find
the following conditions: － Terminal loosen out the highest voltage as the reference below
95v from the recorded voltage, then calculate
－ Fit inappropriate
the difference of the voltage of each fuel
－ Broken locks injector nozzle and reference voltage. If it is
－ Terminal deformation or damage and failure greater than 0.6v, that indicates it should be
with the wiring connection changed due to failure and the nozzle with
measured voltage higher than 9.5v also
Use the appropriate match terminal to test indicates a malfunction.
tensile for appropriateness.
Wiring harness damage
Acceptable difference higher/lower than
Highest voltage reading 10°C-35°C （50°F-95°F）
6.9v 6.9v

Injector number Voltage Difference value Pass/Failure

1 9.8 － Failure

2 6.6 0.3 Pass

3 6.9 0 Pass

4 5.8 1.1 Failure

Fuel injector coil test - engine coolant temperature (ECT) exceeds 10°C-35°C （50°F-
95°F）
Step Action Numeric value Yes No
Has Powertrain On Board(OBD) System Check Go to Powertrain
been executed? On Board
1 － Go to Step 2 Diagnosis (OBD)
System Check

Fuel injector coil test - engine coolant temperature (ECT) exceeds 10°C-35°C （50°F-
95°F） (Cont’ d)
Step Action Numeric value Yes No
6-164 Engine Controls Engine

1. When the engine is turned OFF, TURN ON Go to Fuel Injector

the ignition Coil Test - engine
2. Use malfunction diagnostic instrument to cooling
10°C-35°C (50°F- temperature (ECT)
2 monitor the engine cooling liquid temperature Go to Step 3
95°F) exceeds 10°C-
parameter
If measured value is between the specified value? 35°C
(50°F-95°F)

Note:Fuel system may not be applied with

pressure.Refer to Fuel Pressure Release
Pressure
1. Install J39021 fuel injector coil/equalizer
tester, J39021-210 fuel injector selector
switch box and J39021-410 fuel injector coil
test wiring harness.
2. Select the coil test on the fuel injector tester
0.5AMP position
3. Connect the lead of the DMM to the fuel
3 injector tester and select DC voltage tenths 9.5v Go to Step 5 Go to Step 4
scale.
4. Select an fuel injector on the J39021-210
injector selector switch box.
5. Press down Press Start Test button on the
fuel injector coil/equalizer tester。
6. After the first second, record the lowest
reading.
7. For each of the fuel injector, repeat this
test.Is the fuel injector reading abnormal or
exceeds the specified value range?

1. From the recorded readings, identify the

highest voltage.
2. Subtract all other voltage reading from the Go to Fuel Injector
4 highest recorded voltage respectively. 6.9v Go to Step 5
Balance Test
Is there exists any difference exceeding the
specified value?

1. Remove the upper intake manifold.

2. Test the fuel injector wiring harness between
connector and fuel injector for the following
conditions:
5 There exists an open or short circuit to － Go to Step 7 Go to Step 6
the ground in the fuel injector wiring
harness.
Poor terminal contact in the fuel injector.
Do you find and correct any of the conditions?

Replace the malfunction fuel injector.Refer to

6 Electric Fuel Pump Replacement － Go to Step 7 －
Is the replacement operation finished?

If there still exist any driving performance Go to

problem? corresponding
7 － diagnostic System OK
malfunction code
table

6.4.4.68 Fuel Tank Leakage Inspection remarks

Engine Engine Controls 6-165

Before performing fuel tank leakage inspection, detected.Sample must be clear and transparent.If the
place the chemical extinguisher near the sample is feculence or polluted by water (a layer of
working area. water appears on the sample lower part), this
Before removing the suspected leak fuel tank, procedure should not be employed and fuel system
identify the fuel hose not leaking to the fuel must be clean.
tank.Additionally, you still need to identify no 1. Use a particular oil duct of 100 millilitre with 1
leakage around the fuel transmitter pad. millilitre scale to fill 90 millilitre of fuel.
1. Leak of fuel system pressure.Refer to 2. Fill 10 milllilitre of water to allow it reaching full
Fuel Pressure Release Pressure scale of 100 millimitre and install the plug.
2. Remove the fuel tank, refer to Fuel Tank 3. Shake with great force the oil duct for
Replacement 1015seconds.
3. Block all outlet as per the following steps: 4. Release pressure among them, and carefully
Install the filler port journal and hear the sound of plug.
ventilation hose, upper journal 5. Reinstall the plug, and shake with great force
assembly, and install the filler port the oil duct for 10-15 seconds.
cover cap. 6. Place the oil duct on the horizontal surface for
Use seal to install the fuel tank 5 minutes, allowing the liquid to produce
transmitter, and block the oil duct with delamination.
the male plug. If there is alcohol in the fuel, the capacity of the lower
Install a short oil duct to the fuel tank part (including alcohol and water) will exceeds 10
oil gauge breather pipe. millilitre.For example, if the bottom layer is increased
4. Apply air pressure to the fuel tank vent to 15 millimitre, this indicates at least 5 percent
hole duct.Allow the pressure to reach 7-10 alcohol in the fuel. Actual alcohol content may be
kilopascal (1-1.5p/sq.mi.), and clamp the slightly much more, because this procedure has not
fuel filler hose to maintain the pressure. completely absorbed alcohol in the fuel.
5. Use soap or immersed method to inspect The malfunction cause lies in the fuel system corrosion,
the leakage postion.If leakage observed, further to cause the fuel filter blockage, rubber part
replace the fuel tank.Refer to Rear damage and/or air-fuel mixture air become thinner.
Window Replacement. Type and thickness of alcohol employed in the
finished fuel is different with each other Effect of
some alcohol type to the fuel system components is
6.4.4.69 Alcohol/fuel pollution diagnosis higher than other alcohol type.If the higher alcohol
thickness is suspected in the fuel, causing the driving
Alcohol thickness in fuel greater than 10%, and it is
performance to decrease, then the following
harmful to the fuel system components, which could
procedures can be employed to detect the alcohol in
cause driving performance malfunction, such as
the fuel.
gasp, insufficient power, flat spot, and not start etc.
The malfunction cause lies in the fuel system corrosion,
further to cause the fuel filter blockage, rubber part 6.4.4.70 Electric ignition (EI) system
damage and/or air-fuel mixture air become thiner.
diagnosis
Type and thickness of alcohol employed in the
finished fuel is different with each other Effect of Refer to Engine Control Module Schematic Diagram
some alcohol type to the fuel system components is in
higher than other alcohol type.If the higher alcohol Wiring System
thickness is suspected in the fuel, causing the driving Circuit description
performance to decrease, then the following Auxiliary ignition inspection test for existence of spark
procedures can be employed to detect the alcohol in plug, spark wiring or ignition control module and
the fuel. remarks malfunction of a coil.This table need J26792spark
Fuel sample should be drawn from the fuel tank bottom, tester （ST125）
allowing that any moisture in the fuel tank could be
Electric ignition mechanism (EI) System Malfunction Diagnosis
6-166 Engine Controls Engine

Action Numeric value Yes No

Whether having executed Powertrain On Go to Powertrain
Board(OBD) System Check? On Board
－ Go to Step 2 Diagnosis (OBD)
System Check

Use （J26792）spark tester to test each cylinder

for spark. If you observe any cylinder without － Go to Step 3 Go to Step 6
spark?

Notice: Spark to ignition control module

wiring electroarcing or ignition coil to ignition
control electroarcing may cause flat spot or
not start Go to Powertrain
Inspect and test the spark plug wire of affected On Board
－ Go to Step 4
cylinder, ignition coil and spark plug for short to Diagnosis (OBD)
ground or ignition to grounding.If carbon creepage System Check
or corrosion appears, replace the affected 2
components.
Do you find and correct any of the conditions?

Test the affected spark plug wire resistance for

appropriateness. Go to Powertrain
Replace the spark plug wire quite different with On Board
1,968ohm/m Go to Step 5
the specification. Diagnosis (OBD)
Do you find and correct any of the conditions? System Check

Replace the affected cylinder coil with a known

good coil. Go to Powertrain
If the malfunction follows the affected coil, replace On Board
－ Go to Step 10
the coil. Diagnosis (OBD)
Do you find and correct any of the conditions? System Check

Inspect the spark plug wiring for appropriateness,

and ignition sequence for correctiveness.If the Go to Powertrain
spark plug wiring not correct, you need to On Board
－ Go to Step 7
rearrange the wiring. Diagnosis (OBD)
Do you find and correct any of the conditions? System Check

Use the DMM to inspect the spark plug for internal Go to Powertrain
short to ground. On Board
Replace any grounded spark plugs found － Diagnosis (OBD) Go to Step 8
Do you find and correct any of the conditions? System Check

1. Remove the spark plug.

2. Inspect the spark plug for damage. Go to Powertrain
3. If any spark plug damage are found, replace On Board
－ －
the affected spark plugs. Diagnosis (OBD)
System Check
Is the replacement operation finished?

1. Disconnect the ignition control module

2. Turn on the ignition switch
3. Use reliable test lamp connected to ground
to probe the ignition power supply circuit of － Go to Step 10 Go to Step 12
the ignition control module.
Does the test light illuminate?
 Engine Engine Controls6-167

Electric ignition mechanism (EI) System Malfunction Diagnosis(Cont’ d)

Step Action Numeric value Yes No
1. Ensure the accumulator voltage to be within
the specified range.
2. Turn off the ignition switch
3. Connect the DMM to the ignition control
module wiring harness connector between
10 the 58X high voltage reference circuit and － Go to Step 13 Go to Step 11
the 58X low voltage reference circuit.
4. Crank the engine while observing the AC
Duty cycle(%)
The DMM indicates If the AC Duty cycle occurs?

Test the 58X curve crank sensor circuit for the

following conditions:
Opened
Short to ground
Go to Powertrain
Short to voltage On Board
11 － Go to Step 14
Short between the 58X high voltage Diagnosis (OBD)
reference and the 58X low voltage reference System Check
circuits.
Repair any damage wire.
Do you find and correct any of the conditions?

Repair the open and short to ground malfunctions Go to Powertrain

in the ignition power supply circuit of the ignition On Board
12 control module. － Diagnosis (OBD) －
Is the repair completed? System Check

Replace the ignition control module Go to Powertrain

Is the replacement operation finished? On Board
13 － Diagnosis (OBD) －
System Check

Replace the 58X crank sensor. Go to Powertrain

Is the replacement operation finished? On Board
14 － Diagnosis (OBD) －
System Check

6.4.5 Repair Instructions

6.4.5.1 Intake Air System Replacement
Removal Procedure
6-168 Engine Controls Engine

1. Disconnect the negative wire of the accumulator.

2. Pull down out the intake air temperature sensor
connector.

606005

3. Screw down the air filter hose clamp

606006
Engine Engine Controls 6-169

4. Take off the air filter hose clamp

606006

5. Take off the air filter inlet pipe.

6. Loosen the air filter cover clamp, and take off the
air filter cover.

607008

7. Take off the air filter

607009
 Engine

8. Take off the air filter box.

Installation Procedure
Engine Engine Controls 6-171

1. Install the air filter box.

2. Install the air filter.
3. Use the compressed air to clean the core filter from
inside to outsideMaximum compressed air pressure
shall not exceed 484 kilopascal.
4. Clean the inner surface of the air filter box.
Note:When the air filter element is fouled, it will not
increase the fuel consumption or carbon monoxide
emission, but it will cause the engine power to decrease.

607009

5. Install the air filter cover.

6. Install the air filter inlet pipe.

607008
 Engine

7. Install the air filter hose.

8. Check the air filter hose for hole, cut, coil cuckling,
or possible damaged hose abrasion point.
Engine Engine Controls 6-173

9. Install the air filter hose clamp.

Tightening
Tighten the air filter hose clamping screw to 2.5-
3.5 N m

607007

10. Connect the air intake temperature sensor to the

wiring harness.
6.4.5.2 Intake air temperature sensor
replacement
Removal Procedure
1. Disconnect the air temperature sensor power
supply.
2. Take out the air temperature sensor from the hose.
Installation Procedure
1. Install the air temperature sensor to the air filter
hose until to the sensor limits.
Note:Use lithium soap to install the sensor, but do not
use ore base grease (petroleum)Plug the wiring harness
606006 to the power supply connector of the air temperature
sensor.

606005
 Engine

6.4.5.3 Throttle Position Sensor

Replacement
Removal Procedure
1.

607012

Disconnect the wiring harness from the power

supply connector of throttle position sensor.
Engine Engine Controls 6-175

Screw down the throttle position sensor bolt.

3. Carefully take down the throttle position sensor.

607013

Installation Procedure
1. Install the throttle position sensor.
Note:Inspect the valve cross latch if it is tightly
secured on the sensor.
2. Connect and tighten the throttle position sensor
screw.
Tightening
Tighten the throttle position sensor bolt to 3N m.

607013
 Engine

2.
3. Insert the electric connector to the throttle
position sensor.

607012

6.4.5.4 Idle Air Control Valve

Replacement
Removal Procedure
Caution: Before removing IAC valve connector, the
ignition start key must be turned off for at least 10
senconds.During this period of time, the valve returns
to the static position.
Engine Engine Controls 6-177

1. Disconnect the electric connector of idle air

control valve from the wiring harness.
Screw down the idle air control valve bolt, and
take it off.
3. Carefully take the idle air control valve from the
throttle body.

606016
606017

Installation Procedure
1. Use a sealing ring (if any） to install the idle air
control valve.
2. Use the fixture adhesive (Leitai) to install the
idle air control valve screw and tighten it.
Tightening
Tighten the idle air control vale screw to 3N m.

606017
 Engine

2.

606016

3. Connect the wiring harness to the idle air

control valve connector.

6.4.5.5 Throttle body replacement

Engine Engine Controls 6-179

Removal Procedure
1. Disengage the throttle cable and throttle body
camshaft and inlet manifold bracket.

606018
 Engine

2.
Allow the crankshaft positive (positive voltage)
ventilation hose and camshaft bracket hood
cover to be disconnected, to allow the vacuum
hose and camshaft bracket hood cover to be
disconnected.
Engine Engine Controls 6-181

3. Allow the canister purge pipe and throttle body

to be disconnected.
4. Disconnect the throttle body heating pipe and
throttle， use the commercial hose clip for
clamping and carefully clean the throttle body.
5. Disconnect all electric connection of the throttle
body
6. Disengage the return spring from the throttle
body.
7. Screw off and take off the throttle body nut.

606019

8. Carefully remove throttle body.

607020

607021
 Engine

2.

607022

9. Carefully remove the throttle body gasket.

Installation Procedure
Note:Remove and clean residues on the gasket.
Engine Engine Controls 6-183

1. Install new gasket (component

number:90411524 or 92089888)

607022
 Engine

2.
Install the throttle body, and fix the nut and
tighten.
Tightening
Engine Engine Controls 6-185

Tighten the throttle body nut to 9 N m.

3. Install the throttle body return spring.

607021

607020
 Engine

606018

606019

4. Connect the vacuum hose to the camshaft

bracket hood cover, and connect the
ventilation hose to the camshaft bracket hood
cover.
Engine Engine Controls 6-187

5. Connect the throttle cable and throttle body

camshaft and inlet manifold bracket.
6. Connect the canister blowpipe.
7. Connect the throttle body heating pipe and
throttle body.
8. Connect all electrical connection between the
wiring harness and the throttle body.
 Engine

6.4.5.6 Fuel Track Replacement

Removal Procedure

607024

607026

1. Disconnect the connector from the fuel injector.

2. Disengage the vacuum pipe and pressure
regulator.
Engine Engine Controls 6-189

3. Use the special tool J-370088-A to take of the

inlet and outlet oil passage pipe from the fuel
distribution line.
Caution: Fuel in the system has been always under
pressure, which must be released before removal of
the oil line.
4. Screw down and take off bolts on the fuel
distribution line.

607025

5. Take out the fuel rail together with fuel injector

and pressure regulator.Carefully lift it up and
avoid to damage of the fuel injector sealing
ring.

606027
 Engine

Installation Procedure

606027

607025

1. Install the fuel rail with fuel injector and

pressure regulator together.Carefully lift it up
and avoiding to damage of the fuel injector
sealing ring.Use a thin layer of Vaseline to
lubricate the sealing ring.
Engine Engine Controls 6-191

2. Install the fuel rail bolt and tighten Tighten

Tighten the fuel rail to 10N m.
 Engine

607026

607024

3. Connect the vehicle oil line with the fuel rail

inlet and outlet pipe.
Engine Engine Controls 6-193

4. Connect the vacuum pipe to the pressure

regulator.
5. Connect the power supply connector of the
fuel injector with the wiring harness.
 Engine

6.4.5.6 Fuel Injector Replacement

Removal Procedure
1. Remove the fuel distribution line from the
engine.Refer to Electric Fuel Rail Replacement
2. Remove the fuel injector clamp of the fuel
injector of the fuel rail, remove the clamp with
the screw driver.
3. Carefully remove the fuel injector from the fuel
rail and avoiding damage of the sealing ring.
Installation Procedure
1. Carefully insert the fuel injector into the fuel
rail, and inspect the sealing ring for deviation
or kinks.Use a thin layer of Vaseline to
lubricate the sealing ring.
2. Slide the fuel injector clamp toward the fuel rail
until it is clamped tight.
3. Install the fuel rail.Refer to Electric Fuel Rail
Replacement

6.4.5.8 Fuel Pressure regulator

Replacement
Removal Procedure
1. Remove the fuel distribution line from the
engine.Refer to Electric Fuel Rail Replacement
2. Screw down the pressure regulator from the
fuel rail
3. Remove the pressure regulator from the fuel
rail
4. Remove the pressure regulator gascket.
Installation Procedure
1. Install the pressure regulator gasket.
2. Install the pressure regulator to the fuel rail.
3. Tighten the pressure regulator on the fuel rail.
Tighten
Tighten the fuel pressure regulator to 6N m。
Engine Engine Controls 6-195

4. Install the fuel rail to the engine.Refer to

Electric
Fuel Rail Replacement
 Engine

6.4.5.9 Oxygen Sensor Replacement

Removal Procedure
1. Take off the power supply of the wiring harness
from the oxygen sensor.
Engine Engine Controls 6-197

2. Take off the oxygen sensor from the clamp

braket.

3. Screw down the oxygen sensor from the

exhaustion manifold.

607033

607034
 Engine

Installation Procedure

607034

607033

1. Install the oxygen sensor to the exhaustion

manifold and tighten. Tightening
Tighten the oxygen sensor to 42+4 N m.
Engine Engine Controls 6-199

2. Connect the oxygen sensor connector to the

holder bracket.
3. Connect the wiring harness with the oxygen
sensor.
 Engine

6.4.5.10 Intake Manifold Absolute

Pressure Sensor (MAP) Replacement
Removal Procedure
1. Remove the electric connector and vacuum
pressure hose from the manifold pressure
sensor.
2. Screw down the tightening nut.
Engine Engine Controls 6-201

3. Remove the sensor from the front wall plate.

Installation Procedure
1. Install the sensor to the double head bolt welded
on the front wall plate.
2. Tighten the nut.
Tightening
Tighten the intake manifold absolute pressure
607036 sensor nut to 3 N m.
3. Connect the vacuum hose and electric
connector.
6.4.5.11Crankshaft Position Sensor
(CPS) Replacement
Removal Procedure

607036
 Engine

606039

606039

1. Disconnect the wiring harness connector of the

crankshaft sensor from the engine wiring
harness, and take off the wiring harness from
Engine Engine Controls 6-203

under the clamp behind the timing belt rear

cover.
2. Remove the crankshaft position sensor from
bracket of the oil pump housing

Installation Procedure
1. Insert the sensor to the braket.
Note: ensure the braket and sensor absolutely clean,
otherwise the dimensional distance between the
sensor and sawtooth disc will be affected, thus
having an effect on the signal sent to the electronic
control module.
2. Tighten the bolt
Tightening
Tighten the crankshaft position sensor bolt to
9+1 N m。
3. Clamp the wiring harness of crankshaft box
position sensor to the clamp of the timing belt
sheath, and connect the power supply connector
with engine wiring harness.
Note:When routing, the development heat area and
that could produce abrasion to the cable should be
avoided.
4. Adjust the reference span between the
crankshaft position sensor and the signal trigger
plate.
－Use the feeler gauge to measure the
crankshaft position sensor and signal
trigger plate.
 Engine

606040

(Attached to the crankshaft accessory transmission

belt pulley, indicated by the arrow) interval span. Metric
value should be 1.0+0.7 mm.
Note:If the metric value cannot be reached, the

607043

crankshaft position sensor bracket must be replaced.

Engine Engine Controls 6-205

6.4.5.12 Coolant Temperature Sensor

(CTS) Replacement
Removal Procedure
1. Open the sealing cover of the coolant
compensation box, allowing the cooling system
to decompress. Refer to Drain and Refill Cooling
System in Engine Cooling System
 Engine

607044

607044

2. Disconnect the wiring harness connector from

the coolant temperature sensor.
3. Screw down the coolant temperature sensor
from the cylinder cover.
Engine Engine Controls 6-207

4. Collect overflow coolant.

Installation Procedure
1. Install the coolant temperature sensor to the
cylinder head. Tightening
Tighten the coolant temperature sensor to 15+3
N m。
607057 2. Connect the wiring harness connector.
3. Charge and discharge air in the coolant system.
Ensure the antifreeze able to reach -30 ℃ .
6.4.5.13 Knock Sensor (KS)
Replacement
Removal Procedure
1. Disconnect the wiring connector from the wiring
harness.
2. Take off the connector from the bracket.
3. Screw off the bolt, and take off the knock
sensor.

607057
 Engine

Installation Procedure
1. Use the bolt to install the knock sensor to the
cylinder body, and screw up. Tightening
Tighten the knock sensor bolt to 20+4 N m.
2. Connect the knock sensor to the wiring
harness, and clamp the connector to the
bracket.
6.4.5.14 Engine Control Module (ECM)
Replacement
Removal Procedure
Engine Engine Controls 6-209

1. Disconnect the negative wire of the

accumulator.
2. Remove the inside panel of the right front door.
3. Remove the right side button and left side screw
under the instrument panel glove box.

607049
607047

4. Screw down the screw of the base board under

the right side column A
5. Take of the base boardRefer to Base Board
Replacement in Interior Trim
6. Expose the electronic control module and wiring
harness.
7. Remove the wiring harness connector from the
wiring harness bracket (2).
8. Screw off the wiring harness bracket bolt (1).
9. Screw of the wiring harness bracket.

607050
607048
 Engine

10. Draw out the electronic control module (1) and

wiring harness connector from the module
bracket (2) horizontally and outward.
11. Disengage the wiring harness connector and the
socket on the electronic control module.
Caution: Ensure to disconnect the connection with the
accumulator for at least 20 seconds before removing
the module connector.
Installation Procedure
Engine Engine Controls 6-211

1. Disengage the wiring harness connector and the

socket on the electronic control module (1).
2. Insert the electronic control module and the
wiring harness connector horizontally into the
module bracket (2).

607050

3. Install the wiring harness bracket （2） .

4. Screw down the wiring harness bracket bolt (1).
5. Connect the wiring harness connector from the
wiring harness bracket.

607049
 Engine

607048

607047

6. Place the base board.Refer to Base Board

Replacement in Interior Trim
7. Install the base board screw Tightening
Tighten the screw to 1.2-1.6 N m.
 Engine Engine Controls 6-213

8. Install the button at the right side, and the screw

at the left side.
9. Install the right door inside panel.
10. Connect the negative cable to the accumulator.
Note:Engine control module equipped on this vehicle
employs electronic erasable and programmable read
only memory.Reprogram must be done after
replacing the engine control module (ECM) For
engine control module (ECM) reprogram method,
refer to the latest Techline program.
6.4.6 Description and Operation － If the fuel injector occurs leakage, the engine
could continue running (diesel effect) after the
6.4.6.1General Description ignition is turned off.
－ If the engine has difficulty to start, inspect the
C16NE engine is installed with improved engine control fuel system, fuel pump relay and ignition
system.The system provides independent fuel injector, system.
which is controlled by the ECM, and it is powered on to
－ Disconnect the grounding wire of the
the fuel injector in pairs, that is to say, for every 180
degree of crank revolution, just make contact in turns accumulator before removing the electronic
to the fuel injector 1, and 4, 2, 3 once a time.Its action components.
is to ensure sufficient fuel combustion in the － When the accumulator connection is
circumstances of maintaining the engine low speed disconnected, all malfunction code stored in the
running and low emission level, to attain the maximum memory cell and correction value of idle and
torque.Ignition is subject to the direct control of the mixture self studied will be cancelled.
direct ignition system. Important repair Notice: To prevent catalytic converter overheated,
description perform cylinder balance test according to the following
－ Only allow to use the PROM assigned for vehicle steps carried out as per the time sequence (if
necessary):
application.
The longest close time of a cylinder is 8
－ Do not let the oxygen sensor to contact fuel and
seconds.
silicone.Do not use gasoline to wash or contact
it. Minimum interval time is 8 seconds to open
and close the cylinder each time.
－ Do not use anti corrosion coating in the catalyst
converter or oxygen sensor and its surrounding
area. 6.4.6.2 Engine Control Module (ECM)
－ Leakage (static air) of the intake and exhaust Description
system before catalytic converter may cause the
oxygen sensor reading error. The Engine Control Module (ECM) is the control
center of the engine management system.It controls
－ Vapor control system leakage may cause idle
datum received from different sensor and
steering angle fluctuation.
 Engine

controller.These information is used for controlling the Idle air control valve controls air when the engine is
engine operation (fuel, ignition advance angle, air running at idle.It can alter the engine speed during the
compressor speed). ECM is responsible for allowing idle duty changing process, avoiding the engine idle,
the engine to play the ideological performance under and keep the lowest speed rotation.Valve position is
the lowest exhaust gas emission. controlled by the engine control module (ECM), which
The control module is behind the panel, and on the adjust the IAC valve according to the idle speed.
front right column. Throttle position sensor (TPS)
1. Electronic Control Module The throttle position sensor is a potentiometer
connected with throttle body shaft, which send
2. Passenger Door
information to the engine control module (ECM), and
these information are the engine power requirement
determined by the throttle position.

607046

6.4.6.3 Air Intake System Description

The system performs collection, cleaning, inspection
and control to air flow, and send it into the intake
manifold where it mixes with fuel.
The system consists of the following components: air
filter, throttle body, air intake temperature (IAT), idle
air control valve (IAC) and throttle body position
sensor (TPS).
Throttle Body
Throttle body controls air flow entered into the intake
manifold.Air flowing into the engine is controlled by
the throttle valve, which is connected with the
acceleration pedal and the pull wire.Except for control
function, there is still holes for transmitting vacuum
signal on the throttle body.
The intake air temperature (IAT) sensor
Intake air temperature utilizes the heat sensor to
control the voltage signal of the ECM.
When the intake air temperature is low, the sensor
has high resistance, therefore with a high voltage at
the ECM.The intake air temperature is used to control
the fuel volume, advance ignition angle and idle air
control
Idle Air Control Valve (IAC)
 Engine Controls 6-215

6.4.6.4 Information Sensor/Switch

Description
Oxygen sensor
The oxygen sensor is installed on the exhaust manifold,
near by the cylinder head.Its action is to monitor the
oxygen content in the exhaust gas, and send information
related with mixed air/fuel ratio to the electronic control
module (ECM).
When the mixture thickness is high, data will be sent to
the ECM, reducing the injected fuel, contrarily when the
mixture thickness is low, increase the injected fuel.

607041

The intake manifold absolute pressure sensor (MAP) is

used to measure the air pressure under some
circumstances, thus allowing the engine control module
(ECM) to perform necessary correction, to compensate
for different height.
The engine control module (ECM) utilizes the MAP
sensor signal to control fuel transmission and ignition
advance angle.
Crankshaft position sensor (CPS)
607031 The system has a sawtoothed disc tightly attached to the
transmission belt pulley of the crankshaft, and still it has
a induction sensor connected with the cylinder radius
Intake Air Manifold Absolute Pressure Sensor position, nearby the sawtoothed disc.There are 58 tooth
(MAP) and a neutral gear for the tooth disc, here with 2 teeth
The intake air manifold absolute pressure sensor (MAP) fewer, and each degree number for inter tooth is 15
is on the front wall panel of the engine compartment. degree.

Its action is to measure the pressure change on the As tooth passes the sensor, the current will change.The
intake air manifold as the engine duty and speed current changing frenquecy may be changed by the
changes, and convert this data to voltage. control unit, and converted into engine speed.
Higher voltage will be produced in the space between 2
Coolant Temperature Sensor (CTS) teeth, thus inform the ECM of the crankshaft position, and
Located at the engine right side, under the direct ignition the ECM will determine the advance angle according to
system (DIS), it action is to inform the engine coolant this.
temperature to the engine compartment control module
(ECM), which reflects the engine temperature.
The ECM utilizes received information to alter the
advance ignition, and change the fuel injection
according to the engine temperature.When the coolant
temperature sensor displays the value of 2.7 V, equaling
to 40 ℃ , inside the Loop Control of the oxygen sensor.
1. Coolant Temperature Sensor (CTS)
2. Connector with the direct ignition module
3. Oxygen sensor
 Engine

6.4.6.5 Oil Rail Description

The oil rail is installed on the inlet manifold, the function of
which is to determine the oil injector position, distributing
pressure fuel to the fuel injector and supporting the
pressure regulator.

607037

Vehicle Speed Sensor (VSS)

The action of the sensor is to inform to the ECM of the
vehicle speed.The module utilizes this information to 607023
control the idle speed, and determine the vehicle if it is
stopped or still running.
ECM counts the signal (rectangular pulse), with km/h as 6.4.6.6 Fuel Injector Description
the unit for calculation of vehicle speed.
The fuel injector is the solenoid controlled by the
Knock sensor (KS) ECM.There is a ball valve, which is normally kept close,
The knock sensor of the engine management system is and opens through the action of the solenoid, so as to
the self produced piezoelectric sensor.It is installed on allow the fuel flow through the fuel injector to the orifice
the engine block, and can produce output voltage plate.The calibrated holes on the orifice plate controls
according to the engine vibration amplitude caused by the fuel flow and form a taper spray, which is sent to the
knock When there is knock existing on the sensor combustion chamber after atomization and gasification.
signal, which is controlled by the ECM through adjusting
the ignition advance angle.
6.4.6.7 Pressure regulator Description
The action of the pressure regulator is to keep the fuel
pressure difference inside the fuel rail and the inlet
manifold as of constant pressure.It increases the fuel
pressure to compensate for engine load as the inlet
manifold pressure increases.When balance is reached
between the calibrated spring, inlet manifold vacuum
and fuel pressure, that is pressure equalizing has been
reached.Pressure regulator is installed on the fuel rail,
as amour type.

607051

6.4.7 Special Tools

 Engine Controls 6-217

Legend Tool Number/Description

TECH2 DTC Inspection

tech-2

J -37088-A
Remove the oil duct from
the fuel distribution line.

J-37088-A
 6-218 Engine Exhaust Engine

6.5 Engine Exhaust

6.5.1 Specification

6.5.1.1 Fastener Tighting torque

Application Specification
Exhaust Pipe Heat Shield Nut 2.5-3.0 N. m

Exhaust Manifold Bolts 15-35 N. m

Exhaust Silencer Inlet Pipe Clamp 25-30 N. m

6.5.1.2 Exhaust System Clearance

Application mm
At empty load, the exhaust system to the body and the heat
shield. 30-53

At full load, the exhaust system to the ground 131

The exhaust system to the catalytic converter heat shield. 36

Exhaust System to the Resonator Heat Shield 30

Exhaust System to the Silencer Heat Shield 30

6.5.2 Diagnostic Information and Procedures

6.5.2.1Tingle and Rattle

Step Action Numeric value Yes No
Inspect for loosening components, such as ear or heat
1 shield etc. － Go to Step 2 Go to Step 3
If there is any loose components?

Tighten all loose fasteners to the specified

torque.Refer to Fastener Tightening Torque The System is
2 － Go to Step 3
If the exhaust system still has tingle and rattle sound? OK.

Inspect for inaccurate components Is

3 there any inaccurate components? － Go to Step 4 －

Positioning System.Inspect the ear and, mounting

bracket for distortion or damage.
When calibrating the system, loosen all fasteners
before correct calibration of all exhaust system The System is
4 － －
components.When tightening fasteners, start from the OK.
vehicle front until to the tail.
If the exhaust system still has tingle and rattle sound?

6.5.2.2 Exhaust Leakage

Numeric
Action value Yes No

d or inaccurate components.
ed or inaccurate － Go to Step 2 Go to Step 3
 Engine Engine Exhaust 6-219

d tighten the connector to the

o Fastener Tightening Torque
－ Go to Step 3 The System is OK.
kage and/or excessive

st manifold or exhaust

st manifold or exhaust － Go to Step 4 Go to Step 5

he specified torque.Refer to
que
－ Go to Step 5 The System is OK.
kage and/or excessive

nifold for crack or break.

－ Go to Step 6 Go to Step 7
rs on the exhaust manifold？
haust manifold.Refer to
ust Manifold Pad
Mechanical － Go to Step 7 The System is OK.
kage and/or excessive

nector for leakage.

age? － Go to Step 8 Go to Step 9

chments position, and tighten

the specification.Refer to
orque and Exhaust Silencer
－ Go to Step 9 The System is OK.
nt Procedure.
kage and/or excessive

clamp for damage or wear. Go to Step

clamp for damage or wear. － Go to Step 11
10
orn gasket and clamping
－ Go to Step 11 The System is OK.
kage and/or excessive

sted exhaust silencer with

pe. Go to Step
sted exhaust silencer with － Go to Step 13
12
pe.

encer with the exhaust pipe

encer Replacement. Go to Step
－ The System is OK.
kage and/or excessive 13

ponent connector or coupling

dvance) for leakage. If there Go to Step
st component connector. － －
14

clamp ring, and tighten the

g.If necessary, weld the
o Fastener Tightening Torque － － The System is OK.
kage and/or excessive

6.5.2.3 Internal Silencer Rattle Sound/Power Damage

Numeric
Action value Yes No
 6-220 Engine Exhaust Engine

s the blocked exhaust system been inspected? To Exhaust

Blockage
－ Go to Step 2 Inspection-1.6L in
the engine control
system

place the exhaust silencer with the exhaust pipe

d tail pipe.
pect the silencer appearance － Go to Step 3 Go to Step 3
here a problem with the silencer?

place the exhaust silencer with the exhaust

e and tail pipe.Refer to Silencer Replacement.
here still power decrease circumstances and/or － Go to Step 4 The System is OK.
ernal rattle sound?

pect the exhaust pipe resonator duct.

here a problem with any of the exhaust resonator － Go to Step 5 The System is OK.
e?

pect the exhaust pipe resonator duct.Refer to

talytic Converter and Resonator Replacement
th exhaust manifold bolt). － － The System is OK.
here still power decrease and/or internal rattle
und?

6.5.2.4 Exhaust Noise

Action Numeric value Yes No
er preheating when in cold weather, inspect the
at shield contacting with the exhaust pipe.Has the Go to
－ Go to Step 2
at shield not been installed or loosen? Step 3

ecessary, replace the fastener of the heat shield. The

here still exhaust noise? － Go to Step 3 System is
OK.

pect the exhaust manifold or duct connector for

kage. Go to
－ Go to Step 4
e there any leaks? Step 5

hten the connection that has leaks according to the

ecifications.Refer to Fastener Tightening Torque System
－ Go to Step 5
es the exhaust noise still exist? OK?

pect the exhaust pipe muffler with exhaust pipe and

pipe. Go to
he exhaust pipe muffler with exhaust pipe and tail － Go to Step 6
Step 7
e burned out or blown out?

place the exhaust pipe muffler with exhaust pipe

d tail pipe.Refer to Muffler Replacement. System
－ Go to Step 7
es the exhaust noise still exist? OK?

pect the crossover exhaust pipe at the manifold

nge for any leaks. Go to
－ Go to Step 8
e there any leaks? Step 9

pair the leaks. System

es the exhaust noise still exist? － Go to Step 9 OK?

6.5.2.4 Exhaust Noise(Cont’ d)

Inspect the exhaust manifold for cracks or breaks. Go to
9 Does any cracks or breaks occur to the exhaust pipe － Go to Step 10 Step 11
?
 Engine Engine Exhaust 6-221

Replace the exhaust manifold.Refer to Exhaust Pipe,

Exhaust Manifold Gasket Replacement in Engine System
10 Mechanical. － Go to Step 11
OK?
Does the exhaust noise still exist?

Inspect the exhaust manifold and the cylinder head for

any leaks? System
11 － Go to Step 12
Are there any leaks? OK?

Tighten the fasteners between the exhaust manifold

and the cylinder head.Refer to Fastener Tightening System
12 Torque in Engine Mechanical. － －
OK?
Does the exhaust noise still exist?

6.5.2.5 Basic Diagnosis Information

Diagnosis

The reasons that possibly cause a high rate of exhaust gas discharge
Excessive carbon monoxide (CO) Main reason
(caused by the air/fuel ratio of high concentration) The vehicle engine runs at a temperature higher than the
normal operating temperatures. Incorrect idle speed
Restricted air filter elements
Restricted hose or correction orifice of crankcase
ventilation system

Excessive hydrocarbon (HC) Main reason

(caused due to the high temperature in the combustion When the vehicle is running, the engine exceeds the
chamber). normal operating temperature.
Vacuum tube is broken, restricted or in improper
installation position.
Incorrect idle speed
Spark plug, high voltage ignition wires
Improper ignition advance angle

Excessive nitrogen oxides (NOx) Possible reasons

(caused due to the high temperature in the combustion Improper ignition advance angle
chamber). Vacuum tube is broken, restricted or in false installation
position.
Note:Excessive carbon monoxide and hydrocarbon is carbon monoxide.When the mixture concentration is related to
the high concentration of air/fuel mixture.High high, the fuel cannot be burned sufficiently, and thus mixture
concentration can accelerate the forming of excessive hydrocarbon is produced.
6.5.3 Repair Instructions
6.5.3.1Exhaust System Check
Inspect the exhaust resonator pipe and the exhaust muffler with exhaust pipe and tail pipe for the following conditions:
－ Broken joint
－ Broken welding
Corrosive damage (Corrosive damage may cause the exhaust system to leak)
－ Inspect the clips, brackets, and the vibration damper for the following conditions:
－ Broken Bolts
－ Stripped bolt threads
－ Corroded bolts
The exhaust system (including the heat shield) must be free of the following conditions:
6-222 Engine Exhaust Engine

－ Leaks
－ Joint
－ Ground
－ Excessive vibration
When the following components are loose or damaged, these conditions may occur.
－ Flange bolts
－ Heat shield
－ Supporting stand, brackets
－ Duct
If these condition occur, inspect the exhaust system.Make calibrations and replace the necessary components, including
new manifold gaskets, nuts.
6.5.3.2 Exhaust Pipe Gasket (Exhaust Manifold Gasket) Repalcement
Removal Procedure
1. Lift up and properly support the vehicle.Refer to Lifting and
Jacking the Vehicle in General Information.
2. Replace the bolts and the spring of exhaust manifold.
Note:Properly support the exhaust system at the location that the
hanger rod is removed.
3. If necessary, remove the hanger rod so as to relocate the
exhaust system in place.
4. Re-locate the exhaust system.
5. Replace the exhaust manifold gaskets.
6. Inspect all the components for the following
conditions:
Cracks
Bending
605001 Stripped bolt threads
Corrosive damage
Leaks
Replace the necessary components. Installation Procedure
Engine Engine Exhaust 6-223
1. Install the exhaust manifold gaskets.
2. Allow the exhaust system to resume the normal location.
3. Connect the hanger rod.
4. Install the exhaust manifold spring and the exhaust manifold
bolts. Tightening
Tighten the exhaust manifold bolts to 15-35 N m. 5. Remove
the support of the exhaust system.
6. Inspect the exhaust system for any leaks and the contact with the
underbody.
7. Lower the vehicle.
6.5.3.3 Exhaust Pipe Muffler Inlet Clamp
Replacement
Removal Procedure
605001
1. Lift up and properly support the vehicle.Refer to Lifting and
Jacking the Vehicle in General Information.
2. Support the exhaust pipe muffler inlet and the exhaust resonator
pipe.
3. Remove the inlet clamp of the exhaust pipe muffler.
4. Inspect all the components for the following conditions:
Cracks
Bending
Corrosive damage
Leaks
Replace the necessary components.

Installation Procedure
605002
1. Install the inlet clamp of the exhaust pipe muffler.
Tightening
Tighten the inlet clamp of the exhaust pipe muffler to 25-30 N m.
Note:(1) The mounting position of exhaust pipe muffler inlet clamp
must be correct.Improper mounting position can cause a severe
leak.When the clamp position is correct, it can cover the inlet slot of
the exhaust pipe muffler, and the covered slot length is about 3/4 of
the clamp width. (2) There is an installation sign (a circular hole)
behind the exhaust muffler pipe.When mounting the exhaust muffler
pipe and the exhaust pipe muffler inlet, the pipe nozzle of the
exhaust pipe muffler inlet must within the installation sign (a circular
hole) range.(3) Inspect the two procedures, then install the inlet
clamp of the exhaust pipe muffler.

605004
6-224 Engine Exhaust Engine
2. Remove the support of the exhaust system.
3. Inspect the system for any leaks.
4. Lower the vehicle.

605003

6.5.3.4 Exhaust System Replacement

Removal Procedure
1. Lift up and properly support the vehicle.Refer to Lifting and
Jacking the Vehicle in General Information.
2. Properly support the exhaust system.
3. Remove the inlet clamp of the exhaust pipe muffler.

605002
Engine Engine Exhaust 6-225

4. Remove the vibration damper tab of the exhaust

pipe rear hanger rod.
5. Remove the vibration damper of the exhaust
pipe rear hanger rod from the exhaust pipe
muffler with exhaust pipe and tail pipe.
6. Replace the exhaust pipe muffler with exhaust
pipe and tail pipe.

605005

7. Remove the vibration damper tab of the exhaust

pipe hanger rod.
8. Remove the vibration damper of exhaust pipe
hanger rod from the hanger rod support of
exhaust resonator pipe.

605006

9. Remove the exhaust manifold bolts and the

exhaust manifold spring.
10. Remove the exhaust pipe resonator and the
catalytic converter.
11. Replace the exhaust manifold gaskets.
Installation Procedure

605007
 Engine

605007

605006

1. Install the exhaust manifold gaskets.

2. Install and properly support the exhaust pipe
muffler and the catalytic converter.
3. Install the exhaust manifold spring and its bolts.
Tightening
Tighten the exhaust manifold bolts to 15-35 N m.
Engine Engine Exhaust 6-227

4. Install the vibration damper of exhaust pipe

hanger rod onto the hanger rod support of
exhaust muffler pipe.
5. Install the vibration damper tab of the exhaust
pipe hanger rod.
 Engine

605005

605004

6. Install the exhaust pipe muffler with exhaust

pipe and tail pipe.
7. Install the vibration damper of exhaust pipe rear
hanger rod onto the exhaust pipe muffler with
exhaust pipe and tail pipe.Viewing from the rear,
the included angle between the two central lines
of vibration damper is about 100 degrees.
8. Install the vibration damper tab of the exhaust
pipe rear hanger rod.
Engine Engine Exhaust 6-229

9. Install the inlet clamp of the exhaust pipe

muffler.Refer to Exhaust Pipe Muffler Inlet
Clamp Replacement.
Tightening
Tighten the inlet clamp of the exhaust pipe
muffler to 25-30 N m.
10. Remove the support of the exhaust system.
11. Inspect the exhaust system for any leaks and
the contact with the underbody.
12. Lower the vehicle.
6.5.3.5 Catalytic Converter and
Resonator Replacement (with Exhaust
Manifold Bolts)
Removal Procedure
 Engine

605002

605008

The catalytic converter and the resonator are welding

connected.Repairing the catalytic converter and the
resonator need repairing the complete
assembly.When repairing the catalytic converter and
the exhaust pipe resonator, the gasket of front flange
must be replaced.Never re-install the original gasket
again.
1. Lift up and properly support the vehicle.Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Properly support the exhaust system.
Engine Engine Exhaust 6-231

3. Remove the inlet clamp of the exhaust pipe

muffler.

4. Remove the vibration damper tab of the exhaust

pipe hanger rod.
5. Remove the vibration damper of exhaust pipe
hanger rod from the hanger rod support of
exhaust resonator pipe.
6. Remove the exhaust manifold bolts and the
exhaust manifold spring.
605001 7. Remove the catalytic converter and the
resonator.
8. Replace the exhaust manifold gaskets.

605001

Installation Procedure
Note:In order to prevent the flexible coupling of the
catalytic converter assembly from being internally
damaged, the converter must be supported.The
vertical movement at the rear of the catalytic converter
assembly must not exceed 6 degrees up or down.
1. Install the new exhaust manifold gaskets.

605008
 Engine
2. Install and support the catalytic converter and
the resonator.
3. Install the exhaust manifold spring and the
exhaust manifold bolts. Tightening
Tighten the exhaust manifold bolts to 15-35 N m.
4. Install the vibration damper of exhaust pipe
hanger rod onto the hanger rod support of
exhaust muffler pipe.
5. Install the vibration damper tab of the exhaust
pipe hanger rod.

605004

6. Install the inlet clamp of the exhaust pipe

muffler.Refer to Exhaust Pipe Muffler Inlet
Clamp Replacement.
Tightening
Tighten the inlet clamp of the exhaust pipe
muffler to 25-30N m.
7. Remove the support of the exhaust system.
8. Inspect for any leaks and the contact with the
underbody.
9. Lower the vehicle.

6.5.3.6 Muffler Replacement

Engine Engine Exhaust 6-233

Removal Procedure
1. Lift up and properly support the vehicle.Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Properly support the exhaust system.
3. Remove the inlet clamp of the exhaust pipe
muffler.
4. Remove the vibration damper tab of the exhaust
pipe rear hanger rod.
5. Remove the vibration damper of the exhaust
pipe rear hanger rod from the exhaust pipe
muffler with exhaust pipe and tail pipe.
6. Replace the exhaust pipe muffler with exhaust
pipe and tail pipe.
605005

605002

Installation Procedure
1. Install and properly support the exhaust pipe
muffler with exhaust pipe and tail pipe.
2. Install the vibration damper of exhaust pipe rear
hanger rod onto the exhaust pipe muffler with
exhaust pipe and tail pipe.Viewing from the rear,
the included angle between the two central lines
of vibration damper is about 100 degrees.
605005 3. Install the removed vibration damper tab of the
exhaust pipe rear hanger rod.

4. Install the inlet clamp of the exhaust pipe

muffler.

605004
 Engine
Refer to Exhaust Pipe Muffler Inlet Clamp
Replacement.
Tightening
Tighten the inlet clamp of the exhaust pipe
muffler to 25-30 N m.
5. Inspect the exhaust system for any leaks and
the contact with the underbody.
6. Remove the support of the exhaust system.
7. Lower the vehicle.
6.5.3.7 Hanger Rod of Exhaust Pipe
Resonator Replacement (Hanger Rod
Support of Exhaust Pipe)
Removal Procedure
Engine Engine Exhaust 6-235

1. Lift up and properly support the vehicle.Refer to

Lifting and Jacking the Vehicle in General
Information.
2. Properly support the exhaust system.
3. Remove the vibration damper tab of the exhaust
pipe hanger rod.
4. Remove the vibration damper of exhaust pipe
hanger rod from the hanger rod support of
exhaust resonator pipe.

605006

Installation Procedure
1. Install the vibration damper of exhaust pipe
hanger rod onto the hanger rod support of
exhaust muffler pipe.
2. Install the vibration damper tab of the exhaust
pipe hanger rod.
3. Remove the support of the exhaust system.
4. Inspect the exhaust system for any leaks and
the contact with the underbody.
5. Lower the vehicle.

605006
 Engine

6.5.3.8 Hanger Rod of Exhaust Pipe

Muffler Replacement (Muffler Rear
Hanger Rod Support)
Removal Procedure
1. Lift up and properly support the vehicle.Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Properly support the exhaust system.
Engine Engine Exhaust 6-237

3. Remove the inlet clamp of the exhaust pipe muffler.

4. Remove the vibration damper tab of the exhaust pipe
rear hanger rod.
5. Remove the vibration damper of exhaust pipe rear
hanger rod from the rear hanger rod support of
exhaust pipe muffler.

605005

Installation Procedure
1. Install the vibration damper of exhaust pipe rear
hanger rod onto the rear hanger rod support of
exhaust pipe muffler.Viewing from the rear, the
included angle between the two central lines of
vibration damper is about 100 degrees.
2. Install the vibration damper tab of the exhaust pipe
rear hanger rod.
3. Install the inlet clamp of the exhaust pipe
muffler.Refer to Exhaust Pipe Muffler Inlet Clamp
Replacement.
Tightening
Tighten the inlet clamp of the exhaust pipe muffler to
25-30 N m.
4. Remove the support of the exhaust system.
5. Inspect the exhaust system for any leaks and the
contact with the underbody.
605005
6. Lower the vehicle.
6.5.3.9 Heat Shield of Catalytic Converter or
Resonator Replacement
Removal Procedure
 Engine

1. Lift
up
and

605009

605009

properly support the vehicle.Refer to Lifting and

Jacking the Vehicle in General Information.
2. Properly support the exhaust system.
3. Remove the catalytic converter and the
resonator.Refer to Catalytic Converter and Resonator
Replacement (with Exhaust Manifold Bolts).
4. Remove the nuts of catalytic converter heat shield or
the nuts of resonator heat shield.
5. Remove the catalytic converter heat shield or the
resonator heat shield.
Engine Engine Exhaust 6-239

Installation Procedure
1. Install the catalytic converter heat shield or the
resonator heat shield.
2. Install the nuts of catalytic converter heat shield or
the nuts of resonator heat shield. Tightening
Tighten the nuts of catalytic converter heat shield or
the nuts of resonator heat shield to 2.5-3 N m.
3. Install the catalytic converter and the resonator.Refer
to Catalytic Converter and Resonator Replacement
(with Exhaust Manifold Bolts).
4. Remove the support of the exhaust system.
5. Inspect the exhaust system for any leaks and the
contact with the underbody.
6. Lower the vehicle.
6.5.3.10 Muffler Heat Shield Replacement
Removal Procedure
 Engine

1. Lift
up
and

605010

605010

properly support the vehicle.Refer to Lifting and

Jacking the Vehicle in General Information.
2. Properly support the exhaust system.
3. Replace the exhaust pipe muffler with exhaust pipe
and tail pipe.Refer to Muffler Replacement.
4. Remove the nuts of muffler heat shield.
5. Remove the muffler heat shield.
 Engine Engine Exhaust 6-241

Installation Procedure
1. Install the muffler heat shield.
2. Install the nuts of muffler heat shield.
Tightening
Tighten the nuts of muffler heat shield to 2.5-3
N m.
3. Install the exhaust pipe muffler with exhaust pipe and
tail pipe.Refer to Muffler Replacement.
4. Remove the support of the exhaust system.
5. Inspect the exhaust system for any leaks and the
contact with the underbody.
6. Lower the vehicle.

6.5.4 Description and Operation specified value), using of spark plug outside the
specified range, and overheated to the engine, all can
6.5.4.1General Description increase the discharge of hydrocarbon (HC) and
nitrogen oxides (NOx). Reduction of the engine ignition
Air pollution and correct vehicle maintenance advance angle can reduce the discharge of NOx, but
increase the HC quantity.
Advanced vehicle concept, especially in the fuel feeding
and ignition system, can reduce the substance amount Crankcase Ventilation System
that may be harmful to the human body and the
During the engine running period, a certain amount of
environment, such as carbon monoxide (CO), unburned material, high corrosive gas and water vapor
hydrocarbon (HC), nitrogen oxides (NOx) and
transfers to the crankcase by means of the piston ring.In
aldehydes.And correct maintenance can be sure to order to prevent the engine lubricating oil from being
reduce the proportion of pollutantelements in the
polluted by these substances, and damaging the piston
exhaust gas composition at the maximum.Improper fuel and the piston ring, etc., it may be removed from the
feeding, incorrect idle speed adjustment, and wrong
crankcase through the air circulation in air filter.
air/fuel mixture ratio adjustment can possibly increase
the discharge of carbon monoxide and After mixing with the air, they flow to the intake manifold,
hydrocarbon.Insufficient adjustment of ignition system then to the combustion chamber for burning. Because
can also increase the hydrocarbon and the nitrogen they are highly pollutant gas, they cannot be discharged
oxides.Using of restricted air filter can cause the fuel air into the atmosphere. Catalytic Converter
ratio to be richer, and thus increase the pollution Catalytic converter is an accessory of the exhaust
discharge. system, being responsible to control the harmful
These examples indicate how incorrect vehicle discharge of exhaust gas.
maintenance will affect the air quality. Catalytic converter equipped vehicle needs the lead free
Strictly observe the SGM vehicle maintenance fuel to be used.
regulations, and contribute to the reduction of air
EVAP Canister - Canister
pollution.
The system controlling the evaporative fuel gas,
Ignition System consisting of an active canister known as Canister.
If all the components of ignition system can operate The system allow the vapor to flow in the fuel system
normally, improve the engine performance under all the through Canister. Even though the engine is turned off,
drive conditions, and reduce the pollution to the they still remain there.When the engine is starting, the
minimum.For example, excessive engine ignition air flow in the intake manifold will absorb the fuel vapor
advance angle (Ignition advance angle exceeds the
 Engine

from the activated carbon, and consume during the

process of engine combustion.
Vapor outlet of Canister is controlled by a solenoid valve,
which receives the signal from the engine management
system.

6.5.4.2 Exhaust System Description

The exhaust system is used to carry over the gas
produced by the engine.When the engine exhaust valve
opens, hot gas created by the engine combustion cycle
is allowed to travel out through the cylinder head into the
exhaust manifold.The exhaust gas mixes with the gas
from other cylinders in the exhaust manifold, and travels
out through a flange port into the catalytic converter and
the exhaust resonatorThe resonator and the muffler are
used to reduce the noise level of exhaust gas.The
exhaust system exits at the rear of vehicle, which can 605006
reduce exhaust noise and fume particles or pollutant
from entry into the vehicle.Hanger rod and vibration
damper of exhaust system are used to support the The exhaust system uses several hanger rods
weight of exhaust system, isolate the engine noise, and vibration dampers.
separate the engine vibration, allow the system far from
the body floor, and reserve an expanding space when
heated for the exhaust system.
Exhaust resonator pipe is supported by the
hanger rod of exhaust resonator pipe.

6.5.4.3 Exhaust Manifold Description

Exhaust manifold is an accessory of the exhaust system,
being used to collect and transfer the hot gas created by
the engine.The exhaust manifold made of the cast iron,
is used to mix the gas from several cylinders.The
exhaust manifold is connected to the cylinder
head.There is a gasket between the exhaust manifold
and the cylinder head.Front exhaust manifold is
connected to the crossover exhaust pipe, and is used to
transfer the exhaust gas from the front engine to the rear 605005
exhaust manifold.The gas is mixed in the rear manifold,
and guided into the exhaust resonator pipe.
There are two vibration dampers of exhaust
6.5.4.4 Muffler Description muffler rear hanger rod, and a rear hanger rod
The muffler reduces the discharging noise of engine bracket of exhaust muffler (welded on the
exhaust gas by the deflector.The deflector inside the underbody) at the rear of muffler.The exhaust
muffler allows the muffler inside to form a passage, thus muffler and the exhaust pipe and tail pipe
reduces the noise level created by the engine constitute the exhaust muffler assembly.
combustion.Install a catalytic converter and a resonator 6.5.4.5 Hanger Rod Description
at the front of muffler, and reduce more noise level. The
exhaust system hanger rod is used to support the weight The exhaust system hanger rod and the vibration
of the exhaust muffler. damper have the following functions:
To support the weight of exhaust system.
To isolate the engine noise.
To separate the engine vibration.
 Engine Exhaust 6-243

To separate the exhaust system from the

underbody so as to allow the exhaust system to
expand when heated.

6.5.4.6 Clean and Maintenance

In order to make the exhaust system perform the
designed functions, always carefully clean all the contact
surfaces.The clean surfaces have the following
advantages:
Avoid adhesiveness Correct calibrated parts allow
the gasket to have a good sealing surface.
Prevent the exhaust system from leaking.
9-244 Safeguard Air Bag system Safeguard Device
6-410 Engine Exhaust Engine
 Safeguard Device Safeguard Air Bag system 9-
245
1. Remove the damaged ceiling panel.